METAL WORK PNEUMATIC REGTRONIC IO-Link Single Stage Pressure Regulator User Manual

PNEUMATIC REGTRONIC IO-Link Single Stage Pressure Regulator
User Manual REGTRONIC IO-Link USER MANUAL

REGTRONIC IO-Link Single Stage Pressure Regulator

INTENDED USE
IO-Link Regtronic is an electronic pressure regulator complying with IO-Link communication standard. It offers advanced diagnostic functions and can be linked to an IO-Link Master module.
It supports COM3 communication, according to V1.1 specification and Class A Port connection.
WARNING
The Regtronic IO-Link must only be used as follows:

• as designated in industrial applications;
• in systems fully assembled and in perfect working order;
• in compliance with the maximum values specified for electrical ratings, pressures and temperatures.
• Only use power supply complying with IEC 742/EN60742/VDE0551 with at least 4kV insulation resistance (PELV).

TARGET GROUP
This manual is intended exclusively for technicians qualified in control and automation technology, who have acquired experience in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and Fieldbus systems.

FEATURES

• Electrical connection: M12 5-pin connector.
• Preset pressure range 0.05-10 bar with possible full scale and minimum pressure regulation.
• 10-300 mbar adjustable deadland.
• Supply pressure: FS+ at least 1 bar, max 11 bar.
• 24 VDC power supply.
• IP65 index of protection.
• LED indicating pressure achieved and IO-Link diagnostics.
• Graphical display and keypad to display the pressure, unit of measurement and parameter setting.

INSTALLATION / OPERATION

Before carrying out any installation or maintenance work, switch off the following:

• compressed air supply;
• the operating power supply to control electronics.

2.1 PNEUMATIC CONNECTION
Pneumatic connection is via the threaded holes in the body.
It is important for the regulator pressure not to exceed 11 bar and the compressed air to be filtered at 10 μm and dried, to prevent impurities or excessive condensate from causing a malfunction.
The supply pressure must always be higher than the preset pressure.
The regulator pressure must be at least 1 bar higher than the full scale value.
If a silencer is mounted on the outlet, the flow rates and response times may vary. Check the silencer periodically for clogging and replace if necessary.
2.2 OPERATING PRINCIPLE
Using a software algorithm, the control circuit compares the input signal with the output pressure measured by the pressure sensor.
When there is a change, it activates the inlet and outlet solenoid valves to re-establish an equilibrium.
This gives an output pressure that is proportional to the input signal.
N.B.: removing the power supply, the outlet pressure doesn’t get discharged.

2.2.1 FUNCTION DIAGRAM

2.3 ELECTRICAL CONNECTION AND DISPLAY ELEMENTS
Connection to the IO-Link network

2.4 ELECTRICAL CONNECTIONS: PIN-OUT OF M12 5-PIN CONNECTOR, code A
The Jetronic is powered and controlled via an M12 5-pin code A connector, which must be properly connected to an IO-Link Master. It is powered directly by the Master.

PIN| Signal| Description of Class A Port| Lead color
---|---|---|---
1| L+| +24VDC Power supply| Brown
2| NC| /| White
3| L –| 0V Power supply| Blue
4| C/Q| IO-Link communication| Black
5| NC| /| Gray

WARNING
Power off the system before plugging or unplugging the connector (risk of functional damage).

COMMISSIONING

3.1 CONNECTIONS TO THE IO-Link REGTRONIC
Connect the M12 connector to the IO-Link master module.
3.2 INSTALLING THE IO-Link REGTRONIC IN AN IO-Link NETWORK
3.2.1 IODD configuration file
The IO-Link Jetronic is supplied complete with the related IODD configuration file Metal Work-REGTRONIC- IODD1.1, available by logging on to on Metal Work website.
3.3 ADDRESSING
IO-Link Jetronic provides:

• 2 output bytes for pressure control;
• 2 input bytes for regulated pressure reading.

SETTING

NB: parameter changes can also be effected through the IO-Link master
In the version with the display, Press OK and ESC together to access the setting menu.
Select the parameter using the arrow keys.
Press ESC to return to the previous page.

During setting, pressure regulation is NOT active.

4.1 DISPLAY
4.1.1 LANGUAGE
English

• Select LANGUAGE using the arrow keys, then press OK.
• Select the desired language using the arrow keys, then press OK.

4.1.2 UNIT OF MEAS
bar
psi
MPa

• Select UNIT OF MEAS. using the arrow keys, then press OK.
• Select the desired unit of measurement using the arrow keys, then press OK.

N.B.: Pressure settings, like pressure regulated, dead band, full scale and minimum pressure, when set by the Master IO-Link, are always defined in mbar.

4.1.3 CONTRAST

• Manual display contrast adjustment.
• Select CONTRAST using the arrow keys, then press OK.
• Select the value using the arrow keys, then press OK.
• Compensation as a function of temperature is automatic.

4.1.4 ORIENTATION
Allows you to rotate the display 180 °

• Select ORIENTAT.
• Press OK to rotate the display

4.2 SET UP
4.2.1 INPUT
IO-Link
Keypad

• Select INPUT using the arrow keys, then press OK.
• Select the type of input using the arrow keys and then press OK.
• For the type of keypad input, set the pressure value using the arrow keys. When you press the display buttons, the set pressure appears; when you release them, the preset pressure is displayed.

4.2.2 DEAD BAND
This indicates the pressure range in proximity to the set pressure, within which regulation is active. The deadland is + and – the set value.
It is advisable to enter low values, 10 or 15 mbar, only if high regulation accuracy is required. High accuracy involves more work for the solenoid valves.

• Select DEADB using the arrow keys, then press OK.
• Enter the value using the arrow keys, then press OK.

4.2.3 FULL SCALE
This indicates the maximum preset pressure. The analog command is divided over the Full Scale. The analog output signal indicates that the preset pressure is 0-10 VDC for 0-10 bar.
Examples with maximum preset pressure 3, 5 and 10 bar

For optimal regulation, the feed pressure must be FS + 1 bar.

4.2.4 MINIMUM PRESSURE
Indicates the minimum regulated pressure with set 0V (4 mA). The value can be set between 0 and 50% of the Full Scale set. The reference set is divided between the Minimum Pressure value and the Full Scale value.

The minimum value which can be set with Keyboard Set is the Minimum Pressure value.

4.2.5 SPEED REGULATION CONTROL
Can be used to change the regulator response speed

4.2.6 ZERO SETTING (TEMPERATURE COMPENSATION)
The instrument is calibrated at an ambient temperature of 20°C. The pressure value measured by the internal transducer can vary with the ambient temperature and it may be necessary to reset the reading.
The value read can be reset through the reset function.
The function is only active if the pressure displayed is less than 150 mbar.
Upon zero resetting, the temperature compensation activates and the consequent change in pressure is automatically compensated.

CAUTION: the resetting has an effect on the calibration of the instrument. Before making it, make sure the supply pressure has been removed and the output circuit is disconnected.

4.3 DEBUG
Utility used for checking correct operation of the two solenoid valves.

• Select DEBUG and press OK.
• Select PIN and press OK. The in solenoid valve activates and the pressure increases.
• Press OK. The in solenoid valve deactivates and pressure stabilizes.
• Select POUT and press OK. The out solenoid valve activates and pressure decreases.
• Press OK, the out solenoid valve deactivates and pressure stabilizes.

4.4 PASSWORD
This is a three-digit code used to protect the set configuration.

• Select SET PASSWORD with the arrow keys and click OK. On the setting page, use the arrow keys to enter the desired value and click OK to confirm. The system then displays the confirmation message “PASSWORD SAVED”.
• Select PASSWORD and click OK to enable/disable the function. If the password set to ON, it prevents access to the configuration menu.
  When you press OK+ESC together to access the configuration menu, you are prompted to enter the password.
  Enter the saved password. You can use the arrow keys to change the value or click OK to change the field.
  If the password is set to OFF, it is not enabled.
  If you forget the password, contact the manufacturer to obtain a password reset code.

ACCESS TO THE MENU

• Press OK to display the set parameters.
• Press OK and ESC together to access the parameter setting menu..
• Use the up and down arrows to scroll through the menu and modify the parameters.

N.B.: * REGULATOR: regulation algorithm optimized for the type of regulator:
0 = Regtronic 1/8 – Regtronic 1/4 – Regtronic New Deal – Regtronic 400
1 = Regtronic 300
2 = Regtronic M5

DIAGNOSTICS

6.1 IO-Link NODE DIAGNOSTIC MODE
The diagnostics of the IO-Link node is determined by the state of the COM.

LED INTERFACE

| LED PRESSURE| SOLUTION
---|---|---

| Flashing| In regulation
****| ON| Regulation OFF

Ο

| OFF| No IO-Link power supply
| |
| LED IO-Link| SOLUTION

| ON| Operating state

| Flashing| Pre-operating state

| ON| IO-Link communication error

| Flashing| IO-Link supply error (under-voltage or overvoltage)

TROUBLESHOOTING

supply, make sure it is enough and check the wiring is in accordance with the wiring diagram
The unit does not respond or responds wrongly to the setpoint| Wrong input signal configuration| Configure the appropriate type of input from the menu
Check the signal wire is connected to the right pin
The unit does not reach the desired pressure| Setpoint too low
The full-scale setting is at a lower pressure than desired
The supply pressure is too low| Provide a suitable setpoint
Set the full scale correctly
Increase the supply pressure
The display shows an unreal value| Wrong unit of measurement| Check the unit of measurement
The display is difficult to read| Poor contrast| Adjust the contrast
The unit adjusts continually| Air leak in the circuit after the unit Continuous variation in  volume  Deadland too small| Eliminate the leak
Normal behavior; the unit has to keep adjusting the maintain the preset pressure
Increase the deadland
Other problems| Contact the manufacturer|

7.1 LIST OF ALLARMS

sufficient voltage.
Supply voltage alarm too low| Supply voltage below 18 V| Switch the unit off and back on again. If the alarm persists, contact the manufacturer.

Alarm P. INP CORTOC. 0V| Supply solenoid valve has short-circuited
Alarm P. OUT CORTOC. 0V| Drain solenoid valve has short-circuited
P. INP alarm DISCONNECTED| Fill solenoid valve disconnected
P. OUT alarm DISCONNECTED| Drain solenoid valve disconnected
PRESSURE OUT OF RANGE ALARM| Downstream pressure exceeds 10200 mbar| Check to see if the drain is blocked. The alarm resets automatically when the pressure drops below the threshold.

INSTALLING THE REGTRONIC IN AN IO-LINK NETWORK

8.1 Example of TIA Portal configuration
The IO-Link Jetronic controls the pressure, using 2 output bytes and 2 input bytes.
S7 PCT configuration
Upload the IODD Jetronic IODD file to the catalogue. Select the 02282REGTRONIC file and install it in the designated port.

Configuration of unit parameters

In addition to the display-configurable parameters, two more parameters are available:
– Target safe condition – sets the status of the regulator in the event of communication failure with the Master (with power supply on).
0 Target = the pressure remains set to the last value
1 Target = the pressure is set to 0.
– Data storage
Changing parameters from the PLC programmed
Use the Siemens Function Block IO_LINK_DEVICE [FB5001] to change the operating parameters from the PLC programmed. Refer to the relevant Siemens manual for correct use.
Set the ‘back-up level’ parameter to OFF to resume the configured data at restart, otherwise the parameters set to “Unit Parameters” will be restored at restart.

Parameter| Index| Sub Index| Data type| Range| Hex format| Default
---|---|---|---|---|---|---
Unit Of Mesa| 73| 0| UINT 8 bit| 0 = bar
1 = MP
2 = psi| 00…02| 0 = bar
Dead Band| 72| 0| UINT 16 bit| 0…300 mbar| 00 00…01 2C| 50 mbar
Full Scale| 68| 0| UINT 16 bit| 100…10000 mbar| 00 64 ….27 10| 10000 mbar
Minimum Pressure| 67| 0| UINT 16 bit| 0..50% FS| 00 00…13 88| 0 mbar
Regulation speed| 74| 0| UINT 8 bit| 0…10| 00….0A| 10
Type of regulator| 71| 0| UINT 8 bit| 0..2| 00…02| /
Target safe condition| 70| 0| UINT 8 bit| 0..1| 00…01| 0

Any unit alarms can be displayed in the same way.

81

| 0| Record 32 bit – 10 fields
Voltage too high| 1| Boolean
Voltage too low| 2| Boolean
Incorrect parameters| 3| Boolean
Incorrect I4.0 parameters| 4| Boolean
Pressure too high| 5| Boolean
Faulty pressure sensor| 6| Boolean
Solenoid pilot P1 short-circuited| 7| Boolean
Solenoid pilot P2 short-circuited| 8| Boolean
Solenoid pilot P1 interrupted| 9| Boolean
Solenoid pilot P2 interrupted| 10| Boolean

8.2 Installation without using the IODD configuration file “MetalWork- REGTRONIC-20190613-IODD1.1”
Some Master modules do not use the IODD file for the configuration of operating parameters.
In this case, the device must be configured manually.
8.3 Example of configuration with a SICK Gateway Profinet/ IO-Link Master
Profinet Device Configuration
Install the Gateway in the Profinet Controller development environment.
Configuring the selected IO-Link port, with 2 byte Input and 2 byte Output (I/O_2/_2byte)
First load the Controller project and connect the Regtronic to the associated IO-Link port.
Parameter Configuration
The parameters of the unit can be configured by accessing the Gateway via a browser, by typing in the IP address in the bar, which can be retrieved in the accompanying documentation together with Login and Password.
Selecting the port to which the Regtronic has been connected will display all the data and parameters stored in the device.

The Process Data area displays the state of Inputs.
The operating parameters can be entered in the Parameter Data area. The parameters must be entered using the specific index indicated on page 11.

TECHNICAL DATA

Threaded port|
---|---
Fluid|
MIN inlet pressure| bar
MAX inlet pressure| bar
Temperature range| °C
Pressure regulation range| bar
Flow rate at 6.3 bar ∆P 0.5| Nl/min
Flow rate at 6.3 bar ∆P 1| Nl/min
Exhaust flow rate at 6.3 bar with 0.1 bar overpressure| Nl/min
Exhaust flow rate at 6.3 bar with 0.5 bar overpressure| Nl/min
Response time with ∆P =1 bar| olume [cc]
from 6 to 7 bar| s
from 7 to 6 bar| s
Weight| kg
Class of protection|
Hysteresis|
Repeatability|
Sensitivity/Dead-band
Output pressure (display version)| Accuracy
| Unit of measurement
| Minimum resolution
Temperature characteristics
Installation position|
Notes|
REGTRONIC| REGTRONIC NEW DEAL| REGTRONIC 300| REGTRONIC 400
---|---|---|---
M5| 1     1/8″| 1/4″| 3/4″| 1″| 1/2″| 3/4″| 1″| 1″ 1   1/4″| 1   1/2″| 2″
Filtered, unlubricated air.
The air must be filtered at least 10 µm and without condensation.
Regulation pressure + 1 bar
11
from 0 to 50
from 0.05 to 10 (settable full scale and minimum pressure)
10| 1300| 1500| 10000| 4500| 18000| 20000
10| 1450| 1700| 13000| 7000| |
2| 600| 1300| 1800| 250| 400| 400
9| 1000| 1500| 2000| 500| 850| 850
| | | | | | | |
100| 100| 1000| 100| 1000| 1000| 1000| 1000| 1000
0.5| 0.1| 0.15| 0.1| 0.15| 0.27| 0.25| 0.2| 0.2
0.55| 0.1| 0.15| 0.1| 0.15| 0.27| 0.33| 0.35| 0.35
0.2| 0.38| 0.38| 1.3| 1.5| 5| 5.8

IP 65
± 0.2% (Full scale)
± 0.2% (Full scale)
setting range 10 to 300 mbar
± 0.3% (Full scale)
bar, MPa, psi
0.01 bar – 0.001 MPa – 0.01 psi
max 2 mbar / °C
In any position

9.1 IO-Link ELECTRICAL CONNECTION

TECHNICAL DATA|
---|---
Fieldbus| IO-Link version 1.1
Communication speed Kbps| 230.4 (COM3)
Vendor ID / Device ID| 1046 (hex 0x0416) / 32 (hex 0x000020)
Minimum cycle time ms| 2.8
Process data length| 2 byte of Input / 2 byte of Output
Supply voltage range                                          VDC| from 18 to 30
Maximum admissible voltage                                   VDC| 32 *
Protection| Module protected from overload and polarity inversion. Outputs protected from overloads and short-circuits.
Connections| Fieldbus: M12 male, A-coded – Port Class A.
Diagnostics| IO-Link: via local LED lights and software messages.
Power supply current absorption| Max 150 mA to 18 V

• IIMPORTANT! Voltage greater than 32VDC will damage the system irreparably.

DIAGNOSTICS I4.0

The new advanced Link Regtronic IO-Link diagnostics, called Regtronic I4.0, provides conventional maintenance with a powerful tool of analysis to ensure reliable, safe and long-lasting operation of the production units.
Maintenance operations are rationalised and optimised through the development of preventive maintenance to:
– prevent breakdowns;
– intervene preventatively to avoid plant shutdowns;
– have all the information relating to operation of equipment in real time;
– monitor the end-of-life of component parts;
– optimize the management of spare parts in the warehouse.
All this makes it possible to convert the data collected into concrete actions, using standard BOXI IO-Link units, without the need for additional modules.

10.1 Description of Regtronic I4.0 functions System data
– unit activation counter;
– total working time;
– voltage too-low alarm counter;
– voltage too-high alarm counter;
– alarm for incorrect parameters;
– pressure sensor faulty.

Solenoid pilot data
The following data is permanently stored for each of the two solenoid pilots:
– cycle counter;
– total solenoid pilot activation time counter;
– activation of a report indicating operating cycle exceeding 60%;
– Short-Circuiting Alarm counter;
– Circuit-Open Alarm counter.
Data in hexadecimal format is available as system variables using the IO-Link tools made available by the manufacturers of Master modules, such as the Siemens Function Block IO_LINK_DEVICE [FB5001]. Refer to the relevant Siemens manual for correct use.

Parameter list

System data

Function| Index| SubIndex| Format
Aggregate data| ****

81

| 0| 12 byte – 6 fields
Number of switches ON| 1| UINT 32 bit
Total operating time (hours)| 2| UINT 32 bit
Number of voltage too-high alarms| 3| UINT 8 bit
Number of voltage too-low alarms| 4| UINT 8 bit
Number of wrong parameter alarms| 5| UINT 8 bit
Number of disconnected pressure sensor alarms| 6| UINT 8 bit
Solenoid pilot data

Function| Index| SubIndex| Data type
P IN Average operating cycle exceeding 60%| ****

66

| 1| UINT 8 bit
P IN Number of short circuit alarms| 2| UINT 8 bit
P IN Number of interrupted circuit alarms| 3| UINT 8 bit
P IN Total number of cycles| 4| UINT 32 bit
P IN Total activation time| 5| UINT 32 bit
P OUT Average operating cycle exceeding 60%| 6| UINT 8 bit
P OUT Number of short circuit alarms| 7| UINT 8 bit
P OUT Number of interrupted circuit alarms| 8| UINT 8 bit
P OUT Total number of cycles| 9| UINT 32 bit
P OUT Total activation time| 10| UINT 32 bit

Example of display in Siemens S7-PCT

NOTES

www.metalwork.eu
M0030212 IT_EN – IM04_11/2022

Documents / Resources

| METAL WORK PNEUMATIC REGTRONIC IO-Link Single Stage Pressure Regulator [pdf] User Manual
REGTRONIC IO-Link, Single Stage Pressure Regulator, Pressure Regulator, Single Stage Regulator, Regulator, REGTRONIC IO-Link Pressure Regulator
---|---

References

• Metal Work S.p.A.

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