gefran ILI Series User manual

PRESSURE SENSORS FOR HIGH
TEMPERATURE IO-Link IMPACT
Cod. 80618 edit. 12/2019 - ENG

280618_MAN_IO-LINK IMPACT_12-2019_ENG
INDEX
1. GENERAL INFORMATION...............................................................................................................................................................4
1.1. General information .................................................................................................................................................................4
1.2. Copyright..................................................................................................................................................................................4
1.3. Correct use ..............................................................................................................................................................................4
2. MELT IO-LINK...................................................................................................................................................................................4
2.1. Impact IO-Link models.............................................................................................................................................................4
2.2. Transducer General Information .............................................................................................................................................4
2.3. Models .....................................................................................................................................................................................5
3. TECHNICAL DATA ...........................................................................................................................................................................6
4. MECHANICAL DIMENSIONS...........................................................................................................................................................7
5. INSTALLATION AND POSITIONING ON THE MACHINE ...............................................................................................................7
5.1. Installation seat........................................................................................................................................................................7
5.2. Drilling tool kit...........................................................................................................................................................................8
5.3. Torquing the sensor ...............................................................................................................................................................10
5.4. Connecting amplier ..............................................................................................................................................................10
6. INSTALLATION AND ELECTRICAL CONNECTIONS................................................................................................................... 11
6.1. General precautions............................................................................................................................................................... 11
6.2. Electrical installation .............................................................................................................................................................. 11
6.3. Standard reference ................................................................................................................................................................13
6.4. EMC and RoHS Requisites....................................................................................................................................................13
7. COMMAND MODES ......................................................................................................................................................................14
7.1. IO-Link Information ...............................................................................................................................................................14
7.2. SIO mode and IO-Link mode .................................................................................................................................................14
7.3. Process Data mapping (IO-Link)............................................................................................................................................14
7.4. Parameterization data............................................................................................................................................................15
7.5. LED behavior .........................................................................................................................................................................21
7.6. Switching signal channels (SSCs) conguration....................................................................................................................22
7.7. Reranging (LRV/URV) – only for SIL 2 / PL d analog output version –..................................................................................24
7.8. Relay Threshold change – only for SIL 2 / PL d relay output version – .................................................................................25
7.9. Damping lter parameter .......................................................................................................................................................25
7.10. Autozero command..............................................................................................................................................................25
7.11. Enable CAL parameter.........................................................................................................................................................26
7.12. Analog Out Type parameter .................................................................................................................................................26
7.13. Autocompensation effect on Impact series ..........................................................................................................................26
8. MAINTENANCE..............................................................................................................................................................................27
8.1. Maintenance ..........................................................................................................................................................................27
8.2. Transport, storage and disposal
9. FUNCTIONAL SAFETY NOTES (FOR SIL 2 / PL d CERTIFIED VERSIONS ONLY) -waiting for Notied Body certication-............28
9.1. Application..............................................................................................................................................................................28
9.2. Restrictions of use .................................................................................................................................................................30
9.3. Maintenance and periodic checks..........................................................................................................................................30
9.4. Mean Time to Restoration .....................................................................................................................................................31
9.5. Indication on response times .................................................................................................................................................31
9.6. Effects on the safety function of deviations in performance...................................................................................................31
9.7. Inhibition and suspension of the safety function ....................................................................................................................31
9.8. Indications and alarms...........................................................................................................................................................32

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10. RELAY APPLICATION NOTES ....................................................................................................................................................33
11. RESOLUTION PROBLEMS .........................................................................................................................................................37
12. APPENDIX B: IP PROTECTION...................................................................................................................................................38
13. APPENDIX C: ACCURACY CLASS.............................................................................................................................................39
13.1. Calibration Curve .................................................................................................................................................................39
13.2. Repeatability ........................................................................................................................................................................39
13.3. Hysteresis ............................................................................................................................................................................40
13.4. Linearity ...............................................................................................................................................................................40
14. APPENDIX D: REGISTRATION MAINTENANCE........................................................................................................................41

480618_MAN_IO-LINK IMPACT_12-2019_ENG
1. GENERAL INFORMATION
1.1. General information
This manual refers to the following products:
ILI and must be kept near the equipment for easy reading and consultation.
It must be read, understood, and strictly follow in order to avoid and prevent accidents and/or malfunctions.
Gefran will not be liable for any injury to people and/or damage to property deriving from disregard of this manual.
1.2. Copyright
Any reproduction of this document, even partial or for internal use, requires Gefran’s approval.
1.3. Correct use
Gefran Melt pressure sensors are designed and built to measure the pressure and temperature variable of melted plastic at different
temperatures according to the lling uid used.
The correct temperature range is:
• Up to 350°C
If the sensors are used as a safety component in accordante with the Machinery Directive, the equipment builder must take all
necessary precautions to ensure that any malfunctions of the Melt pressure sensor do not injury to people and/or damage to property.
Installation and maintenance must only be carried out by suitably skilled and qualied personnel.
2. MELT IO-LINK
2.1. IMPACT IO-LINK MODELS
IMPACT “ILI” series of Gefran, are pressure transmitters, without transmission uid, for using in High temperature process environment
(up to 350°C). Pressure is transduced by a micro-worked silicon structure (MEMS) and the operating principle is “piezoresistive”.
“IMPACT” is Gefran’s exclusive series of high-temperature pressure sensors that use the piezoresistive principle.
This new series “ILI” with “IO-Link” digital output is a Smart device specically designed to meet the requirements of “Industry 4.0”
environment, with auxiliary information suitable to prevent machine downtime.
The main characteristic of “IMPACT” sensors is that they do not contain any transmission uid.
The sensitive element, directly positioned behind the contact membrane, is realised in silicon through microprocessing techniques.
The micro structure includes the measurement membrane and piezoresistors.
The minimum deection required by the sensitive element makes it possible to use very robust mechanics.
The process contact membrane can be up to 15 times thicker than the membrane used in traditional Melt sensors.
Supplied in 2 different congurations, rigid stem, and rigid + exible and 4 mechanics, single and modular xed and single and
modular oating, the Melt sensors of GEFRAN are able to meet all installation requirements in the eld.
The coverage relative to the pressures that can be detected by the sensor is almost total; we start from the probe with a minimum
range of 0-10 bar to arrive at a version with a scale of 0-1000bar. All models in the catalogue can be supplied in two different accuracy
classes; in particular class M, with accuracy 0.5%FS and class H, with 0.25%FS accuracy.
Thanks to PLd and SIL2 approvals, this product is suitable for Functional Safety applications.
2.2. Transducer General Information
IO-Link transducer offers different options related to process data conguration and functional features (see datasheet for selection
of ordering codes):
• Standard transducer with only IO-Link pressure data available
• T integrated transducer with IO-Link pressure + tip temperature measurement data available
• SIL 2 / PL d certied transducer with IO-Link output + Analog output (Voltage or Current output), available in standard and T
integrated version
• SIL 2 / PL d certied transducer with IO-Link output + Relay output, available in standard and T integrated version

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2.3. Models
DIGITAL OUTPUT
ILI0 ILI1

680618_MAN_IO-LINK IMPACT_12-2019_ENG
3. TECHNICAL DATA
MELT IMPACT PRESSURE TRANSDUCERS
ILI series
Table 1
Accuracy (1) H <±0.25%FS (100...1000 bar)
M <±0.5%FS (10...1000 bar)
Thermal drift in compesated range:
Zero / Calibration / Sensibility < 0.02% FS/°C
Measuring ranges 0…10 to 0…1200 bar
0…150 to 0...15000 psi
Maximum overpressure (without degrading performances) 1.5 x FS (up to 1200 bar/ 17400 psi max)
Measurement principle Piezoresistive
Power supply 18...30 Vdc
Maximum current absorption 1W (1,2W with optional relay)
Zero offset < ± 0.25% FS
Zero adjustment “Autozero” function
Communication interface IO-Link
Min Cycle time 2,7 ms (2 bytes PDI)
3,5 ms (4 bytes PDI)
IO-Link version 1.1
Transmission type COM2 (38.4 kB)
Prole Smart Sensor Generic Prole
SIO mode Yes
Required class for Master port A
Pressure process data resolution 14 bit
Temperature process data resolution 16 bit
Analog output resolution 16 bit
Rangeability 3:1 (Analog output option)
Calibration signal 80% FS
Reverse polarity protection on power supply YES
Compensated temperature range (housing) 0...+85°C
Operating temperature range (housing) -30...+85°C
Storage temperature range (housing) -40...+125°C
Diaphragm maximum temperature 23…350 °C / 660 °F
Zero drift on process temp. 20 to 350°C < ± 1.2%FS
Span drift on process temp. 20 to 350°C < ± 1%FS
Integral temperature (optional) Accuracy ± 2 °C
Standard material in contact with process medium
Diaphragm:
• 15-5PH with GTP+ coating
Stem:
• 17-4 PH
Protection degree (5 pole female connector) IP65 with suitable mating connector
Insulation resistance (at 50Vdc) >1000 Mohm
Electromagnetic compatibility – Emission
EN 61326-1
EN 61326-2-3
EN61326-3-1
Electromagnetic compatibility – Immunity
EN 61326-1
EN 61326-2-3
EN61326-3-1
FS = Full scale output :
(1) BFSL method (Best Fit Straight Line): includes combined effects of Non-Linearity, Hysteresis and Repeatability (according to IEC 62828-2).
Sensors are manufactured in compliance with:
- EMC compatibility directive
- RoHS directive
- Machinery directive
Electrical installation requirements and Conformity certicate are available on our web site: www.gefran.com

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4. MECHANICAL DIMENSIONS
For the mechanical dimensions keep as reference the product datasheets or Gefran website www.gefran.com
5. INSTALLATION AND POSITIONING ON THE MACHINE
TECHNICAL DATA
Extrusion processes require very high temperatures. Extrusion pressure can be checked by means of especially designed transducers.
The IMPACT series sensors are suitable for pressure measurements with high temperature and are based on the piezoresistive
technology.
Following advice for extending the sensors lifetime:
a) Avoid shocks and abrasions to the in contact diaphragm. Protect the transducer with its cover each time you remove it from its seat.
b) The seat must be prepared perfectly and with appropriate tools in order to respect the depth and axiality of the holes and tapping.
Pay particular attention to the coaxiality of the holes to the thread, because diaxialities greater than 0.2 mm will break the transducer during
assembly. It is essential that hole depth guarantee the absence of chambers or air pockets in which extrusion material may be trapped.
To prevent contact with the extrusion screw or with tools used to clean the extrusion chamber, the front diaphragm must not extend
from the inner wall of the extruder.
c) Before assembling the transducer in machines already in operation, make sure that the housing is clean.
Remove any residual with the suitable cleaning device.
d) The transducer should be removed only with the machine empty (without pressure) but still hot.
e) The transducer should be cleaned with solvents for the material being processed.
Any mechanical action on the contact diaphragm modifies its operation and could break it.
5.1. Installation seat
The installation seat has to be realized:
Incorrect working or shape of the side can result in properties out of specification, bad behaviour or damage to the sensor.
The side should be clean and without any polymer residual.
D1 1/2-20UNF M18x1.5
D2 .313 ±.001”
[7.95 ±0.02mm]
.398 ±.001”
[10.10 ±0.02mm]
D3 .454 ±.004”
[11.53 ±0.1mm]
.634 ±.004”
[16.10 ±0.1mm]
D4 .515” [13mm]
minimum
.790” [20mm]
minimum
A.225” [5.72mm]
minimum
.240” [6.10mm]
minimum
B.17” [4.3mm]
maximum
.16” [4.0mm]
maximum
C.75” [19mm] .99” [25mm]

880618_MAN_IO-LINK IMPACT_12-2019_ENG
Drilling kit
A drilling kit with formed tools for drilling, reaming and tapping is available to facilitate correct preparation of the assembly seat.
The assembly seat must be perfect to assure proper transducer function and long lifetime. Drilling kits are available in the following
versions: KF12, KF18.
Drilling procedure
1) To drill hole (D4) up to a distance from the hole equal to the sum of (A+B+C) (tool 3).
2) Make the pass through hole (D2) by the tool 1.
3) To create the seal seat at a distance from the hole equal to dimension (A) (tool 4).
4) With a roughing tap, create threading 1/2-20UNF-2B (recognizable from the greater number of threads beveled at the
mouth) (tool 5).
5) With a finishing tap, go over threading 1/2-20UNF-2B up to a distance from the bottom equal to the sum of (A+B) (tool 6).
6) To ream the hole (D2) with reamer (tool 2).
Installation seat check
The dimensions of the assembly seat have to be checked after preparation and before the transducer installation.
Use dummy plug SC 12/18 as follows:
1) Coat the end of the rod with the appropriate ink.
2) Lubricate the threaded part to prevent friction.
3) Insert the dummy plug and screw it fully down.
4) Remove the rod and examine it.
With the exception of 45° surfaces, the ink should be intact on the entire surface.
5.2. DRILLING TOOL KIT
CORRECT SEAL
VERSION
CODE KF12 KF18
THREADING
TYPE 1/2-20UNF-2B M18x1.5
1Ø 7.6 Ø 9.75
2Ø 7.95 Ø 10.1
3Ø 13 Ø 20
4Ø 11.5 with
pilot guide
Ø 16 with
pilot guide
51/2-20UNF-2B
roughing
M18x1.5
roughing
61/2-20UNF-2B
finishing
M18x1.5
finishing
CORRECT INSTALLATION
WRONG
WRONG
WRONG
CORRECT
contact surface

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TRANSDUCER INSTALLATION
Installation procedure
1) Make sure the drilling procedure has been realized correctly. If the sensor is installed in a previously used hole, make sure the
hole is completely clean and free of any plastic residual.
2) Remove the protective cap from the sensor top.
3) Lubrificate the thread with non-grip grease such as Neverseez (Bostik), or C5A (Felpro), or equivalent.
4) Insert firmly the sensor into the hole, first by hand and then with a wrench, 1/4 turn at a time.
Recommended torque: 40 Nm.
NOTE: Please pay particular attention to the sensor installation when it’s provided in its fixed mechanis configuration.
In this case, during the clamping phase any misalignment. Has tube avoided, otherwise a possible interference of the sensor mechanical
coupling can occur.
Calibration procedure (Analog output option)
Bring the system to work temperature with the transducer installed and connected to the measurement instrument without any pressure
applied.
The measurement chain connected to the transducer is calibrated as follows:
1) Reset the indication on the instrument to reset the temperature variation zero shift. Use the Autozero function to run the reset (see par.7).
a) For correct zero resetting, run Autozero only after work temperature has been completely reached.
2) Calibrate the instrument and have it display the calibration value (80% of full scale) (see par.7).
3) If the instrument does not exactly indicate zero, repeat points 1 and 2. In this way, the instrument is calibrated to give the exact
indication in the chosen engineering unit.
Calibration procedure (IO-Link output)
Bring the system to work temperature with the transducer installed and connected to the measurement instrument without any pressure
applied.
The measurement chain connected to the transducer is calibrated as follows:
1) Use the Autozero function to run the reset (see par. 7) ; run Autozero only after work temperature has been completely reached.
2) Calibrate the instrument and have it display the calibration value (80% of full scale). (see par. 7)
3) If the instrument does not exactly indicate zero, repeat points 1 and 2. In this way, the instrument is calibrated to give the exact
indication in the chosen engineering unit.
Removal (Figure 1)
To remove the transducer from its seat and carry on the working process, dummy plugs with identical mechanical dimensions are available.
The dummy plugs differ by type of threading; max pressure range is 2000 bar for all rods.
The dummy plugs are available in the following versions: SC12 1/2-20UNF seat - SC18 M18x1,5 seat
Brackets (Figure 2)
Models with flexible sheaths require the housing precise fixing. Suitable fastening brackets (SF18) are recommended.
Remember that the fastening point must be vibration-free (vibrations affect the measurement) and that temperatures must not exceed the
maximum temperature range for the strain gauge housing (as stated on the sensor technical sheet).
Extruder starting
Bring the system to working temperature with the transducer installed and without any pressure applied.
Wait until all the material is at the same temperature to prevent the transducer damage by semi-solid material.
Seat cleaning & Cleaning tool
As mentioned in the notes, the seat must be cleaned before the transducer installation.
The cleaning tool is a hard metal cutting tool specially designed to remove working materials residuals.
Recommended procedure (Figure 3)
The following procedure must be implemented with the material in a fluid condition.
1) Insert the tool in the seat and screw down the cutting rod (normally a 1/4 turn at a time).
2) Turn the pilot cutter clockwise until there is no resistance to cutting.
3) Repeat the procedure until the seat is completely clean.
For constructive reasons, the maximum torque applicable to the cutter is 15 Nm (1.5 Kgm).
If the hole occlusion requires higher torque for removal, use the drilling kit and follow the recommended procedure.
The cleaning tool is available in the following versions: CT12 1/2-20UNF seat - CT18 M18x1,5 seat.
Figure 1 Figure 2 Figure 3

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ORDER CODES FOR TOOLS and ACCESSORIES
5.3. TORQUING THE SENSOR
Screw the sensor after checking the correct shape of the side.
Hold the flexible part while screwing the jam bushing.
For safety operations at least 6 pitch of the jam bushing must be screwed into the hole.
The torque must be 40 Nm.
5.4. CONNECTING AMPLIFIER (only for modular versions)
The electronics must be connected to the primary part by aligning the 2 red points on each connector.
Take care not to force the connectors together: check the correct aligning of the 2 red points.
Screw the sensor after checking the correct shape of the side.
Hold the flexible part while screwing the jam bushing.
flexible sheath to the machine. Take care not to fix the sheath to parts heated at over than 220°C.
Screw the electrical cable connector to the electronics and switch on the sensor.
Wait 60 seconds before starting to operate the transducer.
To disconnect the electronics from the primary sensor, take care to handle the two connectors next to the red points and not to
force the disconnection.
Remark:
In modular versions the decoupling between the electronics and the primary element is not allowed.
CLEANING TOOL KIT
1/2-20UNF 12
M18x1,5 18
CT
MOUNTING BRACKET SF 18 DUMMY PLUG
1/2-20UNF 12
M18x1,5 18
SC
DRILL KIT
1/2-20UNF 12
M18x1,5 18
KF