Technical description
ULTRAFLOW® 54 DN150-250
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 DN150-250
2
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
Contents
1 General description ........................................................................................................ 5
2 Data ............................................................................................................................... 6
2.1 Electrical data ........................................................................................................................................ 6
2.2 Mechanical data .................................................................................................................................... 6
2.3 Flow data ............................................................................................................................................... 7
2.4 Material ................................................................................................................................................. 7
3 Type overview ................................................................................................................. 8
4 Ordering details.............................................................................................................. 9
4.1 Type numbers of ULTRAFLOW® 54 for MULTICAL® .................................................................................... 9
4.2 Type numbers of separate ULTRAFLOW® 54 ............................................................................................ 9
4.2.1 Ordering details of separate ULTRAFLOW® 54 .................................................................................. 10
4.2.2 Type numbers of output and supply modules .................................................................................. 10
4.2.3 Programming variants of pulse figures and pulse durations ............................................................. 11
4.3 Accessories ......................................................................................................................................... 12
4.3.1 Cables............................................................................................................................................ 13
5 Dimensioned sketches .................................................................................................. 14
6 Pressure loss ................................................................................................................ 16
7 Installation ................................................................................................................... 17
7.1 Installation angle of ULTRAFLOW® 54 ................................................................................................... 18
7.1.1 Mounting ULTRAFLOW® 54 in lifting ring .......................................................................................... 18
7.2 Mounting of ULTRAFLOW® 54 electronics box ....................................................................................... 19
7.2.1 Orientation of flow sensor electronics box ...................................................................................... 20
7.3 Straight inlet ........................................................................................................................................ 21
7.4 Operating pressure .............................................................................................................................. 21
7.5 Connection to calculator ...................................................................................................................... 22
7.5.1 ULTRAFLOW® 54 and MULTICAL®, galvanically coupled ................................................................... 22
7.5.2 ULTRAFLOW® 54 and MULTICAL®, galvanically separated ................................................................ 22
7.6 Connection of power supply ................................................................................................................. 24
7.6.1 Battery supply ................................................................................................................................ 24
7.6.2 Mains supply modules ................................................................................................................... 24
7.6.3 Mains supply cable ........................................................................................................................ 25
7.6.4 Danish regulations for the connection of mains operated meters ..................................................... 25
7.6.5 Cable connections .......................................................................................................................... 26
7.6.6 Change of supply unit ..................................................................................................................... 26
7.7 Example of connection of ULTRAFLOW® 54 for MULTICAL® .................................................................... 27
7.8 Calculator with two flow sensors .......................................................................................................... 28
7.9 Testing the function ............................................................................................................................. 28
8 Functional description .................................................................................................. 29
8.1 Ultrasound combined with piezo ceramics ........................................................................................... 29
8.2 Principles ............................................................................................................................................ 29
8.3 Transient time method ......................................................................................................................... 29
8.4 Signal paths ........................................................................................................................................ 31
8.5 Measuring sequences .......................................................................................................................... 31
8.6 Function .............................................................................................................................................. 32
8.7 Guidelines for dimensioning ULTRAFLOW® ........................................................................................... 33
8.8 Pulse output ........................................................................................................................................ 34
5512-876 GB/04-2012/Rev. F1
3
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
8.8.1 Galvanically coupled ...................................................................................................................... 34
8.8.2 Galvanically separated................................................................................................................... 35
8.9 Pulse emission ................................................................................................................................... 37
8.10
Accuracy ........................................................................................................................................ 37
8.11
Power consumption ....................................................................................................................... 38
8.12
Interface plug/serial data............................................................................................................... 38
8.13
Test mode ..................................................................................................................................... 39
8.14
Externally controlled start/stop ...................................................................................................... 39
8.15
Calibration procedure using serial data and externally controlled start/stop .................................. 40
9 Calibrating ULTRAFLOW® .............................................................................................. 41
9.1 Test instructions for ULTRAFLOW 54, DN150-250 ............................................................................... 41
9.1.1 Installation angle for ULTRAFLOW® ................................................................................................. 41
9.1.2 Technical data ............................................................................................................................... 41
9.1.3 Connection .................................................................................................................................... 42
9.2 Sealing ............................................................................................................................................... 43
9.3 Optimization in connection with calibration......................................................................................... 44
9.4 PULSE TESTER ..................................................................................................................................... 45
9.4.1 Technical data of PULSE TESTER ..................................................................................................... 45
9.4.2 Hold-function ................................................................................................................................ 47
9.4.3 Push-button functions ................................................................................................................... 47
9.4.4 Use of PULSE TESTER ..................................................................................................................... 47
9.4.5 Spare parts .................................................................................................................................... 48
9.4.6 Battery replacement ...................................................................................................................... 48
10 METERTOOL ................................................................................................................. 49
10.1
Introduction .................................................................................................................................. 49
10.2
System Requirements for PC .......................................................................................................... 49
10.2.1 Interface .................................................................................................................................... 49
10.2.2 Installation ................................................................................................................................ 51
10.3
METERTOOL for ULTRAFLOW® X4 .................................................................................................... 52
10.3.1 Files .......................................................................................................................................... 52
10.3.2 Utilities ..................................................................................................................................... 52
10.3.3 Windows ................................................................................................................................... 52
10.3.4 Help .......................................................................................................................................... 53
10.4
Application .................................................................................................................................... 53
10.4.1 COM-port selection .................................................................................................................... 53
10.4.2 Flow meter adjustment .............................................................................................................. 54
10.4.3 Programming of standard flow curve .......................................................................................... 54
10.4.4 Pulse Divider ............................................................................................................................. 55
10.4.5 Meter type ................................................................................................................................. 57
10.4.6 Help .......................................................................................................................................... 57
10.5
Update .......................................................................................................................................... 58
11 Troubleshooting ........................................................................................................... 59
12 Approvals..................................................................................................................... 60
12.1
Measuring Instruments Directive .................................................................................................... 60
12.2
CE-Marking .................................................................................................................................... 60
12.3
Declaration of conformity ............................................................................................................... 61
13 Disposal ....................................................................................................................... 62
14 Documents ................................................................................................................... 63
4
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
1 General description
ULTRAFLOW® 54 DN150-250 is a static flow sensor based on the ultrasonic measuring principle. It is primarily
used as a volume flow sensor for energy meters such as MULTICAL®. ULTRAFLOW® 54 DN150-250 has been
designed for use in heating and cooling installations where water is the heat-bearing medium.
ULTRAFLOW® 54 DN150-250 employs ultrasonic measuring techniques and microprocessor technology. All
calculating and flow measuring circuits are collected on one single board, thus providing a compact and rational
design and, in addition, exceptionally high measuring accuracy and reliability is obtained.
The volume is measured using bidirectional ultrasonic technique based on the transit time method, with proven
long-term stability and accuracy. Four ultrasonic transducers are used to send sound signals 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 signal cable is used to connect ULTRAFLOW® 54 DN150-250 to the Kamstrup MULTICAL® 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.
ULTRAFLOW® 54 DN150-250 is available with internal supply, e.g. if the distance between MULTICAL® and
ULTRAFLOW® is 10 meters or more. If ULTRAFLOW® 54 DN150-250 is used for other equipment (e.g. other brands
of calculators), the sensor must be fitted with a galvanically separated output module and a supply of its own.
5512-876 GB/04-2012/Rev. F1
5
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
2 Data
ULTRAFLOW®54 DN150-250
2.1 Electrical data
Supply voltage 3.6 V ± 0.1 V
Supply, galvanically coupled output
module (Y=1)
Powered by MULTICAL®
Supply, galvanically separated output
module (Y=2) 1)
Mains supply 230 VAC +15/-30%, 50 Hz
24 VAC ±50%, 50 Hz
Power consumption
< 1 W
Backup Integral SuperCap eliminates interruptions due to short-term power failures
Supply, galvanically separated output
module (Y=3)
Battery 3.65 VDC, D-cell lithium
Replacement interval
6-years @ t
< 30°C
BAT
Mains supply 230 VAC +15/-30%, 50 Hz
24 VAC ±50%, 50 Hz
Power consumption
< 1 W
Backup Integral SuperCap eliminates interruptions due to short-term power failures
Signal cable length, from flow sensor
Max. 10 m (powered by calculator)
electronics box with galvanically
coupled output module (Y=1)
Signal cable length, from flow sensor
electronics box with galvanically
Depending on calculator (use of own supply in ULTRAFLOW®).
See paragraph 7.5.2 for applications with MULTICAL®
separated output module (Y=2 and 3)
EMC data Fulfil DS/EN 1434:2007 class C, MID E1 and E2
2.2 Mechanical data
Metrological class 2 or 3
Environmental class Fulfils DS/EN 1434 class C
Ambient temperature 5…55°C (indoors)
Protection class IP67 When installed properly. See paragraph 7.2
Humidity 93% RH non-condensing
Mechanical environment MID M1 and M2
Temperature of medium 2…150°C (Heat-, heat/cooling meters)
2…50°C (Cooling meters)
At medium temperatures above 90°C (T
> 90°C)
med
or medium temperature more than 5°C below
ambient temperature (T
med
< T
amb
- 5°C), the
electronics box must be wall mounted or
mounted via the enclosed distance piece.
Storage temp. empty
-25…70°C, 60°C if battery mounted/enclosed
sensor
Pressure stage PN25
1)
It is possible to use battery supply in combination with output module (Y=2), e.g. for temporary supply of flow sensors installed at
construction sites.
6
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
p
1)
2)
qi:qpqs:q
1)
2)
2.3 Flow data
Nom. flow q
[m³/h] [mm] [imp/l]
150 DN150 1 1:100 2:1 450 0.02 300
250 DN150 0.6 1:100 2:1 750 0.055 500
400 DN150 0.4 1:100 2:1 1125 0.04 800
400 DN200 0.4 1:100 2:1 1125 0.01 800
400 DN250 0.4 1:100 2:1 1125 0.01 800
600 DN200 0.25 1:100 2:1 1800 0.022 1200
600 DN250 0.25 1:100 2:1 1800 0.022 1200
1000 DN250 0.15 1:100 2:1 3000 0.015 2000
Standard pulse figure. Appears from ULTRAFLOW® label. For other pulse figures see paragraph 4.
Saturation flow. Max. pulse frequency, 128 Hz, is maintained at higher flow rates.
2.4 Material
Wetted parts
Housing Stainless steel, W.no. 1.4307
Transducer holder Stainless steel, W.no. 1.4308
Transducer Titanium
Gaskets Fibre
Electronics box
Nom. diameter Pulse figures
Dynamic range
Table 1
Flow @ 125 Hz
p
[m³/h] [bar] [l/h]
∆∆∆∆p @ qpMin. Cutoff
Base, cover Thermoplastic, PC 10% GF
Fitting hardware, Thermoplastic, PPS 40% GF
distance piece for
electronics box
Signal cable (optional for separate ULTRAFLOW® 54)
Silicone cable (3x0.5 mm2)
Power supply cable 24/230 VAC (optional)
Cable with PVC-mantle (2x0.75 mm²)
5512-876 GB/04-2012/Rev. F1
7
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
p
[m³/h]
1000
DN250x600 mm
3 Type overview
Nom. flow q
150 DN150x500 mm
250 DN150x500 mm
400 DN150x500 mm DN200x500 mm DN250x600 mm
600 DN200x500 mm DN250x600 mm
Flange EN 1092, PN25
Overall lengths
Table 2
8
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
p qi qs
[m³/h]
[m³/h]
[m³/h]
[mm]
[imp/l]
65-5-
FGCR
-XXX *)
1000102000
DN250
25
600
0.15
493
Stainless steel
p qi qs
[m³/h]
[m³/h]
[m³/h]
[mm]
65-5-
FGCR
-YZ
-XXX *)
1000102000
DN250
25
600
Stainless steel
4 Ordering details
4.1 Type numbers of ULTRAFLOW® 54 for MULTICAL®
The table below shows a list of type numbers for ULTRAFLOW® 54 ordered with MULTICAL®
Type number CCC
65-5- FCCN -XXX 150 1.5 300 DN150 25 500 1 447 (489) Stainless steel
65-5- FDCN -XXX 250 2.5 500 DN150 25 500 0.6 481 Stainless steel
65-5- FECN -XXX 400 4 800 DN150 25 500 0.4 491 Stainless steel
65-5- FECP -XXX 400 4 800 DN200 25 500 0.4 491 Stainless steel
65-5- FECR -XXX 400 4 800 DN250 25 600 0.4 491 Stainless steel
65-5- FFCP -XXX *) 600 6 1200 DN200 25 500 0.25 492 Stainless steel
65-5- FFCR -XXX *) 600 6 1200 DN250 25 600 0.25 492 Stainless steel
XXX, code re marking and final assembly.
*) Cannot be delivered with MID approval
q
Connection PN
[mm] [bar]
Length Pulse figure
Material
flow sensor case
Table 3
4.2 Type numbers of separate ULTRAFLOW® 54
Type number
65-5- FCCN -YZ -XXX 150 1.5 300 DN150 25 500 Stainless steel
65-5- FDCN -YZ -XXX 250 2.5 500 DN150 25 500 Stainless steel
65-5- FECN -YZ -XXX 400 4 800 DN150 25 500 Stainless steel
65-5- FECP -YZ -XXX 400 4 800 DN200 25 500 Stainless steel
65-5- FECR -YZ -XXX 400 4 800 DN250 25 600 Stainless steel
65-5- FFCP -YZ -XXX *) 600 6 1200 DN200 25 500 Stainless steel
65-5- FFCR -YZ -XXX *) 600 6 1200 DN250 25 600 Stainless steel
q
Connection PN
[mm] [bar]
Length
Material
flow sensor case
XXX, code re marking and final assembly.
*) Cannot be delivered with MID approval
Table 4
5512-876 GB/04-2012/Rev. F1
9
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
0 (powered by MULTICAL
)
4.2.1 Ordering details of separate ULTRAFLOW® 54
Type number composition of separate ULTRAFLOW® 54
ULTRAFLOW® 54. Type no: 65-5
Dynamic range and flow
Connection and overall length
Output module
Supply module
Final assembly and marking
- XX XX - Y Z - XXX
In addition to the basic variants listed above in
Table 3
, you must select output module (Y), supply module (Z) as
well as pulse figure programming (CC) and pulse duration (E).
The variant with galvanically coupled output module (Y=1) is solely for use together with MULTICAL®.
The variant with galvanically separated output module (Y=2 or 3) is used in the following situations:
1) More than 10 m cable length between MULTICAL® and ULTRAFLOW® is required.
2) As flow sensor no. 2 in connection with MULTICAL®. If two flow sensors are used together with
MULTICAL®, one must include a galvanically separated output module (Y=2 or 3). For further details see
paragraph 7.8 Calculator with two flow sensors
.
3) Together with other equipment/foreign calculators.
Please note:
Flow info cannot be read if output module with galvanic separation is used.
4.2.2 Type numbers of output and supply modules
Type number overview of output modules (Y) and supply modules (Z) for separate ULTRAFLOW® 54.
Y Output module Corresponding supply module
1 Galvanically coupled module
2 Galvanically separated module 0, 7, 8
3 Galvanically separated module 0, 2, 7, 8
Z Supply module Corresponding output module
0 No supply 1, 2, 3
2 Battery, D-cell 3
7 230 VAC supply module 2, 3
8 24 VAC supply module 2, 3
Table 5. Output modules (Y) and supply modules (Z).
®
10
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
4.2.3 Programming variants of pulse figures and pulse durations
Overview of programming variants as to pulse figures (CC) and pulse durations (E) for separate ULTRAFLOW
q
p
[m³/h] [imp/l] [l/pulse] CC [ms] (E=1) [ms] (E=4) [ms] (E=5) [ms] (E=6)
150 1 33 3.9 - - - Default
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
Pulse figure
Pulse duration
250 0.6 43 3.9 - - - Default
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 0.4 63 3.9 - - - Default
400 100 35 - 20 50 400 250 65 - 20 50 100
400 1000 36 - 20 50 100
400 2500 66 - 20 50 100
600 0.25 14 3.9 - - - Default
600 100 35 - 20 50 600 250 65 - 20 50 600 1000 36 - 20 50 100
600 2500 66 - 20 50 100
1000 0.15 54 3.9 - - - Default
1000 (0.25) 4 14 3.9 - - - *)
1000 100 35 - 20 50 1000 250 65 - 20 50 1000 1000 36 - 20 50 100
1000 2500 66 - 20 50 100
*) Spare part for ULTRAFLOW® type 65-S/R/T. Configured 65-5-FGCR. No flow info.
®
Table 6. Pulse figures (CC) and pulse durations (E).
5512-876 GB/04-2012/Rev. F1
11
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
2
)
2
)
4.3 Accessories
Please note that not all article numbers mentioned in the table can be directly ordered, some must be ordered via
our service department.
Article number Description
65-000-000-2000 D-cell lithium battery with two-pole connector
3026-477 1) Fitting for D-cell battery
1650-157 1) Plug for cable connection
1)
Obligatory when changing from mains supply module to battery supply.
Article number
65-000-000-7000
65-000-000-8000
Description
230 VAC supply module
24 VAC supply module
5000-290 Cable between supply module and output module
Note
(when ordering ULTRAFLOW®)
Enclosed if battery
supply or “No supply” is
selected
Enclosed if battery
supply or “No supply” is
selected
Note
(when ordering ULTRAFLOW®)
Enclosed if supply
module is selected
5000-286 24/230 V AC power cable Optional
2)
Including 5000-290.
Article number
Description
5550-1061 Output module (Y=1), galvanically coupled
5550-1062 Output module (Y=2), galvanically separated
Output module (Y=3), galvanically separated,
5550-1219
“Low power”
Note
(when ordering ULTRAFLOW®)
12
5512-876 GB/04-2012/Rev. F1
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
Article number
Description
Note
(when ordering ULTRAFLOW®)
Default for ULTRAFLOW®
ordered with MULTICAL
5000-333 2.5 m silicone cable (3-wire)
Optional for separate
ULTRAFLOW®
5000-259 5 m silicone cable (3-wire) Optional
5000-270 10 m silicone cable (3-wire) Optional
3026-207 Mounting fitting for electronics box Enclosed (mounted)
6561-332 Short distance piece (article)
3026-507 Long distance piece Enclosed
1051-006 Collar band for short and long distance piece Enclosed
1150-140 Gasket, DN150 PN25 (1 pc) Enclosed (2 pcs.)
1150-139 Gasket, DN200 PN25 (1 pc) Enclosed (2 pcs.)
1150-141 Gasket, DN250 PN25 (1 pc) Enclosed (2 pcs.)
®
4.3.1 Cables
ULTRAFLOW® 54 DN150-250, when ordered with MULTICAL®, is delivered with 2.5 m signal cable, optionally 5 or
10 m. The cable is mounted in the ULTRAFLOW® 54 electronics box and in MULTICAL® 6xx. When ULTRAFLOW® 54
is ordered with MULTICAL® 8xx, the calculator is delivered separately. Hence the cable is only mounted in the
ULTRAFLOW® 54 electronics box.
ULTRAFLOW® 54 DN150-250, when ordered as a separate flow sensor, is optionally available with signal cable in
lengths of 2.5, 5 or 10 m. The cable is mounted in the ULTRAFLOW® 54 electronics box.
If 24/230 VAC supply module is selected, the sensor is optionally available with power supply cable. The cable is
mounted in the sensor's electronics box from the factory.
5512-876 GB/04-2012/Rev. F1
13
TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-250
5 Dimensioned sketches
All measurements are in mm, unless otherwise stated.
Figure 1
Flange EN 1092-1, PN25
Nom.
diameter
Nom. flow q
L D k B1 Bolts
p
Steel tube
length
[m³/h] Quantity Thread d2 C [[