METAL WORK M0030401 FLUX 1 IO Link Digital Flowmeter and Pressure Sensor Installation Guide

METAL WORK M0030401 FLUX 1 IO Link Digital Flowmeter and Pressure Sensor

Product Specifications

• Product Name: FLUX IO-Link Digital Flowmeter and Pressure Sensor
• Model Number: M0030401 IM05
• Website: www.metalwork.eu.

Product Usage Instructions

Installation:

Straight Piping:
The pipe must be straight, and the passage section must be constant.

Length of pipes:

Electrical Connection:

• Use a 5-pin M12 connector cod. A for electrical connection to a Master IO-Link.
• Power is supplied directly by the Master.

Displaying Operating Data (For Models with Display):

• Icons of functions are displayed at the top of the screen.
• Displayed Parameters: Flow rate (Nl/min), Power (kW), Mass flow rate (kg/min), Measurement time.

I/O:

Parameters:

• Flow: Output switches based on flow values.
• Pressure: Output switches based on pressure values.

Frequently Asked Questions (FAQ):

• Q: What should I do if the device is not functioning properly?
  A: Ensure that the electrical connections are secure and free from interference. Check for any damage to the components and follow the installation instructions carefully.

• Q: How often should I clean the filter at the inlet of FLUX?
  A: To maintain measurement accuracy and prevent lubricant residue from damaging the sensor, clean the filter regularly according to the manufacturer’s recommendations.

INTRODUCTION

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 a connection to an IO-Link Master. It supports COM3 communication, by 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 a 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 flow rate measured FLUX 1 2000 Nl/min, FLUX 2 4000 Nl/min, FLUX 3 8000 Nl/min, FLUX 4 15000 Nl/min.
• 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 it 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, by ISO 8573-1.
• Do not use with lubricated air.
• Do not insert foreign objects into the connection ports.

INSTALLATION

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

• Install the device following the arrow indicating the direction of the airflow.
• To connect the inlet side, use a straight pipe* with a minimum length as per the table. 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.
    Pipe length**  | L**

Inlet

| L1

Outlet

---|---|---
FLUX 1| ≥150 mm| ≥50 mm
FLUX 2| ≥200 mm| ≥50 mm
FLUX 3| ≥300 mm| ≥100 mm
FLUX 4| ≥300 mm| ≥100 mm

• 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.

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

• FLUX 1 with Syntesi® size 1;
• FLUX 2 with Syntesi® size 2.

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.

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

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

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 screen.
• 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

MENU ACCESS (ONLY FOR MODELS WITH DISPLAY)

Parameter setting

• Press the SETUP 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.

SYSTEM

• The compressed air system is connected through the threaded holes on the body.
• 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.

SYN filter
Set to ON when the FLUX is installed after a Synthesis unit filter to optimize flow rate reading.

Gas type
Helps optimize the measurement of the current flow and consumption figures.

• Types of gas: Air
  • Helium
  • CO2
  • Nitrogen

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.

I/O

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.

Parameters

• Contact type: NO/NC
• Reference:
  • FLOW: The output switches according to flow values.
  • Threshold Setting: function – LEVEL SWITCH, BAND SWITCH;
  • OUT SET/HI – Flow value for output activation;
  • OUT RST/LO – Flow value for output de-activation.
  • PRESSURE: The output switches according to pressure values.
  • Threshold Setting: 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
  • The target is reached. The minimum flow rate can be set to 10 Nl for FLUX 1, 20 Nl for
  • FLUX 2, 30 Nl for FLUX 3, and 60 Nl for FLUX 4.

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

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.

PARAMETERS

• Language: Italiano, English, Deutsch, Français, Español.
• Flow rate unit of measurement: Nl/min, Nl/h, Nm3/min, Nm3/h, Nft3/min, Nft3/h.
• Pressure unit of measurement: bar, MPa, psi.

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

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

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.

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

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

COMMISSIONING

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

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.

ADDRESSING

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.

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      Nm3/min| 103| 0| Flow| Nm3/min| Read 4 byte| Hex
Flow      Nm3/h| 104| 0| Flow| Nm3/h| Read 4 byte| Hex
Flow      ft3/min| 105| 0| Flow| ft3/min| Read 4 byte| Hex
Flow      ft3/h| 106| 0| Flow| ft3/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| 02| 0| Value = Dec 160

Hex 0xA0

| Write 1 byte| Hex

Configuration of parameters from Master IO-Link

Parameter

| Index| Subindex| Description|

Data type

---|---|---|---|---
Display – Flow rate unit of measurement| 65| 0| 0 = Nl_min

1 = Nl_h

2 = Nm3_min

3 = Nm3_h

4 = ft3/min

5 = ft3/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 enables status| 69| 0| 0 = NO

1 = NC

| R/W 1 byte
Digital output enables 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| The 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 output-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 color

changes to yellow

| R/W 4 byte
Display – FLUX Off color| Nl/h| 78| 0| Flow rate value at which the color

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

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:

Codice Hex| Codice DEC| Meaning|

Note

---|---|---|---
0xD5| 213| Flow sensor failure| Contact Service
0xD1| 209| Pressure sensor failure| Contact Service
0xCC| 204| Analog output failure| If a power failure or the current is too high, check the device is connected to a proper input.
0xB0| 176| Digital output failure.| Power failure or current too high.
0x16| 22| Flash memory reset or corrupted /

E2prom 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

• IMPORTANT! Voltage greater than 32VDC will damage the system irreparably.
• In versions with pressure transducer.
• Accuracy referred to compressed air gas, at a pressure of 5 bar and a fluid temperature of 25°C ±10°C.
• 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).
• Available only for versions with display.

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