Why is consumption measurement so important?
Compressed Air is not Free!
Example:Medium-sized production plant
|Company size||200 employees|
|Typical compressor capacity||16m3/min=960m3/h|
|Efficiency factor||80% including night – idling|
|Electrical power input||100 kW|
|Daily operation time||2 shift operation / 16 h|
|Annual operation time||276 days = 4416 h|
|Energy costs||4416 h x 80 kW x €0,21 € 74.000 =US$ 110.000|
|Leakages||approx. 20 to 30% of the total consumption, this is typical for old plants approx. 15.000 € = 22.500 US$|
We offer compressed air metering systems that can:
Measure exact consumption, give you weekly or monthly read outs for cost accounting and employee information.
Determine peak consumption so that you know whether your compressor supply enough air or whether you have to expect bottle-necks
Determine each pneumatic device consumption as well as diagnose if the tubes have the right diameter, if the machine is optimally adjusted, and identify wear & tear trend of machines.
Assist you in cost accounting per department or large machine.
Improve cost calculations and cost consciousness.
Assist you in leakage detection
Monitor air-consumption during non production times to identify increasing leakage of air.
There are different models to select from in-line and on-line methods of installation.
The Sigma 401 series
Sigma 401 flow / consumption sensor (insertion type)
The Sigma 401 series flow sensor is based on the thermal mass flow principle. It measures volumetric standard flow over a wide measuring range. The result is pressure and temperature independent.
The sensor installation into the pipe is done through a ½” ball valve. This makes it possible to do the installation under pressure without shutting down the compressed air line.The sensor is available in two measuring ranges and with or without display. The version with display shows the actual volumetric flow and the total consumption. Via the keyboard tube diameters and the consumption counter can be set.
Every sensor includes an analogue output (4…20mA) for flow and an isolated pulse output for the consumption counter.
- Integrated display for m3/h and m3
- Depth scale for accurate installation
- Usable from 1/2” to 12” (DN 300)
- Easy installation under pressure
- 4…20 mA analogue output for m3/h resp. m3/min
- Pulse output for m3
- Inner diameter adjustable via keypad
- Consumption counter resettable
- Insertion type sensor for installations under pressure
- Thermal mass flow, independent of pressure and temperature changes
Measured unit m3/h, m3/min, l/min, cfm
Accuracy +- (3% of measured value + 0.3% full scale)
Medium Air, gas, non explosive
Operating temperature -30 … 140 ºC probe tube
-30 … 70 ºC casing
Operating pressure Up to 50 bar
Analogue output : 4 … 20 mA Scaling: 0 … max range
Pulse output 1 pulse per m3
Power supply 12 … 30 VDC, 100 mA
Volumetric Flow ranges
|Inch||mm||Standard [m3/h]||Max [m3/h]|
|The stated flow rates are standard flows at 20 ºC and 1000 mbar|
- compressed air
(*) state type of gas on order
Precise installation and removal under pressure
Precise installation with alignment aid included in set
S421 flow / consumption sensor (in-line measurement)
The consumption sensor S421 is based on the thermal mass flow principle. It measures volumetric standard flow over a wide measuring range. The result is pressure and temperature independent. S421 is an in-line type sensor which is mounted into the pipe. There are 7 models available for ¼”, ½”, ¾”, 1” , 1 ¼”, 1 ½”, and 2” tubes. The version with display shows the actual volumetric flow and the total consumption. The consumption counter can be set via the keyboard. Various settings such as gas type, flow unit, reference standards, can be set ex factory or through our service kit. The service kit consists of a PC software and an interface box which connects the sensor to the USB port of the PC. Every sensor includes an analogue output (4…20mA) for flow and an isolated pulse output for the consumption counter.
- In-line type for high accuracy in small tube diameters.
- Analogue output 4…20 mA, pulse output (galvanically separated).
- Particular suitable for measuring process gases such as N2, Ar, He etc.
- Thermal mass flow, independent of pressure and temperature changes
- Easy installation
- Very fast response time
Applications for S421
- compressed air balancing
- compressed air consumption measurement
- leakage air / leak rate determination
- mobile compressed air measurement in front of single machines / plants
- flow measurement of process gases like e. g. nitrogen, CO2, oxygen, argon, nitrous oxide
- flow measurement at nitrogen generators
S421 Measured unit m3/h, m3/min, l/min, cfm
Accuracy +- (2% of measured value + 0.3% full scale)
Medium Air, non explosive gases (N2, O2, CO2, N2O, Ar)
Operating temperature -30 … 80 ºC
Operating pressure Up to 16 bar (optionally up to PN 40)
Analogue output Signal: 4 … 20 mA
Scaling: 0 … max range
Pulse output 1 pulse per m3
Power supply 24 VDC smoothed ± 15 %
PC connection: SDI interface
Mounting thread meas. section: R 1/4″, R 1/2″, R 3/4″R 1″, R 1 1/4″, R 1 1/2″, R 2″ external thread.
|Volumetric Flow Ranges|
|Inner tube||Measuring range|
|1 1/4″||36.8||0.7||480 m3/h|
|1 1/2″||41.8||1.0||550 m3/h|
SIGMA 430 – HIGH TEMPERATURE (up to 200 °C) APPLICATIONS FLOW / CONSUMPTION SENSOR
Sigma 430 is an insertion type flow meter using the pitot tube principle, designed for flow and consumption measurement in wet air, high mass flow or high velocity applications. Installation requires a G3/4″ connection and the mounting stem is graduated to simplify centering the sensor tip for pipe sizes up to 12″ diameter (DN300). Contact us for larger diameters.
Sigma 430 has a new 3 line colour display displaying flow, velocity and pressure with bluetooth interface for remote sensor configuration. Sigma 430 offers a choice of communication options including 4-20mA, pulse and SDI (our Digital Interface), Modbus/RTU and MBUS.
Pressure range up to 1.6MPa
Output 4-20mA, SDI, Modbus/RTU, MBUS
Optional colour display
Sigma 430 is ideal for measuring at the compressor outlet as the pitot tube design is not damaged by the very wet gas unlike thermal mass flow sensors which cannot be used here. Sigma 430 offers FAD calculation facilities for accurate measurement of compressor performance.
Sigma 450 Heavy duty industry Flow meter
S450 has been designed for harsh environments. The NEMA 4X housing with IP67 is able to withstand all weather conditions. All parts which come into contact with the measuring device are manufactured from stainless 316L steel. This enables the use of the sensor in the pharmaceutical and food industry but also for measuring aggressive and polluted gas.
The measuring of compressed air and gasses in explosion sensitive areas is made possible through choosing the ATEX implementation. Various gases can be measured, such as air, oxygen, argon, CO2, natural gas, hydrogen, methane and so forth. In principle, any gas mixture is to be measured when its components are known and its composition is constant.
In the modern production world instrumentation should provide interfaces to the existing factory and automation systems. S450 compressed air flowmeters supports a wide variety of connection forms which include the traditional 4…20 mA and pulse output, fieldbus interface for HART, Modbus and M-Bus. The C450 has been modularly developed and the desired form of connection is easily chosen.
- Direct measurement of mass flow and standard flow without the need for pressure compensation
- Wide range of tube sizes are supported with insertion type for big pipe diameters and in line types for small pipe diameters
- No moving parts, non clogging
- All parts which come into contact with the measurement medium are manufactured from stainless 316L steel
- Robust metal enclosure suitable for out-door applications in harsh environments.
- Wireless Bluetooth interface for sensor settings on site
- Display shows flow rates, consumption, medium temperature and diagnostic results
- 2 analogue outputs (4-20 mA) and 1 pulse output
- Available options:
- Fieldbus interface: HART, MODBUS, M-BUS
- Hazardous approval ATEX: II 2 G Ex d IIC T4
- 2 directional measurement
- Flow conditioning
|Measuring range:||0.4 … 92.7 sm/s *(standard range calibration)
0.8 … 185 sm/s *(max calibration)
*sm/s: standard meter per second
|Accuracy:||±1.5% of reading +0.3% full scale|
|Stated accuracy at:||Ambient/process temperature 23ºC +/-3ºC
Ambient/process humidity <90%, no condensation
Process pressure at 0.6 MPa
|Repeatability:||0.25% of reading|
|< 5 seconds|
|Sampling rate:||Display and outputs are refreshed every 200 msec.|
|Tube diameter:||Insertion type: DN25…DN1500
In line type: DN15…DN80
|Process connection:||Insertion type: ½” G type thread (ISO 228-1)
In line type: R thread (ISO 7-1), Flange EN 1092-1, ANSI 16.5, JIS B2220
|Measuring medium:||Any gas where the components and the mixing ration are constant and known.
See order information for a list of standard gases.
|Operating temp.:||-40 … +150°C (medium temp. insertion type)
-40 … +100°C (medium temp. in line type)
-40 … +65°C (ambient temp.)
|Operating pressure:||1.6 MPa (16 bar) – insertion type
4.0 MPa (40 bar) – in line type
|Analogue output:||2 x 4 … 20 mA, up to 500 R load, active/passive selectable, measurement channel selectable, scaling programmable|
|Pulse/Alarm output:||Alarm or pulse output. 1 pulse per 1, 10 or 100 consumption units. Alarm programmable.|
|Power supply:||16-30 VDC, 7 W|
|Housing:||NEMA 4X, IP 67|
|Sensor material:||Stainless steel 316L|
ATEX : II 2 G Ex d IIC T4 (Optional)
|Fieldbus (Optional):||MODBUS, HART, M-BUS|
|Configuration interface:||Service kit