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CS 400

Warranty

CS 400

CS 400 thermal mass flow sensor


Features

CS provides a warranty for this product of 24 months covering the material and workmanship
under the stated operating conditions from the date of delivery.

Please report any findings immediately and within the warranty time guaranteed by us.

Excluded from this warranty is damage caused by improper use and non-adherence to the
instruction manual.

The warranty is also cancelled once the measuring instrument has been opened provided this
is not described in the instruction manual for maintenance purposes. This is also the case if
the serial number has been changed, damaged or removed.

If in addition to the warranty service necessary repairs, adjustments or similar are carried out,
the warranty services are free of charge but there is a charge for other services such as
transport and packing costs. Other claims, especially those for damage occurring outside the
instrument are not included unless responsibility is legally binding.

Insertion type sensor for installations under


pressure
Thermal mass flow, independent of pressure
and temperature changes
IP65 casing provides robust protection in rough
industrial environment
Very fast response time
High accuracy and wide measuring range
Tube diameters of 1/2 to 12 . Other diameters
on request

ATTENTION: Batteries have a reduced warranty time of 12 months.


The CS flow sensor CS 400 is based on the thermal
mass flow principle. It measure 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 ball valve. This makes it
possible to do the installation under pressure without
shutting down the compressed air line.

CS-iTEC GmbH
Werkstrasse 2
D-79426 Buggingen
Germany
Tel: +49 (0) 7631 9387 387
Fax: +49 (0) 7631 9387 388
Email: sales@cs-itec.com
Website: http://www.cs-itec.com

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.

CS Instruments (Asia) Co. Ltd.

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 a interface box which connects the sensor to the USB port of
the PC.

Room 31, Cambridge Plaza, Tower B


188 San Wan Road, Sheung Shui,
Hong Kong
Tel: +86 (0) 755 8619 3164
Fax: +86 (0) 755 8619 3165
Email: sales@csinstrument.com
Website: http://www.csinstrument.com

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0970 0007 CS 400 English, V4.8, 07.02.14

Every sensor includes an analogue output (420mA)


for flow and one pulse output for the consumption counter.

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Order information

Important information
The operating instructions must be read in full and carefully observed before starting up the device. The manufacturer cannot be held liable for any damage which occurs as a result of nonobservance or non-compliance with this manual.

T
h
r
e
a
d

CS 400

Should the device be tampered with in any manner other than a procedure which is described and
specified in the manual, the warranty is cancelled and the manufacturer is exempt from liability.
The device is destined exclusively for the described application.
CS offers no guarantee for the suitability for any other purpose and is not liable for errors which
may have slipped into this operating manual. They are also not liable for consequential damage
resulting from the delivery, capability or use of this device.

Area of application
The CS 400 product range is designed for stationary and mobile use in compressed air pipes, air
ducts or shafts. It is used for the measurement and control of flow and air consumption in compressed air and other gases.
The principle of measurement is based on the evacuation of heat from an electrically heated sensor into the surrounding air flow.
The measuring devices operate independently of pressure and temperature.
When the sensor is fitted in a pipe, the output signal from the speed of flow is used to calculate
the standard volume flow or mass flow of the medium.

0970 0007 CS 400 English, V4.8, 07.02.14

D
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C
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D
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0695 4001

CS 400 insertion type flow sensor, 220 mm shaft

0695 4011

CS 400 insertion type flow sensor, 160 mm shaft

0695 4021

CS 400 insertion type flow sensor, 330 mm shaft

0695 4031
A1004
A1005
A1006
A1023
A1024
A1007
A1008
A1009
A1010
A1011
A1012
A1013
A1015

A1020
A1021

A1022

0553 0104

Sensor cable 5 m, with M12 connector, open wires

0553 0105

Sensor cable 10 m, with M12 connector, open wires

0554 2005

Service kit for sensor configuration including software

0554 0007

Power supply wall mountable, input: 85...264 VAC, output: 24 VDC, 15W

CS 400 insertion type flow sensor, 400 mm shaft


A
B
C
A
B
A
B
C
D
E
F
G

H
A

B
C
A
B

G
NPT
PT
Flow from left to right
Flow from right to left
Air
CO2
O2 (oil and grease free cleansed)
N2
He
Ar
NG
Others (please specify the gas or gas mix)
Standard range calibration
Max range calibration
High speed range calibration
No display
With display

0554 0107

Mains unit 100-240 VAC / 24 VDC, 0.5 A for CS 400 / CS 200 Series, 2 m cable

3200 0001

Flow calibration with certificate

3200 0005
3200 0020

Oil & grease free cleaned option for flow sensors (for Oxygen it is already included in A 1009)
Real gas calibration in selected gas to ensure best accuracy

0553 0122

Sensor cable, 5 pole, AWG24, 5.0 mm outer diameter, black (per meter)

0970 0007 CS 400 English, V4.8, 07.02.14

19

CS 400

Pulse output

CS 400

Notes on safety
Please read prior to operation!

CS 400 will send out one pulse per m3, l or ft3. This pulse output can be connected to an external counter to count the total consumption. The numbers of m per second are summed up and
indicated after one second. Pulse lengths depending on consumption rate.

Do not exceed the pressure range of 50 bar.


Observe the measuring range of the sensor.
Overheating destroys probes.
Observe permissible storage, transport and operating temperatures.
Improper handling or use of force when opening the device cancels all warranty claims.
Adjustment and calibration work must only be carried out by trained personnel from the field
of measuring and control engineering.
Always observe the direction of flow when positioning the sensor.
The screwed fixture must be pressure tight.
The adapter sleeve must be tightened with a torque of 20 30 Nm.
Avoid condensation on the sensor element or water drops in the measuring air at all costs
as they cause faulty measuring results.
The values of the inlet and outlet sections must not fall below the specified minimum values
as this causes increased deviations in the measuring results.

Installation considerations
In order to maintain the accuracy stipulated in the data sheets, the sensor must be inserted in
the centre of a straight pipe section with unhindered flow characteristics.
Unhindered flow characteristics are achieved if the sections in front of the sensor (inlet) and
behind the sensor (outlet) are sufficiently long, absolutely straight and lack obstructions such
as edges, seams, curves etc.
Careful attention must be paid to the design of the outlet section as obstructions can cause
counter-flow turbulence as well as turbulence in the direction of the flow.

Analogue output

The sensor is for indoor use only! If installed outdoors, the sensor must be protected
from direct sun and rain!

The analogue output is scaled ex factory to the maximum flow rate. Whenever diameters are
changed the scaling of the analogue output should also be changed to cover the new flow range.
This can be done by the srevice kit (0554 2005).

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0970 0007 CS 400 English, V4.8, 07.02.14

Attention:
We strongly recommend not to install CS 400 permanently in wet environment as it exists
usually right after compressor outputs. It will cause wrong measurements and can degrade the
sensor. Only temporary installations should be done.

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

L
L1

L2
D/2

Display consumption?
Yes (No)

D/2

D
flow
L
L1
L2
D

D/2

If the zero consumption reset is


disabled, it goes to
Display contrast
directly.

D/2

= Length of the entire measurement section


= Length of inlet section
= Length of outlet section
= Diameter of tube

Zero consumption?
Yes (No)

Display contrast:
Up - Change
Enter - OK

Table of inlet / outlet sections

Display consumption. Press Upkey to select Yes or No. Press


Enter-key to confirm and go to
next page.

Reset consumption to zero. Press


Up-key to select Yes or No. Press
Enter-key to confirm and go to
next page.

Display contrast can be adjusted.


Press Up-key to adjust it. Press
Enter-key to confirm and go to
next page.

The following table shows the equalising sections necessary in relation to existing obstructions.
Flow obstruction

Min. length

Min. length

before the measurement section

inlet (L1)

outlet (L2)

Slight curve (bend < 90)

12 x D

5xD

Reduction (Tube narrows towards measurement


section)

15 x D

5xD

Expansion (Tube expands towards measurement


section)

15 x D

5xD

90 bend or T piece

15 x D

5xD

2 x 90 bends on one level

20 x D

5xD

2 x 90 bends 3 dimensional change of direction

35 x D

5xD

Shut-off valve

45 x D

5xD

The respective minimum values required are indicated here. If it is not possible to observe the
stipulated equalising sections, considerable deviations in measuring results must be expected.
Please contact us in this case for flow conditioning solutions.

0970 0007 CS 400 English, V4.8, 07.02.14

Display upside down?


Yes (No)

System reset

Set direction of the display. Press


Up-key to select Yes or No. Press
Enter-key to confirm. The setting
will be saved automatically.

Online value will be shown in 3


seconds automatically.

Online value

Notes:
1. To abort the entry process keep Enter-key pressed for 3 seconds.
2. Online value will be shown automatically if there is no key pressed for more
than 20 seconds.

0970 0007 CS 400 English, V4.8, 07.02.14

17

CS 400

CS 400

Configuration setting

Sensor installation

CS 400 is usually configued ex factory according to customer settings ordered.

The sensor head must be placed in the centre of the pipe. Therefore the probe shaft has a scale.
To determine the right position measure the length from the marked position to the centre of the
tube. The probe then will be inserted up to this measure and then tightened up. Also consider the
flow direction which should match with the arrows at the casing. Use the alignment tool to align
the flow direction

In case settings have to be changed, please keep the Enter-key () pressed for 3 seconds, CS 400 will ask to enter the unlock key.

Online value

After 3 seconds

Wrong unlock
code
Unlock code is not
correct.

Input unlock code 12. Selected


digit will be blinking. Press Up-key

Incorrect
input
Input unlock code:12

00

to modify. Press Enter-key to


confirm, shift to next digit or go to
next page.

Measure from here to the tube


center

Read the insertion position here

Hint for the installation with ball valve:

Correct input

Ball valve R 1/2, DN 15

Diameter:
150.0

Unit:
m3/h

Display velocity?
Yes (No)

Set diameter. Selected digit will


be blinking. Press Up-key to modify. Press Enter-key to confirm,
shift to next digit or go to next
page.

Set the unit of flow. Press Up-key


to modify. Press Enter-key to
confirm and go to next page.

Display velocity. Press Up-key to


select Yes or No. Press Enter-key
to confirm and go to next page.

Passage ball valve minimum 15 mm

Consider the flow direction should match with


the arrows at the casing.

Safety information
Installation is carried out by inserting the connection thread (1/2'' thread, SW 27) into the connection piece. The sensor is then inserted to the required immersion depth and aligned according to
the direction of air flow. A depth scale engraved on the probe tube will assist you, along with a
flow alignment arrow and an aligning aid.
Once the sensor has been aligned, the adapter sleeve must be tightened with the stipulated
torque (SW 17).
Attention: Alignment of the sensor must not be modified when tightening the connection thread
and adapter sleeve.

Display volume flow?


Yes (No)

Display flow. Press Up-key to


select Yes or No. Press Enter-key
to confirm and go to next page.

If this should occur, check the immersion depth and alignment again and correct if necessary.
The angular deviation should not be greater than +- 2 in relation to the ideal position as otherwise
the measuring accuracy will decrease.

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0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Special indicators

Installation Procedures
1. Weld nozzle onto the pipe and drill a hole

If this icon is shown on the top right corner of LCD it


means that CS 400 has been connected to CS 325. In
such case, all the key function are disabled.

Max. 30mm

View the diameter

Enter

Note:
1. Specification of the nozzle is G 1/2, male tread.

By pressing the Enter-key the current diameter setting


can be shown.
It will go back to online value automactally in 3 seconds.

Diameter

2. Avoid breaking through the tube wall when you are welding the nozzle. Otherwise
tube inside will be out of flatness. This will generate turbulence and measuring accuracy will be effected.
3. Make sure the pipe has no pressure inside when you drill the hole. Diameter of the
hole must be 13 mm, otherwise the shaft can not be inserted.

030.0
mm

Wrong information

4. Use CS spot drilling device (p/n: 0530 1108) to drill the hole if system is not allowed
to shut down.
Error:
Auto transmission!

2. Mount ball valve onto the nozzle

Error:
Communication fail!

Error:
Sensor unmatch!

It will show this message if Auto transmission function


of the sensor was enabled. Please contact technician of
CS for such case.

As soon as communication fails, the instrument will


show this message. Please restart the power supply to
fix the problem. If it is still there please contact technician of CS.

If the sensor is not matching the display setting, the


instrument will show this frame. Please contact technician of CS for such case.

Note:
1. Make ball valve close. It must be a full port ball valve.
2. Use high pressure installation device (p/n: 0530 1105) when operating pressure is
larger than 15 bar.
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0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

15

CS 400

Operation

CS 400
3. Screw flow sensor onto the ball valve

Enter ( )

Up ( )
Touch the button on the top of CS 400 for operation.

Note:

Starting process

1. Underlay the O-ring at thread of ball valve before screwing flow sensor.
Reset

2. Coil Teflon tape onto the thread before screwing flow sensor.
After power on, the display will go through an initialisation
procedure.

Initializing...

4. Open the ball valve

2 sec.

Software: 1.31

Software version

1 sec.

Note:
Sensor connecting...

5 sec.

3457
m3/h

1. Use one hand holding the head or body


of CS 400 while you open the ball valve
with another hand.

Showing online value. CS 400 can display up to 3 channels: velocity, flow and consumption. User can configure
every channel to let it display or not. If all three channels
was configured to no display, the flow channel will be still
there. Ex-factory, CS 400 was configured to display standard volumetric flow and consumption. CS 400 will toggle

2. Open the ball valve slowly.

among the channels every 3 seconds.

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0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Technical data

5. Insert flow sensor into the center of the pipe

Measured unit:

OD = Outer Diameter
Engraved
depth scale

X=

OD
2

Accuracy:

(3% of measured value + 0.3% full scale)


Temperature drift: 0.05 % / K
Pressure drift: 0.5 % / MPa

Stated accuracy at:

Ambient/process temperature 23 C +-3C


Ambient/process humidity < 90 %, no condensation
Process pressure at 0.6 MPa

Tube diameter:

1/2 to 12 (bigger diameters on request, diameter is programmed


ex factory or via service kit or key board)

Principle of measurement:

Thermal mass flow

Sensor:

Glass coated resistive sensor

Measuring medium:

Air, gas (non corrosive gas)

Operating temperature:

-30 to 140C probe tube


-30 to 70 C housing
0 to 50 C display

Operating pressure:

up to 5.0 MPa

Analogue output:

Signal: 4 to 20 mA
Scaling: 0 to maximum volume flow
Accuracy: 0.06 mA

Pulse output:

1 pulse per m, amplitude: + Vb, 10 mA (active signal)


1 pulse per m, isolated switch, max 30 VDC, 10 mA
(pulse length: 30-120 ms, depends on consumption rate)

Power supply:

12-30 VDC, 100 mA

Display:

128 x 64 pixel, with backlight

Transport temperature:

without display: -30 ... 70 C

Insertion depth = x + y
Locking nut

m/h, m/min, l/min, cfm, m/s, kg/min, kg/h, kg/s


(Based on standard DIN 1945. ISO 1217: 20C and 1000 hPa)

Read Insertion depth here!!


Top end of ball valve

Safety ring
y
x
OD

6. Screw locking nut and adjust insertion depth slightly

Note:
Insertion depth must be read out at the top of
locking nut when the locking nut screws tightly.
So you must push the shaft a little more when
you screw the locking nut.
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0970 0007 CS 400 English, V4.8, 07.02.14

with display:

0970 0007 CS 400 English, V4.8, 07.02.14

-10 60 C

13

CS 400

CS 400
7. Adjust direction

Dimensions

This key is a standard


configuration for CS 400.

Note:
Make sure actual flow
direction is same as the
arrow shows.

M12 connector

8. Final check
The sensor is delivered with two M12 connectors. The user can connect the supply and signals according to the connection diagram on
top. If a connection cable is ordered (0553
0104, 0553 0105) M12 connector is replaced by
a connection cable, with open wires at one side
(see color code in table above) and M12 connector at another side.

Check installation depth. Sometimes the shaft maybe pushed out a little by compressed air / gas. Then you need to make it correct and screw locking nut a little tighter.
Dont forget adjust direction again because locking nut may have changed a little.
9. Connect cable
Warning!
Dont screw it with bulls strength! Otherwise, it will
damage the connecting pins.
The cable is connected to the sensor through a so
called M12 connector.
Connection procedures:

Align 5 pins of CS 400 with 5 holes of M12 connector through the alignment mark.

Screw white steel thread slightly. If you feel hard to


screw it, dont continue with strength but unscrew
and check if you have aligned it.
Only screw white steel part, dont screw blank plastic part!
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0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

Measuring ranges

CS 400
Please note:

Inner diameter

Standard

Max

High Speed

The consumption sensor CS 400 corresponds with the latest state of technology and
can generally be used for burnable and non-burnable gases.

Inch

mm

from ... to

from ... to

from ... to

1/2''

16.1

0.15 ... 45.6 m/h

0.3 ... 91.0 m/h

0.3 ... 110.2 m/h

3/4''

21.7

0.3 ... 89.1 m/h

0.4 ... 177.8 m/h

0.4 ... 215.3 m/h

1''

27.3

0.5 ... 147.7 m/h

0.6 ... 294.7 m/h

0.6 ... 356.9 m/h

1 1/4''

36.0

0.9 ... 266.3 m/h

1.2 ... 531.5 m/h

1.2 ... 643.5 m/h

1 1/2''

41.9

1.2 ... 366.7 m/h

1.5 ... 731.9 m/h

1.5 ... 886.2 m/h

2''

53.1

2 ... 600.1 m/h

2.5 ... 1197.6 m/h

3 ... 1450.0 m/h

2 1/2''

68.9

3.5 ... 1026.5 m/h

5 ... 2048.6 m/h

5 ... 2480.4 m/h

3''

80.9

5 ... 1424.4 m/h

7 ... 2842.7 m/h

7 ... 3441.9 m/h

4''

100.0

10 ... 2183.3 m/h

12 ... 4357.2 m/h

12 ... 5275.7 m/h

SDI:

Digital signal (internal use)

5''

125.0

13 ... 3419.6 m/h

18 ... 6824.4 m/h

18 ... 8263.1 m/h

-VB:

Negative supply voltage

6''

150.0

18 ... 4930.1 m/h

25 ... 9838.9 m/h

25 ... 11913.1 m/h

+VB:

Positive supply voltage

8"

200.0

26 ... 8785.6 m/h

33 ... 17533.3 m/h

42 ... 21229.5 m/h

+I:

Positive 4..20 mA signal

+P:

Pulse output

NC:

not connected

SEL:

internal signal

SW:

Isolated pulse switch output

DIR:

flow direction input

10"

250.0

40 ... 13743.9 m/h

52 ... 27428.5 m/h

60 ... 33210.7 m/h

12 ''

300.0

60 ... 19814.8 m/h

80 ... 39544.1 m/h

100 ... 47880.4 m/h

If this consumption sensor is used for measurement of burnable gases (e. g. natural
gas) we explicitly point out that the sensor has no hazardous approval, however, it
can be used for burnable gases.
For the use in e. g. natural gas the sensor will be calibrated in natural gas. The calibration protocol (inspection certificate) is included in the scope of delivery.
The area outside the pipe (environment of the sensor) is not allowed to be an explosive
area.

Connection diagram

A
B

The above flow rates are standard flows with reference to P = 1000 hPa and T = 20 C
The table below shows max flow rates in a 2 pipe of different gases at Norm conditions
of P = 1013.25 hPa and T = 0 C.
Gas

Symbol

Air

Standard

Max

552

1101

1334

Argon

Ar

971

1937

2346

Carbon dioxide

CO2

552

1103

1335

Nitrogen

N2

534

1065

1290

Oxygen

O2

572

1142

1383

Nitrous oxide

N2O

589

1175

1423

Natural gas

NG

355

709

858

10

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

SDI

-VB

+VB

+I

+P

SEL

-VB

DIR

SW

SW

Wire color

Brown

White

Blue

Black

Grey

High Speed

0970 0007 CS 400 English, V4.8, 07.02.14

Attention: The signals DIR, SW, SW are available on CS 400 / CS 420 only if the serial
number consists of an 8 at this position: XXXX 7XXX

0970 0007 CS 400 English, V4.8, 07.02.14

11

CS 400

Measuring ranges

CS 400
Please note:

Inner diameter

Standard

Max

High Speed

The consumption sensor CS 400 corresponds with the latest state of technology and
can generally be used for burnable and non-burnable gases.

Inch

mm

from ... to

from ... to

from ... to

1/2''

16.1

0.15 ... 45.6 m/h

0.3 ... 91.0 m/h

0.3 ... 110.2 m/h

3/4''

21.7

0.3 ... 89.1 m/h

0.4 ... 177.8 m/h

0.4 ... 215.3 m/h

1''

27.3

0.5 ... 147.7 m/h

0.6 ... 294.7 m/h

0.6 ... 356.9 m/h

1 1/4''

36.0

0.9 ... 266.3 m/h

1.2 ... 531.5 m/h

1.2 ... 643.5 m/h

1 1/2''

41.9

1.2 ... 366.7 m/h

1.5 ... 731.9 m/h

1.5 ... 886.2 m/h

2''

53.1

2 ... 600.1 m/h

2.5 ... 1197.6 m/h

3 ... 1450.0 m/h

2 1/2''

68.9

3.5 ... 1026.5 m/h

5 ... 2048.6 m/h

5 ... 2480.4 m/h

3''

80.9

5 ... 1424.4 m/h

7 ... 2842.7 m/h

7 ... 3441.9 m/h

4''

100.0

10 ... 2183.3 m/h

12 ... 4357.2 m/h

12 ... 5275.7 m/h

SDI:

Digital signal (internal use)

5''

125.0

13 ... 3419.6 m/h

18 ... 6824.4 m/h

18 ... 8263.1 m/h

-VB:

Negative supply voltage

6''

150.0

18 ... 4930.1 m/h

25 ... 9838.9 m/h

25 ... 11913.1 m/h

+VB:

Positive supply voltage

8"

200.0

26 ... 8785.6 m/h

33 ... 17533.3 m/h

42 ... 21229.5 m/h

+I:

Positive 4..20 mA signal

+P:

Pulse output

NC:

not connected

SEL:

internal signal

SW:

Isolated pulse switch output

DIR:

flow direction input

10"

250.0

40 ... 13743.9 m/h

52 ... 27428.5 m/h

60 ... 33210.7 m/h

12 ''

300.0

60 ... 19814.8 m/h

80 ... 39544.1 m/h

100 ... 47880.4 m/h

If this consumption sensor is used for measurement of burnable gases (e. g. natural
gas) we explicitly point out that the sensor has no hazardous approval, however, it
can be used for burnable gases.
For the use in e. g. natural gas the sensor will be calibrated in natural gas. The calibration protocol (inspection certificate) is included in the scope of delivery.
The area outside the pipe (environment of the sensor) is not allowed to be an explosive
area.

Connection diagram

A
B

The above flow rates are standard flows with reference to P = 1000 hPa and T = 20 C
The table below shows max flow rates in a 2 pipe of different gases at Norm conditions
of P = 1013.25 hPa and T = 0 C.
Gas

Symbol

Air

Standard

Max

552

1101

1334

Argon

Ar

971

1937

2346

Carbon dioxide

CO2

552

1103

1335

Nitrogen

N2

534

1065

1290

Oxygen

O2

572

1142

1383

Nitrous oxide

N2O

589

1175

1423

Natural gas

NG

355

709

858

10

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

SDI

-VB

+VB

+I

+P

SEL

-VB

DIR

SW

SW

Wire color

Brown

White

Blue

Black

Grey

High Speed

0970 0007 CS 400 English, V4.8, 07.02.14

Attention: The signals DIR, SW, SW are available on CS 400 / CS 420 only if the serial
number consists of an 8 at this position: XXXX 7XXX

0970 0007 CS 400 English, V4.8, 07.02.14

11

CS 400

CS 400
7. Adjust direction

Dimensions

This key is a standard


configuration for CS 400.

Note:
Make sure actual flow
direction is same as the
arrow shows.

M12 connector

8. Final check
The sensor is delivered with two M12 connectors. The user can connect the supply and signals according to the connection diagram on
top. If a connection cable is ordered (0553
0104, 0553 0105) M12 connector is replaced by
a connection cable, with open wires at one side
(see color code in table above) and M12 connector at another side.

Check installation depth. Sometimes the shaft maybe pushed out a little by compressed air / gas. Then you need to make it correct and screw locking nut a little tighter.
Dont forget adjust direction again because locking nut may have changed a little.
9. Connect cable
Warning!
Dont screw it with bulls strength! Otherwise, it will
damage the connecting pins.
The cable is connected to the sensor through a so
called M12 connector.
Connection procedures:

Align 5 pins of CS 400 with 5 holes of M12 connector through the alignment mark.

Screw white steel thread slightly. If you feel hard to


screw it, dont continue with strength but unscrew
and check if you have aligned it.
Only screw white steel part, dont screw blank plastic part!
12

0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Technical data

5. Insert flow sensor into the center of the pipe

Measured unit:

OD = Outer Diameter
Engraved
depth scale

X=

OD
2

Accuracy:

(3% of measured value + 0.3% full scale)


Temperature drift: 0.05 % / K
Pressure drift: 0.5 % / MPa

Stated accuracy at:

Ambient/process temperature 23 C +-3C


Ambient/process humidity < 90 %, no condensation
Process pressure at 0.6 MPa

Tube diameter:

1/2 to 12 (bigger diameters on request, diameter is programmed


ex factory or via service kit or key board)

Principle of measurement:

Thermal mass flow

Sensor:

Glass coated resistive sensor

Measuring medium:

Air, gas (non corrosive gas)

Operating temperature:

-30 to 140C probe tube


-30 to 70 C housing
0 to 50 C display

Operating pressure:

up to 5.0 MPa

Analogue output:

Signal: 4 to 20 mA
Scaling: 0 to maximum volume flow
Accuracy: 0.06 mA

Pulse output:

1 pulse per m, amplitude: + Vb, 10 mA (active signal)


1 pulse per m, isolated switch, max 30 VDC, 10 mA
(pulse length: 30-120 ms, depends on consumption rate)

Power supply:

12-30 VDC, 100 mA

Display:

128 x 64 pixel, with backlight

Transport temperature:

without display: -30 ... 70 C

Insertion depth = x + y
Locking nut

m/h, m/min, l/min, cfm, m/s, kg/min, kg/h, kg/s


(Based on standard DIN 1945. ISO 1217: 20C and 1000 hPa)

Read Insertion depth here!!


Top end of ball valve

Safety ring
y
x
OD

6. Screw locking nut and adjust insertion depth slightly

Note:
Insertion depth must be read out at the top of
locking nut when the locking nut screws tightly.
So you must push the shaft a little more when
you screw the locking nut.
8

0970 0007 CS 400 English, V4.8, 07.02.14

with display:

0970 0007 CS 400 English, V4.8, 07.02.14

-10 60 C

13

CS 400

Operation

CS 400
3. Screw flow sensor onto the ball valve

Enter ( )

Up ( )
Touch the button on the top of CS 400 for operation.

Note:

Starting process

1. Underlay the O-ring at thread of ball valve before screwing flow sensor.
Reset

2. Coil Teflon tape onto the thread before screwing flow sensor.
After power on, the display will go through an initialisation
procedure.

Initializing...

4. Open the ball valve

2 sec.

Software: 1.31

Software version

1 sec.

Note:
Sensor connecting...

5 sec.

3457
m3/h

1. Use one hand holding the head or body


of CS 400 while you open the ball valve
with another hand.

Showing online value. CS 400 can display up to 3 channels: velocity, flow and consumption. User can configure
every channel to let it display or not. If all three channels
was configured to no display, the flow channel will be still
there. Ex-factory, CS 400 was configured to display standard volumetric flow and consumption. CS 400 will toggle

2. Open the ball valve slowly.

among the channels every 3 seconds.

14

0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Special indicators

Installation Procedures
1. Weld nozzle onto the pipe and drill a hole

If this icon is shown on the top right corner of LCD it


means that CS 400 has been connected to CS 325. In
such case, all the key function are disabled.

Max. 30mm

View the diameter

Enter

Note:
1. Specification of the nozzle is G 1/2, male tread.

By pressing the Enter-key the current diameter setting


can be shown.
It will go back to online value automactally in 3 seconds.

Diameter

2. Avoid breaking through the tube wall when you are welding the nozzle. Otherwise
tube inside will be out of flatness. This will generate turbulence and measuring accuracy will be effected.
3. Make sure the pipe has no pressure inside when you drill the hole. Diameter of the
hole must be 13 mm, otherwise the shaft can not be inserted.

030.0
mm

Wrong information

4. Use CS spot drilling device (p/n: 0530 1108) to drill the hole if system is not allowed
to shut down.
Error:
Auto transmission!

2. Mount ball valve onto the nozzle

Error:
Communication fail!

Error:
Sensor unmatch!

It will show this message if Auto transmission function


of the sensor was enabled. Please contact technician of
CS for such case.

As soon as communication fails, the instrument will


show this message. Please restart the power supply to
fix the problem. If it is still there please contact technician of CS.

If the sensor is not matching the display setting, the


instrument will show this frame. Please contact technician of CS for such case.

Note:
1. Make ball valve close. It must be a full port ball valve.
2. Use high pressure installation device (p/n: 0530 1105) when operating pressure is
larger than 15 bar.
6

0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

15

CS 400

CS 400

Configuration setting

Sensor installation

CS 400 is usually configued ex factory according to customer settings ordered.

The sensor head must be placed in the centre of the pipe. Therefore the probe shaft has a scale.
To determine the right position measure the length from the marked position to the centre of the
tube. The probe then will be inserted up to this measure and then tightened up. Also consider the
flow direction which should match with the arrows at the casing. Use the alignment tool to align
the flow direction

In case settings have to be changed, please keep the Enter-key () pressed for 3 seconds, CS 400 will ask to enter the unlock key.

Online value

After 3 seconds

Wrong unlock
code
Unlock code is not
correct.

Input unlock code 12. Selected


digit will be blinking. Press Up-key

Incorrect
input
Input unlock code:12

00

to modify. Press Enter-key to


confirm, shift to next digit or go to
next page.

Measure from here to the tube


center

Read the insertion position here

Hint for the installation with ball valve:

Correct input

Ball valve R 1/2, DN 15

Diameter:
150.0

Unit:
m3/h

Display velocity?
Yes (No)

Set diameter. Selected digit will


be blinking. Press Up-key to modify. Press Enter-key to confirm,
shift to next digit or go to next
page.

Set the unit of flow. Press Up-key


to modify. Press Enter-key to
confirm and go to next page.

Display velocity. Press Up-key to


select Yes or No. Press Enter-key
to confirm and go to next page.

Passage ball valve minimum 15 mm

Consider the flow direction should match with


the arrows at the casing.

Safety information
Installation is carried out by inserting the connection thread (1/2'' thread, SW 27) into the connection piece. The sensor is then inserted to the required immersion depth and aligned according to
the direction of air flow. A depth scale engraved on the probe tube will assist you, along with a
flow alignment arrow and an aligning aid.
Once the sensor has been aligned, the adapter sleeve must be tightened with the stipulated
torque (SW 17).
Attention: Alignment of the sensor must not be modified when tightening the connection thread
and adapter sleeve.

Display volume flow?


Yes (No)

Display flow. Press Up-key to


select Yes or No. Press Enter-key
to confirm and go to next page.

If this should occur, check the immersion depth and alignment again and correct if necessary.
The angular deviation should not be greater than +- 2 in relation to the ideal position as otherwise
the measuring accuracy will decrease.

16

0970 0007 CS 400 English, V4.8, 07.02.14

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

L
L1

L2
D/2

Display consumption?
Yes (No)

D/2

D
flow
L
L1
L2
D

D/2

If the zero consumption reset is


disabled, it goes to
Display contrast
directly.

D/2

= Length of the entire measurement section


= Length of inlet section
= Length of outlet section
= Diameter of tube

Zero consumption?
Yes (No)

Display contrast:
Up - Change
Enter - OK

Table of inlet / outlet sections

Display consumption. Press Upkey to select Yes or No. Press


Enter-key to confirm and go to
next page.

Reset consumption to zero. Press


Up-key to select Yes or No. Press
Enter-key to confirm and go to
next page.

Display contrast can be adjusted.


Press Up-key to adjust it. Press
Enter-key to confirm and go to
next page.

The following table shows the equalising sections necessary in relation to existing obstructions.
Flow obstruction

Min. length

Min. length

before the measurement section

inlet (L1)

outlet (L2)

Slight curve (bend < 90)

12 x D

5xD

Reduction (Tube narrows towards measurement


section)

15 x D

5xD

Expansion (Tube expands towards measurement


section)

15 x D

5xD

90 bend or T piece

15 x D

5xD

2 x 90 bends on one level

20 x D

5xD

2 x 90 bends 3 dimensional change of direction

35 x D

5xD

Shut-off valve

45 x D

5xD

The respective minimum values required are indicated here. If it is not possible to observe the
stipulated equalising sections, considerable deviations in measuring results must be expected.
Please contact us in this case for flow conditioning solutions.

0970 0007 CS 400 English, V4.8, 07.02.14

Display upside down?


Yes (No)

System reset

Set direction of the display. Press


Up-key to select Yes or No. Press
Enter-key to confirm. The setting
will be saved automatically.

Online value will be shown in 3


seconds automatically.

Online value

Notes:
1. To abort the entry process keep Enter-key pressed for 3 seconds.
2. Online value will be shown automatically if there is no key pressed for more
than 20 seconds.

0970 0007 CS 400 English, V4.8, 07.02.14

17

CS 400

Pulse output

CS 400

Notes on safety
Please read prior to operation!

CS 400 will send out one pulse per m3, l or ft3. This pulse output can be connected to an external counter to count the total consumption. The numbers of m per second are summed up and
indicated after one second. Pulse lengths depending on consumption rate.

Do not exceed the pressure range of 50 bar.


Observe the measuring range of the sensor.
Overheating destroys probes.
Observe permissible storage, transport and operating temperatures.
Improper handling or use of force when opening the device cancels all warranty claims.
Adjustment and calibration work must only be carried out by trained personnel from the field
of measuring and control engineering.
Always observe the direction of flow when positioning the sensor.
The screwed fixture must be pressure tight.
The adapter sleeve must be tightened with a torque of 20 30 Nm.
Avoid condensation on the sensor element or water drops in the measuring air at all costs
as they cause faulty measuring results.
The values of the inlet and outlet sections must not fall below the specified minimum values
as this causes increased deviations in the measuring results.

Installation considerations
In order to maintain the accuracy stipulated in the data sheets, the sensor must be inserted in
the centre of a straight pipe section with unhindered flow characteristics.
Unhindered flow characteristics are achieved if the sections in front of the sensor (inlet) and
behind the sensor (outlet) are sufficiently long, absolutely straight and lack obstructions such
as edges, seams, curves etc.
Careful attention must be paid to the design of the outlet section as obstructions can cause
counter-flow turbulence as well as turbulence in the direction of the flow.

Analogue output

The sensor is for indoor use only! If installed outdoors, the sensor must be protected
from direct sun and rain!

The analogue output is scaled ex factory to the maximum flow rate. Whenever diameters are
changed the scaling of the analogue output should also be changed to cover the new flow range.
This can be done by the srevice kit (0554 2005).

18

0970 0007 CS 400 English, V4.8, 07.02.14

Attention:
We strongly recommend not to install CS 400 permanently in wet environment as it exists
usually right after compressor outputs. It will cause wrong measurements and can degrade the
sensor. Only temporary installations should be done.

0970 0007 CS 400 English, V4.8, 07.02.14

CS 400

CS 400

Order information

Important information
The operating instructions must be read in full and carefully observed before starting up the device. The manufacturer cannot be held liable for any damage which occurs as a result of nonobservance or non-compliance with this manual.

T
h
r
e
a
d

CS 400

Should the device be tampered with in any manner other than a procedure which is described and
specified in the manual, the warranty is cancelled and the manufacturer is exempt from liability.
The device is destined exclusively for the described application.
CS offers no guarantee for the suitability for any other purpose and is not liable for errors which
may have slipped into this operating manual. They are also not liable for consequential damage
resulting from the delivery, capability or use of this device.

Area of application
The CS 400 product range is designed for stationary and mobile use in compressed air pipes, air
ducts or shafts. It is used for the measurement and control of flow and air consumption in compressed air and other gases.
The principle of measurement is based on the evacuation of heat from an electrically heated sensor into the surrounding air flow.
The measuring devices operate independently of pressure and temperature.
When the sensor is fitted in a pipe, the output signal from the speed of flow is used to calculate
the standard volume flow or mass flow of the medium.

0970 0007 CS 400 English, V4.8, 07.02.14

D
i
r
e
c
t
i
o
n

M
e
d
i
u
m

C
a
li
b
r
a
ti
o
n

D
i
s
p
l
a
y

0695 4001

CS 400 insertion type flow sensor, 220 mm shaft

0695 4011

CS 400 insertion type flow sensor, 160 mm shaft

0695 4021

CS 400 insertion type flow sensor, 330 mm shaft

0695 4031
A1004
A1005
A1006
A1023
A1024
A1007
A1008
A1009
A1010
A1011
A1012
A1013
A1015

A1020
A1021

A1022

0553 0104

Sensor cable 5 m, with M12 connector, open wires

0553 0105

Sensor cable 10 m, with M12 connector, open wires

0554 2005

Service kit for sensor configuration including software

0554 0007

Power supply wall mountable, input: 85...264 VAC, output: 24 VDC, 15W

CS 400 insertion type flow sensor, 400 mm shaft


A
B
C
A
B
A
B
C
D
E
F
G

H
A

B
C
A
B

G
NPT
PT
Flow from left to right
Flow from right to left
Air
CO2
O2 (oil and grease free cleansed)
N2
He
Ar
NG
Others (please specify the gas or gas mix)
Standard range calibration
Max range calibration
High speed range calibration
No display
With display

0554 0107

Mains unit 100-240 VAC / 24 VDC, 0.5 A for CS 400 / CS 200 Series, 2 m cable

3200 0001

Flow calibration with certificate

3200 0005
3200 0020

Oil & grease free cleaned option for flow sensors (for Oxygen it is already included in A 1009)
Real gas calibration in selected gas to ensure best accuracy

0553 0122

Sensor cable, 5 pole, AWG24, 5.0 mm outer diameter, black (per meter)

0970 0007 CS 400 English, V4.8, 07.02.14

19

CS 400

Warranty

CS 400

CS 400 thermal mass flow sensor


Features

CS provides a warranty for this product of 24 months covering the material and workmanship
under the stated operating conditions from the date of delivery.

Please report any findings immediately and within the warranty time guaranteed by us.

Excluded from this warranty is damage caused by improper use and non-adherence to the
instruction manual.

The warranty is also cancelled once the measuring instrument has been opened provided this
is not described in the instruction manual for maintenance purposes. This is also the case if
the serial number has been changed, damaged or removed.

If in addition to the warranty service necessary repairs, adjustments or similar are carried out,
the warranty services are free of charge but there is a charge for other services such as
transport and packing costs. Other claims, especially those for damage occurring outside the
instrument are not included unless responsibility is legally binding.

Insertion type sensor for installations under


pressure
Thermal mass flow, independent of pressure
and temperature changes
IP65 casing provides robust protection in rough
industrial environment
Very fast response time
High accuracy and wide measuring range
Tube diameters of 1/2 to 12 . Other diameters
on request

ATTENTION: Batteries have a reduced warranty time of 12 months.


The CS flow sensor CS 400 is based on the thermal
mass flow principle. It measure 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 ball valve. This makes it
possible to do the installation under pressure without
shutting down the compressed air line.

CS-iTEC GmbH
Werkstrasse 2
D-79426 Buggingen
Germany
Tel: +49 (0) 7631 9387 387
Fax: +49 (0) 7631 9387 388
Email: sales@cs-itec.com
Website: http://www.cs-itec.com

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.

CS Instruments (Asia) Co. Ltd.

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 a interface box which connects the sensor to the USB port of
the PC.

Room 31, Cambridge Plaza, Tower B


188 San Wan Road, Sheung Shui,
Hong Kong
Tel: +86 (0) 755 8619 3164
Fax: +86 (0) 755 8619 3165
Email: sales@csinstrument.com
Website: http://www.csinstrument.com

20

0970 0007 CS 400 English, V4.8, 07.02.14

Every sensor includes an analogue output (420mA)


for flow and one pulse output for the consumption counter.

0970 0007 CS 400 English, V4.8, 07.02.14

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