SUTO S450 Manual

English
Instruction and operation manual
S450
Thermal mass flow sensor
for heavy duty industries

Dear Customer,
Thank you for choosing our product.
Please read this manual in full before starting up the device and
carefully observe the instructions stated. The manufacturer cannot be
held liable for any damage which occurs as a result of non-observance
or non-compliance with this manual.
Should the device be tampered with in any manner other than a
procedure which is described and specified in the manual, the warranty
is void and the manufacturer is e empt from liability.
The device is destined e clusively for the described application.
SUTO offers no guarantee for the suitability for any other purpose.
SUTO is also not liable for consequential damage resulting from the
delivery, capability or use of this device.
2 S450

Table of Contents
1 Safety instructions......................................................................4
2 Registered trademarks.................................................................6
3 Application.................................................................................7
4 Features....................................................................................7
5 Technical data.............................................................................8
5.1 General................................................................................8
5.2 Electrical data.......................................................................9
5.3 Output signals......................................................................9
5.4 Accuracy .............................................................................9
5.5 Flow ranges..........................................................................9
6 Dimensional drawing..................................................................11
7 Determining the installation point................................................12
7.1 Inlet and outlet sections.......................................................13
8 Installation ..............................................................................15
8.1 Installation requirements......................................................15
8.2 Installation procedure .........................................................16
8.2.1 Determining the insertion depth of the sensor...................16
8.2.2 Installing the sensor......................................................17
8.2.3 Removing the sensor......................................................18
8.3 Electrical connection............................................................18
8.3.1 Connection diagram.......................................................19
8.3.2 Pin assignment..............................................................19
9 Signal outputs..........................................................................21
9.1 Analog and pulse outputs ....................................................21
9.1.1 Analog output...............................................................21
9.1.2 Pulse output..................................................................21
9.2 HART output ......................................................................23
9.3 Modbus output ...................................................................23
9.4 M-Bus output .....................................................................25
10 Configuration..........................................................................25
11 Optional accessories................................................................27
11.1 Sensor display...................................................................27
11.2 Service kit........................................................................27
12 Calibration..............................................................................28
13 Maintenance...........................................................................28
14 Disposal or waste....................................................................28
15 Appendi - Modbus communication e ample...............................29
S450 3

1 Safety instructions
1 Safety instructions
Please check if this instruction manual matches the
product type.
Please observe all notes and instructions indicated in this
manual. It contains essential information which must be
observed before and during installation, operation and
maintenance. Therefore this instruction manual must be read carefully
by the technician as well as by the responsible user or qualified
personnel.
This instruction manual must be available at the operation site of the
flow sensor at any time. In case of any obscurities or questions,
regarding this manual or the product, please contact the manufacturer.
ARNING!
Compressed air!
Any contact with quickly escaping air or bursting
parts of the compressed air system can lead to
serious injuries or even death!
•Do not e ceed the ma imum permitted pressure range (see
sensors label).
•Only use pressure tight installation material.
•Avoid that persons get hit escaping air or bursting parts of the
instrument.
•The system must be pressureless during maintenance work.
ARNING!
Voltage used for supply!
Any contact with energized parts of the product, may
lead to an electrical shock which can lead to serious
injuries or even death!
•Consider all regulations for electrical installations.
•The system must be disconnected from any power supply during
maintenance work.
•Any electrical work on the system is only allowed by authorized
qualified personal.
4 S450

1 Safety instructions
ATTENTION!
Permitted operating parameters!
Observe the permitted operating parameters, any
operation exceeding this parameters can lead to
malfunctions and may lead to damage on the
instrument or the system.
•Do not e ceed the permitted operating parameters.
•Make sure the product is operated in its permitted limitations.
•Do not e ceed or undercut the permitted storage and operation
temperature and pressure.
•The product should be maintained and calibrated frequently, at
least annually.
General safety instructions
•It is allowed to use the product in e plosive areas. Please contact
the manufacturer.
•Please observe the national regulations before/during installation
and operation.
Remarks
•It is not allowed to disassemble the product.
•Always use spanner to mount the product properly.
ATTENTION!
Measurement values can be affected by malfunction!
The product must be installed properly and
frequently maintained, otherwise it may lead to
wrong measurement values, which can lead to
wrong results.
•Always observe the direction of the flow when installing the
sensor. The direction is indicated on the housing.
•Do not e ceed the ma imum operation temperature at the sensors
tip.
•Avoid condensation on the sensor element as this will affect the
accuracy enormously.
S450 5

1 Safety instructions
Storage and transportation
•Make sure that the transportation temperature of the sensor
without display is between -30 ... +70°C and with display between
-10 ... +60°C.
•For transportation it is recommended to use the packaging which
comes with the sensor.
•Please make sure that the storage temperature of the sensor is
between -10 ... +50°C.
•Avoid direct UV and solar radiation during storage.
•For the storage the humidity must be <90% with no condensation.
2 Registered trademarks
SUTO®Registered trademark of SUTO iTEC
MODBUS®Registered trademark of the Modbus Organization,
Hopkinton, USA
HART®Registered trademark of the HART Communication
Foundation, Austin, USA
PROFIBUS® Registered trademark of the PROFIBUS User
Organization, Karlsruhe, Germany
Android™,
Google Play
Trademarks of Google LLC
6 S450

3 Application
3 Application
The S450 flow sensor is designed for the e plosive areas and is mainly
used to measure compressed air and process gases in industrial
environments.
The S450 can measure the following parameters for the compressed air
or gases:
•Velocity
•Volume flow
•Total consumption
The default factory settings are: Velocity in m/s, Volume flow in m3/h
and Total Consumption in m3. Other units can be programmed by the
optional display or the service kit.
4 Features
•Direct measurement of mass flow and standard flow without the
need of pressure and temperature compensation.
•Insertion type for bigger pipes.
•No moving parts, no clogging.
•All Sensor parts which come into contact with the measurement
medium are made of stainless steel 316L.
•Robust metal enclosure suitable for outdoor applications in harsh
environments.
•Wireless Bluetooth interface for onsite sensor settings.
•Optional display showing flow rate, consumption, medium
temperature and diagnostic result.
S450 7

5 Technical data
5 Technical data
5.1 General
Measuring range 0.4 ... 92.7 sm/s (standard range calibration)
0.8 ... 185 sm/s (ma range calibration)
1.0 … 224 sm/s (high speed calibration)
(See Section 4.5 for flow measurement
ranges in different tube diameters)
* sm/s: standard meter per second
Parameters Standard unit flow: m3/h
Available units: m3/min, l/min, l/s, cfm,
kg/h, kg/min, kg/s
Standard velocity
unit:
m/s
Reference conditions ISO1217, 20 °C, 1000 mbar (Standard-Unit)
DIN1343, 0 °C, 1013.25 mbar (Norm-Unit)
Principle of measurement Thermal mass flow
Sensor Resistive sensor
Measured medium Air, gas (non corrosive gas)
Operating temperature -40 ... +150°C (Medium temperature)
-40 ... +65°C (Ambient temperature)
Humidity of the meas.
medium
< 90%, no condensation
Operating pressure 0 ... 4.0 MPa (>1.6 MPa needs the
installation device.)
Housing material Al alloy
Material of the probe
tube, sensor head and
screwing
Stainless steel 1.4404 (SUS 316L)
Protection class IP67
Dimensions See dimensional drawing on the ne t page
Display (optional) 128 64
Tube diameter From DN15 (1/2”) upwards
8 S450

5 Technical data
Screwing thread G1/2” (ISO 228/1)
Weight 1.75 kg (220 mm version)
5.2 Electrical data
Power supply 16 ... 30 VDC, 5 W
5.3 Output signals
Analog output See section 9.1.1
Pulse output See section 9.1.2
HART output See section 9.2
Modbus output See section 9.3
M-Bus output See section 9.4
5.4 Accuracy
Accuracy* ±(1.5% of reading + 0.3% full scale)
Repeatability 0.25% of reading
Stated accuracy at Ambient/process temperature 23°C±3°C
Ambient/process humidity <90%
Process pressure at 0.6 MPa
* The specified accuracy is valid only within the minimum and ma imum
flow rates that are stated in section 5.5.
5.5 Flow ranges
The flow ranges are stated under the following conditions:
•Standard flow in air
•Reference pressure: 1000 hPa
•Reference Temperature: +20°C
S450 9

5 Technical data
Inch DN
1/2” DN15 0.2 ... 45.6 0.4 ... 91.0 0.48 ... 110.16
3/4” DN20 0.4 ... 89.1 0.9 ... 177.8 1.09 ... 215.3
1” DN25 0.6 ... 147.7 1.2 ... 294.7 1.82 ... 356.85
1 1/2”
DN40 1.5 ... 366.7 2.9 ... 731.9 4.36 ... 886.18
2” DN50 2.4 ... 600 4.8 ... 1198 7.26 ... 1450.04
2 1/2”
DN65 4.1 ... 1027 8.2 ... 2049 12.1 ... 2480.44
3” DN80 5.7 ... 1424 11.4 ... 2841 16.94 ... 3441.91
4” DN100 8.7 ... 2183 17.4 ... 4357 24.2 ... 5275.71
5” DN125 20 ... 3419.6 38 ... 6824.4 45.9 ... 8263.09
6” DN150 20 ... 4930 39 ... 9839 70.18 ... 11913.10
8” DN200 35 ... 8786 70 ... 17533 106.48 ... 21229.51
10” DN250 55 ... 13744 110 ... 27429 165.77 ... 33210.69
12” DN300 79 ... 19815 158 ... 39544 239.58 ... 47880.39
S-Range (m3/h) M-Range (m3/h) HS-Range (m3/h)
Remarks:
•To calculate flow ranges based on pipe and reference conditions in
your site, download and install the "Flow range calculator" tool for
free from http://www.suto-itec.com.
•To fast access the tool download page, enter "flowrange" (without
spaces) in the search field, and click the tool in the search result.
10 S450

6 Dimensional drawing
6 Dimensional drawing
S450 11

7 Determining the installation point
7 Determining the installation point
To maintain the accuracy stated in the technical data, 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 after the sensor (outlet) are sufficiently long,
absolutely straight and free of obstructions such as edges, seams,
curves etc..
Please consider that enough space e ists at your site for an adequate
installation as described in this manual.
ATTENTION!
rong measurement may occur if the sensor is not
installed correctly.
•Pay careful attention to the design of the inlet and outlet sections.
Obstructions can cause counter-flow turbulence as well as
turbulence in the direction of the flow.
•It is strongly recommend not to install S450 permanently in wet
environment which e ists usually right after a compressor outlet.
12 S450

7 Determining the installation point
7.1 Inlet and outlet sections
The following figures show the necessary equalizing sections in relation
to e isting obstructions. If it is not possible to observe the indicated
equalizing sections, deviations in measuring results have to be
e pected.
Remark: If there is any combination of below situations, the longest
straight inlet section must be maintained.
•E pansion •Reduction
•90° Bend •2×90° Bend
S450 13

7 Determining the installation point
•3 dimensional Bend •T-piece
•Shut-off valve •Filter or similar (unknown
objects)
14 S450

8 Installation
8 Installation
Before installing the sensor, please make sure that all components listed
below are included in your package.
Qty Description Item No.
1 Sensor S695 0450
1 Sealing ring No P/N
1 Alignment key No P/N
1 G ½” ball valve A554 0008
1 USB Bluetooth dongle No P/N
1 USB disk(with the service Software stored) No P/N
1 Instruction manual No P/N
1 Calibration certificate No P/N
ATTENTION!
Do not insert the sensor with strong force. It may
happen that the probe tip strikes on the pipe inner
wall and causes the sensor damaged!
8.1 Installation requirements
To install the sensor a ball valve or a nozzle is needed.
•The inner thread must be G 1/2”.
•The diameter of the hole must be ≥ 13mm. Otherwise the shaft
can not be inserted in.
S450 15

8 Installation
8.2 Installation procedure
The following steps e plain the procedure of an appropriate installation.
8.2.1 Determining the insertion depth of the sensor
The probe tip must be placed in the center of the pipe. For this the
probe shaft has a scale. To determine the right position please calculate
the insertion depth as described below.
Insertion depth=x+y
x=OD
2;OD=Outer diameter of pipe
E ample for a 2” pipe and an 87 mm ball valve:
y=87 mm ; OD=60.3 mm
x=OD
2=60.3 mm 2=30.15 mm
Insertion depth=30.15 mm+87 mm=117.15 mm
16 S450

8 Installation
8.2.2 Installing the sensor
First please observe the flow direction indicated on
the shaft. It must match the flow direction of the
compressed air or gas.
1. Close the ball valve.
2. The probe tip must be be completely covered by
the connection head (see photo on the left).
3. Underlay the “O-shaped” sealing ring to the
groove in the connection head.
4. Screw the connection head tightly to the ball
valve
5. Align the flow sensor with the flow direction by
observing the flow direction indicated on the shaft.
6. Open the ball valve and tighten the clamp sleeve
manually.
7. Move the flow sensor slightly to the determined
insertion depth by means of the scale.
8. Tighten the clamp sleeve at the connection head
so that the flow sensor can no longer be moved by
the pressure in the pipe. However it should be
possible to move the sensor shaft by hand.
9. With the aid of the alignment key, make sure that
the actual flow direction is same as the arrow shown
on the housing. (The angle deviation should not be
larger than ± 2° to the perfect position, please see
picture on the ne t page.).
10. Tighten the clamp sleeve with the clamping
torque 20 … 30 Nm.
11. Check the installation depth again because
sometimes the shaft is moved from its original
position by the compressed air.
S450 17

8 Installation
Ma imum angle deviation of a proper installation:
8.2.3 Removing the sensor
1. Hold the flow sensor firmly.
2. Release the clamp sleeve from the connection head.
3. Pull out the shaft slowly until the value “10” can be read at the
scale.
4. Close the ball valve.
5. Release the connection head and unscrew the flow sensor.
8.3 Electrical connection
When installing the cables please consider following point:
•Keep the stripped and twisted length of cable shield as short as
possible.
•Screen and ground the signal lines.
•Unused cable entries must be closed with closers.
•Cable outer diameter should be between 6 and 8 mm.
•Single wire cross-section should be between 0.25 ... 0.75 mm2.
•The thread size for the cable glands is M20 / 1.5.
18 S450

8 Installation
8.3.1 Connection diagram
Remove the back cover from the S450, and the pin layout is shown
below.
8.3.2 Pin assignment
S450 provides four output options. The pin assignment of these options
are given in the following table.
Pin Output options
Pulse and analog Modbus M-Bus HART
1 GNDSDI GNDSDI GNDSDI GNDSDI
2 +VB+VB+VB+VB
3 -VB-VB-VB-VB
4 SDI SDI SDI SDI
5 DIR DIR DIR DIR
6 DIR DIR DIR DIR
7 SW SW SW NA
8 SW SW SW NA
9 -I1-I1-I1-I1 / -HART
S450 19

8 Installation
10 +I1+I1+I1+I1 / +HART
11 -I2+D M NA
12 +I2-D M NA
13 NA GNDMNA NA
14 Earth Earth Earth Earth
15 Earth Earth Earth Earth
16 Earth Earth Earth Earth
Legend to pin assignment
SDI = Digital signal (internal use) SW = Isolated Pulse output
GNDSDI = Ground for SDI DIR = Flow direction input
+VB= Positive supply voltage +D = Modbus data+
-VB= Negative supply voltage -D = Modbus data -
+l1= Positive signal output
(analog output 1)
M = M-Bus data
-I1= Negative signal output
(analog output 1)
NA Not applicable
+l2= Positive signal output
(analog output 2)
-I2= Negative signal output
(analog output 2)
20 S450