CS Instruments VA 525 User manual

VA 525 EN V1.01 Page 1 of 41
EN –English
Instruction manual
VA 525
Compact inline flow sensor with
integrated flow straightener

Foreword
VA 525 EN V1.01 page 2o 41
I. Foreword
Dear customer,
thank you very much for deciding in favour of the VA 525. 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 525 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
Am Oxer 28c
D-24955 Harrislee
Tel.: [phone]
Fax: [phone]
Mail: [email protected]
Web: http://www.cs-instruments.com

Table of Content
VA 525 EN V1.01 Page 3 of 41
II. Table of Contents
I. Foreword ....................................................................................................................... 2
II. Table of Contents ...................................................................................................... 3
1Intended use.................................................................................................................. 5
2Safety instructions........................................................................................................ 5
3Instruments description ............................................................................................... 6
4Technical data............................................................................................................... 7
5Scaling Analogue output Comprssed Air................................................................. 8
6Installation Description ................................................................................................ 9
6.1 Installation of VA 525............................................................................................................ 9
7Flow measuring ranges...............................................................................................10
7.1 Flow for different gases....................................................................................................... 10
8Dimensions ..................................................................................................................11
9Electrical wiring ...........................................................................................................12
9.1 Modbus RTU, 4…20mA, Pulse, MBus or Ethernet............................................................ 12
9.2 Connection diagrams .......................................................................................................... 13
9.2.1 Modbus............................................................................................................................ 13
9.2.2 4..20mA / Impuls.............................................................................................................. 13
9.2.3 MBus................................................................................................................................ 13
9.2.4 Ethernet (optional PoE) .................................................................................................. 14

Table of Content
VA 525 EN V1.01 page 4o 41
10 Operation...................................................................................................................15
10.1 Initialization .......................................................................................................................... 16
10.2 Main menu after switching on ............................................................................................ 16
10.3 Settings................................................................................................................................. 17
10.3.1 Settings Setup.................................................................................................................. 18
10.3.1.1 Input / change tube diameter.................................................................................... 18
10.3.1.2 Input / change consumption counter........................................................................ 19
10.3.1.3 Definition of the units for flow, velocity, temperature and pressure ......................... 19
10.3.1.4 Advanced settings .................................................................................................... 20
10.3.1.4.1 Definition of the reference conditions................................................................... 20
10.3.1.4.2 Time setting for filtering........................................................................................ 22
10.3.1.5 Setting of Zeropoint and Low-flow cut off................................................................. 23
10.3.1.6 Pressur settings........................................................................................................ 24
10.3.2 Modbus settings............................................................................................................... 25
10.3.2.1 Modbus RTU Setup.................................................................................................. 25
10.3.3 Ethernet (Modbus TCP)................................................................................................... 26
10.3.3.1.1 Network Setup DHCP........................................................................................... 26
10.3.3.2 Network Settings static IP......................................................................................... 27
10.3.3.3 Modbus TCP Settings............................................................................................... 28
10.3.3.4 Modbus Settings (2001…2005)............................................................................. 29
10.3.3.5 Values Register (1001 …1500) ................................................................................ 29
10.3.4 Pulse /Alarm..................................................................................................................... 31
10.3.4.1 Pulse output.............................................................................................................. 31
10.3.5 User Setup....................................................................................................................... 32
10.3.5.1 Password.................................................................................................................. 32
10.3.5.2 Language.................................................................................................................. 32
10.3.5.3 Display / Touch......................................................................................................... 33
10.3.6 Advanced......................................................................................................................... 33
10.3.7 4 -20mA ........................................................................................................................... 34
10.3.8 VA 525 Info...................................................................................................................... 36
10.4 MBus...................................................................................................................................... 37
10.4.1 Default Settings communication...................................................................................... 37
10.4.2 Default values transmitted............................................................................................... 37
11 Status / Error messages...........................................................................................38
11.1 Status messages.................................................................................................................. 38
11.2 Error messages.................................................................................................................... 39
12 Maintenance..............................................................................................................40
13 Cleaning of the sensor head....................................................................................40
14 Re-Calibration...........................................................................................................40
15 Spare parts and repair..............................................................................................40
16 Calibration.................................................................................................................40
17 Warranty....................................................................................................................40

Instruments decription
VA 525 EN V1.01 Page 5 of 41
1 Intended use
The VA 525 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 525 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.
2Safety 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 525 which you would
like to dispose of.
Qualified employees from the measurement and control technology branch should only carry
out adjustments and calibrations.

Instruments decription
VA 525 EN V1.01 Page 6 of 41
3Instruments description
The newly developed VA 525 combines modern digital interfaces for connection to energy
monitoring systems with a small, compact design. The VA 525 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)
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)
Calibration Analog output 4..20mA
Read out service data
sensor diagnosis

Technische Daten
VA 525 EN V1.01 Page 7 of 41
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/h, m³/min, l/min, l/s, kg/h, kg/min, g/s, lb/min, lb/h Cfm,
m/s,ft/min
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,
Power supply: 18 to 36 VDC
Power consumption: max. 5W
Digital output: RS 485 (Modbus RTU)
MBus (optinal)
Ethernet oder Ethernet-PoE (optional)
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 (optinal)
Mounting thread: G ¼”,, G ½”, G ¾”, G1", G 1¼”G 1½”, G 2”
measuring block
Material measuring block: Aluminium
Protection calss: IP65
* m.v. = measured values
f.s. = full scale

Scaling Analogue output
VA 525 EN V1.01 Page 8 of 41
5Scaling Analogue output Comprssed Air
Reference DIN1945/ ISO 1217: 20°C, 1000 mbar (Reference during calibration)
Description
Version
Analogue output
VA 525 with integrated ¼” measuring block
Low Speed
4… 20 mA =
0...25 l/min
Standard
0...50 l/min
Max
0...105 l/min
High Speed
0...130 l/min
VA 525 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 525 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 525 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 525 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 525 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 525 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

Measuring ranges
VA 525 EN V1.01 Page 9 of 41
6Installation Description
6.1 Installation of VA 525
The sensor VA 525 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.

Measuring ranges
VA 525 EN V1.01 Page 10 of 41
7Flow measuring ranges
7.1 Flow for different gases
1/4"
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
Analog
output
20mA
l/min
[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
25
20
45
75
140
195
320
Standard
50
45
85
145
265
365
600
Max
105
90
175
290
530
730
1195
High Speed
130
110
215
355
640
885
1450
Adjustment to DIN 1343: 0°C, 1013,25 mbar
Air
Low Speed
25
20
40
70
130
180
295
Standard
50
40
80
135
240
335
550
Max
100
80
160
270
485
670
1100
High Speed
120
100
195
325
590
815
1330
Argon
(Ar)
Low Speed
45
35
75
120
220
305
505
Standard
85
70
135
230
415
570
935
Max
170
140
275
460
830
1140
1870
High Speed
205
170
335
555
1005
1385
2265
Carbon dioxide
(CO2)
Low Speed
25
20
45
75
140
195
320
Standard
50
45
85
145
260
360
590
Max
105
90
175
290
525
720
1185
High Speed
130
105
210
350
635
875
1430
Nitrogen
(N2)
Low Speed
25
20
40
70
130
180
295
Standard
50
40
80
135
240
335
550
Max
100
80
160
270
485
670
1100
High Speed
120
100
195
325
590
815
1330
Oxygen f
(O2)
Low Speed
25
20
45
75
135
185
305
Standard
50
40
80
140
250
345
570
Max
100
85
165
280
505
695
1140
High Speed
125
105
205
340
610
845
1380
Nitrous oxide
(N2O)
Low Speed
25
20
45
75
140
190
315
Standard
50
40
85
140
260
355
585
Max
105
85
170
285
520
715
1170
High Speed
125
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.

Dimensions
VA 525 EN V1.01 Page 11 of 41
8Dimensions
Nominal
width
Connection
thread
L
[mm]
B
[mm]
H1
[mm]
H
[mm]
A
[mm]
DN 8
G 1/4"
135
55
50
109,1
15
DN 15
G 1/2"
135
55
50
109,1
20
DN 20
G 3/4"
135
55
50
109,1
20
DN 25
G 1"
135
55
50
109,1
25
DN 32
G1 1/4"
135
80
80
139,1
25
DN 40
G1 1/2"
135
80
80
139,1
25
DN 50
G 2"
135
80
80
139,1
30

Electrical wiring
VA 525 EN V1.01 Page 12 of 41
9Electrical wiring
9.1 Modbus RTU, 4…20mA, Pulse, MBus or Ethernet
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
Version Modbus
+VB
RS 485 (A)
-VB
RS 485 (B)
NC
Connector plug A
(Version 4..20mA)
+VB
Pulse
galv. isolated
-VB
Pulse
galv. isolated
I+
4..20 mA
Connector plug A
Version MBus
+VB
NC
-VB
MBus
MBus
Colours 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 B
MBus
MBus (reverse polarity protected)
If no connection cable 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)
Connection plug A
Connection plug B
(OptionEthernet)

Electrical wiring
VA 525 EN V1.01 page 13 o 41
9.2 Connection diagrams
9.2.1 Modbus
3
4
5
1
2
+ VB
- VB
Blau / Blue
Weiss / White
Schwarz / Black
Modbus (B)
Modbus (A)
Braun / Brown
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.
Alternatively, a 120R resistor can be installed in the plug between pin 2 and pin 4.
9.2.2 4..20mA / Impuls
3
4
5
1
2
+ VB
- VB
4 … 20mA
+ -
Grau / Grey
Blau / Blue
Weiss / White
Schwarz / Black
Braun / Brown
9.2.3 MBus
3
4
5
1
2
+ VB
- VB
Blau / Blue
Grau / Grey
Schwarz / Black MBus
MBus
Braun / Brown

Electrical wiring
VA 525 EN V1.01 page 14 o 41
9.2.4 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.
*PoE: Power over Ethernet

Operation
VA 525 EN V1.01 Page 15 of 41
10 Operation
Remark: Only for version with display
The operation of the VA 525 is done by the two capacitive key buttons Up () and Enter ()
“Up“ ( ) “OK“ ( )

Operation
VA 525 EN V1.01 page 16 o 41
10.1 Initialization
10.2 Main menu after switching on
HW Version Page-No.
*** VA 520 ***
Gas /
Status info
SW Version Modbus ID
Switching to pages 2-5 or back by pressing key „“Available only with option „Pressure”
AV-Time ( Period for average value calculation) could be changed under Sensor Setup.-Advanced–AV-Time
After switching on the VA 525, the initialized
screen is displayed followed by the main
menu.
VA 525

Operation
VA 525 EN V1.01 page 17 o 41
10.3 Settings
The settings menu could accessed by pressing the key „OK“, selection of „Yes“” with button „“.
Then the entry hast o be confimed with „OK“.
But the access to the settings menu is password protected.
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“
Menu items
4..20mA / pulse alarm,
Network setup
MBus
only available with corresponding sensor version.
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 525 EN V1.01 page 18 o 41
10.3.1 Settings Setup
Settings Sensor Setup
10.3.1.1 Input / change tube diameter
For the VA 525 not adjustable (suspended) as voted on included measuring section with corresponding
measurement block diameter.
For changes, first select the menu item
with key „“and then confirm it with
“OK“.
Diameter

Operation
VA 525 EN V1.01 page 19 o 41
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“.
Unit selection:
according to chapter 10.3.1.3
Direct selection of the unit button and
call of the unit page with „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 525 EN V1.01 page 20 o 41
10.3.1.4 Advanced settings
Setup Sensor SetupAdvanced
10.3.1.4.1 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 presetting 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  Ref. Settings
To make changes, first select a menu with
button „“and confirm selection by pressing
„OK“ .
Duc
Volume Type