Kamstrup ULTRAFLOW 54, ULTRAFLOW 34 Technical Description

Technical Description

ULTRAFLOW® 54 ULTRAFLOW® 34

Kamstrup A/S Industrivej 28, Stilling DK-8660 Skanderborg TEL: +45 89 93 10 00 FAX: +45 89 93 10 01 info@kamstrup.com www.kamstrup.com

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Contents

1 General description ........................................................................................................ 6

2 Data ............................................................................................................................... 7

2.1

Electrical data ...................................................................................................................................... 7

2.2

Mechanical data ................................................................................................................................... 7

2.3

Flow data ............................................................................................................................................. 8

2.4

Materials .............................................................................................................................................. 8

3 Type overview ................................................................................................................. 9

4 Ordering details ............................................................................................................ 10

4.1

ULTRAFLOW® 54 ................................................................................................................................. 10

4.2

ULTRAFLOW® 34 ................................................................................................................................. 11

4.3

Accessories for ULTRAFLOW® .............................................................................................................. 11

4.4

Pulse Transmitter and Pulse Divider .................................................................................................... 12

4.5

Type number composition of Pulse Transmitter and Pulse Divider ....................................................... 12

4.5.1 Output module and supply module ................................................................................................. 12

4.6

Pulse Divider configuration CCC-DD-E-MMM ........................................................................................ 13

4.7

Accessories for Pulse Transmitter and Pulse Divider ............................................................................ 15

4.7.1 Cables............................................................................................................................................ 15

5 Dimensional sketches ................................................................................................... 16

5.1

ULTRAFLOW® ...................................................................................................................................... 16

5.2

Pulse Transmitter and Pulse Divider .................................................................................................... 20

6 Pressure loss ................................................................................................................ 21

7 Installation ................................................................................................................... 22

7.1

Installation angle for ULTRAFLOW®...................................................................................................... 23

7.2

Straight inlet ...................................................................................................................................... 24

7.3

Operating pressure ............................................................................................................................. 24

7.4

Humidity and condensation ................................................................................................................ 25

7.4.1 Orientation of Pulse Transmitter and Pulse Divider .......................................................................... 25

7.5

Installation examples ......................................................................................................................... 26

7.6

Electrical connection of ULTRAFLOW® and MULTICAL® ......................................................................... 28

7.7

Electrical connection of Pulse Transmitter and Pulse Divider ............................................................... 28

7.7.1 Cable length ................................................................................................................................... 30

7.8

Connection of power supply ............................................................................................................... 31

7.8.1 Battery supply ................................................................................................................................ 31

7.8.2 Mains supply modules ................................................................................................................... 31

7.8.3 Mains supply cable ........................................................................................................................ 32

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.8.4 Cable connections ......................................................................................................................... 32

7.8.5 Change of supply unit .................................................................................................................... 32

7.9

Example of connecting ULTRAFLOW® and MULTICAL® ......................................................................... 33

7.10 Example of connecting Pulse Transmitter ........................................................................................... 33

7.11 Calculator with two flow sensors ........................................................................................................ 34

7.12 Operational check ............................................................................................................................. 34

8 Functional description .................................................................................................. 35

8.1

Ultrasound combined with piezo ceramics ......................................................................................... 35

8.2

Principles .......................................................................................................................................... 35

8.3

Transient time method ....................................................................................................................... 35

8.4

Signal paths ...................................................................................................................................... 37

8.5

Measuring sequences ........................................................................................................................ 37

8.6

Function ............................................................................................................................................ 38

8.7

Guidelines for dimensioning ULTRAFLOW® ......................................................................................... 40

8.8

Pulse output of ULTRAFLOW® ............................................................................................................. 41

8.9

Pulse output of Pulse Transmitter and Pulse Divider ........................................................................... 42

8.9.1 Galvanically separated output module (Y=2) .................................................................................. 42

8.9.2 Galvanically separated output module (Y=3) .................................................................................. 43

8.10 Pulse emission .................................................................................................................................. 44

8.11 Accuracy............................................................................................................................................ 44

8.12 Power consumption ........................................................................................................................... 45

8.13 Interface connector/serial data .......................................................................................................... 45

8.14 Test mode ......................................................................................................................................... 46

8.15 Externally controlled start/stop .......................................................................................................... 46

8.16 Calibration using serial data and externally controlled start/stop ...................................................... 47

9 Calibrating ULTRAFLOW® .............................................................................................. 48

9.1

Installation ........................................................................................................................................ 48

9.2

Technical data for ULTRAFLOW ......................................................................................................... 48

9.3

Connection ........................................................................................................................................ 49

9.4

Start-up ............................................................................................................................................. 50

9.5

Measuring flow .................................................................................................................................. 50

9.6

Evacuation ........................................................................................................................................ 50

9.7

Suggested test points ........................................................................................................................ 51

9.8

Sealing .............................................................................................................................................. 52

9.9

Optimization in connection with calibration ....................................................................................... 53

9.10 PULSE TESTER .................................................................................................................................... 54

9.10.1 Technical data for PULSE TESTER ................................................................................................ 54

9.10.2 Hold function ............................................................................................................................. 56

9.10.3 Push-button functions ............................................................................................................... 56

9.10.4 Using the PULSE TESTER ............................................................................................................ 56

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

9.10.5 Spare parts ................................................................................................................................ 57

9.10.6 Changing the battery .................................................................................................................. 57

10 METERTOOL .............................................................................................................. 58

10.1 Introduction ....................................................................................................................................... 58

10.2 System requirements for PC ................................................................................................................ 58

10.2.1 Interface..................................................................................................................................... 58

10.2.2 Installation ................................................................................................................................. 62

10.3 METERTOOL for ULTRAFLOW® X4 ......................................................................................................... 63

10.3.1 Files ........................................................................................................................................... 63

10.3.2 Utilities ...................................................................................................................................... 63

10.3.3 Windows .................................................................................................................................... 64

10.3.4 Help ........................................................................................................................................... 64

10.4 Application ........................................................................................................................................ 65

10.4.1 COM-port selection ..................................................................................................................... 65

10.4.2 Flow meter adjustment ............................................................................................................... 66

10.4.3 Programming of standard flow curve ........................................................................................... 66

10.4.4 Pulse Divider type No. 66-99-607................................................................................................ 67

10.4.5 Pulse Divider type No. 66-99-907................................................................................................ 68

10.4.6 Pulse Configuration DN150-DN250 ............................................................................................. 69

10.4.7 Meter type .................................................................................................................................. 71

10.5 Update ............................................................................................................................................... 72

11 Approvals ................................................................................................................. 73

11.1 The Measuring Instruments Directive .................................................................................................. 73

11.2 CE marking ......................................................................................................................................... 73

11.3 Declaration of conformity ................................................................................................................... 74

12 Troubleshooting ....................................................................................................... 75

13 Disposal ................................................................................................................... 76

14 Documents ............................................................................................................... 77

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

1 General description

ULTRAFLOW® is a static flow sensor based on the ultrasonic principle. It is primarily used as a volume flow sensor for thermal energy meters such as MULTICAL®. ULTRAFLOW® 54 has been designed for use in heating installations where water is the heat-bearing medium, whereas ULTRAFLOW® 34 has been designed for use in cooling and heat/cooling installations where water is the heat-bearing medium.

ULTRAFLOW® employs ultrasonic measuring techniques and microprocessor technology. All calculating and measuring circuits are collected on one single board, providing a compact and rational design in addition to exceptionally high measuring accuracy and reliability.

The flow is measured using bidirectional ultrasonic technique based on the transit time method, proven a longterm stable and accurate measuring principle. Two ultrasonic transducers are used to send the sound signal both against and with the flow. The ultrasonic signal travelling with the flow reaches the opposite transducer first. The time difference between the two signals can be converted into flow velocity and thereby also volume.

A three-wire pulse cable is used to connect ULTRAFLOW® to the calculator. The cable supplies the flow sensor and also transfers the signal from sensor to calculator. A signal corresponding to the flow – or more correctly, a number of pulses proportional to the water volume flowing through - is transmitted.

Where ULTRAFLOW® is to be used as a flow sensor with built-in supply, e.g. if the distance between MULTICAL® and ULTRAFLOW® is 10 m or more, a Pulse Transmitter can be supplied as an accessory. If ULTRAFLOW® is used as pulse generator for other equipment, it must be connected through a Pulse Transmitter. If a different meter factor is required, ULTRAFLOW® is connected through a Pulse Divider. Pulse Transmitter and Pulse Divider have a built-in supply for ULTRAFLOW® and a galvanically separated pulse output.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Power consumption mains

use of

medium

temperature more than 5 °C below ambient

calculator and Pulse

ivider may not be mounted on

mounting is

2 Data

ULTRAFLOW® 54 and 34

2.1 Electrical data

Supply voltage 3.6 VDC ± 0.1 VDC Battery

(Pulse Transmitter/ Pulse Divider)

Replacement interval

Mains supply (Pulse Transmitter/ Pulse Divider)

supply Back-up mains supply Integral SuperCap eliminates interruptions due to short-term power-cuts Cable length, flow sensor Max. 10 m Cable length,

Pulse Transmitter/ Pulse Divider

EMC data Fulfils DS/EN 1434:2007 class C, MID E1 and E2

3.65 VDC, D-cell lithium

6 years @ t 230 VAC +15/-30 %, 50 Hz

24 VAC ±50 %, 50 Hz

< 1 W

Depending on the calculator

< 30 °C

BAT

For output module (Y=3)

2.2 Mechanical data

Metrological class 2 or 3 Environmental class Fulfils DS/EN 1434 class C Mechanical environment MID M1 Ambient temperature 5…55 °C (indoor installation) Protection class

Flow sensor Pulse Transmitter/

Pulse Divider

Humidity

ULTRAFLOW® 54 ULTRAFLOW® 34

Temperature of medium

ULTRAFLOW® 54 ULTRAFLOW® 34

Storage and transport temp. empty sensor

Pressure stage PN16, PS16 and PN25, PS25

IP65 IP67

Non-condensing, < 93 % RH Condensing (periodically)

15…130 °C or 15…90 °C 2…130 °C or 2…50 °C

-25…60 °C

When installed properly. See paragraph 7 Installation.

At medium temperature above 90 °C, the flange meters is recommended.

At medium temperature above 90 °C or at

temperature (T Transmitter/Pulse D the flow sensor. Instead wall recommended.

med

< T

- 5 °C),

amb

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

100

DN100 & DN125

1.5

1:100

2:1

300

0.07

200

2.3 Flow data

Nom. flow q

[m³/h] [mm] [imp/l]

0.6 DN15 & DN20 300 1:100 2:1 1.5 0.04 2

1.5 DN15 & DN20 100 1:100 2:1 4.5 0.22 3

2.5 DN20 60 1:100 2:1 7.5 0.03 5

3.5 DN25 50 1:100 2:1 9 0.07 7 6 DN25 & DN32 25 1:100 2:1 18 0.2 12

10 DN40 15 1:100 2:1 30 0.06 20 15 DN50 10 1:100 2:1 45 0.14 30 25 DN65 6 1:100 2:1 75 0.06 50 40 DN80 5 1:100 2:1 90 0.05 80 60 DN100 2.5 1:100 2:1 180 0.03 120

The meter factor appears from the meter´s type label.

Saturation flow (125 Hz. Max. pulse frequency 128 Hz is maintained at higher flow).

Nom. diameter

Meter factor

Dynamic range

Table 1. Flow data.

2.4 Materials

Wetted parts

ULTRAFLOW®, qp 0.6 and 1.5 m³/h

Housing, gland DZR brass (Dezincification resistant brass) Housing, flange Stainless steel, W.no. 1.4308 Transducer Stainless steel, W.no. 1.4401 Gaskets EPDM Reflectors Thermoplastic, PES 30 % GF and stainless steel, W.no. 1.4301 Measuring tube Thermoplastic, PES 30 % GF

qi:q

∆∆∆∆

Flow@125 Hz

qs:q

[m³/h] [bar] [l/h]

p@q

Min. cutoff

ULTRAFLOW®, qp 2.5 to 100 m³/h

Housing, gland DZR brass (Dezincification resistant brass) Housing, flange Red brass, RG5 or stainless steel, W.no. 1.4308 (see par. 4 Ordering details) Transducer Stainless steel, W.no. 1.4401 Gaskets EPDM Reflectors Stainless steel, W.no. 1.4301 Measuring tube Thermoplastic, PES 30 % GF

Electronics housing, ULTRAFLOW®

Base Thermoplastic, PBT 30 % GF Cover Thermoplastic, PC 20 % GF

Housing, Pulse Transmitter/Pulse Divider

Base, cover Thermoplastic, PC 10 % GF

Signal cable

Silicone cable (3x0.5 mm2)

Mains supply cable 24/230 VAC (optional for mains supplied Pulse Transmitter/Pulse DIvider)

Cable with PVC-mantle (2x0.75 mm²)

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

3 Type overview

Nom. flow q

[m³/h]

0.6 G¾Bx110 mm G1Bx130 mm

1.5 G¾Bx110 mm G¾Bx165 mm G1Bx130 mm G1Bx190 mm

2.5 G1Bx190 mm DN20x190 mm

3.5 G5/4Bx260 mm DN25x260 mm 6 G5/4Bx260 mm DN25x260 mm

10 G2Bx300 mm DN40x300 mm (DN40x250 mm) 15 DN50x270 mm 25 DN65x300 mm 40 DN80x300 mm 60 DN100x360 mm

100 DN100x360 mm DN125x350 mm

(...) Country specific variants

(DN50x250 mm)

(DN80x350 mm)

(DN100x400 mm)

(G1Bx190 mm)

(G1Bx130 mm)

(G1½Bx260 mm)

Installation dimensions

Table 2. Type overview.

Thread EN ISO 228-1

Flange EN 1092, PN25. Flange facing type B, raised face

(G1Bx110 mm) (G1Bx165 mm) (DN20x190 mm)

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

p qi qs

65-5-

FBCM

-XXX

1001200

DN125

350

1.5

480 (488)

Stainless steel

4 Ordering details

4.1 ULTRAFLOW® 54

Type number

[m³/h] [m³/h] [m³/h] [mm] [imp/l]

Connection

Length Meter factor CCC

(high res.)

Material

65-5- CAAA -XXX 0.6 0.006 1.2 G¾B (R½) 16 110 300 416 (484) Brass 65-5- CAAD -XXX 0.6 0.006 1.2 G1B (R¾) 16 130 300 416 (484) Brass

(65-5- CAAF -XXX) 0.6 0.006 1.2 G1B (R¾) 16 190 300 416 (484) Brass (65-5- CDA1 -XXX) 1.5 0.015 3 G1B (R¾) 16 110 100 419 (407) Brass

65-5- CDAA -XXX 1.5 0.015 3 G¾B (R½) 16 110 100 419 (407) Brass 65-5- CDAC -XXX 1.5 0.015 3 G¾B (R½) 16 165 100 419 (407) Brass 65-5- CDAD -XXX 1.5 0.015 3 G1B (R¾) 16 130 100 419 (407) Brass

(65-5- CDAE -XXX) 1.5 0.015 3 G1B (R¾) 16 165 100 419 (407) Brass

65-5- CDAF -XXX 1.5 0.015 3 G1B (R¾) 16 190 100 419 (407) Brass

(65-5- CDCA -XXX) 1.5 0.015 3 DN20 25 190 100 419 (407) Stainless steel (65-5- CEAD -XXX) 2.5 0.025 5 G1B (R¾) 16 130 60 498 (-) Brass

65-5- CEAF -XXX 2.5 0.025 5 G1B (R¾) 16 190 60 498 (-) Brass 65-5- CECA -XXX 2.5 0.025 5 DN20 25 190 60 498 (-) Stainless steel 65-5- CGAG -XXX 3.5 0.035 7 G5/4B (R1) 16 260 50 451 (436) Brass 65-5- CGCB -XXX 3.5 0.035 7 DN25 25 260 50 451 (436) Stainless steel 65-5- CHAG -XXX 6 0.06 12 G5/4B (R1) 16 260 25 437 (438) Brass

(65-5- CHAH -XXX) 6 0.06 12 G1½B (R5/4) 16 260 25 437 (438) Brass

65-5- CHCB -XXX 6 0.06 12 DN25 25 260 25 437 (438) Stainless steel 65-5- CJAJ -XXX 10 0.1 20 G2B (R1½) 16 300 15 478 (483) Brass

(65-5- CJB2 -XXX) 10 0.1 20 DN40 16 250 15 478 (483) Red brass

65-5- CJCD -XXX 10 0.1 20 DN40 25 300 15 478 (483) Stainless steel

(65-5- CKC4 -XXX) 15 0.15 30 DN50 25 250 10 420 (485) Stainless steel

65-5- CKCE -XXX 15 0.15 30 DN50 25 270 10 420 (485) Stainless steel 65-5- CLCG -XXX 25 0.25 50 DN65 25 300 6 479 (-) Stainless steel 65-5- CMCH -XXX 40 0.4 80 DN80 25 300 5 458 (486) Stainless steel

(65-5- CMCJ -XXX) 40 0.4 80 DN80 25 350 5 458 (486) Stainless steel

65-5- FACL -XXX 60 0.6 120 DN100 25 360 2.5 470 (487) Stainless steel

(65-5- FAD5 -XXX) 60 0.6 120 DN100 16 400 2.5 470 (487) Stainless steel

65-5- FBCL -XXX 100 1 200 DN100 25 360 1.5 480 (488) Stainless steel

XXX - code for final assembly, approvals etc. - determined by Kamstrup. A few variants may not be available in national approvals.

(…) Country specific variants

Table 3. Type numbers of ULTRAFLOW® 54.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

p qi qs

CGAG

CMCH

65-3-

FBCM

-XXX

1001200

DN125

350

1.5

480 (488)

Stainless steel

Size

Nipple

Union

Type no.

(2 pcs.)

DN15

R½G¾ -

6561-323

DN20

R¾G1 -

6561-324

DN25

G5/4

6561-325

DN32

R5/4

G1½

6561-314

DN40

R1½

6561-315

Size (union)

Type no.

Size

Type no.

G¾

2210-061

DN20

2210-147

2210-062

DN25

2210-133

G5/4

2210-063

DN40

2210-132

G1½

2210-064

DN50

2210-099

2210-065

DN65

2210-141

DN80

2210-140

DN100

1150-142

DN125

1150-153

4.2 ULTRAFLOW® 34

Type number

65-3- CDAA -XXX 1.5 0.015 3 G¾B (R½) 16 110 100 419 (407) Brass 65-3- CDAD -XXX 1.5 0.015 3 G1B (R¾) 16 130 100 419 (407) Brass 65-3- CEAF -XXX 2.5 0.025 5 G1B (R¾) 16 190 60 498 (-) Brass 65-365-3- CHAG -XXX 6 0.06 12 G5/4B (R1) 16 260 25 437 (438) Brass 65-3- CJAJ -XXX 10 0.1 20 G2B (R1½) 16 300 15 478 (483) Brass 65-3- CJCD -XXX 10 0.1 20 DN40 25 300 15 478 (483) Stainless steel 65-3- CKCE -XXX 15 0.15 30 DN50 25 270 10 420 (485) Stainless steel 65-3- CLCG -XXX 25 0.25 50 DN65 25 300 6 479 (-) Stainless steel 65-365-3- FACL -XXX 60 0.6 120 DN100 25 360 2.5 470 (487) Stainless steel 65-3- FBCL -XXX 100 1 200 DN100 25 360 1.5 480 (488) Stainless steel

XXX - code for final assembly, approvals etc. - determined by Kamstrup. A few variants may not be available in national approvals.

-XXX 3.5 0.035 7 G5/4B (R1) 16 260 50 451 (436) Brass

-XXX 40 0.4 80 DN80 25 300 5 458 (486) Stainless steel

[m³/h] [m³/h] [m³/h] [mm] [imp/l] (high res.)

Connection

Table 4. Type numbers of ULTRAFLOW® 34.

Length Meter factor CCC

Material

4.3 Accessories for ULTRAFLOW®

Table 5. Glands including gaskets (PN16).

Gaskets for glands

Glands

Gaskets for

flange meters PN25

Table 6. Gaskets.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Pulse Transmitter 66 99 903 -

4.4 Pulse Transmitter and Pulse Divider

Pulse Transmitter and Pulse Divider are available with built-in supply for ULTRAFLOW®. The options are battery, 24 VAC or 230 VAC supply.

Pulse Transmitter and Pulse Divider are available with galvanically separated output module. See paragraph 4.5.1 below.

Galvanic separation is used in the following situations:

1) More than 10 meter cable length between MULTICAL® and ULTRAFLOW® is required.

2) For flow sensor no. 2 in connection with MULTICAL®. If two flow sensors are used together with MULTICAL®, one must be galvanically separated.

For further info, see paragraph 7.11 Calculator with two flow sensors.

3) ULTRAFLOW® is connected to other equipment/foreign calculators.

Note: Flow-info is not possible if Pulse Transmitter or Pulse Divider is used.

4.5 Type number composition of Pulse Transmitter and Pulse Divider

Pulse Divider 66 99 907 -

Output module

Supply module

Final assembly and marking

4.5.1 Output module and supply module

Y Output module Corresponding supply module

2 Galvanically separated module 0, 7, 8 3 Galvanically separated module, low power 0, 2, 7, 8

Z Supply module Corresponding output module

0 No supply 2, 3 2 Battery, D-cell 3 7 230 VAC supply module 2, 3 8 24 VAC supply module 2, 3

Y Z - XXX

Table 7. Output module (Y) and supply module (Z) for Pulse Transmitter and Pulse Divider.

Pulse Transmitter and Pulse Divider are available with one of two different galvanically separated output modules. One output module (Y=2) for use of long cables (up to 100 metres towards MULTICAL®) and one output module (Y=3) for battery supply with a battery lifetime of minimum 6 years. Output module (Y=3) is default.

For further info, see paragraph 7.7 Electrical connection of Pulse Transmitter and Pulse Divider.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

0.6

116

300

3.9

---

Default

1.5

119

100

3.9

---

Default

2.5

198603.9

Default

3.5

151503.9

---

Default

137253.9

Default

178153.9

---

Default

17963.9

---

Default

4.6 Pulse Divider configuration CCC-DD-E-MMM

Pulse Divider is configured for ULTRAFLOW® meter factor (CCC) as well as the required meter factor (DD) and pulse duration (E) for the Pulse Divider according to Table 8 and Table 9.

MMM indicates customer label.

CCC

[m³/h] [imp/l] [l/imp] Divider DD [ms] [ms] (E=4) [ms] (E=5) [ms] (E=6)

0.6 1 300 33 - 20 50 100

0.6 2.5 750 63 - - - 100

1.5 1 100 33 - 20 50 100

1.5 2.5 250 63 - - - 100

1.5 10 1000 34 - - - 100

2.5 1 60 33 - 20 50 100

2.5 2.5 150 63 - - - 100

2.5 10 600 34 - - - 100

3.5 1 50 33 - 20 50 -

3.5 2.5 125 63 - - - 100

3.5 10 500 34 - - - 100

3.5 25 1250 64 - - - 100

6 1 25 33 - 20 50 6 2.5 62.5 63 - - - 100 6 10 250 34 - - - 100 6 25 625 64 - - - 100

Meter factor Pulse duration

- - -

10 1 15 33 - 20 50 10 10 150 34 - - - 100 10 25 375 64 - - - 100

15 120 10 3.9

15 1 10 33 - 20 - 15 10 100 34 - - 50 100 15 25 250 64 - - - 100 15 100 1000 35 - - - 100

25 1 6 33 - 20 - 25 10 60 34 - - 50 100 25 25 150 64 - - - 100 25 100 600 35 - - - 100

- - -

Table 8. Configuration options as to meter factor (DD) and pulse duration (E) for

Pulse Divider when connected to ULTRALFOW® 54 or 34, qp 0.6…25.

5512-385 GB/02.2014/Rev. H1

Default

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

15853.9

Default

170

2.5

3.9

Default

CCC

[m³/h] [imp/l] [l/imp] Divider DD [ms] [ms] (E=4) [ms] (E=5) [ms] (E=6)

40 10 50 34 - 20 50 40 25 125 64 - - - 100 40 100 500 35 - - - 100 40 250 1250 65 - - - 100

60 10 25 34 - 20 50 60 25 62.5 64 - - - 100 60 100 250 35 - - - 100 60 250 625 65 - - - 100

100 180 1.5 3.9

100 10 15 34 - 20 50 100 100 150 35 - - - 100 100 250 375 65 - - - 100

Meter factor Pulse duration

- - -

Default

Table 9. Configuration options as to meter factor (DD) and pulse duration (E) for

Pulse Divider when connected to ULTRALFOW® 54 or 34, qp 40…100.

Based on a qp value, a meter factor for the Pulse Divider is chosen in Table 8 or Table 9. The valid possible pulse durations are listed on the same line as the chosen meter factor.

Example: For ULTRAFLOW® 54 qp 40 m3/h (5 imp/l, CCC=158) a meter factor for the Pulse Divider of 10 l/imp (DD=34) is required. Based on this meter factor one of the pulse durations, 20 milliseconds (E=4) or 50 milliseconds (E=5) is selected.

For older types of ULTRAFLOW® (e.g. ULTRAFLOW® type 65), where the correlation between qp and meter factor

(CCC) is not ambiguous, the correct configuration is made by using the flow sensor’s meter factor [imp/l].

Default values in Table 8 and Table 9 are meter factor and pulse duration values for ULTRAFLOW® 54 and 34.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Enclosed if supply module

4.7 Accessories for Pulse Transmitter and Pulse Divider

Please note that not all article numbers in Table 10 can be directly ordered. Some must be ordered via Kamstrup service department

Article number Description

(when ordering Pulse Transmitter/Pulse Divider)

65-000-000-2000 D-cell lithium battery with two-pole connector

Note

3026-477

1650-157

65-000-000-7000

65-000-000-8000

Fitting for D-cell battery

Plug for cable connection

230 VAC supply module

24 VAC supply module

5000-290 Cable between supply module and output module

Enclosed if battery supply or “No supply” is selected

is selected

5000-286 24/230 VAC power cable Optional

66-99-012 Output module (Y=2), galvanically separated

66-99-013

Output module (Y=3), galvanically separated, “Low power”

5000-333 2.5 m silicone cable (3-wire) Optional

5000-259 5 m silicone cable (3-wire) Optional

5000-270 10 m silicone cable (3-wire) Optional

3026-207 Bracket for wall munting Optional

Obligatory when changing from mains supply module to battery supply.

Including 5000-290.

Table 10. Accessories for Pulse Transmitter and Pulse Divider.

4.7.1 Cables

Pulse Transmitter and Pulse Divider are optionally available with signal cable in lengths of 2.5, 5 or 10 metres. The signal cable is mounted from the factory.

If 24/230 VAC supply module is selected, Pulse Transmitter and Pusle Divider are optionally available with mains supply cable. The cable is mounted from the factory.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

5 Dimensional sketches

All measurements are in mm, unless otherwise stated.

5.1 ULTRAFLOW®

ULTRAFLOW®, G¾B and G1B

Thread EN ISO 228-1

Thread L M H2 A B1 B2 H1

G¾B 110 L/2 89 10.5 58 35 55 0.8

G1B 110 L/2 89 10.5 58 35 55 0.9

G1B (qp 0.6;1.5) 130 L/2 89 20.5 58 35 55 1.1

G1B (qp 2.5) 130 L/2 89 20.5 58 35 55 0.9

G¾B 165 L/2 89 20.5 58 35 55 1.2

G1B 165 L/2 89 20.5 58 35 55 1.2

G1B (qp 0.6;1.5) 190 L/2 89 20.5 58 35 55 1.5

G1B (qp 2.5) 190 L/2 89 20.5 58 36 55 1.3

Figure 1

Approx.

weight

[[[[kg]]]]

Table 11

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

ULTRAFLOW®, G5/4B, G1½B and G2B

Figure 2

Thread EN ISO 228-1

Approx.

Thread L M H2 A B1 B2 H1 D

G5/4B 260 L/2 89 17 58 22 55 ø43 2.3

G1½B 260 L/2 89 30 58 37 55 ø61 4.5

G2B 300 L/2 89 21 65 31 55 ø61 4.5

Table 12

weight

[[[[kg]]]]

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

ULTRAFLOW®, DN20 to DN50

Figure 3

Flange EN 1092, PN25. Flange facing type B, raised face

Nom. Bolts

diameter L M H2 B1 D H k Number Thread

DN20 190 L/2 89 58 105 95 75 4 M12 14 2.9

DN25 260 L/2 89 58 115 106 85 4 M12 14 5.0

DN40 250 L/2 89

DN40 300 L/2 89

DN50 250 155 89

DN50 270 155 89

<D/2

150 136 110

165 145 125

Table 13

Approx.

weight

4 M16 18 7.9

4 M16 18 8.3

4 M16 18 9.8

4 M16 18 10.1

[[[[kg]]]]

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

ULTRAFLOW®, DN65 to DN125

Figure 4

Flange EN 1092, PN25. Flange facing type B, raised face

Nom.

Diameter

DN65 300 170 89

DN80 300 170 89

DN80 350 170 89

DN100 360 210 89

DN100 400 210 89

DN125 350 212 89

Bolts

L M H2 B1 D H k Number Thread

<H/2

185 168 145

200 184 160

235 220 190

220 210 180

270 260 220

Table 14

Approx.

weight

8 M16 18 13.2

8 M16 18 16.8

8 M16 18 18.6

8 M20 22 21.7

8 M16 18 22.8

8 M24 28 28.2

[[[[kg]]]]

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

5.2 Pulse Transmitter and Pulse Divider

Figure 5. Pulse Transmitter/Pulse Divider

front view.

Figure 7. Wall mounted Pulse

Transmitter/Pulse Divider.

Figure 6. Pulse Transmitter/Pulse Divider

side view.

Figure 8. Pulse Transmitter/Pulse Divider

mounted on ULTRAFLOW®.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

60 & 100

DN100 & DN125

373

187

6 Pressure loss

The pressure loss in a flow sensor is stated as the maximum pressure loss at qp. According to EN 1434 the maximum pressure loss must not exceed 0.25 bar, unless the energy meter includes a flow controller or functions as pressure reducing equipment.

The pressure loss in a sensor increases with the square of the flow and can be stated as:

pkvQ ∆×=

where:

Q =volume flow rate [m³/h]

kv=volume flow rate at 1 bar pressure loss

∆p=pressure loss [bar]

Graph kv

A 0.6 & 1.5 DN15 & DN20 3.2 1.6 B 2.5 & 3.5 & 6 DN20, DN25 & DN32 13.4 6.7 C 10 & 15 DN40 & DN50 40 20 D 25 DN65 102 51 E 40 DN80 179 90

[m³/h] [mm] [m³/h]

Nom. diameter Q@0.25 bar

Table 15. Pressure loss table.

∆p ULTRAFLOW®54 and 34

A B C D E F

0,1

∆p [bar]

0,01

0,1 1 10 100 1000

Flow [m³/h]

Diagram 1. Pressure loss chart for ULTRAFLOW® 54 and 34.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7 Installation

Prior to installation of the flow sensor, the system should be flushed and protection plugs/plastic diaphragms removed from the flow sensor.

Correct position of the flow sensor (flow or return) appears from the front label of MULTICAL®. The flow direction is indicated by an arrow on the side of the flow sensor.

Glands and gaskets are mounted as shown in Figure 15, page 26.

Pressure stage of ULTRAFLOW®: PN16/PN25, see marking. Flow sensor marking does not cover included

accessories.

Temperature of medium, ULTRAFLOW® 54: 15…130 °C/15…90 °C, see marking.

Temperature of medium, ULTRAFLOW® 34: 2…130 °C/2…50 °C, see marking.

Mechanical environment: M1 (fixed installation with minimum vibration).

Electromagnetic environment: E1 and E2 (housing/light industry). The meter’s signal cables must be drawn at

min. 25 cm distance from other installations.

Climatic environment: Installation must take place in environments with non-condensing humidity as well as in closed locations (indoors). However, ULTRAFLOW® 34 may be installed in environments with periodically condensing humidity.

The ambient temperature must be within 5…55 °C.

Maintenance and repair: The flow sensor is verified separately and can, therefore, be separated from the calculator.

ULTRAFLOW® can only be direct connected to Kamstrup’s calculators on terminals 11-9-10, as shown in paragraph

7.6 Electrical connection of ULTRAFLOW® and MULTICAL®. Connection to other types of calculators requires the use

of a Pulse Transmitter or Pulse Divider.

It is permissible to replace the supply and change the supply type in Pulse Transmitter/Pulse Divider. For battery supply a lithium battery with connector from Kamstrup A/S must be used. Lithium batteries must be correctly handled and disposed of (see Kamstrup document 5510-408, ”Lithium batteries - Handling and disposal”).

It is also permissible to replace the output module in Pulse Transmitter/Pulse Divider

Other repairs require subsequent re-verification in an accredited laboratory.

Note: Please make sure that the meter factor is identical on flow sensor and calculator.

At medium temperature above 90 °C, the use of flange meters is recommended. At medium temperature above 90 °C or at medium temperature more than 5 °C below ambient temperature

< T

med

wall mounting is recommended.

In order to prevent cavitation the back pressure at ULTRAFLOW® must be min. 1.5 bar at qp and min. 2.5 bar at qs. This applies to temperatures up to approx. 80 °C.

ULTRAFLOW® must not be exposed to pressure lower than the ambient pressure (vacuum).

ULTRAFLOW® 54 should not be insulated or enclosed as the natural ventilation around the meter is prevented.

- 5 °C), calculator and Pulse transmitter/Pulse divider may not be mounted on the flow sensor. Instead

amb

ULTRAFLOW® 34 should not be insulated or enclosed as condensation around the meter will be trapped.

If, after careful consideration, ULTRAFLOW® is insulated anyway, the electronics housing must remain uninsulated.

When the installation has been completed, water flow can be turned on. The valve on the inlet side must be opened first.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.1 Installation angle for ULTRAFLOW®

ULTRAFLOW® 54 and 34 may be installed horizontally, vertically or at an angle.

Important!

For ULTRAFLOW® 54 and 34 the electronics housing must be placed on the side (when installed horizontally).

ULTRAFLOW® 54 may be turned up to ±45°

Figure 9

around the pipe axis.

ULTRAFLOW® 34 may be turned up to +45° around the pipe axis as shown in Figure 10.

Figure 10

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.2 Straight inlet

ULTRAFLOW® 54 requires neither straight inlet nor straight outlet to meet the Measuring Instruments Directive (MID) 2004/22/ EC, OIML R75:2002 and EN 1434:2007. A straight inlet section will only be necessary in case of heavy flow disturbances before the meter. We recommend following the guidelines of CEN CR 13582.

Optimal position can be obtained if you take the below-mentioned installation methods into consideration:

A Recommended flow sensor position

B Recommended flow sensor position

C Unacceptable position due to risk of air

build-up

D Acceptable in closed systems.

Unacceptable position in open systems due to risk of air build-up.

E A flow sensor should not be placed

immediately after a valve, except from closing valves (ball valve type), which must be completely open when not used

Figure 11

For general information concerning installation see CEN report DS/CEN/CR 13582, Heat meter Installation. Instructions in selection, installation and use of heat meters.

for closing

F A flow sensor should not be placed at the

inlet side of a pump

G A flow sensor should not be placed after a

double bend in two planes

7.3 Operating pressure

In order to prevent cavitation the back pressure at ULTRAFLOW® must be min. 1.5 bar at qp and min. 2.5 bar at qs. This applies to temperatures up to approx. 80 °C. ULTRAFLOW® must not be exposed to pressure lower than the ambient pressure (vacuum). For further information on operating pressure, see paragraph 8.7 Guidelines for dimensioning ULTRAFLOW®.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.4 Humidity and condensation

If ULTRAFLOW 12 below.

ULTRAFLOW® 34 can be installed in environments with periodically condensing humidity, but ought neither to be insulated nor wrapped as condensation water on the meter is thereby entrapped.

Furthermore, wires/cables must in general hang freely downwards after cable connections to form a drip nose for drainage of water and condensation.

is installed in moist environments, it must be turned +45° around the pipe axis as shown in Figure

Figure 12

7.4.1 Orientation of Pulse Transmitter and Pulse Divider

Mounting the Pulse Transmitter and Pulse Divider, the cable connections must always be horizontally or downwards oriented in order to avoid the risk of water and condensation being led into the box via the cables.

This is specially important in moist environments.

Furthermore, wires/cables must in general hang freely downwards after the cable connections to form a drip nose for drainage of water and condensation.

Max. 90° Max. 90°

Figure 13. Orientation of Pulse Transmitter/Pulse Divider.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.5 Installation examples

Figure 14. Threaded meter with MULTICAL® mounted on ULTRAFLOW®.

Glands and short direct sensor fitted into ULTRAFLOW® (only G¾B (R½) and G1B (R¾)).

The short direct sensor from Kamstrup can only be mounted in PN16 installations. The blind plug mounted in the ULTRAFLOW® flow part can be used in connection with both PN16 and PN25. The flow sensor can be used in both PN16 and PN25 installations and can be supplied marked either PN16 or PN25 as desired. Supplied glands, if any, can only be used for PN16. For PN25 installations shall be used suitable PN25 glands.

In connection with G¾Bx110 mm and G1Bx110 mm, it must be checked that 10 mm thread run-out is sufficient. See Figure 15 below.

Figure 15. ULTRAFLOW® with gland and short direct sensor.

Figure 16. Flange meter with MULTICAL® mounted on ULTRAFLOW®.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Figure 17. Wall mounted Pulse

Transmitter/Pulse Divider.

Figure 18. Pulse Transmitter/Pulse Divider

mounted on ULTRAFLOW®.

Note: At medium temperature above 90 °C or at medium temperature more than 5 °C below ambient temperature (T

< T

med

- 5 °C), calculator and Pulse transmitter/Pulse divider may not be mounted on the flow sensor. Instead

amb

wall mounting is recommended.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.6 Electrical connection of ULTRAFLOW® and MULTICAL®

ULTRAFLOW®

Blue (ground)

Red (supply)

Yellow (signal)

Table 16. Connecting ULTRAFLOW® and MULTICAL®.

Please note that using long signal cables requires careful consideration in connection with installation. There must be a distance of min. 25 cm between signal cables and all other cables to prevent electrical disturbance.

→→→→

MULTICAL®

7.7 Electrical connection of Pulse Transmitter and Pulse Divider

If ULTRAFLOW® and MULTICAL® are connected via a Pulse Transmitter, ULTRAFLOW® is galvanically separated from MULTICAL®.

Note: Flow-info is not possible if Pulse Transmitter is used.

If ULTRAFLOW® is connected to other equipment than MULTICAL®, always connect ULTRAFLOW® via Pulse Transmitter or Pulse Divider.

ULTRAFLOW®

Blue (ground)

Red (supply)

Yellow (signal)

Table 17. Connecting ULTRAFLOW® and MULTICAL® via Pulse Transmitter/Pulse Divider.

*) Pulse Divider is not normally used together with MULTICAL®.

→→→→

Pulse Transmitter/

Pulse Divider *)

Input Output

11 11A

9 9A

10 10A

→→→→

MULTICAL®

Diagram 2. Three-wire connection of Pulse Transmitter with output module (Y=2)

to MULTICAL® 602/801. Cable length up to 25 metres.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Diagram 3. Three-wire connection of Pulse Transmitter with output module (Y=3)

to MULTICAL® 602/801. Cable length up to 25 metres.

Diagram 4. Two-wire connection of Pulse Transmitter with output module (Y=2)

to MULTICAL® /801. Cable length up to 100 metres.

Diagram 5. Two-wire connection of Pulse Transmitter with output module (Y=2)

to MULTICAL® 602-D and external 24 VDC supply. Cable length up to 100 metres.

See paragraph 7.10 Example of connecting Pulse Transmitter.

For connection of Pulse Transmitter and Pulse Divider to other calculators please see paragraph 8.9 Pulse output of Pulse Transmitter and Pulse Divider.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.7.1 Cable length

Maximum allowable cable length between Pulse Transmitter/Pulse Divider and MULTICAL® depends on the output module used in Pulse Transmitter/Pulse Divider as well as how the MULTICAL® calculator is connected.

Pulse Transmitter/Pulse

Divider output module 2-wire connection 3-wire connection

Y=2 < 100 m *) < 25 m Y=3 N/A < 25 m

*) MULTICAL® 601/602 must have sensor connection type D and external 24 VDC supply.

MULTICAL® 601/602/801

Table 18. Maximum cable length between Pulse Transmitter/

Pulse Divider and MULTICAL®.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.8 Connection of power supply

If ULTRAFLOW® is connected via Pulse Transmitter or Pulse Divider, ULTRAFLOW® is powered by the supply module/battery in the Pulse Transmitter/Pulse Divider.

7.8.1 Battery supply

Pulse Transmitter/Pulse Divider is fitted with a D-cell lithium battery with connector. The battery plug is connected to the output module.

Optimal battery lifetime is obtained by keeping the battery temperature below 30 °C, e.g. by wall mounting the Pulse Transmitter/Pulse Divider.

The voltage of a lithium battery is almost constant throughout the lifetime of the battery (approx. 3.65 V). Therefore, it is not possible to determine the remaining capacity of the battery by measuring the voltage.

The battery cannot and must not be charged and must not be short-circuited.

The battery supply may only be replaced by a corresponding lithium battery with connector from Kamstrup A/S. Used batteries must be handed in for approved destruction, e.g. at Kamstrup A/S. (See Kamstrup document 5510408, ”Lithium batteries - Handling and disposal”).

7.8.2 Mains supply modules

The mains supply modules are protection class II and are connected to the output module via a small two-wire cable with plugs. The modules are powered via a two-wire mains supply cable (without earth connection) through the cable connector of the Pulse Transmitter/Pulse Divider. Use supply cable with an outer diameter of maximum 10 mm and ensure correct stripping of insulation as well as correct tightening of cable connection (see paragraph

7.8.4).

Max. permitted fuse: 6 A

230 VAC

This PCB module is galvanically separated from the mains supply and is suitable for direct 230 VAC mains installation. The module includes a double-chamber safety transformer, which fulfils double-isolation requirements when the cover is mounted on the Pulse Transmitter/Pulse Divider. Power consumption is less than 1 VA/1 W.

National regulations for electric installations must be observed. The 230 VAC module can be connected/disconnected by the district heating station’s personnel, whereas the fixed 230 VAC installation to the main electrical panel must be carried out by an authorized electrician.

24 VAC

This PCB module is galvanically separated from the 24 VAC mains supply and is both suitable for industrial installations with joint 24 VAC supply and individual installations, which are supplied by a separate 230/24 VAC safety transformer in the main electrical panel. The module includes a double-chamber safety transformer, which fulfils double-isolation requirements when the cover is mounted on the Pulse Transmitter/Pulse Divider. Power consumption is less than 1 VA/1 W.

Diagram 6

National regulations for electric installations must be observed. The 24 VAC module can be connected/disconnected by the district heating station’s personnel, whereas the fixed 230/24 VAC installation in the main electrical panel must only be carried out by an authorized electrician.

Note: This module cannot be supplied by 24 VDC (direct current).

5512-385 GB/02.2014/Rev. H1

Diagram 7

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

230/24 VAC safety transformer

The 24 VAC module is specially suited for installation together with a 230/24 VAC safety transformer, e.g. type 66-99-403, which can be installed in the main electrical panel before the safety relay. When the transformer is used, the total power consumption of the meter incl. the 230/24 VAC transformer will not exceed 1.7 W.

Figure 19

7.8.3 Mains supply cable

Pulse Transmitter/Pulse Divider is available with mains supply cable H05 VV-F for either 24 V or 230 V (l=1.5 m):

Figure 20. Mains cable (2x0.75 mm²), max. 6 A fuse.

”H05 VV-F” is the designation of a strong PVC mantle, which withstands max. 70 °C. Therefore, the mains cable must be installed with sufficient distance to hot pipes etc.

7.8.4 Cable connections

Cable dimension in connections for signal cable: 2…6 mm

Cable dimension in connections for mains supply cable: 4.5…10 mm

Tightening torque: Maximum 4 Nm (cable strain relief minimum 40 N according to EN 61558)

Please note: When supplied by battery the unused cable connection must be sealed off as shown in Figure 22, page 33.

7.8.5 Change of supply unit

The supply unit of Pulse Transmitter/Pulse Divider can be changed from mains supply to battery or visa versa as the needs of the supply company change. Thus, it can be an advantage to temporarily change mains supplied Pulse Transmitter/Pulse Divider to battery supplied, e.g. in case of buildings under construction where the mains supply can be unstable or periodically missing.

Please note that for Pulse Transmitter/Pulse Divider the supply type appears from the label. If the original supply type is changed, it will no longer be in accordance with the label.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.9 Example of connecting ULTRAFLOW® and MULTICAL®

Figure 21. ULTRAFLOW® 54 connected to MULTICAL® 602.

See paragraph 7.6 for electrical wiring.

7.10 Example of connecting Pulse Transmitter

Figure 22. ULTRAFLOW® 54 connected to battery supplied Pulse Transmitter. MULTICAL® 602

connected to the Pulse Transmitter's output module (Y=3).

Please note: If battery supplied, the right cable connection of the Pulse Transmitter is plugged.

Figure 23. ULTRAFLOW® 54 connected to Pulse Transmitter with 230 VAC supply. MULTICAL® 801

is connected to the Pulse Transmitter's output module (Y=2).

See paragraph 7.7 for electrical wiring.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

7.11 Calculator with two flow sensors

MULTICAL 602 and 801 can be used in various applications with two flow sensors, e.g. leak surveillance and open systems. When two ULTRAFLOW are direct connected to one MULTICAL, a close electric coupling between the two pipes ought to be carried out as a main rule. If the two pipes are installed in a heat exchanger, close to the flow sensors, however, the heat exchanger will provide the necessary electric coupling.

Electric coupling

Figure 24. Forward and return pipes are closely electrically coupled.

No welded joints occur.

In installations where the electric coupling cannot be carried out, or where welding in the pipe system can occur, the cable from one ULTRAFLOW must be routed through a Pulse Transmitter with galvanic separation before the cable enters MULTICAL.

Figure 25.Forward and return pipes are not necessarily closely coupled.

Electric welding *) can occur.

Electric welding must always be carried out with the earth pole closest to the welding point. Damage to meters

due to welding is not comprised by Kamstrup’s factory guarantee.

7.12 Operational check

Carry out an operational check when the complete meter (flow sensor and calculator) has been installed and connected. Open thermoregulators and cocks to establish water flow through the installation. Activate the top key of the calculator and check that the displayed values for temperatures and water flow are credible values.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Against the flow

With the flow

8 Functional description

8.1 Ultrasound combined with piezo ceramics

Flow sensor manufacturers have been working on alternative techniques to replace the mechanical principle. Research and development at Kamstrup has proved that ultrasonic measuring is the most viable solution. Combined with microprocessor technology and piezo ceramics, ultrasonic measuring is not only accurate but also reliable.

8.2 Principles

The thickness of a piezo ceramic element changes when exposed to an electric field (voltage). When the element is influenced mechanically, a corresponding electric charge is generated. In this way the piezo ceramic element can function either as a sender or a receiver or both.

Within ultrasonic flow measuring there are two main principles: the transit time method and the Doppler method.

The Doppler method is based on the frequency shifting which is generated when sound is reflected by a moving particle. This is very similar to the effect you experience when a car drives by. The sound (the frequency) decreases when the car passes by.

8.3 Transient time method

The transient time method used in ULTRAFLOW® utilizes the fact that it takes an ultrasonic signal emitted in the opposite direction of the flow longer time to travel from sender to receiver than a signal sent in the same direction as the flow.

The transient time difference of a flow sensor is very small (nanoseconds). Therefore, the time difference is measured as a phase difference between the two 1 MHz sound signals to obtain the necessary accuracy.

PHASE DIFFERENCE

SIGNAL

Diagram 8

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

FCF

−−+

In principle, flow is determined by measuring the flow velocity and multiplying it by the area of the measuring pipe:

AFQ

where:

is the flow

is the flow velocity

Is the area of the measuring pipe

The area and the length, which the signal travels in the sensor, are well-known factors. The length which the signal travels can be expressed as

T =

where:

is the measuring distance

is the sound propagation velocity

VTL

, which can also be written as:

is the time

The time can be expressed as the difference between the signal sent with the flow and the signal sent against the flow.

 

 

In connection with ultrasonic flow sensors the velocities

FCV −=

where:

Using the above formula you get:

And

is the velocity of sound in water

×=∆

−

which can also be written as:

×=∆





−×=∆





and

FCV +=

respectively

−

can be stated as:

)()(

FCFC

)()(

FCFC

+×−

×=∆⇒

−

FC 〉〉

can be omitted and the formula reduced as follows:

×∆

In order to minimize the influence from variations of the velocity of sound in water, the velocity is measured via a number of absolute time measurements between the two transducers. These measurements are subsequently, in the built-in ASIC, converted into the current velocity of sound which is used in connection with flow calculations.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

8.4 Signal paths

Figure 26. qp 0.6…1.5 m³/h

Parallel

The sound path is parallel to the measuring pipe and sound is sent from the transducers via reflectors.

Figure 27. qp 2.5…100 m³/h

Triangle

The sound path covers the measuring pipe in a triangle and sound is sent from the transducers round the measuring pipe via reflectors.

8.5 Measuring sequences

During flow measuring ULTRAFLOW® passes through a number of sequences, which are repeated at fixed intervals. Deviations only occur when the meter is in test mode and connecting the supply during initialization/start-up.

The difference between the main routines in normal and verification mode is the frequency of the measurements, on which pulse emission is based.

It may take up to 16 seconds to obtain correct function after a power cut.

5512-385 GB/02.2014/Rev. H1

TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

8.6 Function

In the meter’s working range from min. cut-off to saturation flow there is a linear connection between the water volume flowing through and the number of pulses being emitted. An example of the connection between flow and pulse frequency for ULTRAFLOW® qp 1.5 m³/h is shown below (Diagram 9).

Flow frequency (qp 1.5 m³/h)

140

120

100

Frequency [Hz]

-0,5 0,5 1,5 2,5 3,5 4,5

Min. cutoff

0.5 1.5 2.5 3.5 4.5

Flow [m³/h]

Saturation flow (125 Hz)

Diagram 9. Flow frequency qp 1.5 m³/h.

If the flow is lower than min. cut-off or negative, ULTRAFLOW® emits no pulses.

At flows above the flow corresponding to pulse emission at a max. pulse frequency of 128 Hz, the max. pulse frequency will be maintained.

Table 19 overleaf shows the flow at max. pulse frequency 128 Hz for the various flow sizes and meter factors.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Meter factor Flow at 128 Hz

[m³/h] [imp/l] [m³/h]

0.6 300 1.54

1.5 100 4.61

2.5 60 7.68

3.5 50 9.22 6 25 18.4

10 15 30.7 15 10 46.1 25 6 76.8 40 5 92.2 60 2.5 184.3

100 1.5 307.2

Table 19. Flow at max. pulse frequency (128 Hz).

According to DS/EN 1434 the upper flow limit qs is the highest flow at which the flow sensor may operate for short periods of time (<1h/day, <200h/year) without exceeding max. permissible errors. ULTRAFLOW® has no functional limitations during the period when the meter operates above qp.

Please note, however, that high flow velocities may cause cavitation, especially at low static pressure. See

paragraph 8.7 Guidelines for dimensioning ULTRAFLOW®.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

back pressure

100

1.5

200

2.5

8.7 Guidelines for dimensioning ULTRAFLOW®

In connection with installations it has proved to be practical to work with larger pressures than the ones stated below:

Nominal flow q

Recommended

Max. flow q

Recommended

[m³/h] [bar] [m³/h] [bar]

0.6 1 1.2 2

1.5 1.5 3 2.5

2.5 1 5 2

3.5 1 7 2 6 1.5 12 2.5

10 1 20 2 15 1.5 30 2.5 25 1 50 2 40 1.5 80 2.5 60 1 120 2

Table 20. Recommended minimum back pressure.

The purpose of recommended back pressure is to avoid measuring errors due to cavitation or air in the water.

It is not necessarily cavitation in the flow sensor itself, but also bubbles from cavitating pumps or regulating valves mounted before the sensor. It can take some time for these bubbles to dissolve in the water.

In addition, the water may contain air, which is dissolved in the water. The amount of air which can be dissolved in water depends on the pressure and the temperature. This means that air bubbles can be formed because of a drop of pressure e.g. due to an absolute speed rise in a contraction or over the meter.

The risk of these factors affecting accuracy is reduced by maintaining a fair pressure in the installation.

In relation to above table, the steam pressure at current temperature must also be considered. Table 20 applies to temperatures up to approx. 80 °C. Furthermore, it must be considered that the above-mentioned pressure is the back pressure at the sensor and that the pressure is lower after a contraction than before one (e.g. cones). This means that the pressure – when measured elsewhere - might be different from the pressure at the sensor.

This can be explained by combining the continuity equation and Bernoulli’s equation. The total energy from the flow will be identical at any cross section. It can be reduced to: P + ½ρv2 = constant.

When dimensioning the flow sensor, this must be taken into consideration, especially if the sensor is used within the scope of EN 1434 between qp and qs, and in case of heavy contractions of the pipe.

Steampressure

2,5

1,5

[bar]

0,5

80 85 90 95 100 105 110 115 120 125 130

[°C]

Diagram 10. Steam pressure.

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8.8 Pulse output of ULTRAFLOW®

ULTRAFLOW® 54 and 34

Type Push-Pull

Output impedance ~10 kΩ

Pulse duration 2…5 ms

Pause Depending on current pulse frequency

Diagram 11. Block diagram for ULTRAFLOW®.

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8.9 Pulse output of Pulse Transmitter and Pulse Divider

8.9.1 Galvanically separated output module (Y=2)

Pulse Transmitter/Pulse Divider is powered by the built-in supply module (Z=7 or 8).

Cable length to Pulse Transmitter/Pulse Divider depends on calculator.

To calculator:

Type: Open collector.

Connection: Can be connected as two-wire or as three-wire via the built-in 56.2 kΩpull-up.

Module Y=2 OC and OD (OB) Kam

Max input voltage 6 V 30 V Max input current 0,1 mA 12 mA ON condition U ≤ 0,3 V @ 0,1 mA OFF condition R ≥ 6 MΩ R ≥ 6 MΩ

UCE ≤ 2,5 V @ 12 mA

Table 21

Concerning meter factor and pulse duration, see paragraph 4.6 Pulse Divider configuration CCC-DD-E-MMM.

Diagram 12. Block diagram for galvanically separated output module (Y=2).

Figure 28. Galvanically separated output module (Y=2).

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8.9.2 Galvanically separated output module (Y=3)

Pulse Transmitter/Pulse Divider is powered by the built-in supply module (Z=2, 7 or 8).

Cable length to Pulse Transmitter/Pulse Divider depends on calculator.

To calculator:

Type: Open collector.

Connection: Can be connected as three-wire via the built-in 39.2 kΩpull-up.

Module Y=3 OC and OD

Max input voltage 6 V Max input current 0,1 mA ON condition U ≤ 0,3 V @ 0,1 mA OFF condition R ≥ 6 MΩ

Table 22

Concerning meter factor and pulse duration, see paragraph 4.6 Pulse Divider configuration CCC-DD-E-MMM.

Diagram 13. Block diagram for galvanically separated output module (Y=3).

Figure 29. Galvanically separated output module (Y=3). Note the omitted components

in the encircled area compared to output module (Y=2).

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8.10 Pulse emission

Pulses are emitted at intervals of 1 second. The number of pulses to be emitted is calculated every second. Pulses are emitted in bursts with a pulse duration of 2…5 ms and pauses depending on the current pulse frequency. The duration of the pauses between the individual bursts is approx. 30 ms.

The transmitted pulse signal is the average determination of a series of flow measurements. This means that during start-up there will be a transient phenomenon until correct flow signal has been obtained. Furthermore, this brings about a pulse tail of up to 8 seconds in case of sudden hold.

8.11 Accuracy

ULTRAFLOW® 54 and 34 have been developed as a volume flow sensor for use with energy meters according to DS/EN 1434. Permitted tolerances in DS/EN 1434 for flow sensors with a dynamic range of 1:100 (qi:qp) are shown in Diagram 14. The tolerances are defined for classes 2 and 3 with following formulas:

Class 2:

Class 3:

DS/EN 1434 defines following dynamic ranges (qi:qp): 1:10, 1:25, 1:50, 1:100 and 1:250.

×+ 02.02

but max. 5 %

×+ 05.03

but max. 5 %

In connection with accuracies the range from qp to qs is defined as max. flow short-term, where tolerances are adhered to. There are no requirements as to the relationship between qp and qs. See Table 1 for information on qs for ULTRAFLOW®.

To ensure that the sensors meet the tolerance requirements, DS/EN 1434-5 specifies calibration requirements in connection with verification of sensors. The requirements for flow sensors are that they have to be tested at following 3 points:

qi…1.1 x qi, 0.1 x qp..0.11 x qp and 0.9 x qp…qp

During testing the water temperature must be 50 °C ±5 °C for ULTRAFLOW® as a heat meter.

For ULTRAFLOW® as a cooling meter the water temperature must be 15 °C ±5 °C

Further requirements are that the tolerance of the equipment used to perform the test must be less than 1/5 MPE (Max. Permissible Error) in order for the acceptance limit to be equal to MPE. If the equipment does not meet this standard, the acceptance limit must be reduced by the tolerance of the equipment.

ULTRAFLOW® will typically do better than half of the permitted tolerance according to DS/EN 1434 class 2.

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EN143 4 cl.2

½ EN143 4 cl.2

Flow sensor tolerances qi:qp 1:100 (qp 1.5 m³/h)

EN143 4 cl.3

Tolerances [%]

0,01 0,1 1 10

0.01

0.1

0.1 x qp

Flow [m³/h]

qsqp0,1x qp

Diagram 14. Flow sensor tolerances qi:qp 1:100 for qp 1.5 m³/h.

8.12 Power consumption

The current consumption of ULTRAFLOW® is as follows:

Max. average 50 µA

Max. current 7 mA (max. 40 ms)

8.13 Interface connector/serial data

ULTRAFLOW® 54 and 34 is fitted with a four-pole connector under the cover. Thus, it is not possible to access this connector without breaking the seal. On delivery, the cover will be sealed with a factory seal and in connection with verified sensors it will be a laboratory seal (legal seal).

The connector is used for:

• Programming sensor, including adjusting the flow curves by means of METERTOOL

• Setting the sensor to test mode

• Reading accumulated water quantity in connection with calibration

• External control of start/stop in connection with calibration

The interface connector is constructed as shown in Figure 30.

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Figure 30. Interface connector.

The electronics are encapsulated in ULTRAFLOW® 34, and, thus, the four-pole connector is not directly available. In order to gain access to pin 4 an adapter with four-pole connector is used (see Figure 43, page 60). Before clicking the adapter onto the electronics housing, a hole is drilled in the cover of the electronics housing at the marking (ø2 mm, max. drilling depth 10 mm). (See Figure 31.) Subsequently the signal cable is connected to the terminals of the adapter. (See par. 7.6.)

Meter interface

Pin 1 Vcc

Pin 2 Gnd

Pin 3 Pulse out

Pin 4 Access control

Figure 31. Drilling marking on

ULTRAFLOW® 34 cover.

8.14 Test mode

To minimize the time spent on calibration, ULTRAFLOW® 54 and 34 can be switched into test mode. In test mode (verification mode) the measuring routines only take one fourth of the time they take in normal mode.

ULTRAFLOW® is put into test mode by connecting pin 4 of the internal connector to ground (Figure 30) and subsequently connect the supply. After approx. 1 second the sensor goes into test mode and the connection between pin 4 and ground is disconnected.

Test mode is ended by disconnecting the supply to the sensor.

Note: An ULTRAFLOW® in test mode uses approx. 3 times as much power as in normal mode. However, this does not influence the total battery lifetime of the energy meter.

8.15 Externally controlled start/stop

In connection with calibration by means of serial data, e.g. in connection with NOWA, ULTRAFLOW® 54 and 34 can be monitored by an external signal when it is in test mode (see paragraph 8.14 Test mode). This is done by grounding pin 4 of the internal connector when starting the test and removing it when the test has been completed. The volume of water that has been accumulated during the test can be read serially.

The accumulation is based on the same data as those used for calculating the number of pulses to be emitted.

In addition to accumulating water volume during test, the sensor corrects for the excess quantity measured in connection with start as well as the quantity lacking in connection with stop. These deviations occur because the sensor measures flow at regular intervals, as illustrated in Figure 32 below.

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Figure 32

The excess water quantity in connection with start is the water volume that runs through the sensor during the time

before the first accumulation

with stop is the water volume passing through the sensor during the time stop

The volume accumulated during the test can be stated as:

within the test period. In the same way the lacking quantity in connection

from the last accumulation

until

∑

...

+++

8.16 Calibration using serial data and externally controlled start/stop

The routine for calibrating ULTRAFLOW® using serial data is outlined below.

Figure 33

The sensor must be in test mode (see paragraph 8.14 Test mode).

Calibration is started by connecting the 4th pin of the internal plug (see Figure 33), simultaneously with starting the test. E.g. this might take place at the same time as the master meter is started or at the same time as the diverter to the weight is being changed. ULTRAFLOW® accumulates the water volume until you disconnect pin 4 and terminate the test. Subsequently, the volume accumulated during the test can be read with respect to start and stop. From the test has been completed until the accumulated quantity of water can be read, minimum 2 seconds must pass (T

Pulse emission stops when pin 4 is disconnected. The read water quantity and the number of emitted pulses may differ as the pulse emission is controlled at intervals of 1 second.

read

). No communication must take place with ULTRAFLOW® during testing.

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9 Calibrating ULTRAFLOW

Calibration can be based on:

• Pulses in standard mode

• Pulses in test mode

• Pulses using PULSE TESTER type 66-99-279

• Serial data with the meter in test mode (e.g. used in connection with NOWA)

9.1 Installation

The installation angle must be taken into account installing ULTRAFLOW. See the restrictions in paragraph 7 Installation. Also see paragraph 9.9 Optimization in connection with calibration.

9.2 Technical data for ULTRAFLOW

[m³/h] [imp/l] [m³/h]

0.6 300 1.54

1.5 100 4.61

2.5 60 7.68

3.5 50 9.22 6 25 18.4

10 15 30.7 15 10 46.1 25 6 76.8 40 5 92.2 60 2.5 184.3

100 1.5 307.2



Meter factor Flow at 128 Hz

Table 23. Output signal.

Output ULTRAFLOW®

Type Push-Pull

Output impedance ~10 kΩ

Pulse duration 2…5 ms

Pause Depending on current pulse frequency

Diagram 15. Block diagram for ULTRAFLOW

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9.3 Connection

Connection via three-wire cable from ULTRALFOW®

Yellow Signal

Red Supply

Blue Ground

Supply 3.6 VDC ± 0.1 VDC

Output when using Pulse Transmitter/Pulse Divider with galvanically separated output module (Y=2)

Type Open collector. Can be connected as two-wire or three-wire via the built-in pull-up resistance

of 56.2 kΩ.

Module Y=2 OC and OD (OB) Kam

Max input voltage 6 V 30 V Max input current 0,1 mA 12 mA ON condition U ≤ 0,3 V @ 0,1 mA OFF condition R ≥ 6 MΩ R ≥ 6 MΩ

UCE ≤ 2,5 V @ 12 mA

Table 24

Diagram 16. Block diagram for galvanically separated output module (Y=2).

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Output when using Pulse Transmitter/Pulse Divider with galvanically separated output module (Y=3)

Type Open collector. Can be connected as three-wire via the built-in pull-up resistance of 39.2 kΩ.

Module Y=3 OC and OD

Max input voltage 6 V Max input current 0,1 mA ON condition U ≤ 0,3 V @ 0,1 mA OFF condition R ≥ 6 MΩ

Table 25

Diagram 17. Block diagram for galvanically separated output module (Y=3).

9.4 Start-up

16 seconds must elapse from start-up to calibration in order to allow a true reading to be reached.

9.5 Measuring flow

To obtain correct flow measurement, the duration of calibration must be minimum 2 minutes.

9.6 Evacuation

ULTRAFLOW® must NOT be evacuated (subjected to vacuum).

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Nom. flow

Meter factor

pqpqi

pqi

100

1.5

10011032065000

333

1000

9.7 Suggested test points

Test quantitiesTest durationTest point

[m³/h] [imp/l] [m³/h] [m³/h] [m³/h] [min] [min] [min] [kg] [kg] [kg]

0.6 300 0.6 0.006 0.06 3 20 6 30 2 6

1.5 100 1.5 0.015 0.15 3 20 4 75 5 10

2.5 60 2.5 0.025 0.25 3 20.2 4.8 125 8,4 20

3.5 50 3.5 0.035 0.35 3 17.1 6 175 10 35 6 25 6 0.06 0.6 3 20 4 300 20 40

10 15 10 0.1 1 3 20.4 6 500 34 100 15 10 15 0.15 1.5 3 20 6 750 50 150 25 6 25 0.25 2.5 3 20.2 6 1250 84 250 40 5 40 0.4 4 3 15 6 2000 100 400 60 2.5 60 0.6 6 3 20 6 3000 200 600

Table 26. Table for ULTRAFLOW including suggested test points, test durations and test quantities.

0.1xq

0.1xqpq

0.1xq

The suggested test parameters are based on EN 1434-5 and qi:qp 1:100.

The test set-ups have been selected on the basis of the following requirements:

Minimum test duration of 3 minutes

Water volumes of qi and 0.1xqp of minimum 10 % of the water volume per hour

Water volume of 0.1xqp corresponding to minimum 1000 pulses

Water volume of qi corresponding to minimum 500 pulses

These suggested test points can be optimized for each test rig as well as for the test purpose.

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9.8 Sealing

ULTRAFLOW® is sealed from the factory. Verified sensor will be supplied with laboratory marks and a year mark as shown in Figure 34.

If the seal of a verified sensor is broken, the sensor must be verified before being installed in a location demanding verification.

Figure 34. MID sealing of ULTRAFLOW®.

On the drawings the sealing is divided into following groups:

D Module D/F label or security seal (depending on type label).

S Security seal. Covering screws.

T Type label (as void label or with security seal D).

I Installation seal (wire and seal or sealing label).

Note: Sealing requirements may vary as a consequence of national regulations.

Figure 35. MID sealing of Pulse Divider.

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9.9 Optimization in connection with calibration

To make a rational test of ULTRAFLOW® it must be possible to reproduce test results. This is also very important if the sensors tested are to be adjusted.

Experience shows that ULTRAFLOW® operates with standard deviations of 0.3…0.4 % at qi and 0.2…0.3 % at qp. This is standard deviations at 300…500 pulses at qi, 3000…5000 at qp , and flying start/stop.

In connection with optimization of calibration the following aspects should be taken into account:

Pressure: Optimal working pressure is 4…6 bar of static pressure. This minimizes the risk of air and cavitation.

Temperature: Calibration temperature according to DS/EN 1434-5 is 50 °C ± 5 °C for heat meters and 15 °C ± 5 °C

for cooling meters.

Water quality: No requirements.

Installation - mechanical conditions:

To avoid flow disturbances inlet pipes and distance pieces must have the same nominal diameter as the sensors (see Table 27). There should be minimum 5 x DN between the sensors. With bends etc. there should be a minimum distance of 10 x DN. If tests are made at low flow through a bypass at right angles to the pipe, it would be an advantage to mount an absorber of pressure fluctuations due to the angle of the inlet pipe. This can be a flexible tube on the bypass. In addition, it would be advantageous to fit a flow straightener before the first distance piece. Flow disturbances such as pulsations, e.g. pump fluctuations must be minimized. In connection with calibration, a code of practice concerning distance pieces has been made on the basis of years of experience:

The length of the distance piece must be 10 x DN.

The diameter of the distance piece must be:

Connection Distance piece Gland

G¾ (R½) DN15 ø15 ø14 G1 (R¾) DN20 ø20 ø19,5 DN20 ø20 G5/4 (R1) DN25 ø25 ø25,5 DN25 ø25 G1½ (R5/4) DN32 ø32 ø32 G2 (R1½) DN40 ø40 ø39 DN40 ø40 DN50 ø50 DN65 ø65 DN80 ø80 DN100 ø100 DN125 ø125

Table 27. Distance pieces.

Installation - electrical conditions:

To avoid external disturbances and to achieve an electrical interface as that of MULTICAL®, we recommend that you use a PULSE TESTER. See paragraph 9.10.

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9.10 PULSE TESTER

During a calibration process it is often practical to use PULSE TESTER type 66-99-279 with the following functions:

Galvanically separated pulse outputs

Integral supply for ULTRAFLOW

LCD-display with counter

Externally controlled ”Hold” function

Can be fitted directly in a MULTICAL base unit

9.10.1 Technical data for PULSE TESTER

Pulse inputs (M1/M2)

Counter inputs Max. frequency: 128 Hz

Active signal Amplitude: 2.5 - 5 Vpp

Pulse duration > 1 ms

Passive signal Internal pull-up 680 kΩ

Internal supply 3.65 V lithium battery

Note: There are one or two pulse inputs/outputs depending on the choice of base unit

Figure 36

1 Flow sensor with transistor output

The transmitter is normally an optocoupler with FET or transistor output to be connected to terminals 10 and 11 for water meter M1 or terminals 69 and 11 for water meter M2.

The leak current of the transistor must not exceed 1 µA in off-state, and UCE in on-state must not exceed 0.5 VDC.

2 Flow sensor with relay or reed-switch output

The transmitter is a reed-switch, which is normally mounted on vane wheel and Woltmann meters, or the relay output from e.g. MID-meters. This type of transmitter should not be used as the quick pulse input may cause bounce problems.

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3 Flow sensor with active pulse output, powered by the PULSE TESTER

This connection is used together with either Kamstrup’s ULTRAFLOW or Kamstrup’s electronic pick-up for vane wheel meters.

Connection (M1) 9: Red (9A) 10: Yellow (10A) 11: Blue (11A)

Connection (M2) 9: Red (9A) 69: Yellow (10A) 11: Blue (11A)

Table 28

4 Flow sensor with active output and integral supply

Flow sensors with active signal output must be connected as shown in Figure 37. The signal level must be between 3.5 and 5 V. Higher signal levels can be connected via a passive voltage divider, e.g. of 47 kΩ/10 kΩ at a signal level of 24 V.

Pulse outputs (M1/M2)

Two-wire connection:

Voltage < 24 V

Load > 1.5 kΩ

Three-wire connection

Voltage 5...30 V

Load > 5 kΩ

Figure 37

The outputs are galvanically separated and protected against overvoltage and reversed polarity.

Max. counter capacity before overflow is 9,999,999 counts.

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9.10.2 Hold function

When the Hold input is activated (high level applied to input), counting stops.

When the Hold signal is removed (low level applied to input), counting restarts.

The counters can also be reset by pressing the right key on the front panel (Reset).

Hold input Galvanically isolated

Input protection Against reversed polarity

“Open input” Count (see Figure 38)

Figure 38

9.10.3 Push-button functions

Figure 39. The left push button shifts between readings/counts of the two flow sensor inputs. In the display M1

and M2 respectively indicate the currently displayed flow sensor inputs/counters.

Figure 40. The right push-button resets both counters (M1 and M2).

9.10.4 Using the PULSE TESTER

The PULSE TESTER can be used as follows:

Standing start/stop of flow sensor using the integral pulse counters.

Standing start/stop of flow sensor using the pulse outputs for external test equipment.

Flying start/stop of flow sensor using the integral counters controlled by external equipment (Sample & Hold).

Flying start/stop of flow sensor using the pulse outputs controlled by external equipment (Sample & Hold).

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9.10.5 Spare parts

Description Type No.

Battery D-cell 66-00-200-100

Cable retainer (secures the battery) 1650-099

2-pole plug (female) 1643-185

3-pole plug (female) 1643-187

PCB (66-R) 5550-517

Table 29. Spare parts for PULSE TESTER.

9.10.6 Changing the battery

If the PULSE TESTER is used continuously we recommend that the battery is replaced once a year.

Connect the battery to the terminals marked ”batt.”, the red wire to + and the black one to -.

Current consumption:

Curent consumption with no sensors connected 400 µA Max. current consumption with two ULTRAFLOW® connected 1.5 mA

Note: If the base unit is fitted with battery or externally supplied, the PULSE TESTER’s integral supply must be disconnected (the plug must be removed).

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10 METERTOOL

10.1 Introduction

METERTOOL is a collection of programs used for servicing Kamstrup heat meters.

”METERTOOL for ULTRAFLOW software makes it possible to adjust ULTRAFLOW® X4.

”METERTOOL for ULTRAFLOW programming/adjusting ULTRAFLOW® X4. Furthermore, It is used for programming the Pulse Divider.

10.2 System requirements for PC

METERTOOL requires minimum Windows XP SP3, Windows Vista or Windows 7 (32-bits or 64-bits) or newer as well as Microsoft Internet Explorer 5.01.

Minimum requirements:

Pentium 4 or equivalent (Atom processor/netbooks/mini PCs are not supported)

2 GB RAM

X4” is a Windows®-based software. In combination with a PC and interface the

X4” has been developed to provide laboratories a simple and efficient access to

10 GB HD

Display resolution 1024 x 768

USB as well as CD-ROM drive

Printer installed

Administrator rights to the PC are required in order to install and use the programs. The programs must be installed under the login to be subsequently used for the programs.

10.2.1 Interface

The following interfaces can be used:

Interface for Type No. Description

ULTRAFLOW® 54 66-99-141 Cable with USB plug for PC and 4-pole plug for ULTRAFLOW® 54 and

Pulse Divider 66-99-907.

ULTRAFLOW® 14/24 66-99-002 Adapter for connecting ULTRAFLOW® 14/24. Plugged onto 66-99-141.

ULTRAFLOW® 34 66-99-006 Adapter for connecting ULTRAFLOW® 34. Plugged onto 66-99-141.

Pulse Divider 66-99-140 Cable with serial plug for PC and 8-pole plug for Pulse Divider 66-99-607.

Table 30. Communication interfaces.

NOTE: The supply to ULTRAFLOW® and/or Pulse Divider, if any, must be disconnected during programming. The sensors are powered via the connected communication interface.

The USB Interface (66-99-141) includes a converter box which secures galvanic separation of the supply to the flow sensor.

In order to mount the plug in the flow sensor, the sealing cover must be removed. If the sensor is used where verification is required, an authorised laboratory must reverify and reseal the sensor before it is remounted. The positions of laboratory labels and year marks appear from Figure 34 and Figure 35.

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Figure 41. Location of the four-pole plug in ULTRAFLOW® 54.

Figure 42. Location of the four-pole plug incl. ULTRAFLOW® 14

adapter in ULTRAFLOW® 14/24 (MULTICAL® 61/62).

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Figure 43. Location of the four-pole plug including ULTRAFLOW® 34 adapter on ULTRAFLOW® 34.

Figure 44. Location of the four-pole plug in ULTRAFLOW® 54 DN150…250.

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Figure 45. Location of the eight-pole plug in Pulse Divider 66-99-607.

Figure 46. Location of the four-pole plug in Pulse Divider 66-99-907.

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10.2.2 Installation

Check that system requirements are fulfilled.

Close other open programs before starting the installation.

Insert the CD into the drive and follow the program’s instructions during the installation.

NOTE: The files used for installation must be saved on a CD or in a local folder in the PC. Installation is not possible using files from a USB-stick or an external drive.

If the installation program does not start automatically, the installation can be started by typing “D:\CD\launch.exe” under "Run" in the Start menu (provided that the drive specification of the CD is “D”).

When the installation has been completed, the icon “KAMSTRUP METERTOOL” will appear from the Start menu and as a link on the desktop. Click on the new icon “KAMSTRUP METERTOOL” for the list of ”METERTOOL” programs selected during installation to be displayed. Double-click on “METERTOOL UFx4” in order to start the program METERTOOL for ULTRAFLOW

X4.

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10.3 METERTOOL for ULTRAFLOW

The menu structure of METERTOOL for ULTRAFLOW

X4 is as follows:

10.3.1 Files

The menu ”Files” includes:

Setup: Update of program and database (internet

connection required) and setup of COM-port for interface for flow sensor and Pulse Divider.

Exit: Terminates METERTOOL.

Force Database Update: Forced online-update of flow sensor database.

10.3.2 Utilities

The menu ”Utilities” includes:

Flow Meter Adjustment: Reading and correction of flow curve.

Program Flow Meter: Programming standard flow curve for

flow sensor.

Pulse Divider: Programming of Pulse Divider 66-99-

607.

Pulse Configuration Programming of meter factor and DN150-DN250: pulse duration for ULTRAFLOW® 54 DN150…250.

Meter Type: Information on flow sensor and equipment.

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10.3.3 Windows

The function makes it possible to change between the open dialog boxes of the program.

10.3.4 Help

About: Includes program numbers and revisions

of the various components of the installed version.

User manual: Opens web browser to Kamstrup’s

website with technical descriptions for heat and cooling meters, water meters and flow sensors.

(Internet connection required)

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10.4 Application

Flow sensor adjustment.

Before adjusting a sensor you must make sure that the sensor operates satisfactorily in the flow rig in question. See paragraph 9 Calibrating ULTRAFLOW®.

If it is necessary to adjust the sensor more than a few per cent, the sensor is probably defective, or has a different error, and should not be adjusted.

10.4.1 COM-port selection

Open ”Setup”

Select a COM-port for ULTRAFLOW

The USB driver must be installed before connecting the interface.

The related COM-port will not appear from the list until the USB interface has been connected.

Select COM-port for Pulse Divider.

X4.

Activate ”Save” in order to save the selected ports.

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10.4.2 Flow meter adjustment

Open ”Flow Meter Adjustment”

”Read from Meter”: Reads data from the connected flow sensor.

Flow curve number - e.g. 5925346 - and meter dimensions appear from the heading. This number will also appear from the meter’s label.

The field “Flow Curve” shows the values of the sensor in question compared to the standard curve. These values are also shown in the form of a graph.

”Write to Meter”: Writes the correction to the connected flow sensor. The required correction of qi, 0.1xqp

and qp can be entered into the field ”Flow Curve Correction”.

After the adjustment the flow sensor is ready for renewed test.

10.4.3 Programming of standard flow curve

Open ”Program Flow Meter”

The 59xxxxx number appears from the sensor's type label.

”Write to Meter”: Programs the flow sensor

with the selected standard flow curve. *)

The flow sensor is now ready for test.

*) METERTOOL automatically configures ULTRAFLOW® 54 DN150…250 to Kamstrup default meter factor (Table 33, page 70). If an alternative meter factor is required, please refer to paragraph 10.4.6 Pulse Configuration DN150- DN250.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

[m³/h]

[imp/l]

[l/imp]

0.6

3001300

2.5

750

1.5

1001100

2.5

250101000

2.5601602.5

15010600

3501502.5

12510500

3.5502.5

12510500251250

62510

25025625

102510

25025625

101510

15025375

151010

10025250

100

1000

250

2500

251010

10025250

100

1000

250

2500

256106025

150

100

600

250

1500

40525

125

100

500

250

1250

2.5

100

250

625

100

1.5

100

150

250

375

1501100

100

250

1000

2500

250

0.6

10060250

150

1000

600

2500

1500

400

0.4

250

100

1000

400

2500

1000

600

0.25

1000

250

2500

625

1000

0.25

1000

250

2500

625

10.4.4 Pulse Divider type No. 66-99-607

Setup and programming of Pulse Divider type No. 66-99-607. A Pulse Divider is used for adapting flow signals to calculators, e.g. if a “foreign” calculator is connected to Kamstrup ULTRAFLOW® and the coding (number of pulses CCC or pulse duration) does not correspond.

Open ”Pulse Divider”

”Read”: Reads the current coding of the Pulse Divider. ”Write”: Programs the Pulse Divider with the entered data. ”Label type”: Makes it possible to select position on Kamstrup label sheet. ”Print”: Prints Pulse Divider label on the standard printer selected in the PC. ”Close”: Terminates Pulse Divider.

ULTRAFLOW

Meter factor

Divider

Meter factor

Pulse Divider

Divider

Meter factor

Divider

Meter factor

Divider

Table 31. Pulse division table (pulse duration divided pulses std. 100 ms).

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

Meter factor

[m³/h]

[imp/l]

[l/imp]

0.6

3001300

2.5

750

1.5

1001100

2.5

250

2.5601602.5

150

3501502.5

125

3.5501502.5

125

62512525

625

102512525

625

101511525

375

151010

10025250

251010

10025250

256106025

150

405105025

125

2.51025

250

625

100

1.51015

250

375

1501100

100

250

0.6

10060250

150

400

0.4

10040250

100

600

0.25

100252500

625

1000

0.25

100252500

625

ULTRAFLOW

Pulse Divider & 11EVL Pulse Divider & 11 EVL

(pulse duration 50 ms) (pulse duration 100 ms)

Meter factor Divider Meter factor Divider

Table 32. Pulse division table for use together with Kamstrup EVL.

For other variants, please see installation guide for Pulse Divider, Kamstrup document No. 5511-727.

10.4.5 Pulse Divider type No. 66-99-907

Readout and programming of Pulse Divider type No. 66-99-907 is not supported by the existing version of METERTOOL (rev. M1).

Instead we refer to a new version of METERTOOL, ”METERTOOL HCW”, which has just been released.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

10.4.6 Pulse Configuration DN150-DN250

Programming of meter factor and pulse duration for ULTRAFLOW® 54 DN150…250. ”Pulse Configuration DN150DN250” is used to change meter factor and pulse duration to match calculator and other equipment. E.g. if ULTRAFLOW® is connected to a calculator which does not support Kamstrup’s fast pulses. See programming options.

Open ”Pulse Configuration DN150-DN250”

”qp”: Based on the program-

med standard flow curve.

”Meter factor”: Only the valid meter

factors are available.

”Pulse duration”: Only the valid pulse

durations are available.

”Write”: Programs ULTRAFLOW® 54

DN150…250 according to the selected values.

Table 33

for valid

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

[m³/h]

[imp/l]

[l/pulse]

[ms] (E=1)

[ms] (E=4)

[ms] (E=5)

[ms] (E=6)

150133

3.9---Default

250

0.6433.9---Default

400

0.4633.9---Default

600

0.25143.9---Default

1000

0.15243.9---Default

1000

2500

66-2050100

150 10 34 - 20 - 150 25 64 - 20 - 150 100 35 - 20 50 100 150 250 65 - 20 50 100 150 1000 36 - 20 50 100 150 2500 66 - 20 50 100

250 10 34 - 20 - 250 25 64 - 20 - 250 100 35 - 20 50 100 250 250 65 - 20 50 100 250 1000 36 - 20 50 100 250 2500 66 - 20 50 100

400 100 35 - 20 50 400 250 65 - 20 50 100 400 1000 36 - 20 50 100 400 2500 66 - 20 50 100

600 100 35 - 20 50 600 250 65 - 20 50 600 1000 36 - 20 50 100 600 2500 66 - 20 50 100

Meter factor Pulse duration

1000 (0.25) 4 14 3.9 - - - *) 1000 100 35 - 20 50 1000 250 65 - 20 50 1000 1000 36 - 20 50 100

*) Spare part for ULTRAFLOW® type 65-S/R/T. Configured 65-5-FGCR. No flow info.

Table 33. Programming options as to meter factor (CC) and pulse

duration (E) for ULTRAFLOW® 54 DN150…250.

Based on a qp value a meter factor in

Table 33

is chosen. The valid pulse durations are listed in the same line as

the chosen meter factor.

Example: For ULTRAFLOW® with 54 qp of 400 m3/h a meter factor of 100 l/pulse (CC=35) is required. Based on this meter factor one of the pulse durations, 20 milliseconds (E4) or 50 milliseconds (E5) is selected.

Default values in

Table 33

are programming values for ULTRAFLOW® 54 DN150…250 when connected to a

Kamstrup MULTICAL® calculator.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

10.4.7 Meter type

Open ”Meter type”

Reads flow sensor information.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

10.5 Update

The program includes a database comprising data of the variants released at the time the program was produced. Both program and database are updated regularly.

Open ”Setup”

Select “Update program”

“Update”: If a new version of METETOOL is

available on Kamstrup’s server it is possible to update the program online.

(Internet connection required)

Choose “Update database”

“Update”: The database at Kamstrup is

updated daily. If a newer version is available, the database can be updated online from Kamstrup’s server.

(Internet connection required)

When update is completed METERTOOL will restart.

Open ”Force Database Update”

Forced update of the database. When update is completed METERTOOL will restart.

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

11 Approvals

11.1 The Measuring Instruments Directive

ULTRAFLOW® 54 and 34 are supplied with a CE-marking according to MID (2004/22/EC). The certificates have the following numbers:

B-module: DK-0200-MI004-008

D-module: DK-0200-MIQA-001

Please contact Kamstrup A/S for further details on type approval and verification.

11.2 CE marking

ULTRAFLOW

54 and 34 are marked according to the following directives:

EMC directive 2004/108/EC

LV directive 2006/95/EC (when connected to mains supplied Pulse Transmitter or Pulse Divider)

PE directive 97/23/EC (DN50…DN125) category I

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

11.3 Declaration of conformity

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

12 Troubleshooting

Before sending in the sensor for repair or testing, please use the error detection table below to help you clarify the possible cause of the problem.

Symptom Possible cause Proposal for correction

No updating of display values No power supply Replace battery or check mains supply

No display function (blank display)

No accumulation of m³ No volume pulses

Erroneous accumulation of m³ Erroneous programming Check that meter factors of calculator and

No voltage supply and backup

Incorrect connection Check flow sensor connection

Flow sensor is inverted Check flow sensor direction

Air in sensor/cavitation Check installation angle. Check if there is

Flow sensor error Replace the flow sensor/Send meter for

Air in sensor/cavitation Check the installation angle. Check if there

Flow sensor error Replace the flow meter/send sensor for

Replace back-up cell. Replace battery or check mains supply

(Check with PULSE TESTER, if necessary)

air in the system or cavitation from valves and pumps. If possible, try to increase the static pressure

repair

flow sensor correspond

is air in the system or cavitation from valves and pumps. Increase the static pressure, if possible

repair

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

13 Disposal

Kamstrup A/S holds an environmental certification according to ISO 14001, and as part of Kamstrup’s environment policy materials which can be recovered environmentally correctly are used to the greatest possible extent.

Kamstrup A/S has climate accounts (Carbon footprint) for all meter types.

As of August 2005 heat meters from Kamstrup are marked according to the EU directive 2002/96/EEA and the standard EN 50419.

The purpose of the marking is to inform our customers that the heat meter cannot be disposed of as ordinary waste.

••••

Disposal by Kamstrup A/S

Kamstrup accepts worn-out meters for environmentally correct disposal according to previous agreement. The disposal is free of charge to our customers, except for the cost of transportation to Kamstrup.

••••

The customer sends for disposal

The meters must not be disassembled prior to dispatch. The complete meter is handed in for approved national/local disposal. Enclose a copy of this page in order to inform the recipient of the contents.

Please note that lithium cells and meters containing lithium cells must be shipped as dangerous goods. Please see Kamstrup document 5510-408, ”Lithium batteries - Handling and disposal”.

Meter part Material Recommended disposal

Lithium cells in Pulse Transmitter/ Pulse Divider (D-cell)

PCBs in Pulse Transmitter, Pulse Divider and ULTRAFLOW

Flow sensor cables Copper with silicone mantle Cable recycling Plastic parts, cast PES, PBT and PC. See material data Plastic recycling

ULTRAFLOW® meter case Packing Recycled cardboard and EPS Cardboard recycling (Resy) and EPS

Lithium and thionyl chloride > UN 3091 < D-cell: 4.9 g lithium

Coppered epoxy laminate,

components soldered on

DZR brass/red brass/stainless steel Metal recycling

Approved deposit of lithium cells

PCB scrap for concentration to noble metals

recycling

Please direct any questions concerning environmental matters to:

Kamstrup A/S

FAO: Environmental and quality

assurance department

Fax.: +45 89 93 10 01

info@kamstrup.com

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TECHNICAL DESCRIPTION ULTRAFLOW® 54 and 34

14 Documents

Danish English German Russian

Technical description 5512-384 5512-385 5512-575 5512-576

Data sheet 5810-588 5810-589 5810-590 5810-593

Installation instruction 5512-951 5512-952 5512-953 5512-956

Table 34

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Kamstrup ULTRAFLOW 54, ULTRAFLOW 34 Technical Description

Specifications and Main Features

Frequently Asked Questions

User Manual