- Ready-to-use compact design to minimise installation effort - therefore no volume corrector required
- Provides Flow, Total consumption, Temperature and Pressure
- Differential pressure sensor element with unique sensitivity, measures highly accurately at < 2 m/s
- Large flow measuring range with extended measuring span thanks to the use of measuring sections with a reduced inner diameter
- Smaller inlet sections due to the use of an averaging pitot tube
- Robust design, no moving parts
- Sensor head can be removed for calibration
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- Accuracy < 0.5 % confirmed by DIN EN ISO/IEC 17025 certificate
- Large measuring span > 1:130
- Very fast measuring, detection of peaks, no transient response as with ultrasonic gas meters
- No long inlet sections required
- Extremely low pressure loss, with max. flow < 70 mbar
- Can be used for practically all gases (by simply entering the respective gas density)
- Pressure range up to 16 bar (g), 30 bar (g)/100 bar (g) on request
- Direct display of standardised volume Nm3, Nm3/h, according to DIN 1343 or ISO 1217 compressed air standard
- Further Measured values: Temperature in °C or F, Pressure, Differential pressure in bar, psi etc.
- All common output signals: Modbus RTU, Modbus TCP, POE, MBus, 4 ... 20 mA
- ATEX version for highly flammable and combustible Gases in progress
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- Measurement of mass flow direct output of standard volume flow
- Highly accurate at small as well as higher flow rates
- Pressure and temperature compensated by the thermal mass flow principle
- Quick and easy installation via a ½" ball valve
- No moving parts, thus low maintenance
- Vanishingly low pressure drop due to vanishingly low blockage of the diameter
- Can be used for compressed air and non-corrosive gases such as nitrogen, oxygen, argon, helium, etc.
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- Measurement of mass flow rate, output of standard volume flow rate
- High accuracy for both small and large flows
- Pressure and temperature compensated by the thermal mass flow principle
- Easy installation and removal of the sensor, the integrated measuring section can remain in the line for cleaning or recalibration of the sensor and can simply be closed with a sealing cap
- No moving parts, therefore low maintenance
- Vanishingly low pressure loss due to vanishingly low blockage of the diameter
- Can be used for compressed air and non-corrosive gases such as nitrogen, oxygen, argon, helium, etc.
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- Screw thread for easy installation in existing piping through integrated measuring block (suitable for 1/2“, 3/4 ̋, 1“, 1 1⁄4 ̋, 1 1⁄2“ or 2" lines)
- Compact, small design - for use in machines, behind maintenance unit at the end user
- All interfaces are programmable via the display
- Modbus RTU output
- 4...20mA analog output for actual flow
- Pulse output total flow (counter reading), galvanically isolated. Optionally M-Bus, Ethernet-Interface, or PoE
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- Current consumption in m³/h, l / min, ...
- Total consumption (meter reading) in m³, l, kg
- Temperature measurement
- Optional: Pressure measurement
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- All wetted parts are made of stainless steel, especially for applications with high demands on cleanliness and surface quality
- Rough industrial applications can be realized due to robust aluminum housing
- Recommended for flammable gases such as natural gas, hydrogen, biogas, etc. due to ATEX or DVGW approval
- Measurement of mass flow rate, direct output of standard volume flow rate
- Highly accurate at small as well as large flows
- Pressure and temperature compensated by the thermal mass flow principle
- Quick and easy installation via a standard ½'' ball valve
- No moving parts, therefore low maintenance
- Vanishingly low pressure loss due to vanishingly low blockage of the diameter
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Flow meter VA 570 is supplied with an integrated measuring section for compressed air and gas pipes. The measuring sections are available in flanged version or with R resp. NPT thread.
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- Direct display in Nm3/h, or NI/min and temperature in C°
- Calorimetric measuring principle - no additional pressure and temperature measurement necessary
- High measurement accuracy ¼ to 3 inches
- IVA 500 and IVA 550 insert version from ½ inch to DN 400 / DN 500
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- Pressure sensors (high and low pressure)
- Flow sensors, VA 500 / VA 520
- Temperature sensors Pt 100, Pt 1000 / 4...20 mA
- Dew point sensors FA 510 / FA 515
- Effective power meters
- Opitonal third-party sensors with the following signals: 0...1/10 V, 0/4...20 mA, Pt 100, Pt 1000, pulse, Modbus
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- Particularly suitable for extremely high flow rates
- Extremely fast response time: 100 ms
- Flow, total consumption, temperature and pressure
- Measurement at high temperatures, max. temperature 200 °C
- Measurement in various gases by selecting gas type, on request
- Can be used in pipes from DN 20 to DN 500
- Installation via 1/2" ball valve under pressure
- RS 485 interface (Modbus-RTU), 4...20 mA, pulse output as standard
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Vane anemometer with telescopic sensor – ideal for carrying out airflow measurements in air ducts.
- Permanently connected telescopic sensor – maximum length 890 mm, diameter 16 mm
- Airflow measurements, selective and time mean values for calculating air volume
- Hold function; min/max display; auto power off
- Calibration certificate and batteries included
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Integrated totalling function (totaliser) for calculating the total consumption
- High accuracy: defined inner diameter (DN15) enables adjustment to standard volumetric flow
- Easy to install and to operate
testo 6441 compressed air counter with integrated inflow/outflow, diameter DN15 (1/2), with analog, pulse and switch output
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Integrated totalling function (totaliser) for calculating the total consumption
- High accuracy: defined inner diameter (DN25) enables adjustment to standard volumetric flow
- Easy to install and to operate
testo 6442 compressed air counter with integrated inflow/outflow, diameter DN25 (1), with analog, pulse and switch output
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Datasheet
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User Manual
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Integrated totalling function (totaliser) for calculating the total consumption
- High accuracy: defined inner diameter (DN25) enables adjustment to standard volumetric flow
- Easy to install and to operate
testo 6442 compressed air counter with integrated inflow/outflow, diameter DN25 (1), with analog, pulse and switch output
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Datasheet
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Integrated totalling function (totaliser) for calculating the total consumption
- High accuracy: defined inner diameter (DN50) enables adjustment to standard volumetric flow
- Easy to install and to operate
testo 6444 compressed air counter with integrated inflow/outflow, diameter DN50 (2), with analog, pulse and switch output
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Integrated totalling function (totaliser) for calculating the total consumption
- Flexible mounting with measuring block, pipe clamp or as a measurement fitting
- Easy operation with a variety of options (signal outputs, physical unit, etc.)
testo 6446 compressed air counter for larger diameters, without probe removal, selectable diameters DN65 (2 1/2)/DN80 (3)/DN100 (4)/DN125 (5)/DN150 (6)/DN200 (8)/DN250 (10), with analog, pulse and switch output
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- Transmitter with selectable signal outputs: analog output, pulse output, 2 switching outputs
- Quick, safe assembly/disassembly of the bar probe thanks to reverse running protection and ball valve
- Assembly of the whole transmitter possible under pressure
- Easy operation with a variety of options (signal outputs, physical unit, etc.)
testo 6448 compressed air counter for the determination, monitoring and reporting of compressed air consumption
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Gas & Compressed Air Consumption Meters – transparent costs, efficiency & leak control
Gas and compressed air meters capture consumption for energy management (e.g., ISO 50001), cost allocation, process monitoring, and leak reduction. Depending on the medium and accuracy needs, options include thermal mass meters, vortex (with T/p), ultrasonic, turbine/rotary gas meters as well as differential-pressure (DP) primary elements with transmitters.
Features (model-dependent): standard/operating volume and mass flow, wide turndown, direction detection, dataloggers, communications (4–20 mA/HART, Modbus/RS-485, Profinet/EtherNet/IP, M-Bus/BACnet, IO-Link), ATEX/IECEx, SIL, plus cloud/IIoT connectivity for dashboards and alarms.
ICS Schneider Messtechnik supports principle selection, sizing (DN, pressure/temperature, humidity), calibration (ISO/DAkkS), leak monitoring and integration into PLC/SCADA/EMS.
FAQ on Gas & Compressed Air Consumption Meters
Answers on measuring principles, standard conditions, accuracy/turndown, installation, moisture/dew point, energy reporting, calibration and digitalization.
Which measuring principles are used for gases/compressed air?
Thermal mass for large turndown and easy retrofits, vortex for compressed air/process gases and steam, ultrasonic for large lines or bidirectional flow, turbine/rotary gas meters for fiscal-grade accuracy, and DP (orifice/venturi) with T/p compensation for robust industrial service.
Standard volume, operating volume or mass flow—what’s the difference?
Standard volume refers to defined p/T (e.g., 1.013 bar, 0 °C). Operating volume is at actual p/T. Mass flow is independent of p/T. For cost benchmarking and ISO 50001, standard volume or mass is typically used.
What accuracies are typical?
| Principle | Accuracy (typ.) | Turndown (typ.) |
|---|---|---|
| Thermal (gas) | ±1…2% of rate | up to 1:100…1:1000 |
| Vortex | ±0.75…1.5% of rate | 1:20…1:30 |
| Ultrasonic (gas) | ±0.5…1.5% of rate | 1:50…1:200 |
| Turbine/rotary gas | ±0.2…1% of rate | 1:10…1:20 |
How do pressure and temperature affect the reading?
Gases are compressible. Without T/p compensation, operating volume differs from standard volume. Thermal mass meters provide mass directly; vortex/ultrasonic/turbine typically require pressure/temperature inputs for normalization.
What’s best for compressed air?
Thermal mass meters are common thanks to wide turndown, simple installation (insertion/in-line), and direct mass flow. Alternatively vortex when temperatures are high or T/p is already available.
How are leaks detected and quantified?
Via base-load analysis outside production hours, zonal metering per hall/branch, and alarm thresholds (limits/trends). Automatically log events and link to tickets/work orders.
How do I integrate meters into ISO 50001/EMS?
Map measuring points to energy meters, generate load profiles and KPIs (e.g., Nm³/product), assign cost centers and tariffs, and transmit data via fieldbus/Ethernet/M-Bus to the energy management system.
What straight runs/influences should I consider?
Principle-specific: vortex e.g., 15D/5D; ultrasonic 10–20D/5–10D. Thermal needs a stable profile (see manufacturer). Minimize disturbances (elbows, valves, compressors) and vibration.
How do humidity, oil and particles affect measurement?
Condensate/oil biases readings and can foul sensors. Size dryers/filters correctly; for near-saturated air, position meters after aftercoolers and monitor dew point.
How do I determine the correct DN?
Design for velocity and pressure loss. Too low velocity → unstable signal; too high → uncertainty/Δp. For insertion probes, ensure proper centering and insertion depth.
Are fiscal/legal-for-trade versions available?
Yes—PTB/MID-compliant meters (e.g., turbine/rotary/ultrasonic) with volume correctors (T/p) exist for natural gas and process gases. For compressed air, internal cost allocation is usually sufficient.
How is normalization to, e.g., Nm³ done?
Measured value + T/p → conversion to standard conditions (e.g., 0 °C/1.013 bar). Many devices/ex-controllers output live normalized values (Nm³/h, SCFM) and totals.
What signals & interfaces are available?
4–20 mA/HART, pulse/frequency, relay, Modbus/RS-485, Profinet/EtherNet/IP, IO-Link, M-Bus/BACnet. Optional web server, MQTT/REST for IIoT.
How do I calibrate/verify gas & compressed air meters?
Factory/DAkkS calibration. In the field: master meter comparisons, calibration simulators, leakage baseline. Keep traceable documentation with serial/meter point ID.
What ingress protection/ATEX/SIL options exist?
Depending on device: IP65…IP67, ATEX/IECEx for Zones 1/2, and SIL for safety loops. In Ex areas, select suitable barriers/power supplies and respect EPL.
How should I set limits & alarms?
Configure min/max flow, leakage thresholds (off-shift), pressure drop indicators, and trend alarms (rising base load) with notifications to email/SCADA.
What are common pitfalls?
- Wrong standard conditions → agree a site standard
- Too little straight run → relocate or add a conditioner
- Condensate/oil carryover → check treatment and separators
- Sensor fouling → maintenance plan, filters, bypass
- Wrong DN → re-size for velocity/Δp
How do I link consumption to costs?
Store tariffs (€/Nm³ or €/kWh) in the EMS, map to cost centers, report by shift/line/product, and use Sankey/Pareto analyses to drive savings projects.
How do I plan measuring points in existing networks?
Segment the network into zones, define main/sub/point-of-use meters, provide bypasses for service, include pressure/temperature taps and communications from the start.
Do you offer support for selection & commissioning?
Yes. We select the measuring principle, size DN/straight runs, provide calibration certificates, set up communications and dashboards, and support leak-hunting campaigns.