CS Instruments VA 521 User manual

VA 521 English V1.20 Page 1 of 39
Instruction manual
VA 521
Compact inline flow sensor with
integrated flow straightener
with Display, 4 ... 20 mA and pulse output (galv. isolated)
EN –English

Foreword
VA 521 EN V1.20 Page 2o 39
I. Foreword
Dear customer,
thank you very much for deciding in favour of the VA 521. Please read this
installation and operation manual carefully before mounting and initiating the device
and follow our advice. A riskless operation and a correct functioning of the
VA 521 are only guaranteed in case of careful observation of the described
instructions and notes
Sales Office South / Geschäftsstelle Süd
Zindelsteiner Str. 15
D-78052 VS-Tannheim
Tel.: [phone]
Fax: [phone]
Mail: [email protected]
Web: http://www.cs-instruments.com
Sales Office North / Geschäftsstelle Nord
Gewerbehof 14
D-24955 Harrislee
Tel.: [phone]
Fax: [phone]
Mail: [email protected]
Web: http://www.cs-instruments.com

Table of Content
VA 521 English V1.20 Page 3 of 39
II. Table of Contents
I. Foreword ....................................................................................................................... 2
II. Table of Contents ...................................................................................................... 3
1Safety instructions........................................................................................................ 5
2Instruments description ............................................................................................... 6
3Technical data............................................................................................................... 8
4Scaling Analogue output Comprssed Air................................................................. 9
5Installation Description ...............................................................................................10
5.1 Pipe/tube requirements ...................................................... Fehler! Textmarke nicht definiert.
5.2 Inlet / outlet runs ................................................................. Fehler! Textmarke nicht definiert.
5.3 Installation of VA 521......................................................... Fehler! Textmarke nicht definiert.
5.4 Displayhead Position........................................................................................................... 10
6Flow measuring ranges...............................................................................................11
6.1 Flow for different gases....................................................................................................... 11
7Dimensions ..................................................................................................................12
7.1 With measurement section and screw-in thread.............................................................. 12
7.2 With measurement section and flange (Material stainless steel 1.4404):...............Fehler!
Textmarke nicht definiert.
8Electrical wiring ...........................................................................................................13
8.1 Pulse or MBus...................................................................................................................... 13
8.2 Ethernet (optional PoE) ...................................................................................................... 14

Table of Content
VA 521 EN V1.20 Page 4o 39
9Operation......................................................................................................................15
9.1 Initialization .......................................................................................................................... 16
9.2 Main menu ............................................................................................................................ 16
9.3 Settings................................................................................................................................. 17
9.3.1 Sensor Setup................................................................................................................... 17
9.3.1.1 Input / change tube diameter.................................................................................... 17
9.3.1.2 Input / change consumption counter........................................................................ 18
9.3.1.3 Definition of the units for flow, velocity, temperature and pressure ......................... 18
9.3.1.4 Definition of the reference conditions....................................................................... 19
9.3.1.5 Setting of Zeropoint and Low-flow cut off................................................................. 21
9.3.2 Modbus RTU Setup ......................................................................................................... 22
9.3.3 Modbus TCP (Optional)................................................................................................... 23
9.3.3.1 Network Setup DHCP............................................................................................... 23
9.3.3.2 Network Settings static IP......................................................................................... 24
9.3.3.3 Modbus TCP Settings............................................................................................... 25
9.3.3.4 Modbus Settings (2001…2005)............................................................................. 26
9.3.3.5 Values Register (1001 …1500) ................................................................................ 26
9.3.4 Pulse /Alarm..................................................................................................................... 28
9.3.4.1 Pulse output.............................................................................................................. 28
9.3.5 User Setup....................................................................................................................... 29
9.3.5.1 Password.................................................................................................................. 29
9.3.5.2 Language.................................................................................................................. 29
9.3.5.3 Display / Touch......................................................................................................... 30
9.3.6 Advanced......................................................................................................................... 30
9.3.7 4 -20mA ........................................................................................................................... 31
9.3.8 VA 521 Info...................................................................................................................... 33
9.4 MBus...................................................................................................................................... 34
9.4.1 Default Settings communication...................................................................................... 34
9.4.2 Default values transmitted............................................................................................... 34
10 Status / Error messages...........................................................................................35
10.1 Status messages.................................................................................................................. 35
10.2 Error messages.................................................................................................................... 36
11 Maintenance..............................................................................................................37
12 Cleaning of the sensor head....................................................................................37
13 Re-Calibration...........................................................................................................37
14 Spare parts and repair..............................................................................................37
15 Calibration.................................................................................................................37
16 Warranty....................................................................................................................37

Safety instructions
VA 521 English V1.20 Page 5 of 39
1Safety instructions
Please read carefully before starting the device!
Warning: Do not exceed the pressure range of 16 bar!
Observe the measuring range of the sensor!
Always observe the direction of flow when positioning the sensor!
The screwed fixture must be pressure tight.
It is absolutely necessary to avoid condensation on the sensor element or water drops in the
measuring air as they may cause faulty measuring results.
The manufacturer cannot be held liable for any damage which occurs as a result of non-
observance or non-compliance with these instructions. 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.
We offer no guarantee for the suitability for any other purpose and are not liable for errors
which may have slipped into this operation manual. We are also not liable for consequential
damage resulting from the delivery, capability or use of this device.
We offer you to take back the instruments of the instruments family VA 521 which you would
like to dispose of.
Qualified employees from the measurement and control technology branch should only carry
out adjustments and calibrations.
The consumption sensor VA 521 works according to the calorimetric measuring procedure.
Flammable gases
If this consumption sensor is used for measurement of flammable gases (e. g. natural gas
and so on) we expressly would like to point out that the sensor has no DVGW admission,
however, it can be used for measurements in natural gas. A DVGW admission is not
mandatory.
The consumption sensor corresponds with the current state of technology and basically it can be used
in any flammable and non-flammable gases.
If the sensor is used e.g. in the medium natural gas, the sensor will be adjusted for natural
gas. The calibration protocol (inspection certificate) will be included in the scope of delivery.
The area outside the pipeline (ambient area of the sensor) must not be an explosive area.
The installation has to be carried out by authorized professionals.

Instruments decription
VA 521 English V1.20 Page 6 of 39
2Instruments description
The newly developed VA 521 combines modern digital interfaces for connection to energy
monitoring systems with a small, compact design. The VA 521 is always used when many
machines (compressed air consumers) are to be connected/integrated to a energy
monitoring network.
Special features:
Compact, small design - for use in machines, behind the maintenance unit on the
final consumers
Screw-in thread for easy installation in existing pipelines due to integrated measuring
block
-Sizes : ¼", ½" ¾", 1" 1 ¼" , 1 ½" and 2"
Integrated flow straighteners (no inlet runs necessary, except ¼”)
Integrated display with presentation of 2 values
-Flow & Consumption,
-Speed & Temperature
Operation via integrated keyboard
-Units selection
freely selectable. m³/h, m³/min, l/min, l/s, kg/h, kg/min, g/s, lb/min, lb/h
cfm, m/s,ft/min
Digital interfaces
-Modbus RTU (RS485)
-Ethernet
-MBus
Analog interfaces
-4..20mA
-Pulse output galv. insulated.
Pressure measurement (optional)
Noze The optional CS Instruments Service Software enables you to:
Selection/conversion of gas type (air, nitrogen, argon, nitrous oxide, CO2, oxygen)
Scaling Analog output 4..20mA
Read out service data
Sensor diagnosis

Instruments decription
VA 521 English V1.20 Page 7 of 39

3 Intended use
The VA 521 consumption sensor is used for continuous flow measurements.
The VA 525 consumption sensor is designed and constructed exclusively for the intended
purpose described here and may only be used accordingly.
The user must check whether the instrument is suitable for the selected application. It must
be ensured that the medium is compatible with the wetted parts. The technical data listed in
the data sheet are binding.
Improper handling or operation outside the technical specifications is not permitted. Claims of
any kind based on improper use are excluded.
Operating principle:
The VA 521 consumption probe operates according to the calorimetric measuring method.
The basis of this measuring method is the electrical heating of the mechanically protected
built-in sensor. The mass flow, the volume flow and the flow velocity can be measured and
determined by the resulting heat flow to the passing medium (gas).
With the calorimetric measurement method (based on the measurement principle), the
operating temperature and pressure of the medium have no influence on the measurement
result, only the material data of the gas component are decisive.

Technische Daten
VA 521 English V1.20 Page 8 of 39
4Technical data
Measurement: Flow and consumption
Reference Standard: Standard settings ex works:
DIN 1945, ISO 1217 at 20°C and 1000 mbar
Selectable Units m³/h (Standard settings ex works)
m³/min, l/min, l/s, ft/min, cfm, m/s, kg/h, kg/min, kg/s
Measuring principle: calorimetric measurement
Sensor: Pt45, Pt1000
Measuring medium: Air, gases
Operating temperature: -30 ... 80°C probe tube
-20 ... 70°C housing
Operating pressure: up to 16 bar, special version PN 40 (40 bar)
Power supply: 12 to 36 VDC
Power consumption: max. 5W
Digital output: RS 485 (Modbus RTU)
Analog output: 4...20 mA (see chapter 4), max. burden < 500 Ohm
Pulse output: pulse output potential free (dry contact)
passive: max. 48Vdc, 150mA
1 pulse pro m³ resp. pro l,
Valency adjustable with the display keys
Accuracy: ± 1,5 % m.v., ± 0,3 % f. s.*
Display: TFT 1.8 Resolution 220 x 176
Mounting thread: G ¼”,, G ½”, G ¾”, G1", G 1¼” G 1½”, G 2”
measuring block
Material measuring block: Aluminium
Protection class: IP65
* m.v. = measured values
f.s. = full scale

Scaling Analogue output
VA 521 English V1.20 Page 9 of 39
5Scaling Analogue output Compressed Air
Reference DIN1945/ ISO 1217: 20°C, 1000 mbar (Reference during calibration)
Description
Version
Analogue output
VA 521 with integrated ½” measuring block
Low Speed
4… 20 mA =
0...20 m³/h
Standard
0...45 m³/h
Max
0...90 m³/h
High Speed
0...110 m³/h
VA 521 with integrated ¾” measuring block
Low Speed
4… 20 mA =
0...45 m³/h
Standard
0...85 m³/h
Max
0...175 m³/h
High Speed
0...215 m³/h
VA 521 with integrated 1" measuring block
Low Speed
4… 20 mA =
0...75 m³/h
Standard
0...145 m³/h
Max
0...290 m³/h
High Speed
0...355 m³/h
VA 521 with integrated 1¼” measuring
block
Low Speed
4… 20 mA =
0...140 m³/h
Standard
0...265 m³/h
Max
0...530 m³/h
High Speed
0...640 m³/h
VA 521 with integrated 1½” measuring
block
Low Speed
4… 20 mA =
0...195 m³/h
Standard
0...365 m³/h
Max
0...730 m³/h
High Speed
0...885 m³/h
VA 521 with integrated 2" measuring block
Low Speed
4… 20 mA =
0...320 m³/h
Standard
0...600 m³/h
Max
0…1195m³/h
High Speed
0...1450 m³/h

Installation
VA 521 English V1.20 Page 10 of 39
6Installation Description
6.1 Installation of VA 521
The sensor VA 521 is pre-supplied with the measuring block.
An installation at customer site is only allowed in the unpressurized state of the
system.
Tightness of the connection must be checked and ensured
The connecting nut is tightened to a torque of 25 -30 Nm.
It has to be checked whether the VA 521 is correctly installed in the measuring
section, the flow direction arrows must point from the integrated flow straightener
away.
6.2 Display head Position
Fastening screws
The Position of the Display head is twistable by 180 e.g. in
case of reverse flow direction.
For this purpose the 6 fastening screws are to be released
and the display head rotated 180°.
Caution:
It must be ensured that the connection plugs are still plugged
and the gasket is installed correctly.
Flow straightener
Flow

Measuring ranges
VA 521 English V1.20 Page 11 of 39
7Flow measuring ranges
7.1 Flow for different gases
1/2"
3/4"
1"
1 ¼"
1 ½"
2"
Analog
output
20mA
Analog
output
20mA
Analog
output
20mA
Analog
output
20mA
Analog
output
20mA
Analog
output
20mA
[m³/h]
[m³/h]
[m³/h]
[m³/h]
[m³/h]
[m³/h]
Reference DIN1945/ ISO 1217: 20°C, 1000 mbar (Reference during calibration)
Air
Low Speed
20
45
75
140
195
320
Standard
45
85
145
265
365
600
Max
90
175
290
530
730
1195
High Speed
110
215
355
640
885
1450
Adjustment to DIN 1343: 0°C, 1013,25 mbar
Air
Low Speed
20
40
70
130
180
295
Standard
40
80
135
240
335
550
Max
80
160
270
485
670
1100
High Speed
100
195
325
590
815
1330
Argon
(Ar)
Low Speed
35
75
120
220
305
505
Standard
70
135
230
415
570
935
Max
140
275
460
830
1140
1870
High Speed
170
335
555
1005
1385
2265
Carbon dioxide
(CO2)
Low Speed
20
45
75
140
195
320
Standard
45
85
145
260
360
590
Max
90
175
290
525
720
1185
High Speed
105
210
350
635
875
1430
Nitrogen
(N2)
Low Speed
20
40
70
130
180
295
Standard
40
80
135
240
335
550
Max
80
160
270
485
670
1100
High Speed
100
195
325
590
815
1330
Oxygen f
(O2)
Low Speed
20
45
75
135
185
305
Standard
40
80
140
250
345
570
Max
85
165
280
505
695
1140
High Speed
105
205
340
610
845
1380
Nitrous oxide
(N2O)
Low Speed
20
45
75
140
190
315
Standard
40
85
140
260
355
585
Max
85
170
285
520
715
1170
High Speed
105
210
345
630
865
1420
Other gases on request
Please note:
The area outside the pipeline (ambient area of the sensor) must not be an explosive area.

Dimension
VA 521 English V1.20 Page 12 of 39
8Dimensions
8.1 With measurement section and screw-in thread
Pipe size
Thread
L
(mm)
B
(mm)
H
(mm)
H1
(mm)
A1
(mm)
A
(mm)
VA 521 1/2“
DN 15
G1/2"
135
55
190,65
50
25
20
VA 521 3/4“
DN 20
G3/4"
135
55
190,65
50
26
20
VA 521 1“
DN 25
G1"
135
55
190,65
50
33
25
VA 521 1 1/4"
DN 32
G1 1/4"
135
80
215,45
80
35
25
VA 521 1 1/2“
DN 40
G 1 1/2"
135
80
215,45
80
36
25
VA 521 2“
DN 50
G2"
135
80
215,45
80
44
30

Electrical wiring
VA 521 English V1.20 Page 13 of 39
9Electrical wiring
9.1 Modbus RTU, 4…20mA, Pulse or MBus
Attention: Not required connections NC must not be connected to a voltage and/or to protection
earth. Cut and insulate cables.
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Connector plug A
+VB
RS 485 (A)
-VB
RS 485 (B)
I+
4..20 mA
Connector plug B
Pulse output (standard)
NC
GND
DIR
Pulse
galv. isolated
Pulse
gavl. isolated
Connector plug B
Option MBus
NC
GND
DIR
MBus
MBus
Colours pulse cables
0553 0106 (5 m)
0553.0107 (10 m)
brown
white
blue
black
grey
Legend:
-VB
Negative supply voltage 0 V
Pulse
Pulse for consumption
+VB
Positive supply voltage 18...36 VDC smoothed
NC
Must not be connected to a voltage
and/or to protection earth. Please cut
and isolate cables.
I +
Current signal 4...20 mA –selected measured
signal
RS 485 (A)
RS 485 (B)
Modbus RTU A
Modbus RTU A
MBus
MBus (reverse polarity protected)
If no connection cable/ pulse
cable is ordered the sensor will
be supplied with a M12
connector plug. The user can
connect the supply and signal
cables as indicated in the
connection diagram.
.
M12 Connector plug
View from back side
(terminal side)
Connector plug A (M12 - A-coding) Connector plug B (M12 - A-coding)
3
4
5
1
2
+ VB
- VB
4 … 20mA
+ -
Grau / Grey
Blau / Blue
Weiss / White
Schwarz / Black
Modbus (B)
Modbus (A)
Braun / Brown
3
4
5
1
2
Grau / Grey
Schwarz / Black
Impulsausgang / Pulse output
Remark: If the sensor is placed at the end of the Modbus system a termination is required. The sensors have an
internal switchable termination, therefore the 6 fastening screws from the lid are to be released and set
the internal DIP Switch to “On”. It must be ensured that the connection plugs are still plugged and the
gasket is installed correctly, see also chapter 6.2.
Alternatively, a 120R resistor can be installed in the plug between pin 2 and pin 4.
Connector plug A
Connector plug B

Dimension
VA 521 EN V1.20 Page 14 o 39
9.2 Ethernet (optional PoE)
Connector plug B Connection cable
M12 x-coded 8 pole M12 x-coded to RJ45
Data LINES: 1,2 und 3,4
PoE LINES: 5,6 und 7,8
2
81
3
5 4
6
7
M12 x 1
Connection cable: Cat 6.
Remark:
VA521 Power Classification acc. IEEE 802.3af: Class 2 (3,84W –6,49W)
*PoE: Power over Ethernet
Connector plug A
Connector plug B (M12 c-coded

Operation
VA 521 English V1.20 Page 15 of 39
10 Operation
Remark: Only for version with display
“Up“ ( ) “OK“ ( )
The operation of the VA 521 is done by the two capacitive key buttons Up () and Enter ()

Operation
VA 521 EN V1.20 Page 16 o 39
10.1 Initialization
10.2 Main menu
Switching to pages 2-4 or back by pressing key „“
AV-Time (Period for average value calculation) could be changed under Sensor Setup.-Advanced–AV-Time
HW Version Page-No.
*** VA 520 ***
Gas /
Status Info
SW Version Modbus ID
*** VA 520 ***
391.23
391
1 minutes
410,34
1 minute
91,3282.46
After switching on the VA 521, the initialized
screen is displayed followed by the main
menu.

Operation
VA 521 EN V1.20 Page 17 o 39
10.3 Settings
The settings menu could accessed by pressing the key „OK“.
But the access to the settings menu is password protected.
10.3.1 Sensor Setup
Setup Sensor Setup
10.3.1.1 Input / change tube diameter
For VA 521 not adjustable (suspended) as voted on included measuring section with corresponding pipe
diameter.
53.1 mm
For changes, first select the menu item
with key „“and then confirm it with
“OK“.
Selection of a menu item or to change a value
is done with the key „“,a final move to the
chosen menu item or takeover of the value
change needs the confirmation by pressing the
key „OK“
Factory settings for password at the time of
delivery: 0000 (4 times zero).
If required the password could be changed at
Setup–User setup-Password.
.

Operation
VA 521 EN V1.20 Page 18 o 39
10.3.1.2 Input / change consumption counter
Setup Sensor SetupTotal Counter  Unit button
Important!
When the counter reach 100000000 m³ the counter will be reset to zero.
10.3.1.3 Definition of the units for flow, velocity, temperature and pressure
Setup Sensor SetupUnits
In order to change, e.g. the unit, first select by
pressing key „“the button “Unit” and then
key “OK”.
Select with the key „“the correct unit and
then confirm selection by pressing 2x „OK“.
Entering / changing the consumption counter
via button „“, select the respective position
and activate the position with the "OK"
button.
By pressing „“ the position value is
incremented by 1. Complete with "OK" and
activate next number position.
Confirm entry by pressing „OK“.
To make changes to the unit for the respective
measurement value, first select by pressing
„“ the field of the „measurement value“ and
activate „it with „OK“ .
Selection of the new unit with „“
In case the quantity of units selectable are not
presentable on one page, pleas move to next
page by pressing „<<“ .
Confirm selection by pressing 2x „OK“.
Procedure for all 4 measurement variables is
analogous.

Operation
VA 521 EN V1.20 Page 19 o 39
10.3.1.4 Definition of the reference conditions
Here can be defined the desired measured media reference conditions for pressure and temperature
and times for the filter and averaging.
Factory pre-setting for reference temperature and reference pressure are 20 °C, 1000 hPa
All volume flow values (m³/h) and consumption values indicated in the display are
related to 20 °C and 1000 hPa (according to ISO 1217 intake condition)
Alternatively 0 °C and 1013 hPa (=standard cubic meter) can also be entered as a reference.
Do not enter the operation pressure or the operation temperature under reference conditions!
Setup Sensor SetupAdvanced
Setup Sensor Setup Advanced Ref.Pref
Setup Sensor SetupAdvanced 
Ref.Temp
To make changes, first select a menu with
button „“and confirm selection by pressing
„OK“ .
In order to change, e.g. the unit, first select by
pressing key „“the field “Units” and then
key “OK”.
Select with the key „“the correct unit and
then confirm selection by pressing 2x „OK“.
Input / change of the value by selecting the
respective position with button „“and
entering by pressing button „OK“ .
By pressing „“ the position value is
incremented by 1. Complete with "OK" and
activate next number position.
Procedure for changing the reference
temperature is the same.
Under point "Filtertime" together with the
appropriate "Filter Grade" an attenuation can
be defined.
Input values of 0 -10000 in [ms] are possible.

Operation
VA 521 EN V1.20 Page 20 o 39
Setup Sensor SetupAdvanced Filtertime
Setup Sensor SetupAdvanced AV-Time
Under item "Filtertime" "an attenuation can
be defined.
Input values of 0 -10000 in [ms] are possible
The time period for averaging can be entered
here.
Input values of -1440 1 [minutes] are possible.
For average values see display window 3 + 4