METAL WORK FLUX 1 and 2 Analogue Digital Flowmeter and Pressure Sensor User Manual

FLUX 1 – 2 Analogue
DIGITAL FLOWMETER AND PRESSURE SENSOR
USER MANUAL

FLUX Analogue is a control unit for measuring all significant data of the gas concerned.

FLUX 1 and 2 Analogue Digital Flowmeter and Pressure Sensor

INTENDED USE
WARNING
The FLUX Analogue 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 electrical and electronic equipment.

TECHNICAL DATA

• Electrical connection: M12 5-pin connector.
• 12…24 VDC power supply.
• Maximum flowrate measured 2000 Nl/min for FLUX 1 version, 4000 Nl/min for FLUX 2 version.
• Maximum pressure 10 bar.
• Zero internal pressure drop.
• IP65 index of protection.
• Signaling LED.
• Settable analogue output 0/10 VDC, 0/5VDC, 4/20 mA, for flow or pressure.
• Digital output with settable functions.
• Graphic display and keypad for displaying measured values, with units of measurement and parameter setting.

HAZARDS

• Do not use with flammable gases.
• Do not use in an explosive atmosphere.

WARNING

• CANNOT be used as a normal counter available from the trade.
  It has not been designed and approved for use as a legal metrology instrument.

• DO NOT use gases other than those specified; measurement accuracy is not guaranteed and the device may get damaged.

• Do not use it outside the stated specifications.

• The compressed air from the compressor contains impurities (water, oil, dirt or other residues), which may affect accuracy or damage the sensor. Make sure that the air  supplied to the FLUX is properly filtered and has a minimum purity level of 4.7.3, in accordance with ISO 8573-1.

• Do not use with lubricated air.

• Do not insert foreign objects into the connection ports.

INSTALLATION

1.1 PNEUMATIC CONNECTION
Pneumatic connection is via the threaded holes in the body.

• Install the device following the arrow indicating the direction of the air flow.
• To connect the inlet side, use a straight pipe* at least 150 mm-long for FLUX 1 and at least 200 mm-long for FLUX 2.
  If straight piping is not installed, the accuracy may vary from what is stated.
• Straight pipe: the pipe must be straight with a constant cross-section.

• Clean the pipes before installation, uncleaned air may cause malfunctions or damages to the product.
• Make sure that the sealant does not get inside the pipe. Solid or liquid residues could damage the sensor.

When air flow needs to be regulated with a control valve; install the device upstream of the valve.
Otherwise, grease or lubricating oil from the valve could damage the sensor.

• The device can be installed in any direction.

1.2 INTEGRATION WITH COMPONENTS IN THE Syntesi® PRODUCT RANGE
FLUX can be supplemented with Syntesi® component parts:

• FLUX 1 with Syntesi® size 1;
• FLUX 2 with Syntesi® size 2.
  In order to guarantee the stated measurement accuracy and to prevent lubricant residues from damaging the measurement sensor, a filter has to be mounted at the FLUX inlet.
  If the device is fitted with a Syntesi® filter, the SYN filter parameter must be enabled in the system menu to guarantee the stated accuracy (function available only for the version with display).

N.B.: If the FLUX is used downstream a Syntesi® filter, fit it in one of the three positions shown in the figure.

1.3 ELECTRICAL CONNECTION
A 5-pin M12 Code A connector is used for the electrical connection
M12 male connector, A encoding

WARNING
Switch off the mains supply before plugging or unplugging the connector (functional damage hazard).
WARNING
Keep the connecting cable separate from the power cables. The device may not work properly due to electromagnetic interference, strong currents or high voltage.

OPERATING DATA DISPLAY (ONLY FOR MODELS WITH DISPLAY)

Function icons are shown at the top of the display.

Press the two keys indicated by the icon . simultaneously for 1 second to rotate the scree
The arrow keys automatically adapt to the rotation of the screen.
Use the vertical arrow keys to scroll through the display pages.

• page 1: displays the current flow rate.
• page 2: displays the current flow rate and pressure if a pressure sensor is connected, or the current power consumption.
• page 3: displays the current flow rate and power consumption if a pressure sensor is connected.
• page 4: displays the current flow rate and gas mass.
• page 5: displays the current flow rate and air temperature.
• page 6: displays all the current data.
• page 7: displays accumulated consumption.
• page 8: displays the flow rate chart.
• page 9: displays the flow rate and pressure chart, if a pressure sensor is connected.
  Display time can be set to 4 min, 1 hour, 8 hours, 24 hours.

MENU ACCESS (ONLY FOR MODELS WITH DISPLAY)

Parameter setting Press the SET UP buttons simultaneously for 1 second to access the parameter settings.
Use the vertical arrow keys to select the function.
Press the right arrow key to access the function parameters.

Use the vertical arrow keys to change the parameter.
Press the right arrow to confirm.
Press the left arrow to return to the previous menu.

3.1 SYSTEM
The compressed air system is connected through the threaded holes on the body.
In order to prevent impurities or excessive condensation from causing malfunctions, it is recommended to supply the FLUX with dry 20μm-filtered compressed air at a  pressure not exceeding 10 bar.
3.1.1 SYN filter
Set to ON when the FLUX is installed after a Syntesi unit filter to optimise flow rate reading.
3.1.2 Gas type
Helps optimise the measurement of the current flow and consumption figures.
Types of gas: Air
Helium
CO2
Nitrogen

3.1.3 K ENERGY
K-Energy is the amount of Wh consumed to generate 1 Nm³ of compressed air, depending on the efficiency of the production system.
Used to calculate the current power (kW) and accumulated energy (kWh) consumption.
3.2 I/O
3.2.1 Digital input
Version with display
The digital input can be set either as PNP or NPN. When activated for 1 second, it resets the stored consumption values.
Version without display
The digital input is used to select the type of analogue output.
3.2.2 Digital Output – available for models with display
The digital output can be set as a “Normally Open” or “Normally Closed” contact.
It can relate to current flow, pressure or air consumption.

3.2.1.1 Parameters

• Contact type: NO/NC
• Reference:
  – FLOW:
  Threshold Setting: the output switches according to flow values.
  function – LEVEL SWITCH, BAND SWITCH;
  OUT SET/HI – Flow value for output activation;
  OUT RST/LO – Flow value for output de-activation.

PRESSURE:
Threshold Setting: the output switches according to pressure values.
function – LEVEL SWITCH, BAND SWITCH;
OUT SET/HI – Pressure value for output activation;
OUT RST/LO – Pressure value for output de-activation.

VOLUME CONSUMPTION: Function – CONTACT SWITCH, the output switches at the value set under CNT Target;
Function – CYCLIC PULSE, the output switches for 100 ms each time the value set in CNT
Target is reached. The minimum flow rate can be set to 10 Nl for FLUX 1 and 20 Nl for FLUX 2.

FLOW/PRESSURE
DIGITAL OUT MODE NORMALLY OPEN – NO
Level switch mode with hysteresis

DIGITAL OUT MODE NORMALLY CLOSED – NC
VOLUME CONSUMPTION
DIGITAL OUT MODE NORMALLY OPEN – NO
Volume consumption mode

DIGITAL OUT MODE NORMALLY CLOSED – NC
Volume consumption mode

CYCLIC PULSE OUTPUT MODE

3.2.3 Analogue output
Signal: 0/10 V; 0/5 V; 4/20 mA
In the version without display, it is possible to select the type of analogue output 0/10 V or 4/20 mA via the digital input.
Input OFF = analogue out 0/10 V
Input ON = analogue out 4/20 mA
Reference

• Flow rate: the output value refers to the measured flow rate (default setting for models without display).
• Pressure: the output value refers to the measured pressure (for units with a pressure sensor).

3.3. DISPLAY
Is possible to rotate the display by 90°, 180° or 270° to adapt it to the mounting position, by pressing the two keys indicated by the icon for 1 second.

3.3.1 PARAMETERS

• Language: Italiano, English, Deutsch, Français, Español.
• Flow rate unit of measurement: Nl/min, Nl/h, Nm 3/min, Nm 3/h, Nft3 /min, Nft 3/h.
• Pressure unit of measurement: bar, MPa, psi.

Setting the flow rate value display for colour change from orange to yellow.
Can be used to highlight abnormal air consumption.

• SET FL COL. – flow rate value at which the colour changes to yellow.
• RES FL COL. – flow rate value at which the colour reverts to orange.

3.4 SERVICE

• Consumption reset: accumulated consumption is reset.
• Sensor check: with flow rate and pressure at zero, it verifies that the measuring sensor is not faulty.
• Internal temperature: displays the temperature of control electronics.
• Factory reset: resets the factory configuration.

3.5 INFO

• S/N: serial number.
• Software version.
• Diameter: internal passage diameter.
• Pressure: pressure transducer availability.
• Model: type and options available.

MENU ACCESS FROM KEYPAD (ONLY FOR MODELS WITH DISPLAY)

• Press the and buttons simultaneously for 1 second to access the parameter setting menu.
• Use the arrow keys  to scroll through the menu and edit the parameters.
• Press OK to confirm.

THRESHOLD
– FLOW
– PRESSURE

THRESHOLD
– VOLUME CONSUMPTION

DIAGNOSTICS AND TROUBLESHOOTING

MODELS WITH DISPLAY
The display shows the icon and description of the current alarm. The type of alarm is also indicated by the STATE LED AND DIAG status.

| LED STATE| MEANING
---|---|---
| OFF| No power supply, device off
| ON (green)| Operating status (on, voltage within range).
| Flashing (green)| Device malfunction (power supply out of range, flow and/or pressure signal out of range or disconnected, …) 200 ms ON ls OFF.
| LED DIAG| MEANING
| OFF| Digital OUT OFF.
| ON (green)| Digital OUT ON.
| Pulsating flashing (green)| Digital OUT – Consumption counter pulse.
| Flashing (red)| Malfunction due to analogue output 0/10 VDC short-circuited – 4/20 mA open circuit.
Digital output overload or short circuit
| ON (red)| Flow or pressure sensor failure.
| Flashing (green / red)| Alternating flashing — hardware error.

MODELS WITHOUT DISPLAY
The type of alarm is indicated by the LED STATE and DIAG status.

DIGITAL OUTPUT

| FLUX 1 ! FLUX 2
---|---
DIGITAL OUTPUT| n° 1 open collector output NC / NO – PNP / NPN
Maximum current| 100 mA
Residual voltage| 20 mV (with load)
Operating mode, if set on flow rate| Level switch, Band switch, Value switch, Cyclic pulse
Min. accumulated volume by pulse (pulse width 100 msec)| 10/20
| 1
| 1
Response mode, with pressure mode setting| Level switch, Band switch
Hysteresis| Adjustable
Short-circuit protection at output| Yes
DIGITAL INPUT ◆| n° 1 input for the reset of the consumption counters NO – PNP/NPN
Type of input| Voltage 12 -10%    24 +30%
Activation time| min 1 sec

▲ IMPORTANT! Voltage greater than 32VDC will damage the system irreparably.
■ In versions with pressure transducer.
● At a pressure of 5 bar and a fluid temperature of 25°C ±10°C.
◆ Version without display: the digital input selects the type of analogue output from 0 to 10 V and 4 to 20 mA.

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