- 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
 Datasheet |
- 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.
 Datasheet |
| User Manual |
- 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.
| Datasheet |
| User manual |
- 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
| Datasheet |
| User manual |
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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Bedienungsanleitung
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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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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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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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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 (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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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
- 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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Datasheet
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User Manual
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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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Datasheet
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User Manual
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Consumption & Flow Sensors – energy & media monitoring for air, gases & water
Consumption and flow sensors capture instantaneous flow, totalized consumption and—depending on the medium—also mass flow and energy equivalents. Typical use cases: compressed-air monitoring (ISO 50001), leak detection, process/lab gases, cooling/process water and cost-center allocation for utilities.
Available measurement principles (model-dependent): thermal mass flow (compressed air/gases), vortex (steam/liquids/gases), magnetic-inductive (MAG) for conductive liquids, ultrasonic (clamp-on/in-line), turbine/oval gear, and differential-pressure primary elements with transmitters. Outputs: 4–20 mA, 0–10 V, pulse/Hz (K-factor), relays, Modbus RTU/TCP, BACnet, IO-Link, Ethernet.
ICS Schneider Messtechnik assists with selection & sizing, installation, p/T compensation, calibration, data integration (BMS/SCADA/IIoT) and energy reporting.
FAQ on Consumption & Flow Sensors
Answers on selection, installation, standard conditions, p/T compensation, signals, accuracy, calibration and energy monitoring.
Which sensor fits my medium?
| Medium | Recommended principle | Notes |
|---|---|---|
| Compressed air/gases | Thermal mass, vortex, ultrasonic | Use mass-based or apply p/T compensation; observe straight runs |
| Conductive liquids | MAG (electromagnetic) | Independent of density/viscosity; requires full pipe |
| Non-conductive liquids/oils | Ultrasonic, oval gear, turbine | Consider viscosity/profile; may require calibration factor |
| Steam | Vortex, DP with orifice/venturi | High temperature & condensate management; add pressure & temperature |
What’s the difference between volume and mass flow?
Volume flow (m³/h) depends on pressure/temperature. Mass flow (kg/h, or standardized flow Nl/min) is state-independent and often preferred for gas costing/billing.
How do I convert to standard conditions?
For gases: VN = V · (p/pN) · (TN/T) (consider dryness). Commonly pN=1013.25 hPa, TN=273.15/293.15 K per specification.
What installation rules should I follow?
- Straight runs typically ≥10·D upstream / ≥5·D downstream (model-dependent).
- Full pipe for liquids; avoid condensate pockets at the sensor for gas/steam.
- Leak-tight mounting; grounding/shielding per manufacturer.
How do I detect leaks in compressed air?
Measure base load during shutdown (nights/weekends) and compare to targets. Sensors with fine resolution and logging reveal small continuous losses.
How are pulses (K-factor) used?
Pulse/Hz outputs emit a defined quantity per K (e.g., 1 pulse = 1 liter). Ideal for totalizers/data acquisition; adjust scaling if ranges change.
What accuracy is realistic?
Thermal gas: typically ±(1…3 % of reading); vortex/MAG/ultrasonic: ±(0.5…1.0 % of reading); turbine/oval gear: ±(0.5…1.5 % of reading) depending on viscosity and profile.
How do pressure and temperature affect results?
For volume-based gas measurements, p/T changes density → error. Solutions: use mass-based sensors or p/T compensation with additional measurements.
Which interfaces suit energy monitoring?
Modbus RTU/TCP, BACnet, IO-Link, Ethernet, and MQTT via gateways; analog 4–20 mA for PLCs. Use onboard loggers/CSV for ISO 50001 reporting.
How should I choose the measuring range?
Place the typical operating point in the middle third of the range. For highly variable loads select wide turndown or multi-range devices.
How are consumption sensors calibrated?
Gases: master MFM, test leak or bench with p/T capture. Liquids: gravimetric, volumetric prover or transfer standard. Typical interval: annually.
What are common error sources?
- Insufficient straight runs / swirl.
- Leaks / wrong gaskets.
- Wrong medium assumptions (e.g., wet/oily compressed air).
- Incorrect K-factor/scaling in the counter.
How do I integrate sensors with BMS/SCADA/IIoT?
Directly via Modbus/BACnet/IO-Link or through edge gateways (buffering, MQTT/HTTPS, alarms, dashboards/cloud).
How are media costs determined?
Flow × tariff (e.g., €/Nm³, €/m³ water). Sensors with totalizers and load profiles enable cost-center allocation and TUR checks.
Which enclosure ratings & materials make sense?
IP65/67 for harsh areas; wetted parts in stainless steel/PFA; for aggressive media use Hastelloy®/coated inserts. ATEX/IECEx per zone.
What should reports include?
As-found/as-left, test points/ranges, p/T correction, traceability chain, expanded uncertainty (k=2), timestamps and optional energy/cost KPIs.
Do you support sizing & commissioning?
Yes—we recommend the measurement principle/size, define installation conditions, supply calibration certificates and integrate sensors with energy management and SCADA/IIoT.