METAL WORK IM03 Flux 1-2 IO-Link Digital Flowmeter And Pressure Sensor User Manual

M0030401 IM03 – 11/2022
www.metalwork.eu

FLUX 1 – 2 IO-Link
DIGITAL FLOWMETER AND PRESSURE SENSOR
USER MANUAL

IM03 Flux 1-2 IO-Link Digital Flowmeter And Pressure Sensor

FLUX IO-Link is a control unit for measuring all significant data of the gas concerned.
Compliant with IO-Link specifications, it offers advanced diagnostics and provides connection to an IO-Link Master.
It supports COM3 communication, in accordance with V1.1 specification and Class A Port connection.

INTENDED USE

WARNING
The FLUX 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 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.
• 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).

The Syntesi® components can be easily mounted on the outlet side of the FLUX.

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 and must be connected to an IO-Link Master. Power is supplied directly via the Master.

Connection to the IO-Link network
M12 male connector, A encoding

| Port Class A
1 = L+
2 = NC
3 = L4 =
C/Q 5 =NC
---|---
Pin| Signal| Description of Port Class A| Lead colour
---|---|---|---
1| L+| +24VDC power supply| Brown
2| NC| /| White
3| L –| 0VDC power supply| Blue
4| C/Q| IO-Link communication| Black
5| NC| /| Gray

**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 Nm 3 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 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
Level switch mode with hysteresis

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

DIGITAL OUT MODE NORMALLY CLOSED – NC
Volume consumption mode

CYCLIC PULSE OUTPUT MODE

3.3. 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.
• low rate unit of measurement: Nl/min, Nl/h, Nm 3 /min, Nm 3 /h, Nft 3 /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.

• Password: This is a three-digit code used to protect the set configuration.
  If you forget the password, contact the manufacturer to obtain a password reset code

• Factory reset: resets the factory configuration.

3.5 INFO

• S/N: serial number.
• Software version.
• Diameter: diameter of the internal passage.
• 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.

SOGLIE
– FLUSSO
– PRESSIONE

SOGLIE
– CONSUMO VOLUME

COMMISSIONING

INSTALLING THE FLUX IO-Link in an IO-Link NETWORK

5.1 IODD CONFIGURATION FILE
The corresponding “MetalWork-FLUX- _-IODD1 1” IODD configuration file available on the Metal Work website is supplied with the FLUX IO-Link.

5.2 ADDRESSING
5.2.1 Cyclic data

• 4 input bytes for the measured flow [Nl/h]
• 2 input bytes for measured pressure [mbar]
• 1 input byte for status indication (digital switch)
• 1 input byte for diagnostics.

5.2.2 Acyclic data

Function| Index| Subindex| Description| Data type| Format
---|---|---|---|---|---
Temperature °C| 100| 0| Temperature °C| Read 2 byte| Hex
Flow Nl/min| 101| 0| Flow Nl/min| Read 2 byte| Hex
Flow Nl/h| 102| 0| Flow Nl/h| Read 4 byte| Hex
Flow Nm 3/min| 103| 0| Flow Nm 3/min| Read 4 byte| Hex
Flow Nm 3/h| 104| 0| Flow Nm 3/h| Read 4 byte| Hex
Flow ft 3/min| 105| 0| Flow ft3/min| Read 4 byte| Hex
Flow ft 3/h| 106| 0| Flow ft 3/h| Read 4 byte| Hex
Volume consumption Nl| 107| 0| Volume consumption Nl| Read 4 byte| Hex
Energy consumption kWh| 108| 0| Energy consumption kWh| Read 4 byte| Hex
Mass consumption kg| 109| 0| Mass consumption kg| Read 4 byte| Hex
Mass flow rate gr/min| 110| 0| Mass flow rate gr/min| Read 2 byte| Hex
Power W| 111| 0| Power W| Read 2 byte| Hex
Series FLUX| 112| 0| 1 = FLUX 1 2 = FLUX 2| Read 1 byte| Hex
Display| 113| 0| 0 = Not present 1 = Present| Read 1 byte| Hex
Pressure sensor| 115| 0| 0 = Not present 1 = Present| Read 1 byte| Hex
Alarms| 116| 0| 0 = No alarms 1 = Alarm| Read 1 byte| Hex
Consumption reset| 2| 0| Value = Dec 160 Hex 0xA0| Write 1 byte| Hex

5.2.3 Configuration of parameters from Master IO-Link

1 = Nl_h
2 = Nm 3_min
3 = Nm 3_h
4 = ft 3 /min
5 = ft 3/h| R/W 1 byte
GAS type| 66| 0| 0 = Air
1 = Nitrogen
2 = CO2
3 = Helium| R/W 1 byte
Display – Pressure unit of measurement| 67| 0| 0 = bar
1 = MPa
2 = psi| R/W 1 byte
K-Energy Wh/Nm³| 68| 0| DEC value = 100 hex 00 64| R/W 1 byte
Digital output enable status| 69| 0| 0 = NO
1 = NC| R/W 1 byte
Digital output enable reference| 70| 0| 0 = Flow [Nl/h] 1 = Volume consumption
2 = Pressure [mbar]| R/W 1 byte
Digital output function| 71| 0| 0 = level switch
(reference – flow rate or pressure)
1 = band switch
(reference – flow rate or pressure)
2 = contact switch (reference – volume)
3 = cyclic pulse (reference – volume)| R/W 1 byte
Digital output function – Set/High value Nl/h o mbar| 72| 0| Reference value for digital output
activation| R/W4 byte
Digital output function – Set/Low value Nl/h o mbar| 73| 0| Digital output function Reference value for digital outputde-activation| R/W4 byte
Digital output function – counter Nl| 74| 0| Totalizer value for digital output
activation| R/W4 byte
Display – Language| 75| 0| 0 = ENG
1 = ITA
2 = FRA
3 = ESP
4 = DEU| R/W 1 byte
Display – orientation  °| 76| 0| 0, 90, 180, 270| R/W 2 byte
Display – FLUX ON color Nl/h| 77| 0| Flow rate value at which the colour
changes to yellow| R/W 4 byte
Display – FLUX Off color Nl/h| 78| 0| Flow rate value at which the colour
reverts to orange| R/W 4 byte
Syntesi® filter| 79| 0| 0 = Not present
1 = Present| R/W 1 byte

IO-Link NODE DIAGNOSTIC MODE

| LED STATE| MEANING
---|---|---
| OFF| No power supply, device switched off
| ON (green)| Device powered correctly
| Flashing (green)| Device malfunction.
Power supply out of range, faulty sensor.
| LED DIAG| MEANING
| ON (green)| Operating status
| Flashing (green)| Pre-operating status
| ON (red)| IO-Link communication error
| Flashing (red)| IO-Link power supply error (undervoltage or overvoltage)
| OFF| No IO-Link power supply

DIAGNOSTICS AND TROUBLESHOOTING

The diagnostics functions report the status of the device via error codes in hexadecimal or decimal format in order of priority to the controller. The status byte is read by the controller as an input byte.
The table below describes the correct interpretation of the codes:

the device i
s connected to a proper input.
0xB0| 176| Digital output failure.| Power failure or current too high.
0x16| 22| Flash memory reset or corrupted / E 2
prom reset or corrupted or not ready / Measurement log error.| Memory read/write error. Switch the unit off and
on again. If the fault persists, contact service.
0x15| 21| Power supply out of range.| Power the system with a voltage within the permissible operating range.
0x00| 0| The module operates correctly.|

TECHNICAL DATA

| FLUX 1| FLUX 2
---|---|---
Measured flow range
Nl/min| 0 to 2000| 0 to 4000
Fluid| Compressed air free of any lubricants and inert gases
Fluid temperature °C| 0 to 50
Direction of flow| Unidirectional
Measuring method| Thermal
Working pressure range bar| 0 to 10
MPa| 0 to 1
psi| 0 to 145
Pressure drop| None
Temperature range °C| 0 to 50
Threaded ports| 1/2″| 1″
Degree of protection| IP65
Weight g| 585| 705
|
IO-Link supply voltage range VDC| 15 – 27 (with IO-Link Master)
Current consumption mA|  80 mA  (at 24VDC)
DISPLAY
lnstant flow rate Nl/min| 0 to 2200| 0 to 4400
Cumulative flow rate Nl| 999.999.999
Nm 3| 999.999
Nft 3| 35.320.000
Pressure n bar| 0 to 10
Resolution bar| 0.01
| |
PRECISION ●| |
Flow rate| |
Measuring range| 0 to 100% of the full scale
Single unit display accuracy| from 0 to 20% of the FS – better than ±1% of the FS
| from 20% to 100% of the FS – better than ±3% of the FS
Display accuracy of unit installed in an SY unit| from 0 to 20% of the FS – better than ±2% of the FS
| from 20% to 100% of the FS – better than ±6% of the FS
Repeatability|  ±1% of the FS
Temperature characteristic|
Version with pressure transducer| Automatic compensation of fluid temperature from 0 to 50°
| Between 0 and 15°C and between 35 and 50°C ±0.6% of the FS every °C
Version without pressure transducer| Without compensation, between 0 and 15°C and between 35 and 50°C
| ±1.2 % of the FS every °C
Pressure| |
Measuring range bar| 0 to 10
Display accuracy| ±2% of the FS
DIGITAL OUTPUT|
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

■ In versions with pressure transducer.
● At a pressure of 5 bar and a fluid temperature of 25°C ±10°C.

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