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SMC Networks PFCQ531 Series Operation Manual

Flow controller for air (preset input / serial communication specification)
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Document No. DOC1117087
PRODUCT NAME
Flow controller for air
(Preset input / Serial communication specification)
MODEL / Series / Product Number
PFCQ531 Series

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Summary of Contents for SMC Networks PFCQ531 Series

  • Page 1 Document No. DOC1117087 PRODUCT NAME Flow controller for air (Preset input / Serial communication specification) MODEL / Series / Product Number PFCQ531 Series...
  • Page 2 Contents 1. Product Overview and Features ............... 3 2. Safety Instructions .................... 4 3. Items Included in the Package ................. 6 4. Names and Functions of Product Parts ............7 5. How to order ...................... 8 6. Specifications ....................9 6-1 General specifications ................
  • Page 3 12-2 Bracket....................50 12-3 Digital flow monitor................51 13 Separately Sold Products ................54 13-1 Digital flow monitor mounting bracket ..........54 14 Maintenance....................56 14-1 Maintenance and inspection ..............56 14-2 Trouble shooting ..................57 (1) Operation problems ................57 (2) Flow rate control problems ..............
  • Page 4 1. Product Overview and Features This product has two modes: a preset input mode in which it operates by executing preset data based on switch input from an external device such as a PLC, and a serial communication mode in which it operates by serial communication (RS485/Modbus RTU protocol communication method) from an external device.
  • Page 5 Safety Instructions These safety instructions are intended to prevent hazardous situations and/or equipment damage. These instructions indicate the level of potential hazard with the labels of “Caution,” “Warning” or “Danger.” They are all important notes for safety and must be followed in addition to International Standards (ISO/IEC)*1), and other safety regulations. ※1) ISO 4414: Pneumatic fluid power -- General rules and safety requirements for system and their components ISO 4413: Hydraulic fluid power -- General rules and safety requirements for system and their components IEC 60204-1: Safety of machinery -- Electrical equipment of machines (Part 1: General requirements)
  • Page 6 Safety Instructions Caution SMC develops, designs, and manufactures products to be used for automatic control equipment, and provides them for peaceful use in manufacturing industries. Use in non-manufacturing industries is not allowed. Products SMC manufactures and sells cannot be used for the purpose of transactions or certification specified in the Measurement Act of each country.
  • Page 7 3. Items Included in the Package ● Accessories Protective plug PFCQP-910S-31 Flow controller for Air (body) ● Options (The following items are included in the package depending on the model selected for the flow controller for Air.) Digital flow monitor (PFG310-XY-M-Y-X105) Power supply cable (PFCQ531-H2-3) (For preset input and Serial communication specifications)
  • Page 8 4. Names and Functions of Product Parts D-sub connector (CN1) Rotary switch Communication connector (CN2) F.G. Power supply LED Error LED USB connector (CN4) Flow rate display connector (with protective plug) (CN3) Piping port (OUT side) Protective plug Piping port (IN side) Name Function Power supply (PWR)
  • Page 9 5. How to order PFCQ5 31 - 04 - P□□-□□ Flow controller for Air (Display separate type) Rated flow range (flow rate range) 9 to 300L/min Port size Rc1/2 Preset input / Serial Communication specification (See the Input/Output Specification Table.) Option 1 (Power supply cable) None Power supply cable (3m)
  • Page 10 6. Specifications 6-1 General specifications Model PFCQ531-04-P* Dry air, N2 (Air quality classes: JIS B8392-1 1.1.2 to 1.6.2; Fluid Applicable fluid ISO8573-1 1.1.2 to 1.6.2 Detection type Hot wire anemometer Flow rate specifications Rated controlled flow rate range 9 to 300 L/min *2,*3 Set controlled flow rate range 3 to 300 L/min...
  • Page 11 6-2 Electrical specifications Model PFCQ531-04-P* Power supply Power supply voltage Main power supply: 24 VDC +/-10% specifications Signal power supply: 24 VDC +/-10% Current consumption Main power supply: 0.5 A or less Signal power supply: 0.05 A or less Protection Polarity protection Control specifications Valve driving actuator...
  • Page 12 6-3 Functional characteristics (1) Analog output (flow rate out signal) Output type Voltage output Current output 4 mA 20 mA Analog output (Flow rate command signal) (2) IN side straight pipe length and accuracy (reference value) - The smaller the piping size, the more the built-in flow sensor is susceptible to the length of straight pipe.
  • Page 13 7. Dimensions PFCQ531-04-P**-□* ,Thread depth 5 PFCQ531-04-P**-S*...
  • Page 14 with bracket PFCQP-910S-31 Protective plug...
  • Page 15 8. Component Drawing of Parts in Contact with Fluid and Parts Names Components Name Material Remarks Name Material Attachment Tube Stainless steel Stainless steel O-ring Motor body Resin O-ring Stainless steel Spacer Resin Wear ring Stainless steel Rare earth Mesh Magnet Stainless steel Ni plating...
  • Page 16 9. Working Principle This product has a built-in linear motor which changes the valve opening by moving the valve element mounted to the linear motor, and thereby adjusting the flow rate inside the valve. When the flow rate command signal is input to the product, the internal operation circuit performs a comparison calculation with the flow rate measured by the flow sensor.
  • Page 17 10. Installation 10-1 Installation Mounting the bracket - Mount the bracket using hexagon socket head cap screws (4 pcs.). - Apply a tightening torque of 1.4 to 1.6 N.m. 取付ねじ(付属) - To mount the product with a bracket, use M4 screws or equivalent (4 pcs.). - The screws should be prepared by the user.
  • Page 18 Direct mounting - Use M4 screws or equivalent (4 pcs.) for mounting. - The screws should be prepared by the user. - Refer to “7. ” for the threaded hole locations and depth. M4 screws or equivalent (To be prepared by the user) Mounting location - Give consideration to the size of the control panel and the installation method so that the surrounding of the product will be 45...
  • Page 19 10-2 Air supply - Use fluid that is compliant with JIS B 8392-1 1.1.2 to 1.6.2, ISO8573-1 1.1.2 to 1.6.2. Using the following pneumatic circuit satisfies the air quality class described above. Example of a recommended pneumatic circuit (for compressed air) Dryer Air filter Regulator...
  • Page 20 10-3. Piping - Mount the product so that the fluid flows in the direction indicated on the label on the side of the product. Direction of the fluid Label (Example) - Do not mount the product in an orientation with the product bottom surface facing upward (upside down).
  • Page 21 - Apply the correct tightening torque when mounting the product. Refer to the following table for the required torque. - Use a wrench suitable for the required torque. Do not use a wrench with an overall length of 400 mm or longer. - If the screw is tightened at a torque exceeding the tightening torque range, the product may be damaged.
  • Page 22 10-4. Electrical Connection - Be sure to turn off the power before performing wiring. - Use individual wiring routes. Using the same wiring route as a power line or high voltage line may cause malfunction due to noise. - When using a switching power supply, be sure to ground the frame ground (FG) terminal. Also, insert a noise filter, such as a line noise filter and a ferrite, between the product and the switching power supply.
  • Page 23 Details of switch input IN1 Name Contents OPEN Valve fully open command Details of switch outputs OUT1 to OUT3 Name Contents ERROR Error AREA1-3 Range output TOLERANCE Tolerance output ALWAYS Output OFF *1: Selectable by setting software Preset Data Details IN1(*1) Preset data 1(*2) Preset data 2(*2)
  • Page 24 - PNP output specifications D sub-connector pin number DC1(+) Main power supply DC1(-) DC24V DC2(+) Signal power supply DC2(-) DC24V 5kΩ Internal resistance Main Circuit 5kΩ Internal resistance 5kΩ Internal resistance 5kΩ Internal resistance Load OUT1 Load OUT2 Load OUT3 OUTA Load Caution...
  • Page 25 (3) Communication specifications for communication connector The communication connector is used when the flow controller is connected to a host device such as a PLC and operated in serial communication mode. Communication Specifications Item Contents Protocol MODBUS Transmission mode Frame Size Variable length Communication standard RS-485 (Asynchronous)
  • Page 26 Flow controller Host unit Connector No. 2 Connector No. 1 RJ-45 LAN cable (straight) Figure 2 Communication Connector Wiring Overview (5) Flow rate display connector terminal No. The dedicated output for the optional digital flow monitor PFG310-XY-M-Y-X105. When using the digital flow monitor, connect the digital flow monitor PFG310-XY-M-Y-X105 using the optional lead wire with connector (part number ZS-33-D) and the sensor connector (part number ZS-28-C-1).
  • Page 27 (6) Wiring between the flow rate display connector and the digital flow monitor Connector Flow rate display Sensor connector marking No. Pin number connector 1(Brown) DC(+) DC(+) 2(White) N.C. － 3(Black) OUTM DC(-) 4(Blue) DC(-) Digital flow monitor Flow controller for Air (Optional) Lead wire with connector (Optional) ZS-33-D PFCQ531...
  • Page 28 10-5 ID Setting This product can be assigned an ID using the rotary switch on the top face of the main unit; the ID is used when using the setting software in preset input mode or for serial communication connections. It is used for individual identification for daisy-chain connection.
  • Page 29 11 Setup and operation method 11-1 Functions The functions of this product are as follows This product can be set and operated via serial communication. For details on how to use serial communication, refer to the Air Flow Controller Instruction Manual (Serial Communication Modbus Protocol Edition Document No.
  • Page 30 11-2 Setup of setting software This section describes how to start up the setting software and communicate with the controller. (1)Wiring (*1). Connect the PC to the flow controller with a USB cable *1 USB 2.0 or higher モ ニ タ モ...
  • Page 31 (5) Select the input to be used Select from preset input mode or serial communication mode. (6) Controller ID search and selection An ID is set for this product. (The factory default is 01 (1 in the setting software display.) For the ID setting method, refer to 10-5 ID Setting.) Click "Start Search"...
  • Page 32 （6）Main screen The main screen appears, displaying the connected COM port number, controller ID, and communication speed next to the title. Tab to Data Setup and Monitor/Test. Normal Normal Reverse Caution Do not turn off the product or disconnect the USB cable while the configuration software is running.
  • Page 33 11-3 Basic settings Register basic settings. The basic settings can be used to set preset data and items to be output as OUT signals. If the flow controller is connected properly, the data registered in the controller will be displayed immediately after the software is started.
  • Page 34 11-3-2 OUT signal setting 11-3-2-1 ERROR signal setting The ERROR signal turns the OUT signal ON when the following errors occur for the flow controller, and turns OFF when no error occurs. Error signal types are the following items. Switch input error Power-on input error Switch output overcurrent error Signal power supply out of range error...
  • Page 35 11-3-2-2 AREA signal setting The AREA signal turns the OUT output signal ON when the actual flow rate is within the two set flow rates set by the AREA signal (hereinafter referred to as the AREA range), and turns the OUT output signal OFF when it is outside the AREA range.
  • Page 36 11-3-2-3 TOLERANCE signal setting The TOLERANCE signal turns the OUT signal ON when the actual flow rate is within the tolerance to the flow rate command value, and turns the OUT signal OFF when the actual flow rate is outside the tolerance.
  • Page 37 11-3-2-4 ALWAYS OFF signal setting The ALWAYS OFF signal is set when the OUT signal is always OFF. Follow the procedure below to assign a ALWAYS OFF signal to the OUT signal output. (1) Select ALWAYS OFF from the OUT1 to OUT3 setting items on the setting software screen (circled in the red square in the figure below).
  • Page 38 11-3-2-5 Selection of switch output Normal/Reverse The ERROR, AREA, and TOLERANCE signals of the OUT signal can be selected as Normal or Reverse switch output (circled in the red square in the figure below). The Normal output turns ON when the condition for each output signal to occur is met and turns OFF when the condition is not met.
  • Page 39 11-4 Preset input operation After the preset data setting is completed, the flow controller executes flow control of the command flow value corresponding to the preset data when the switch input signal is input to the flow controller according to the following procedure. Table 1 Relationship between each preset data and switch input IN1(*1) Preset data 1...
  • Page 40 User’s operation Operation of the product Stop fluid supply to the IN side Switch inputs IN1 to IN4 to OFF Power LED (green) lights up Apply 24 VDC to main power supply DC1 ・・・・・ Analog output (flow rate output signal) output starts Switch output OUT1 to OUT3 output start Apply 24 VDC to signal power supply DC2...
  • Page 41 －Timing Chart－ Preset input flow control operation Power supply 1 DC2 is turned on within 0.5 seconds after DC1 is turned on Turns on the power supply and warms up for at least 10 min, IN side and then supplies compressed fluid to the IN side. pressure 0MPa IN1 signal is turned off during preset...
  • Page 42 Caution Do not apply a voltage or current outside of the specification range . Failing to do so may cause a product failure. Turn on the signal power supply without supplying compressed fluid to the IN side, and then turn on the main power supply. Allow the product to warm up for at least 10 minutes after the power supply is turned on.
  • Page 43 11-6 Valve fully open operation Input the switch input IN1 according to the following procedure to fully open the valve. When the valve is closed, turning switch input IN1 ON fully opens the valve, and turning switch input IN1 OFF closes the valve. Full valve open operation is not possible during target flow control operation (preset input or serial communication).
  • Page 44 -Timing chart- Valve fully open operation Power supply Turn on DC2 within 0.5 seconds of turning on DC1. Turns on the power supply and warms up for at least 10 min, and then supplies compressed fluid to the IN side. IN side pressure 0MPa...
  • Page 45 Warning Take into account the behaviour when the valve is fully open. In the valve fully open operation, a high flow rate may be applied depending on the operating conditions. Before performing the valve fully open operation, be sure to confirm that there will be no injury to human bodies or damage to devices and equipment.
  • Page 46 11-7 Monitor mode and test mode Switching the tabs on the configuration software screen to Monitor/Test allows you to set the monitor mode and test mode. The monitor mode is enabled when the switch on the screen (circled in green square in the figure below) is moved to the monitor mode side.
  • Page 47 11-8 Setting lock Data settings (preset data and OUT signal output) of the flow controller can be locked on the setting software screen to protect data settings. (1) Lock setting method After uploading the data settings, slide the settings lock switch on the screen (circled in green square in the figure below) to the right.
  • Page 48 11-9 Initialization The flow controller data settings (preset data and OUT signal settings) can be initialized on the setting software screen. (1) Right-click on the title bar of the configuration software. (2) Click "About PFCQ Application" (circled in blue in the figure below) in the menu that appears. (3) Click Initialize (circled in red in the figure below) from the About menu to initialize.
  • Page 49 11-10 Restriction on transition between modes and operations (1) Transition between preset input mode and serial communication mode Shift to preset input mode and serial communication mode is executed when operation of each mode is started from the valve closed state after power-on. Operation in another mode cannot be started during operation in each mode.
  • Page 50 12 Opetion 12-1 Power supply cable PFCQ531-H2-3 Specifications Item Description D-sub connector, 15-pin socket Connector #4-40 UNC screws Sheath outside diameter Φ6.8 mm Minimum bending radius 54 mm Number of cores 14 cores Nominal cross section of Equivalent to AWG26(No.3,4,5,8), AWG28 the conductor Insulator outside diameter 1 mm...
  • Page 51 12-2 Bracket PFCQ531-B1 Item Description Material Stainless steel Weight 30 g Screws for mounting the M4 (4 pcs.) body Screws for fixing Equivalent to M4 the mounting (4 pcs.) frame 1: Provided with the bracket. 2: To be prepared by the customer. For the dimensions after mounting the bracket, refer to “7.
  • Page 52 12-3 Digital flow monitor Digital flow monitor: PFG310-XY-M-Y-X105 Specifications Model PFG310-XY-M-Y-X105 Model PFCQ531 Applicable SMC flow controller Rated flow rate range 3 to 300 L/min Instantaneous flow -15 to 315 L/min Set flow rate range Accumulated flow 0 to 999,999,999,999 L Smallest Instantaneous flow 1 L/min...
  • Page 53 1: The rated flow rate range of the applicable flow controller. 2: When using the accumulated value hold, calculate the product life based on the operating conditions and use the product within the life period. The maximum access limit of the memory device (electronic component) is 1.5 million cycles.
  • Page 54 Warning Do not connect the power and output lead wire and connector. When connecting to the flow controller for air, do not connect the wiring to the power supply and output connectors. Failing to do so may deteriorate the accuracy or cause a vibration.
  • Page 55 13 Separately Sold Products 13-1 Digital flow monitor mounting bracket If a mounting bracket is required for the digital flow monitor, order it separately. Bracket A: ZS-46-A1 dimensions Note: The bracket can be mounted in four directions. Note: Self tapping screw: 3 x 8L nominal diameter (2 pcs.) Bracket B: ZS-46-A2 Note: The bracket can be mounted in four directions.
  • Page 56 Panel mount adapter: ZS-46-B Dimentions0.5-7 Panel mount adapter + Front protective cover: ZS-46-D Dimentions0.5-7...
  • Page 57 14 Maintenance 14-1 Maintenance and inspection Check the following points and contact SMC sales representative if you find any abnormality. (1) Daily inspection - Lighting up and flashing of LEDs (If an abnormality is found in the lighting up and flashing of an LED, refer to “14-3 LED”).
  • Page 58 14-2 Trouble shooting In the event of malfunction, check the following corresponding condition of each problem. If none of the causes corresponding to the condition of the problem can be found and normal conditions are restored by replacing the product, it can be assumed that the product itself is defective.
  • Page 59 (2) Flow rate control problems Condition of Possible causes Investigation method and location of Countermeasures problem of problem possible causes If the specified voltage is not input to the power supply, the power supply No air flows. - Check to see if the power supply LED will not turn ON due to (Preset input LED turns ON.
  • Page 60 If the specified voltage is not input to the power supply, the flow rate command signal will not be input to the No air flows. Signal power - Check the voltage of the signal power internal CPU due to insufficient voltage. (Valve fully supply failure supply connected to the product.
  • Page 61 Condition Possible causes of Investigation method and location of Countermeasures of problem problem possible causes If the operation differential pressure or There is a supply flow rate is insufficient, the error large error becomes large. between By referring to “6-1 General the flow Insufficient supply - Check the pressure at the IN and...
  • Page 62 Condition Possible causes of Investigation method and location of Countermeasures of problem problem possible causes Due to a pressure regulator mounted to the piping port (IN side), the pressure on the IN side may drop if a high flow Pressure - Is the pressure on the IN side rate is applied suddenly.
  • Page 63 (3) Output signal problems Possible Condition of Investigation method and location of causes of Countermeasures problem possible causes problem - Are the input specifications of an Use an external device whose An analog external device connected to the Signal specifications match those of the Output signal is analog output consistent with the mismatch...
  • Page 64 Possible Condition of Investigation method and location of causes of Countermeasures problem possible causes problem The switch Input 24 VDC to the signal power Signal power - Is 24 VDC input to the signal power output does not supply by referring to “10-4. (2) supply failure supply? turn on.
  • Page 65 (4) Flow rate display problem Condition of Possible causes of Investigation method and location of Countermeasures problem problem possible causes The digital flow Connect the wiring correctly by - Is the wiring connected correctly? monitor does referring to “10-4. (4) Wiring between Wiring defect - Is there any broken or short- not display...
  • Page 66 (5) Communication trouble Condition of Possible causes Investigation method and location of Countermeasures problem of problem possible causes - Is the wiring properly connected? Refer to section “10-4 Wiring" for Wiring failure - Are there any broken or short- proper wiring. circuited wires? The Controller Check that the ID setting by...
  • Page 67 14-3 LED indication and error measures Based on the LED colour, turning ON and flashing of the power supply LED and the error LED at the top of the product, the product status can be confirmed. -Normal operation Name Power LED Error LED Contents Measures...
  • Page 68 －Error generation－ Power Name Error LED Contents Treatment method supply LED The following operations were performed - IN1 is ON at the end of preset Reset the signal. input operation Alternatively, turn on the Switch input - IN2 to IN4 are ON at the end of main power supply again error valve fully open operation...
  • Page 69 －Error reset－ If an error occurs, the product turns off current to the motor and closes the valve. After taking measures described in “Measures” reset the error following the method below. (1) Reset the signal Turn off the the switch inputs IN1 to IN4 for at least 1 sec. (2) Turn on the main power supply again Turn off the main power supply (for at least 1 sec) and turn it on again.
  • Page 70 15. Handling Precautions 15-1. Design and selection precautions Warning (1) Be sure to read the Operation Manual. Do not handle the product in a way not described in the Operation Manual or use it outside the specifications because doing so may lead to damage or malfunction of the product. No damage attributable to the handling of the product in a way not described in the Operation Manual or to use of the product outside the specifications will be compensated.
  • Page 71 be insufficient or the product may malfunction or may not satisfy the specifications. (5) If the fluid on the IN side (inlet) of the product is turbulent, accurate measurement may not be possible. If a valve, etc. is used on the IN side (inlet) of the product, flow turbulence may be caused due to changes in the effective area, resulting in an error in the flow rate measurement.
  • Page 72 getting burned. (2) Do not perform operations or configure settings with wet hands. This may cause an electric shock. (3) Do not use a damaged product or a product with missing parts. Failing to do so may cause an electric shock, fire, or injury. (4) Perform mounting, piping, wiring, or inspection work after checking the voltage using a tester, etc.
  • Page 73 Outside of the controllable range, the flow rate may be low, flow rate control may be unstable, the product temperature may be high and so on. (7) Make sure that the pressure on the IN (inlet) and OUT (outlet) sides will not fluctuate. If the pressure on the IN side or the OUT side varies, the flow rate may vary.
  • Page 74 (9) If there is a risk of foreign matter entering the fluid, install a filter or mist separator on the IN side (inlet). Failing to do so may cause failure or malfunction. In addition, accurate measurement and control may no longer be available. (10) Do not mount a lubricator on the IN side (inlet) of the product.
  • Page 75 If a power supply with inrush current prevention specification is used, a voltage drop may occur during flow rate control. (3) Take measures against lightning surges. Isolate the grounding of the surge absorber for lightning from the grounding of the product and its peripheral devices. 15-5.
  • Page 76 noise and surge from entering the signal line from power lines or high voltage cables. (5) Check the wiring before using the product. Miswiring will lead to product damage or malfunction. Make sure that there is no miswiring before starting operation. (6) Do not pull the cables or lead wires with excessive force.
  • Page 77 15-7. Operating environment Warning (1) Do not use the product in an atmosphere where flammable gas, and explosive or corrosive gas are present. Failing to do so may lead to fire, explosion, and corrosion. (2) Do not use the product in a place where dust, water, chemicals, or oil scatter or in a oil vapor atmosphere.
  • Page 78 (10) When mounting the products arranged close to each other, the product temperature may rise, causing failure or malfunction. Mount the products providing a space of at least 20 mm between each other. (11) Use the product in an environment not subject to vibration or impact. Otherwise, malfunction or a failure may be caused.
  • Page 79 Revision history Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362 https://www.smcworld.com Note: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer. © SMC Corporation...