Why is consumption measurement so important?

Example:

Medium-sized production plant
Company size 200 employees
Typical compressor capacity 16m3/min = 960 m3/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 S401 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.

Special Features

• 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

Technical data

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

Applications (*)

• compressed air
• nitrogen
• argon
• helium
• CO2

(*) state type of gas on order

Precise installation and removal under pressure

Alignment aid

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.

Features

• 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

Technical data

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.

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
Bluetooth interface

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.