CGS Inline Aeration Meter

Aeration measurement has never been so easy.

The core element of our CGS (Concentration Gas System) Inline Aeration Meter is a coaxial measuring tube or optionally a screw in-situ sensor without any mechanically moving parts.

The determination of the aeration percentage (gas concentration CG) in two-phase flows is based on an innovative procedure which, in contrast to e.g. the radionuclide, X-ray, Coriolis or ultrasonic method, is hazard-free and constantly accurate between 0.00 vol% and 100.00 vol% entrained gas, no matter the bubble size.

Measuring the change of the fluid admittance (complex impedance) at variable frequencies in comparison to the unaerated medium, CGS offers decisive advantages in all fields of application concerning the gas concentration. Whether it's oil aeration in engines, gear boxes or hydraulic machinery, foamed adhesives or aerated food products: Our CGS is the perfect tool for almost every gas-in-fluid problem.

The CGS can be used in either your mainstream or a bypass assembly. Its measuring principle is freely scalable which allows us to provide a made-to-measure custom sensor for your specific process conditions, if needed.

Another advantage of the CGS is its high resolution. No matter if you have an evenly distributed gas phase with fine microbubbles or "gas slugs" and larger air pockets entrained in your oil: our system allows you to get accurate gas content measurements independently of both the physical form and the flow conditions of your two-phase mixture.

Thanks to the integrated pressure sensor of the inline sensor you can always compare your results through the additional normalized CG0 value, which determines the aeration level at atmospheric pressure.

Key CGS features

Compact, wear-free and highly accurate fluid aeration meter for inline or in-situ installation
Continuous display of the aeration level / concentration of undissolved gas in flowing or stagnant fluids
Constantly high precision from 0.00 to 100.00 vol% aeration (accuracy: +/- 0.10 vol%)
In-line or in-situ gas phase concentration measurement without any mechanically moving parts
Suitable for all electrically non-conductive types of liquids, such as mineral & synthetic engine oils, ATF, hydraulic oils, etc. (specific conductivity < 600 nS/m)
Can be used for mainstream, bypass or in-situ measurement
Fully upscalable measuring principle: different sensor sizes available for different flow rates
Non-destructive, hazard-free measurement, independent of flow type and direction
Integrated temperature and pressure measurement for inline measurement
Live reading of temperature, pressure, CGp (current compressed gas concentration at measured pressure), CG0 (normalized value of gas concentration at atmospheric pressure)
Comparative results due to retroactive accounting of the nomalized, equivalent gas concentration at atmospheric pressure
Fast measuring rates (1 Hz and 10 Hz version available)
Simple and intuitive handling
Portable device (available for 110-240 V AC or 9-36 V DC)
Standard digital interface (RS-232, adaptable to USB) for optional connection to a Windows PC
Intuitive PC software included
Analog output (4...20 mA or 0...10 V) of all measured values

Fields of application

The standard sensor of the CGS is equipped with two UNF 9/16" connector and 3/8" adapters so it can easily be integrated into your fluid circuit. Due to its continuous inline measurement of the volumetric gas concentration in fluids our system offers new possibilities, e.g. for the continuous inline monitoring of oil aeration in hydraulic pipes, combustion engines, turbochargers or gear boxes, or for the optimized application of aerated adhesives.

The CGS aeration meter can furthermore be applied as a control unit in areas of technical production which require gas contents as an important quality feature, or in areas in which the systematic introduction of gas can reduce production costs.

The following fields of application summarize the versatility of the CGS:

Inline live data
Survey and control the important criterion of oil aeration for the design of oil pumps, motors, turbochargers or gear boxes.

Optimization of machines and machine parts
Design new machine elements with reduced oil aeration.

Optimization of fluid development
Develop fluids with optimized aeration and degassing behavior.

Process survey and control
Optimize processes in the application of aerated fluids and adhesives.

Composition

The CGS Inline Aeration Meter consists of only two components: the measuring tube with three integrated sensors (CG sensor, PT100 temperature sensor and pressure sensor) on the one hand, and the corresponding control and evaluating system in an electronic unit on the other hand.

CGS Sensor

Both ends of the standard sensor (picture, left) are equipped with UNF 9/16"-Dash 6 connectors which can be adapted to 3/8" or any other standard fittings to simplify the mounting of your measuring instrument into your fluid circut. The standard sensor is suitable for main stream installation with 0.5 - 5 l/min (< 1.3 gpm). If your application has higher flow rates we recommend a bypass installation with the optional bypass installation kit.

If main stream measurement with higher flow rates is the preferred option, flucon also offers a larger 1" sensor for up to 200 l/min (picture, center). In addition we may manufacture custom sensors suitable for any given flow rate.

As our latest innovation we have designed a miniaturized 3/4" screw-in in-situ sensor (picture, right). This allows for in-situ aeration measurement with minimum immersion depth, e.g. in the oil pan of an electric drive unit.

CGS device

There are different types of housings available for the electronic unit: as alternatives to the aluminum desktop housing (picture, left) with separable LEMO connectors we offer a small compact housing for mobile use (picture, center), as well as a large plastic housing with terminals (picture, right) which is designed for control cabinet installation.

Each CGS device is suited for 110-240 V AC and 9-36 V DC supply. Thus, on-board applications, e.g. with a 12 V battery supply, can be easily realized as well.

Would you like it fast - or superfast?

Once you have decided which sensor and device may be ideal for your application, there is one more thing to decide upon: the required test rate.

While the standard rate is 1 Hz, the high-speed option with a measuring time of only 0.1 sec might come in handy if you're dealing with a highly dynamic application, higher flow rates and/or unsteady, inhomogeneous aeration.

Operating your CGS instrument

No matter the type of sensor or device, or if using the standard or high-speed rate: each CGS can be used in stand-alone mode or is operated with a Windows computer via RS-232/USB. The included and powerful fluconCGS software allows you to record and interpret your tests. It will also help our team support you with your findings, if desired.

If you prefer to process the measured data through a PLC, you may simply use the analog output of the CGS (0...10 V or 4...20 mA) which transfer the measured live data for all relevant parameters.

Calibration

Getting started with your aeration measurement is quite easy: Before initial operation the CGS requires a fluid calibration with your specific oil. This should be done over the full temperature range of your process, with +/- 10°C of recommended extra range. For testing with multiple oils the CGS offers a fluid list which allows you to save up to 20 different substances. This allows you to quickly switch the saved parameters by use of the davice menu or software, e.g. when using the sensor on another testbed that contains a different type of oil.

To make the fluid calibration easier we offer an optional fluid thermostat that is controlled by the CGS device.

Technical data of the CGS

Aeration measuring range (CGp)	0.00 to 100.00 vol% Gas
Accuracy	+/- o.10 vol% Gas
Suitable media & Flow rates	electrically non-conductive fluids/oils for flow rates < 5 l/min (1.3 gpm): use standard sensor for higher rates < 200 l/min: use bypass installation or larger sensor customized sensors for main stream installation with v > 200 l/min available upon request
Measuring time	Standard (1 Hz): 1 sec, High-speed option (10 Hz): 100 ms
Temperature measurement	PT 100, +/- 0.1 °C
Temperature range	-30°C to 150°C
Pressure range	max. 10 bar (any exceeding pressures will compress and dissolve your gas phase - please use a bypass in this case!)
Dimensions measuring tube (WxHxL)	Standard Dash-6 sensor: 40 x 110 x 165 mm; Larger 1" sensor: 60 x 127 x 218 mm Custom-made sizes available upon request
Material measuring tube	Stainless steel (1.4571), PEEK
Connection	Standard sensor: 2x UNF 9/16″-18Gg (dash-6) male w/ screw-on adapters (G 3/8"); Large sensor: 2x G1" female;
Dimension electronic unit (WxHxD)	Standard (Aluminum): 235 x 150 x 370 mm Large (with connecting terminal): 330 x 150 x 300 mm Compact (for mobile applications): 240 x 95 x 115 mm
Data communication (computer)	RS-232 interface (CGS software for WINDOWS included)
Analog output temperature	4-20 mA / 0-10 V
Analog output CGp-signal	4-20 mA / 0-10 V
Analog output CG0-signal	4-20 mA / 0-10 V
Analog output pressure	4-20 mA / 0-10 V
Power supply	110-240 VAC or 9-36 VDC