English Instruction and operation manual S401 Thermal mass flow sensor
Dear Customer, Thank you for choosing our product. Please read the operating instructions in full and carefully observed them before starting up the device. The manufacturer cannot be held liable for any damage which occurs as a result of non-observance or non-compliance with this manual. Should the device be tampered with in any manner other than a procedure which is described and specified in the manual, the warranty is canceled and the manufacturer is exempt from liability.
Table of contents 1. 2. 3. 4. Safety instructions.......................................................................4 Application.................................................................................7 Features.....................................................................................7 Technical data.............................................................................8 4.1 General.................................................................................8 4.
1. Safety instructions 1. Safety instructions Please check if this instruction manual accords to the product type. Please observe all notes and instructions indicated in this manual. It contains essential information which must be observed before and during installation, operation and maintenance. Therefore this instruction manual must be read carefully by the technician as well as by the responsible user / qualified personnel.
1. Safety instructions ATTENTION! Permitted operating parameters! Observe the permitted operating parameters, any operation exceeding this parameters can lead to malfunctions and may lead to damage on the instrument or the system. • Do not exceed the permitted operating parameters. • Make sure the product is operated in its permitted limitations. • Do not exceed or undercut the permitted storage and operation temperature and pressure.
1. Safety instructions Storage and transportation 6 • Make sure that the transportation temperature of the sensor without display is between -30 ... +70°C and with display between -10 ... +50°C. • For storage and transportation it is recommended to use the packaging which comes with the sensor. • Please make sure the storage temperature of the sensor is between -10 ... +50°C. • Avoid direct UV and solar radiation during storage. • For the storage the humidity must be <90%, no condensation.
2. Application 2. Application The S401 is a flow sensor which is designed to measure the consumption of compressed air and gases within the permissible operating parameters. These parameters can be found in the technical data section. The S401 can measure the following values: • Volumetric flow of the compressed air or gas. • Total consumption of the compressed air or gas. The default factory settings are: Volumetric flow in m3/h and Total Consumption in m3.
4. Technical data 4. Technical data 4.1 General Parameters Standard unit flow: m3/h Other units: m3/min, l/min, l/s, cfm, kg/h, kg/min, kg/s Consumption units: m3, ft3 , kg Reference conditions ISO1217 20°C 1000 mbar (Standard-Unit) DIN1343 0°C 1013.25 mbar (Norm-Unit) Principle of measurement Thermal mass flow Sensor Glass coated resistive sensor Measuring medium Air, gas (non corrosive gas) Operating temperature -30 ... +140°C fluid temperature -30 ... +70°C casing -10 ...
4. Technical data 4.2 Electrical data Power supply 15 ... 30 VDC, 200 mA 4.3 Output-signals Analogue output Signal: 4 ... 20 mA, isolated Scaling: 0 to max flow Max load: 250R Pulse output 1 pulse per consumption unit, isolated switch, max. 30 VDC, 200 mA (pulse length: 10 ... 120 ms, depends on flow rate) Modbus output See chapter 9.3 4.4 Accuracy Accuracy* ±(1.5% of reading + 0.3% FS) (optional 1% of reading) Temperature drift: < 0.
4. Technical data 10 4" DN100 100.0 10 ... 2183.3 12 ... 4357.2 12 ... 5275.7 5" DN125 125.0 13 ... 3419.6 18 ... 6824.4 18 ... 8263.1 6" DN150 150.0 18 ... 4930.1 25 ... 9838.9 25 ... 11913.1 8" DN200 200.0 26 ... 8785.6 33 ... 17533.3 42 ... 21229.5 10" DN250 250.0 40 ... 13743.9 52 ... 27428.5 60 ... 33210.7 12" DN300 300.0 60 ... 19814.8 80 ... 39544.1 100 ... 47880.
5. Dimensional drawing 5.
6. Determination of the installation point 6. Determination of the installation point In order to maintain the accuracy stated in the technical data, the sensor must be insert in the centre of a straight pipe section with unhindered flow characteristics. Unhindered flow characteristics are achieved if the section in front of the sensor (inlet) and behind the sensor (outlet) are sufficiently long, absolutely straight and free of obstructions such as edges, seams, curves etc..
7. Inlet and outlet sections 7. Inlet and outlet sections The thermal measuring principle may be sensible to inlet and outlet conditions. For this we recommend the following minimum straight inlet and outlet sections to ensure an accurate measurement. Sensor should be always installed upstream from obstacles like valves, filter, reductions etc. In common the sensor should be installed as far as possible away from any disturbances.
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8. Sensor installation 8. Sensor installation Before installing the sensor, please make sure that all components listed below are included in your package. Qty Description Item no. 1 Sensor S695 S695 S695 S695 1 Sealing ring No P/N 1 Alignment key No P/N 2 M12 plug C219 0059 1 Instruction manual No P/N 1 Calibration certificate No P/N 4100 4101 4102 4103 8.1 Installation requirements To install the sensor, a ball valve or a nozzle is needed. • The inner thread must be G 1/2”.
8. Sensor installation 8.2 Installation procedure The following steps explain the procedure of an appropriate installation. Determination of the insertion depth of the sensor The sensor tip must be placed in the center of the pipe. For this the probe shaft has a scale. To determine the right position please calculate the insertion depth as described below. Center installation is the default and recommended installation type.
8. Sensor installation Alternative Installation Method For bigger pipe diameters (>200 mm) the sensor can be installed with only a 100 mm insertion depth as alternative method. This allows one sensor to be used for all pipe sizes. Attention: This method requires a setting on the local display or through the service software.
8. Sensor installation Installation of the sensor First please observe the flow direction indicated on the housing or on the shaft. It must match the flow direction of the compressed air or gas. 1. Ball valve hast to be closed. 2. The sensor head must be completely covered by the connection thread (see photo on the left). 3. Underlay the “O-ring” at the thread of the ball valve before screwing the flow sensor. 4. Screw the connection thread tightly to the ball valve and align flow sensor to flow direction.
8. Sensor installation Maximum angle deviation of a proper installation: Removal of the sensor 1. Hold the flow sensor. 2. Release the clamp sleeve at the connection thread. 3. Pull out the shaft slowly until the value “10” can be read at the scale. 4. Close the ball valve. 5. Release the connection thread and unscrew the flow sensor.
8. Sensor installation 8.3 Electrical connection The flow sensor is equipped with tow Connector plugs “A” and “B”. The cables are connected to the sensor through the M12 connector.
8. Sensor installation Pin assignment connector plug M12 Output Version Connector Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Modbus (P/N: A1411) A SDI -VB +VB DIR DIR B GND -VB +VB D+ D- 4 ... 20mA plus pulse (P/N: A1410) A SDI -VB +VB DIR DIR B NA SW SW +I -I 4 ...
9. Sensor signal outputs 9. Sensor signal outputs 9.1 Analog output The sensor has an analog output range of 4 ... 20 mA. This output can be scaled to match a desired measuring range. Standard scaling is from 0 to max flow. The corresponding flow in different pipe sizes can be found in the Appendix section. For other ranges, please contact the manufacturer. 9.2 Pulse output The sensor will send out one pulse per consumption unit.
9. Sensor signal outputs In case the flow rate is too high the S401 can not output the pulses with default settings (one pulse per consumption unit). For this the pulse can be set by our service software or a connected display to 1 pulse per 10 consumption units or 1 pulse per 100 consumption units. For example, if set to 1 pulse per 10 m3, the sensor will send one pulse each 10 m3. Example (1 pulse per 10 m3): Volumetric flow [m3/s] ≦ S401 3 Volumetric flow [m3/h] ≦ 10800 Pulse length [ms] Max.
9. Sensor signal outputs 9.2.
9. Sensor signal outputs 9.3 Modbus output Mode : RTU Baud rate : 19200 Device address :1 Framing / parity / stop bit : 8, N, 1 Response time : 1 second Response delay : 0 ms Inter-frame spacing : 7 char Remarks • Modbus communication settings can be changed by the service software. Index Channel description Resolution Format Length Modbus address 0.1 FLOAT 4 Byte 6 1 Flow 2 Consumption 1 UNIT32 4 Byte 8 3 Temperature 0.
10. Sensor display (option) 10. Sensor display (option) With the Sensor display it is possible to show the value of the flow and the consumption. Moreover it shows error messages and it is possible to change the configuration setting of the sensor. “Enter “Up key” = key” “Down = key” = 10.1 Starting process After powered up, the display starts automatically with an initialisation procedure.
10. Sensor display (option) Icons are shown in the status bar indicating status or warnings for the sensor in service. The following table provides descriptions for these icons. Icon Description Icon Description Calibration expired Pressure sensor damaged Temperature over operating range Temperature sensor damaged Flows over measuring range Flow direction Pressure over operating range 10.2 Configuration using the display The following settings can be changed via display or service software.
11. Service App S4C-FS 11. Service App S4C-FS Please download the service app from the Google Play in case you need to have any settings changed on the S401. The app runs on any Android system with BlueTooth supported. To change settings the app needs to scan the QR code on the calibration certificate at first. This ensures that only valid users can access the sensor settings.
12. Calibration 12. Calibration The sensor is calibrated ex work. The exact calibration date is printed on the certificate which is supplied together with the sensor. The accuracy of the sensor is regulated by the onsite conditions, and parameters like oil, high humidity or other impurities can affect the calibration and furthermore the accuracy. However we recommend to calibrate the instrument at least once per year. The calibration is excluded from the instruments warranty.
15. Warranty and packing costs. Excluded from this warranty is: • Damage caused by: ◦ Improper use and non-adherence to the instruction manual. ◦ Use of unsuitable accessories. ◦ External influences (e.g. damage caused by vibration, damage during transportation, excess heat or moisture). The warranty is cancelled: • If the user opens the measurement instrument without a direct request written in this instruction manual.
16. Appendix A - Analogue output 16. Appendix A - Analogue output Scaling table of analogue output: Standard range medium: Air at ISO 1217; 20°C; 1000 mbar inch 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” 2 1/2” 3” 4” 5” 6” 8” 10” 12” S401 Tube PLF mm 0.671 16.10 0.722 21.70 0.746 25.00 0.750 26.00 0.756 27.30 0.761 28.50 0.767 30.00 0.776 32.80 0.784 36.00 0.785 36.30 0.792 39.30 0.793 40.00 0.797 41.80 0.800 43.10 0.804 45.80 0.810 50.00 0.811 51.20 0.812 53.10 0.813 54.50 0.818 57.50 0.820 60.00 0.823 64.
16. Appendix A - Analogue output Max. range medium: Air at ISO1217; 20°C; 1000 mbar Tube inch mm 1/2” 16.10 3/4” 21.70 1” 25.00 26.00 27.30 28.50 30.00 1 1/4” 32.80 36.00 36.30 1 1/2” 39.30 40.00 41.90 43.10 45.80 2” 50.00 51.20 53.10 54.50 57.50 60.00 64.20 2 1/2” 65.00 68.90 70.30 71.10 76.10 3” 80.90 82.50 84.90 90.00 4” 100.00 107.10 110.00 5” 125.00 133.70 6” 150.00 159.30 182.50 190.00 8” 200.00 206.50 10” 250.00 260.40 12” 300.00 309.70 339.60 400.00 500.00 600.00 700.00 32 m3/h 90.98 177.84 243.
17. Appendix B - Modbus communication example 17. Appendix B - Modbus communication example 03 (0x03) Read holding register Request Response Slave address 1 byte Slave address 1 byte Function code 1 byte Function code 1 byte Starting address 1 byte Hi Byte count 1 byte Starting address 1 byte Lo Register Hi 1 byte No. of points Hi 1 byte Register Lo 1 byte No.
17. Appendix B - Modbus communication example 16 (0x10) Write multiple registers Request Response Slave address 1 byte Slave address 1 byte Function code 1 byte Function code 1 byte Starting address 1 byte Hi Starting address 1 byte Hi Starting address 1 byte Lo Starting address 1 byte Lo No. of registers Hi 1 byte No. of registers Hi 1 byte No. of registers Lo 1 byte No.
18. Appendix C - LRC and CRC calculation 18. Appendix C - LRC and CRC calculation LRC generation The Longitudinal Redundancy Checking (LRC) field is one byte, containing an 8–bit binary value. The LRC value is calculated by the transmitting device, which appends the LRC to the message. The device that receives recalculates an LRC during receipt of the message, and compares the calculated value to the actual value it received in the LRC field. If the two values are not equal, an error results.
18. Appendix C - LRC and CRC calculation LRC generation function static unsigned char LRC(unsigned char *auchMsg, unsigned short usDataLen) { unsigned char uchLRC = 0 ; while (usDataLen––) uchLRC += *auchMsg++ ; /* LRC char initialized */ /* pass through message buffer */ /* add buffer byte without carry */ return ((unsigned char)(–((char)uchLRC))) ; /* return twos complement */ } CRC generation The Cyclical Redundancy Checking (CRC) field is two bytes, containing a 16-bit binary value.
18. Appendix C - LRC and CRC calculation 7. The final content of the CRC register is the CRC value. 8. When the CRC is placed into the message, its upper and lower bytes must be swapped as described below. Placing the CRC into the message When the 16-bit CRC (two 8-bit bytes) is transmitted in the message, the low-order byte will be transmitted first, followed by the high-order byte.
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S401
FCC Statement： This device complies with part 15 of the FCC rules Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. NOTE: The manufacturer is not responsible for any radio or TV interference caused by unauthorized modifications to this equipment. Such modifications could void the user’s authority to operate the equipment.
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