Operating Instructions

Capacitive cable electrode for

continuous level measurement

VEGACAL 65
4 … 20 mA/HART - two-wire

Document ID: 30033

Contents

Contents
1 About this document
1.1 Function............................................................................................................................ 4
1.2 Target group...................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety
2.1 Authorised personnel........................................................................................................ 5
2.2 Appropriate use................................................................................................................. 5
2.3 Warning about incorrect use.............................................................................................. 5
2.4 General safety instructions................................................................................................ 5
2.5 Safety label on the instrument........................................................................................... 6
2.6 CE conformity.................................................................................................................... 6
2.7 Fulfillment of NAMUR recommendations.......................................................................... 6
2.8 Safety instructions for Ex areas......................................................................................... 6
2.9 Environmental instructions................................................................................................ 6
3 Product description
3.1 Configuration..................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Operation.......................................................................................................................... 9
3.4 Packaging, transport and storage.................................................................................... 10
3.5 Accessories and replacement parts................................................................................ 10
4 Mounting
4.1 General instructions........................................................................................................ 12
4.2 Mounting instructions...................................................................................................... 14
5 Connecting to power supply
5.1 Preparing the connection................................................................................................ 16
5.2 Connection procedure..................................................................................................... 17
5.3 Wiring plan, single chamber housing.............................................................................. 18
5.4 Wiring plan, double chamber housing............................................................................. 20
5.5 Wiring plan, double chamber housing Ex d..................................................................... 22
5.6 Wiring plan - version IP 66/IP 68, 1 bar............................................................................ 24
6 Set up with the display and adjustment module PLICSCOM
6.1 Short description............................................................................................................. 25
6.2 Insert display and adjustment module............................................................................. 25
6.3 Adjustment system.......................................................................................................... 26
6.4 Setup steps..................................................................................................................... 27
6.5 Menu schematic.............................................................................................................. 37
6.10 Saving the parameter adjustment data............................................................................ 38
7 Set up with PACTware and other adjustment programs
7.1 Connect the PC............................................................................................................... 39
7.2 Parameter adjustment with PACTware............................................................................. 40
7.3 Parameter adjustment with AMS™ and PDM.................................................................. 41
30033-EN-160331

7.4 Saving the parameter adjustment data............................................................................ 42

8 Maintenance and fault rectification
8.1 Maintenance................................................................................................................... 43
8.2 Rectify faults.................................................................................................................... 43

2 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 Contents

8.3 Exchanging the electronics module................................................................................. 45

8.4 Shortening the electrode................................................................................................. 46
8.5 How to proceed if a repair is necessary........................................................................... 46
9 Dismount
9.1 Dismounting steps.......................................................................................................... 48
9.2 Disposal.......................................................................................................................... 48
10 Supplement
10.1 Technical data................................................................................................................. 49
10.2 Dimensions..................................................................................................................... 55
10.3 Industrial property rights.................................................................................................. 60
10.4 Trademark....................................................................................................................... 60

Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery. You can find them listed in chapter "Product descrip-
tion".

Instructions manuals for accessories and replacement parts

Tip:
To ensure reliable setup and operation of your VEGACAL 65, we offer
accessories and replacement parts. The corresponding documenta-
tions are:
30033-EN-160331

• 27720 - VEGADIS 61
• 30531 - Electronics module VEGACAL series 60
• 34296 - Protective cover
• 31088 - Flanges according to DIN-EN-ASME-JIS
Editing status: 2016-02-19

VEGACAL 65 • 4 … 20 mA/HART - two-wire 3

1 About this document

1 About this document

1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tions for maintenance and fault rectification. Please read this informa-
tion before putting the instrument into operation and keep this manual
accessible in the immediate vicinity of the device.

1.2 Target group

This operating instructions manual is directed to trained specialist
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.

1.3 Symbols 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.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 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.
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4 VEGACAL 65 • 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

VEGACAL 65 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.
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.

2.3 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.

2.4 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
30033-EN-160331

be observed.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 5

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
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.

2.7 Fulfillment of 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
For further information see www.namur.de.

2.8 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.

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 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"
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6 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 3 Product description

3 Product description
3.1 Configuration
Scope of delivery The scope of delivery encompasses:
• Level sensor VEGACAL 65
• Documentation
–– This operating instructions manual
–– Safety Manual "Functional safety (SIL)" (optional)
–– Supplementary instructions manual "Heating for display and
adjustment module" (optional)
–– Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors" (optional)
–– Ex-specific "Safety instructions" (with Ex versions)
–– If necessary, further certificates

Constituent parts The VEGACAL 65 consists of the components:

• Process fitting with probe
• Housing with electronics
• Housing cover, optionally available with display and adjustment
module

3
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Fig. 1: VEGACAL 65 - cable version with plastic housing

1 Housing cover with integrated display and adjustment module (optional)
2 Housing with electronics
3 Process fitting

VEGACAL 65 • 4 … 20 mA/HART - two-wire 7

3 Product description

Type label The type label contains the most important data for identification and
use of the instrument:
1 15

2 14

3 13

4 12

5 11
6 10
7 9
8
Fig. 2: Layout of the type label (example)
1 Instrument type
2 Product code
3 Approvals
4 Process and ambient temperature, process pressure
5 Power supply and signal output, electronics
6 Protection rating
7 Probe length
8 Order number
9 Serial number of the instrument
10 Material, wetted parts
11 Symbol of the device protection class
12 Reminder to observe the instrument documentation
13 ID numbers, instrument documentation
14 Notified authority for CE marking
15 Approval directives

With the serial number, you can access the delivery data of the instru-
ment via www.vega.com, "VEGA Tools" and "serial number search".
You can find the serial number on the inside of the instrument as well
as on the type label on the outside.

3.2 Principle of operation

Area of application VEGACAL 65 is a level sensor for use in all areas of industry.
The partly insulated probe is ideal for measurement of bulk solids and
can be also used in non-conductive liquids such as for example oil.
The proven mechanical construction offers high functional safety.

Functional principle Probe, measured product and vessel wall form an electrical capacitor.
The capacitance is influenced by three main factors.
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8 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 3 Product description

3
Fig. 3: Functional principle - Plate capacitor
1 Distance between the electrode surfaces
2 Size of the electrode surfaces
3 Type of dielectric between the electrodes

The probe and the vessel wall are the capacitor plates. The measured
product is the dielectric. Due to the higher dielectric constant of the
product compared to air, the capacitance increases as the probe is
gradually covered.
The capacitance as well as the resistance change are converted by
the electronics module into a level-proportional signal.

Voltage supply 4 … 20 mA/HART two-wire electronics for voltage supply and meas-
ured value transmission on the same cable.
The supply voltage range can differ depending on the instrument
version.
The data for power supply are specified in chapter "Technical data".
The backlight of the display and adjustment module is powered by
the sensor. The prerequisite for this is a supply voltage at a certain
level. The exact voltage specifications are stated in chapter "Technical
data".
The optional heating requires its own operating voltage. You can find
details in the supplementary instructions manual "Heating for display
and adjustment module".
This function is generally not available for approved instruments.

3.3 Operation
The instrument can be adjusted with the following adjustment media:
• With the display and adjustment module
• with the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard, e.g. PACTware and
PC
•
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With manufacturer-specific adjustment programs AMS™ or PDM

• With a HART handheld

VEGACAL 65 • 4 … 20 mA/HART - two-wire 9

3 Product description

3.4 Packaging, transport and storage

Packaging Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
The packaging of standard instruments consists of environment-
friendly, recyclable cardboard. For special versions, PE foam or PE
foil is also used. Dispose of the packaging material via specialised
recycling companies.

Transport Transport must be carried out in due consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.

Transport inspection The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.

Storage Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
Storage and transport • Storage and transport temperature see chapter "Supplement -
temperature Technical data - Ambient conditions"
• Relative humidity 20 … 85 %

3.5 Accessories and replacement parts

PLICSCOM The display and adjustment module PLICSCOM is used for measured
value indication, adjustment and diagnosis. It can be inserted into the
sensor and removed at any time.
You can find further information in the operating instructions "Display
and adjustment module PLICSCOM" (Document-ID 27835).

VEGACONNECT The interface adapter VEGACONNECT enables the connection of

communication-capable instruments to the USB interface of a PC. For
parameter adjustment of these instruments, the adjustment software
PACTware with VEGA-DTM is required.
You can find further information in the operating instructions "Interface
adapter VEGACONNECT" (Document-ID 32628).
30033-EN-160331

VEGADIS 82 VEGADIS 82 is suitable for measured value indication and adjustment

of sensors with HART protocol. It is looped into the 4 … 20 mA/HART
signal cable.

10 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 3 Product description

You can find further information in the operating instructions "VE-

GADIS 82" (Document-ID 45300).

Protective cap The protective cover protects the sensor housing against soiling and
intense heat from solar radiation.
You will find additional information in the supplementary instructions
manual "Protective cover" (Document-ID 34296).

Flanges Screwed flanges are available in different versions according to the

following standards: DIN 2501, EN 1092-1, BS 10, ASME B 16.5,
JIS B 2210-1984, GOST 12821-80.
You can find additional information in the supplementary instructions
manual "Flanges according to DIN-EN-ASME-JIS".
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 11

4 Mounting

4 Mounting
4.1 General instructions
Suitability for the process Make sure that all parts of the instrument coming in direct contact
conditions with the process, especially the sensor element, process seal and
process fitting, are suitable for the existing process conditions, such
as process pressure, process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data" and on the
nameplate.

Installation position Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of a display and adjustment
module. The housing can be rotated by 330° without the use of any
tools. You can also install the display 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.
Ground the probe before welding directly on the rod or cable.

Handling With threaded versions, the housing must not be used to screw in the
instrument. Applying tightening forces on the housing can damage its
internal parts.
Use the hexagon for screwing in.

Moisture Use the recommended cables (see chapter "Connecting to power

supply") and tighten the cable gland.
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 ap-
plies 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.
30033-EN-160331

Fig. 4: Measures against moisture ingress

12 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 4 Mounting

Pressure/Vacuum The process fitting must be sealed if there is gauge or low pressure in
the vessel. Before use, check if the seal material is resistant against
the measured medium and the process temperature.
The max. permissible pressure is specified in chapter "Technical
data" or on the type label of the sensor.
Insulating measures, such as e.g. covering the thread with teflon tape,
can interrupt the necessary electrical connection with metal vessels.
For this reason, ground the probe on the vessel or use a conductive
seal material.

Vessel material Metal vessel

Make sure that the mechanical connection of the probe to the vessel
is electrically conductive to ensure sufficient grounding.
Use conductive seals, such as those made of copper or lead, etc.
Insulating measures, such as covering the thread with Teflon tape,
can interrupt the necessary electrical connection with metal vessels.
For this reason, ground the probe on the vessel or use a conductive
seal material.
Non-conductive vessels
In non-conductive vessels, e.g. plastic tanks, the second pole of the
capacitor must be provided separately.

Vessel forms If possible, the capacitive probe should be mounted vertically or par-
allel to the counter electrode. This applies particularly to applications
in non-conductive products.
In cylindrical tanks, spherical tanks or other asymmetrical tank forms,
nonlinear level values are generated due to the varying distance to
the vessel wall.
Use a concentric tube in non-conductive products or linearize the
meas. signal.

Condensation If condensate forms on the vessel top, the run-off liquid can cause
bridging and hence measurement errors.
For this reason, use a screening tube or a longer insulation. The
length depends on the amount of condensate and the drain-off be-
haviour of the product.

Cable entries - NPT Metric threads

thread In the case of instrument housings with metric thread, the cable
Cable glands glands are screwed in at the factory. They are sealed with plastic
plugs as transport protection.
You have to remove these plugs before electrical connection.

NPT thread
In the case of instrument housings with self-sealing NPT threads, it is
30033-EN-160331

not possible to have the cable entries screwed in at the factory. The
free openings for the cable glands are therefore covered with red dust
protection caps as transport protection.
Prior to setup you have to replace these protective caps with ap-
proved cable glands or close the openings with suitable blind plugs.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 13

4 Mounting

4.2 Mounting instructions

Installation position During operation, the probe must not touch any installations or the
vessel wall. The measured value can also change if the distance to
the vessel wall changes considerably. If necessary, secure the end of
the probe (insulated).
In the gravity weight there is a thread (M12), e.g. for a ring bolt (article
no. 2.27424). The thread is already insulated in the gravity weight with
an adapter.
Make sure that the probe cable is not completely taut. Avoid tensile
loads on the cable.

Fig. 5: Fasten the probe

1 Gravity weight
2 Insulated adapter
3 Lug M12 (article no. 2.27423)

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 vessel bottom.

Inflowing medium If the instrument is mounted in the filling stream, unwanted false
measurement signals can be generated. For this reason, mount the
instrument at a position in the vessel where no disturbances, e.g. from
filling openings, agitators, etc., can occur.
This applies particularly to instrument versions with a longer probe.
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14 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 4 Mounting

Fig. 6: Inflowing medium

30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 15

5 Connecting to power supply

5 Connecting to power supply

5.1 Preparing the connection
Safety instructions Always keep in mind the following safety instructions:
Warning:
Connect only in the complete absence of line voltage.

• The electrical connection must only be carried out by trained

personnel authorised by the plant operator.
• If overvoltage surges are expected, overvoltage arresters should
be installed.

Voltage supply Power supply and current signal are carried on the same two-wire
cable. The operating voltage 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 EN 61140 VDE 0140-1.
Keep in mind the following additional factors that influence the operat-
ing voltage:
• Lower output voltage of the power supply unit under nominal load
(e.g. with a sensor current of 20.5 mA or 22 mA in case of fault)
• 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 61326-1 for industrial areas, screened cable should
be used.
Use cable with round cross section for instruments with housing and
cable gland. To ensure the seal effect of the cable gland (IP protection
rating), find out which cable outer diameter the cable gland is suitable
for.
Use a cable gland fitting the cable diameter.
We generally recommend the use of screened cable for HART multi-
drop mode.

Cable glands Metric threads

In the case of instrument housings with metric thread, the cable
glands are screwed in at the factory. They are sealed with plastic
plugs as transport protection.
You have to remove these plugs before electrical connection.

NPT thread
30033-EN-160331

In the case of instrument housings with self-sealing NPT threads, it is

not possible to have the cable entries screwed in at the factory. The
free openings for the cable glands are therefore covered with red dust
protection caps as transport protection.

16 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 5 Connecting to power supply

Prior to setup you have to replace these protective caps with ap-
proved cable glands or close the openings with suitable blind plugs.
With plastic housing, the NPT cable gland or the Conduit steel tube
must be screwed without grease into the threaded insert.

Cable screening and If screened cable is required, we recommend connecting the cable
grounding screen on both ends to ground potential. In the sensor, the screen
should be connected directly to the internal ground terminal. The
ground terminal on the outside of the housing must be connected to
the ground potential (with low impedance).
In Ex systems, the grounding is carried out according to the installa-
tion regulations.
In electroplating and CCP systems (cathodic corrosion protection) it
must be taken into account that significant potential differences exist.
This can lead to unacceptably high currents in the cable screen if it is
grounded at both ends.
Information:
The metallic parts of the instrument (process fitting, housing, etc.) are
conductively connected to the ground terminal.
Take note of the corresponding installation regulations for Ex applica-
tions. In particular, make sure that no potential equalisation currents
flow over the cable screen. In case of grounding on both sides this
can be achieved by the use of a capacitor or a separate potential
equalisation.

5.2 Connection procedure

Proceed as follows:
1. Unscrew the housing lid
2. If a display and adjustment module is installed, remove it by turn-
ing it to the left.
3. Loosen compression nut of the cable gland and remove blind
plug
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 wir-
ing plan
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VEGACAL 65 • 4 … 20 mA/HART - two-wire 17

5 Connecting to power supply

Fig. 7: 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. Connect the screen to the internal ground terminal, connect the
external ground terminal to potential equalisation
11. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
12. Screw the housing lid back on
The electrical connection is finished.

5.3 Wiring plan, single chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
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18 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 5 Connecting to power supply

Housing overview

5 5 5

1 2 3

5
4

Fig. 8: Material versions, single chamber housing

1 Plastic
2 Aluminium
3 Stainless steel, precision casting
4 Stainless steel, electro-polished
5 Filter element for air pressure compensation of all material versions. Blind
plug with version IP 66/IP 68, 1 bar for Aluminium and stainless steel

Electronics and terminal

compartment

Display
I²C 1

1 2 5 6 7 8
4 2

Fig. 9: Electronics and terminal compartment, 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
30033-EN-160331

4 Spring-loaded terminals for voltage supply

VEGACAL 65 • 4 … 20 mA/HART - two-wire 19

5 Connecting to power supply

Wiring plan

Display
I2C

1 2 5 6 7 8

Fig. 10: Wiring plan, single chamber housing

1 Voltage supply, signal output

5.4 Wiring plan, double chamber housing

The following illustrations apply to the non-Ex and also to the Ex-ia
version.
Housing overview
1 2 3

4 5

Fig. 11: Double chamber housing

1 Housing cover, connection compartment
2 Blind plug or plug M12 x 1 for VEGADIS 61 (optional)
3 Housing cover, electronics compartment
4 Filter element for air pressure compensation
5 Cable gland

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20 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 5 Connecting to power supply

Electronics compartment

Display
1
I²C

1 2 5 6 7 8

3 2

Fig. 12: Electronics compartment, double chamber housing

1 Plug connector for VEGACONNECT (I²C interface)
2 Internal connection cable to the connection compartment
3 Terminals for VEGADIS 81

Terminal compartment
Display

1 2 I2C

Fig. 13: Terminal compartment, double chamber housing

1 Spring-loaded terminals for voltage supply
2 Plug connector for VEGACONNECT (I²C interface)
3 Ground terminal for connection of the cable screen
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VEGACAL 65 • 4 … 20 mA/HART - two-wire 21

5 Connecting to power supply

Wiring plan

I2C

1 2

Fig. 14: Wiring plan, double chamber housing

1 Voltage supply, signal output

5.5 Wiring plan, double chamber housing Ex d

Housing overview
1 2 3

4 5

Fig. 15: Double chamber housing

1 Housing cover, connection compartment
2 Blind plug or plug M12 x 1 for VEGADIS 61 (optional)
3 Housing cover, electronics compartment
4 Filter element for air pressure compensation
5 Cable gland

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22 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 5 Connecting to power supply

Electronics compartment

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 81

Terminal compartment

1 2

Fig. 17: Connection compartment, Ex-d-ia double chamber housing

1 Spring-loaded terminals for power supply and cable screen
2 Ground terminal for connection of the cable screen
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 23

5 Connecting to power supply

Wiring plan

1 2

Fig. 18: Wiring plan, Ex-d-ia double chamber housing

1 Voltage supply, signal output

5.6 Wiring plan - version IP 66/IP 68, 1 bar

Wire assignment, con-
nection cable

2
Fig. 19: Wire assignment, connection cable
1 brown (+) and blue (-) to power supply or to the processing system
2 Shielding

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24 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

6 Set up with the display and adjustment

module PLICSCOM
6.1 Short description
Function/Configuration The display and adjustment module is used for measured value
display, adjustment and diagnosis. It can be mounted in the following
housing versions and instruments:
• 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)
• External display and adjustment unit VEGADIS 61

6.2 Insert display and adjustment module

Mount/dismount display The display and adjustment module can be inserted into the sensor
and adjustment module and removed again at any time. It is not necessary to interrupt the
power supply.
Proceed as follows:
1. Unscrew the housing lid
2. Place the display and adjustment module in the desired position
on the electronics (you can choose any one of four different posi-
tions - each displaced by 90°)
3. Press the display and adjustment module onto the electronics
and turn it to the right until it snaps in
4. 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.
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 25

6 Set up with the display and adjustment module PLICSCOM

Fig. 20: Insert 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 lid with an
inspection glass is required.

6.3 Adjustment system

Fig. 21: Display and adjustment elements

30033-EN-160331

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

Key functions • [OK] key:

26 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

–– Move to the menu overview

–– Confirm selected menu
–– Edit parameter
–– Save value

• [->] key to select:

–– Menu change
–– Select list entry
–– Select editing position

• [+] key:
–– Change value of the parameter

• [ESC] key:
–– Interrupt input
–– Jump to next higher menu

Adjustment system The instrument is operated via the four keys of the display and adjust-
ment module. The individual menu items are shown on the LC display.
You can find the functions of the individual keys in the previous
illustration.

Time functions When the [+] and [->] keys are pressed quickly, the edited value, i.e.
the cursor, moves by one position. When the keys are pressed longer
than 1 s, the cursor moves continuously.
When the [OK] and [ESC] keys are pressed simultaneously for more
than 5 s, the display returns to the main menu. The menu language is
then switched over to "English".
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.

6.4 Setup steps

Switch-on phase After connecting VEGACAL 65 to power supply or after a voltage
recurrence, the instrument carries out a self-check for approx. 30
seconds:
• Internal check of the electronics
• Indication of the instrument type, the firmware as well as the sen-
sor TAGs (sensor designation)
• 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).

Address setting HART In HART-Multidrop mode (several sensors on one input) the address
multidrop must be set before continuing with the parameter adjustment. You
30033-EN-160331

will find a detailed description in the operating instructions manual

"Display and adjustment module" or in the online help of PACTware
or DTM.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 27

6 Set up with the display and adjustment module PLICSCOM

HART mode

Standard
Address 0

Parameter adjustment VEGACAL 65 measures the capacitance of the respective product. To

display the actual level of the product, an allocation of the measured
capacitance to the percentage height must be carried out. For this
adjustment, the capacitance is entered with emptied and filled vessel.
If the vessel cannot be emptied or filled completely, you can carry out
the adjustment also with two known levels - for example with 10 %
and 90 %. The difference between the empty and full adjustment
values should be as large as possible.
The actual level can then be calculated on the basis of these settings.
VEGACAL 65 must be installed. A change of level is necessary for
this adjustment.
In the main menu item "Basic adjustment", the individual submenu
items should be selected one after the other and provided with the
correct parameter values.
Tip:
If the display and adjustment module remains on the probe as a
display, we recommend saving the sensor data in the display and
adjustment module.
Use the function "Copy sensor data".
Start your parameter adjustment with the following menu items of the
basic adjustment:

Carry out min. adjustment To be on the safe side, note the adjustment values for full and empty.
If an adjustment procedure fails, it is not necessary to again carry out
a level change.
These values can be helpful if the electronics has to be exchanged.
% Value
Empty adjustment
Full adjustment
Tab. 1: Adjustment protocol

Tip:
For min. adjustment the vessel should be as empty as possible, and
for max. adjustment, as full as possible. If the vessel is already full,
start with max. adjustment.

Note:
If possible, the vessel should be as empty as possible for min. adjust-
30033-EN-160331

ment.
Proceed as follows:
1. Move from the measured value display to the main menu by
pushing [OK].

28 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

▶ 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 %
=
0.0 pF
54.5 pF

3. Prepare the adjustment value for editing with [OK]. Move to the
selection window with [OK].
Min. adjustment
Accept current measured
value?

Accept?
Edit?

4. Accept the current measured value or move to the editing window

with "Edit". To edit, set the cursor to the requested position with
[->]. Set the requested % value with [+] and save with [OK]. The
cursor jumps to the capacitance value.
5. Enter the current capacitance value in pF (displayed below) for
the empty vessel corresponding to the percentage value.
6. Save the settings with [OK] and move to "Max. adjustment" with
[->].

Carry out max. adjust- Fill the vessel to the highest possible level.
ment
Note:
For max. adjustment, the vessel should be as full as possible. This will
make the calibration more accurate.
Proceed as follows:
Max. adjustment
100.00 %
=
1000 pF
327.4 pF

1. Prepare the adjustment value for editing with [OK]. Move to the
selection window with [OK].
Min. adjustment
Accept current measured
value?

Accept?
Edit?
30033-EN-160331

2. Accept the current measured value or move to the editing window

with "Edit". To edit, set the cursor to the requested position with
[->]. Set the requested % value with [+] and save with [OK]. The
cursor jumps to the capacitance value.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 29

6 Set up with the display and adjustment module PLICSCOM

3. Enter the current capacitance value in pF (displayed below) for

the full vessel corresponding to the percentage value.
4. Save the settings with [OK].

Basic adjustment - Damp- To suppress fluctuations in the measured value display, e. g. caused
ing 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.

Basic adjustment - Lin- A linearisation is necessary for all vessels in which the vessel volume
earization curve does not increase linearly with the level - e.g. in a horizontal cylindri-
cal or spherical tank - and the indication or output of the volume is
required. Corresponding linearisation curves are preprogrammed for
these vessels. They represent the correlation between the level per-
centage 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.
Caution:
Note the following if the VEGACAL 65 with corresponding approval is
used as part of an overfill protection system according to WHG (Water
Resources Act):
If a linearisation curve is selected, the measuring signal is no longer
necessarily linear to the filling height. This must be considered by the
user especially when adjusting the switching point on the limit signal
transmitter.

Basic adjustment - Sen- In this menu item you can enter an unambiguous designation for the
sor TAG sensor, e.g. the measurement loop name or the tank or product des-
ignation. In digital systems and in the documentation of larger plants,
30033-EN-160331

a singular designation should be entered for exact identification of

individual measuring points.

30 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

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.

Display - Displayed value In the menu item "Display" you can define how the measured value
should be presented on the display.
The following indication values are available:
• Height
• Distance
• Current
• Scaled
• Percent
• Lin. percent
The selection "scaled" opens the menu items "Display unit" and
"Scaling". In "Display unit" there are the following options:
• Height
• Ground
• Flow
• Volume
• Without unit
Depending on selection, the different units are in turn available.
In the menu item "Scaling", the requested numerical value with deci-
mal point is entered for 0 % and 100 % of the measured value.
There is the following relationship between the indication value in the
menu "Display" and the adjustment unit in the menu "Device settings":
• Indication value "Distance": Presentation of the measured value in
the selected adjustment unit, e.g. m(d).
Displayed value

Scaled ▼

Display unit

Volume ▼
l▼

Scaling

0 % = 0.0 l
100 % = 100.0 l
30033-EN-160331

Display - Backlight A background lighting integrated by default can be adjusted via the
adjustment menu. The function depends on the height of the supply
voltage. See "Technical data/Voltage supply".

VEGACAL 65 • 4 … 20 mA/HART - two-wire 31

6 Set up with the display and adjustment module PLICSCOM

Backlight

In the default setting, the lightning is switched off.

Diagnosis - Peak value The respective min. and max. measured values are saved in the sen-
sor. The values are displayed in the menu item "Peak values".
• Min. and max. distance in m(d)
• Min. and max. temperature
Peak value indicator

Diagnostics - Device The instrument status is displayed in this menu item. If no failure is
status detected by the sensor, "OK" will be displayed. If a failure is detected,
there will be a sensor-specific flashing fault signal, for example
"E013". The failure is also displayed in clear text, for example "No
measured value available".
Information:
The fault message as well as the clear text indication are also carried
out in the measured value display.

Meas. certainty

Sensor status

Trend recording Up to 3000 measured values are recorded (depending on the sensor)
when starting a "Trend curve". Then the values can be displayed on
a time axis. The oldest measured values are always deleted.
The measured values displayed are in the unit pF.
Trend recording

Presentation of the trend

curve

Information:
The trend recording is not activated when being shipped. It must be
started by the user via the menu item "Start trend curve".
30033-EN-160331

Service - Current output In the menu item "Current output" you determine the behaviour of the
current output during operation and in case of failure. The following
options are available:

32 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

Current output
Characteristics 4 … 20 mA
20 … 4 mA
Failure mode1) Hold value
20.5 mA
22 mA
< 3.6 mA
Min. current 2)
3.8 mA
4 mA
Max. current 3)
20 mA
20.5 mA
The values in bold font represent the data of the factory setting.
In HART multidrop mode, the current is constantly 4 mA. This value
does not change even in case of failure.
Current output

Characteristic: 4-20 mA ▼
Failure mode: 22 mA ▼
Min. current 3.8 mA ▼

Service - Simulation In this menu item you simulate a user-defined level or pressure value
via the current output. This allows you to test the signal path, e.g.
through connected indicating instruments or the input card of the
control system.
The following simulation variables are available:
• Percent
• Current
• Pressure (with pressure transmitters)
• Distance (with radar and guided microwave)
With Profibus PA sensors, the selection of the simulated value is
made via the "Channel" in the menu "Basic adjustments".
How to start the simulation:
1. Push [OK]
2. Select the requested simulation variable with [->] and confirm
with [OK].
3. Set the requested numerical value with [+] and [->].
4. Push [OK]
The simulation is now running, with 4 … 20 mA/HART a current is
outputted and with Profibus PA or Foundation Fieldbus a digital value.
How to interrupt the simulation:
→ Push [ESC]
30033-EN-160331

1)
Value of the current output in case of failure, e.g. if no valid measured value is
delivered.
2)
This value is not underrun during operation.
3)
This value is not exceeded during operation.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 33

6 Set up with the display and adjustment module PLICSCOM

Information:
The simulation is automatically terminated 10 minutes after the last
pressing of a key.
Simulation

Start simulation?

Reset Basic adjustment

If the function "Reset" is carried out, the sensor resets all settings to
default.
The following values will be reset:
Function Reset value
Max. adjustment 3000 pF
Min. adjustment 0 pF
Damping ti 0s
Linearization Linear
Sensor-TAG Sensor
Display %
Current output - characteristics 4 … 20 mA
Current output - max. current 20.5 mA
Current output - min. current 3.8 mA
Current output - failure < 3.6 mA

Special parameters
All special parameters are reset to delivery status.

Peak value indicator

The min. and max. values are reset to the actual value.

Service - Language The sensor is already set to the ordered national language. In this
menu item you can change the language. The following languages are
available, e.g. in software version 3.50:
• Deutsch
• English
• Français
• Espanõl
• Pycckuu
• Italiano
• Netherlands
• Japanese
• Chinese
30033-EN-160331

Language

German

34 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

Service - HART mode HART offers standard and multidrop mode.

The mode "standard" with the fixed address 0 means outputting the
measured value as a 4 … 20 mA signal.
In Multidrop mode, up to 15 sensors can be operated on one two-wire
cable. An address between 1 and 15 must be assigned to each sen-
sor.4)
In this menu item you determine the HART mode and enter the ad-
dress for multidrop.
HART mode

Standard
Address 0

The default setting is standard with address 0.

Copy sensor data With this function

• Load parameter adjustment data from the sensor into the display
and adjustment module
• Write parameter adjustment data from the display and adjustment
module into the sensor
The data are permanently saved in an EEPROM memory in the dis-
play and adjustment module and remain there even in case of power
failure. From there, they can be written into one or several sensors or
kept as backup for a possible sensor exchange.
The type and the volume of the copied data depend on the respective
sensor.
Information:
Before data are written into the sensor, a check is carried out to
determine whether the data fit the sensor. If the data do not fit, a fault
signal is triggered or the function is blocked. When writing data into
the sensor, you will see which instrument type the data originate from
and which TAG-no. this sensor had.
The following items are checked:
• Software version
• WHG approval
• SIL activated
• Measuring principle
• Signal output
Copy sensor data

Copy sensor data?

30033-EN-160331

Service - PIN In this menu item, the PIN is activated/deactivated permanently.

Entering a 4-digit PIN protects the sensor data against unauthorized
4)
The 4 … 20 mA signal of the HART sensor is switched off. The sensor
consumes a constant current of 4 mA. The measuring signal is transmitted
exclusively as digital HART signal.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 35

6 Set up with the display and adjustment module PLICSCOM

access and unintentional modifications. If the PIN is activated perma-

nently, it can be deactivated temporarily (i.e. for approx. 60 min.) in
any menu item. The instrument is delivered with the PIN set to 0000.
PIN

Disable permanently?

Only the following functions are permitted with activated PIN:

• Select menu items and show data
• Read data from the sensor into the display and adjustment mod-
ule.

Info In this menu item the most important sensor information can be
displayed:
• Instrument type
• Serial number: 8-digit number, e.g. 12345678
Instrument type

Serial number
12345678

• Date of manufacture: Date of the factory calibration, e.g. 24. March

2015
• Software version: Edition of the sensor software, e.g. 3.80
Date of manufacture
24. March 2015
Software version
3.80

• Date of last change using PC: Date of the last change of sensor
parameters via PC
Last change using PC

• Sensor details, e.g. approval, process fitting, seal, measuring cell,

measuring range, electronics, housing, cable entry, plug, cable
length etc.
Sensor characteristics

Display now?
30033-EN-160331

36 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 6 Set up with the display and adjustment module PLICSCOM

6.5 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
0.0 pF 1000.0 pF
82.5 pF 327.4 pF

Sensor-TAG 1.5

Sensor

Display

Basic adjustment 2
▶ Display
Diagnostics
Service
Info

Displayed value scaled 2.1 Unit 2.2 Scaling 2.3 Backlight 2.4
Volume
hl 0 % = 000.5 hl Switched on ▼
100 % = 005.0 hl

Diagnostics

Basic adjustment 3
Display
▶ Diagnostics
Service
Info

Peak value indicator 3.1 Sensor status 3.2 Trend recording 3.3

Capacit. min.: 65.7 pF OK Presentation of the trend

Capacit. max.: 782.4 pF curve
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 37

6 Set up with the display and adjustment module PLICSCOM

Service

Basic adjustment 4
Display
Diagnostics
▶ Service
Info

Current output 4.1 Simulation 4.2 Reset 4.3 Language 4.4

Characteristic: 4-20 mA ▼
Fail.mode: < 3.6 mA ▼ Start simulation? Select reset? Deutsch ▼
min. current: 4 mA ▼

HART mode 4.5 Copy sensor data 4.6 PIN 4.7

Standard
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
06. February 2012
Serial number Software version 05. March 2012 Display now?
12345678 1.30

6.10 Saving the parameter adjustment data

We recommended noting the adjusted data, e.g. in this operating
instructions manual, and archiving them afterwards. They are thus
available for multiple use or service purposes.
If VEGACAL 65 is equipped with a display and adjustment module,
the most important data can be read out of the sensor into the display
and adjustment module. The procedure is described in the operating
instructions manual "Display and adjustment module" in the menu
item "Copy sensor data". The data remain there permanently even if
the sensor power supply fails.
If it is necessary to exchange the sensor, the display and adjustment
module is inserted into the replacement instrument and the data are
written into the sensor under the menu item "Copy sensor data".
30033-EN-160331

38 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 7 Set up with PACTware and other adjustment programs

7 Set up with PACTware and other

adjustment programs
7.1 Connect the PC
VEGACONNECT directly
on the sensor 2

Fig. 22: Connection of the PC via VEGACONNECT directly to the sensor

1 USB cable to the PC
2 VEGACONNECT
3 Sensor

VEGACONNECT exter-
nally 1 2

3
TWIST
LO
EN

CK
OP

USB
4

Fig. 23: Connection via VEGACONNECT externally

1 I²C bus (com.) interface on the sensor
2 I²C connection cable of VEGACONNECT
3 VEGACONNECT
30033-EN-160331

4 USB cable to the PC

Necessary components:
• VEGACAL 65
• PC with PACTware and suitable VEGA DTM

VEGACAL 65 • 4 … 20 mA/HART - two-wire 39

7 Set up with PACTware and other adjustment programs

• VEGACONNECT
• Power supply unit or processing system

VEGACONNECT via HART

2 4

CK
LO
TWIST

USB
3 5

N
OPE
Fig. 24: Connecting the PC via HART to the signal cable
1 VEGACAL 65
2 HART resistance 250 Ω (optional depending on evaluation)
3 Connection cable with 2 mm pins and terminals
4 Processing system/PLC/Voltage supply

Necessary components:
• VEGACAL 65
• PC with PACTware and suitable VEGA DTM
• VEGACONNECT
• HART resistance approx. 250 Ω
• Power supply unit or processing system

Note:
With power supply units with integrated HART resistance (internal
resistance approx. 250 Ω), an additional external resistance is not
necessary. This applies, e. g. to the VEGA instruments VEGATRENN
149A, VEGADIS 371, VEGAMET 381. Common Ex separators are
also usually equipped with a sufficient current limitation resistance.
In such cases, VEGACONNECT 4 can be connected parallel to the
4 … 20 mA cable.

7.2 Parameter adjustment with PACTware

Prerequisites For parameter adjustment of the instrument via a Windows PC, the
configuration software PACTware and a suitable instrument driver
(DTM) according to FDT standard are required. The latest PACTware
version as well as all available DTMs are compiled in a DTM Collec-
tion. The DTMs can also be integrated into other frame applications
according to FDT standard.
Note:
30033-EN-160331

To ensure that all instrument functions are supported, you should

always use the latest DTM Collection. Furthermore, not all described
functions are included in older firmware versions. You can download
the latest instrument software from our homepage. A description of
the update procedure is also available in the Internet.

40 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 7 Set up with PACTware and other adjustment programs

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.

Fig. 25: Example of a DTM view

Standard/Full version All device DTMs are available as a free-of-charge standard version
and as a full version that must be purchased. In the standard version,
all functions for complete setup are already included. An assistant for
simple project configuration simplifies the adjustment considerably.
Saving/printing the project as well as import/export functions are also
part of the standard version.
In the full version there is also an extended print function for complete
project documentation as well as a save function for measured value
and echo curves. In addition, there is a tank calculation program as
well as a multiviewer for display and analysis of the saved measured
value and echo curves.
The standard version is available as a download under
www.vega.com/downloads. The full version is available on CD from
the agency serving you.

7.3 Parameter adjustment with AMS™ and PDM

For VEGA sensors, instrument descriptions for the adjustment
programs AMS™ and PDM are available as DD or EDD. The instru-
ment descriptions are already implemented in the current versions of
AMS™ and PDM.
30033-EN-160331

For older versions of AMS™ and PDM, a free-of-charge download is

available via Internet. Move to www.vega.com.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 41

7 Set up with PACTware and other adjustment programs

7.4 Saving the parameter adjustment data

It is recommended to document or save the parameter adjustment
data. That way they are available for multiple use or service purposes.
The VEGA DTM Collection and PACTware in the licensed, profession-
al version provide suitable tools for systematic project documentation
and storage.

30033-EN-160331

42 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 8 Maintenance and fault rectification

8 Maintenance and fault rectification

8.1 Maintenance
If the instrument is used properly, no special maintenance is required
in normal operation.

8.2 Rectify faults

Reaction when malfunc- The operator of the system is responsible for taking suitable meas-
tion occurs ures to rectify faults.

Causes of malfunction VEGACAL 65 offers maximum reliability. Nevertheless, faults can oc-
cur during operation. These may be caused by the following, e.g.:
• Sensor
• Process
• Voltage supply
• Signal processing

Fault rectification 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.

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 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 Connect a multimeter in the suitable measuring range according to

signal the wiring plan.
Error Cause Rectification
4 … 20 mA signal Level fluctuations Set damping via the display and ad-
not stable justment module
4 … 20 mA signal Wrong connection Check connection according to
missing chapter "Connection steps" and if
necessary, correct according to chap-
ter "Wiring plan"
No power supply Check cables for breaks; repair if nec-
essary
Operating voltage Check, adapt if necessary
too low or load re-
sistance too high
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 43

8 Maintenance and fault rectification

Error Cause Rectification

Current sig- Shortcircuit in the Remove the electronics module.
nal greater than probe, e.g. be- Check the resistance between the
22 mA or less cause of moisture marked plug connections. See the fol-
than 3.6 mA in the housing lowing instructions.
Electronics mod- Exchange the instrument or send it in
ule defective for repair

Check the resistance in Remove the electronics module. Check the resistance between the
the probe 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.
30033-EN-160331

44 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 8 Maintenance and fault rectification

Error messages via the

display and adjustment
Error Cause Rectification
module
E013 no measured val- –– Short-circuit due to bridging by con-
ue available ductive buildup between process
fitting and electrode
–– Remove buildup - if necessary,
mount a protective tube
Shortcircuit in the –– Remove the electronics module out
probe, e.g. be- of the probe and check the resistor
cause of moisture between the two marked plug con-
in the housing nections 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
E017 Adjustment span Carry out a fresh adjustment and in-
too small crease the distance between min. and
max. adjustment
E036 no operable sen- Carry out a software update or send
sor software instrument for repair

8.3 Exchanging the electronics module

If the electronics module is defective, it can be replaced by the user.
In Ex applications, only instruments and electronics modules with ap-
propriate Ex approval may be used.
If there is no electronics module available on site, one can be ordered
from the VEGA agency serving you.

Sensor serial number 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 num-
bers are stated on the type label of the instrument or on the delivery
note.
Information:
When loading on site, first of all the order data must be downloaded
from the Internet (see operating instructions manual "Electronics
module").
30033-EN-160331

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 suit-
able electronics module in the following overview.
The oscillators differ only in their signal output and are suitable for all
series 60 sensors.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 45

8 Maintenance and fault rectification

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 ap-
proval may be used.

8.4 Shortening the electrode

Shortening the electrode The probe (cable) can be shortened by any length.
1. Loosen the two pins on the gravity weight (hexagon) and remove
the pins.
2. Pull the cable out of the gravity weight.
3. To avoid splicing of the steel cable, tin the cable before shortening
with a soldering iron and tighten the wire.
4. Shorten the cable with a cut-off wheel or metal saw at the lower
end. Make sure the length is correct before shortening.
70 mm
(2.76")
200 mm (7.87")

Fig. 27: Take the gravity weight into account and shorten the cable respectively

5. Shift the gravity weight again flush to the cable and fix it with the
two pins.
6. Carry out an adjustment. See "Setup procedure, carry out min.
adjustment - carry out max. adjustment".

8.5 How to proceed if a repair is necessary

You can find an instrument return form as well as detailed infor-
mation of the procedure in the download area on our homepage:
30033-EN-160331

www.vega.com.
By doing this you help us carry out the repair quickly and without hav-
ing to call back for needed information.
If a repair is necessary, please proceed as follows:

46 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 8 Maintenance and fault rectification

• 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.
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 47

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, cor-
rosive 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 spe-
cialised recycling companies. We use recyclable materials and have
designed the parts 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 spe-
cialised 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 environ-
ment 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.

30033-EN-160331

48 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

10 Supplement
10.1 Technical data
General data
Material 316L corresponds to 1.4404 or 1.4435
Materials, wetted parts
ƲƲ Process fitting - thread 316L
ƲƲ Process fitting - flange 316L
ƲƲ Process seal Klingersil C-4400
ƲƲ insulation (partly insulated) PA, PTFE
ƲƲ Probe (cable partly PTFE insulated: 316L
ø 6 mm/0.236 in)
ƲƲ Probe (cable PTFE partly insulated: Steel
ø 8 mm/0.315 in)
ƲƲ Gravity weight 316L+PEEK
Materials, non-wetted parts
ƲƲ Plastic housing plastic PBT (Polyester)
ƲƲ Aluminium die-casting housing Aluminium die-casting AlSi10Mg, powder-coated - basis:
Polyester
ƲƲ Stainless steel housing - precision 316L
casting
ƲƲ Stainless steel housing, electropol- 316L
ished
ƲƲ Seal between housing and housing lid NBR (stainless steel housing, precision casting), silicone
(aluminium/plastic housing; stainless steel housing,
electropolished)
ƲƲ Ground terminal 316L
ƲƲ Cable gland PA, stainless steel, brass
ƲƲ Sealing, cable gland NBR
ƲƲ Blind plug, cable gland PA
Process fittings
ƲƲ Pipe thread, cylindrical (DIN 3852-A) G1, G1½
ƲƲ American pipe thread, conical 1 NPT, 1½ NPT
(ASME B1.20.1)
ƲƲ Flanges DIN from DN 50, ASME from 2"
Weight
ƲƲ Instrument weight (depending on 0.8 … 4 kg (0.18 … 8.82 lbs)
process fitting)
ƲƲ Gravity weight 900 g (32 oz)
30033-EN-160331

ƲƲ Cable weight: ø 6 mm (0.236 in) 180 g/m (1.9 oz/ft)

ƲƲ Cable weight: ø 8 mm (0.315 in) 220 g/m (2.4 oz/ft)
Sensor length (L) 0.2 … 32 m (0.656 … 105 ft)
Length screening tube (L) 0.07 … 4 m (0.23 … 13.12 ft)

VEGACAL 65 • 4 … 20 mA/HART - two-wire 49

10 Supplement

Max. tensile load (cable)

ƲƲ PTFE partly insulated: ø 6 mm 10 KN (2248 lbf)
(0.236 in)
ƲƲ PTFE partly insulated: ø 8 mm 10 KN (2248 lbf)
(0.315 in)
Max. torque (process fitting - thread) 100 Nm (73 lbf ft)
Torque for NPT cable glands and Conduit tubes
ƲƲ Plastic housing max. 10 Nm (7.376 lbf ft)
ƲƲ Aluminium/Stainless steel housing max. 50 Nm (36.88 lbf ft)

Output variable
Output signal 4 … 20 mA/HART
HART output values
ƲƲ HART value (Primary Value) Capacitance
ƲƲ HART value (Secondary Value) Capacitance - scaled
Resolution 1.6 µA
Failure signal current output (adjustable) mA value unchanged 20.5 mA, 22 mA, < 3.6 mA (adjust-
able)
Current limitation 22 mA
Load see load diagram under Power supply
Damping (63 % of the input variable) 0 … 999 s, adjustable
Rise time 500 ms (ti: 0 s, 0 … 100 %)
Met NAMUR recommendation NE 43

Input variable
Measured variable level of non-conductive liquids and solids
Measuring principle phase-selective admittance processing (PSA)
Measuring range 0 … 3000 pF
Measuring frequency 270 kHz

Accuracy (according to DIN EN 60770-1)

Reference conditions according to DIN EN 61298-1
ƲƲ Temperature +18 … +30 °C (+64 … +86 °F)
ƲƲ Relative humidity 45 … 75 %
ƲƲ Air pressure 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig)
Temperature error
ƲƲ < 120 pF < 1 pF
ƲƲ > 120 pF 1 % of the current measured value
Linearity error < 0.25 % of the complete measuring range
30033-EN-160331

Ambient conditions
Ambient, storage and transport tempera- -40 … +80 °C (-40 … +176 °F)
ture

50 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

Process conditions
Process pressure
ƲƲ Standard -1 … +64 bar/-100 … 6400 kPa (-14.5 … 928 psig)
ƲƲ with screening tube adapter (PN1) 0 … +1 bar/0 … 100 kPa (0 … 14.5 psig)
Process temperature (thread or flange temperature)
ƲƲ VEGACAL 65 of 316L with cable PT- -50 … +150 °C (-58 … +302 °F)
FE partly insulated ø 6 mm (0.236 in)
ƲƲ with temperature adapter [option -50 … +200 °C (-58 … +392 °F)
with cable PTFE insulated ø 6 mm
(0.236 in)]

2
3
80°C
(176°F)

40°C
(104°F)

0°C
1
(32°F)
-50°C 50°C 100°C 150°C 200°C
(-58°F) (122°F) (212°F) (302°F) (392°F)
-40°C
(-40°F)

Fig. 28: Ambient temperature - Process temperature

1 Process temperature
2 Ambient temperature
3 Temperature range with temperature adapter

Dielectric constant ≥ 1.5

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

Cable entry/plug5)
ƲƲ Single chamber housing –– 1 x cable gland M20 x 1.5 (cable: ø 5 … 9 mm), 1 x
blind plug M20 x 1.5
or:
–– 1 x closing cap M20 x 1.5; 1 x blind plug M20 x 1.5
or:
–– 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
30033-EN-160331

5)
Depending on the version M12 x 1, according to DIN 43650, Harting, 7/8" FF.

VEGACAL 65 • 4 … 20 mA/HART - two-wire 51

10 Supplement

ƲƲ Double chamber housing –– 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
optionally available with 1 x plug M12 x 1 for external
display and adjustment unit
or:
–– 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 exter-
nal display and adjustment unit
or:
–– 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 avail-
able with 1 x plug M12 x 1 for external display and
adjustment unit
Spring-loaded terminals for wire cross- < 2.5 mm² (AWG 14)
section

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

Cable entry
ƲƲ Single chamber housing 1 x IP 68 cable gland M20 x 1.5; 1 x blind plug M20 x 1.5
ƲƲ Double chamber housing 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
ƲƲ Wire cross-section 0.5 mm² (AWG 20)
ƲƲ Wire resistance < 0.036 Ω/m (0.011 Ω/ft)
ƲƲ Tensile strength < 1200 N (270 lbf)
ƲƲ Standard length 5 m (16.4 ft)
ƲƲ Max. length 1000 m (3280 ft)
ƲƲ Min. bending radius 25 mm (0.984 in) with 25 °C (77 °F)
ƲƲ Diameter approx. 8 mm (0.315 in)
ƲƲ Colour - standard PE Black
ƲƲ Colour - standard PUR Blue
ƲƲ Colour - Ex-version Blue

Display and adjustment module

Voltage supply and data transmission through the sensor
Indication LC display in dot matrix
Adjustment elements 4 keys
Protection rating
ƲƲ unassembled IP 20
ƲƲ mounted into the sensor without cover IP 40
30033-EN-160331

Material
ƲƲ Housing ABS
ƲƲ Inspection window Polyester foil

52 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

Voltage supply
Operating voltage 12 … 36 V DC

Ω
1000

750

3
500
2
1
250

4
12 14 16 18 20 22 24 26 28 30 32 34 36 V
Fig. 29: Voltage diagram
1 HART load
2 Voltage limit Ex-ia instrument
3 Voltage limit non-Ex/Ex-d instrument
4 Operating voltage

Operating voltage with illuminated dis- 20 … 36 V DC

play and adjustment module
Permissible residual ripple
ƲƲ < 100 Hz Uss < 1 V
ƲƲ 100 Hz … 10 kHz Uss < 10 mV
Load see diagram

Electrical protective measures

Protection rating

Housing material Version IP-protection class NEMA protection

Plastic Single chamber IP 66/IP 67 NEMA 4X
Double chamber IP 66/IP 67 NEMA 4X
Aluminium Single chamber IP 66/IP 68 (0.2 bar) NEMA 6P
IP 68 (1 bar) NEMA 6P
Double chamber IP 66/IP 67 NEMA 4X
IP 66/IP 68 (0.2 bar) NEMA 6P
IP 68 (1 bar) NEMA 6P
Stainless steel, electro- Single chamber IP 66/IP 68 (0.2 bar) NEMA 6P
polished
Stainless steel, precision Single chamber IP 66/IP 68 (0.2 bar) NEMA 6P
casting IP 68 (1 bar) NEMA 6P
Double chamber IP 66/IP 67 NEMA 4X
30033-EN-160331

IP 66/IP 68 (0.2 bar) NEMA 6P

IP 68 (1 bar) NEMA 6P

VEGACAL 65 • 4 … 20 mA/HART - two-wire 53

10 Supplement

Overvoltage category The feeding power supply unit can be connected to

networks of overvoltage category III.
Protection class II (IEC 61010-1)

Functional safety (SIL)

Functional safety is already activated on instruments with SIL qualification ex factory. On instru-
ments 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

ƲƲ Single channel architecture (1oo1D) up to SIL2
ƲƲ double channel diversitary redundant up to SIL3
architecture (1oo2D)
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, "VEGA Tools"
and "Instrument search" as well as in the general download area.

30033-EN-160331

54 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

10.2 Dimensions
Housing in protection IP 66/IP 68 (0.2 bar)
~ 87 mm (3.43")
~ 69 mm
~ 116 mm (4.57") ø 84 mm
(2.72") ø 77 mm
ø 84 mm (3.31") (3.31")
(3.03")
M16x1,5

116 mm (4.57")
112 mm (4 13/32")

120 mm (4.72")
M20x1,5/ M20x1,5/ M20x1,5
½ NPT ½ NPT
M20x1,5/
1 2 ½ NPT 3

~ 59 mm ~ 69 mm ~ 87 mm (3.43")
(2.32") (2.72") ø 84 mm
ø 80 mm ø 77 mm
(3.15") (3.03") (3.31")

M16x1,5
117 mm (4.61")

120 mm (4.72")
112 mm (4.41")

M20x1,5/ M20x1,5/
½ NPT ½ NPT
M20x1,5/
4 5 ½ NPT 6

Fig. 30: 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 housing (IP 66/IP 67)
2 Aluminium housing
3 Aluminium double chamber housing
4 Stainless steel housing, electropolished
5 Stainless steel housing - precision casting
6 Stainless steel double chamber housing - precision casting
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 55

10 Supplement

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

~ 103 mm ~ 105 mm (4.13")
~ 150 mm (5.91") (4.06") ø 84 mm
ø 77 mm
ø 84 mm (3.31") (3.03") (3.31")

M16x1,5

116 mm (4.57")

117 mm (4.61")

120 mm (4.72")
M20x1,5 M20x1,5 M20x1,5

M20x1,5/
1 2 ½ NPT 3

Fig. 31: 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 housing
2 Stainless steel housing - precision casting
2 Stainless steel double chamber housing - precision casting

30033-EN-160331

56 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

56 mm
(2.21")
G1

22 mm
(0.87")
G 1½
142 mm
(5.59")

ø 6 mm
L

(0.24")
200 mm
(7.87")

ø 30 mm
(1.18")

Fig. 32: VEGACAL 65, cable version with ø 6 mm (0.236 in), threaded version G1 (ISO 228 T1)
L = Sensor length, see chapter "Technical data"
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 57

10 Supplement

56 mm
(2.21")
G1

22 mm
(0.87")
G 1½
142 mm
(5.59")

ø 8 mm
L

(0.32")
200 mm
(7.87")

ø 30 mm
(1.18")

Fig. 33: VEGACAL 65, cable version with ø 8 mm (0.315 in), threaded version G1 (ISO 228 T1)
L = Sensor length, see chapter "Technical data"
30033-EN-160331

58 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 10 Supplement

108 mm (4.25")
ø 40 mm (1.58")

Fig. 34: Temperature adapter

L

(0.28")
7 mm

ø 16 mm
(0.63")
ø 27 mm
(1.06")

Fig. 35: VEGACAL 65, screening tube, for example against strong condensation
L Length of the screening tube, see chapter "Technical data"
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 59

10 Supplement

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 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.
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.

30033-EN-160331

60 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 Notes
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 61

Notes

30033-EN-160331

62 VEGACAL 65 • 4 … 20 mA/HART - two-wire

 Notes
30033-EN-160331

VEGACAL 65 • 4 … 20 mA/HART - two-wire 63

 Printing date:

30033-EN-160331

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: [email protected]
Germany www.vega.com