Levelpro UFM-4000-100, UFM-4000-125, UFM-4000-75, UFM-4000-50 User manual

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Flow Meter for

Dosing + Continous Flow

Operating Manual

Read the user's manual carefully before starting to use the unit or software.

Producer reserves the right to implement changes without prior notice.

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Table of Contents

General safety instructions

1. Planning information

 1.1 Areas of application
 1.2 Measuring principle
 1.3 Operational safety

2. Assambly and installation

 2
 2.2 Assembly of the flowmeter
 2

3. Commissioning

 3
 3.2 Functionalities of flowmeter and default settings
 3
 3.4 General Information

4. Exchange of measuring device

.1 Installation instructions
.3 Electrical wiring

.1 Operation
.3 Overview of default settings

01
02

02
02
03

0
03
04
07

09
0
10
18
18

1

3

9

9

. Technical specifications

5

 5.1 Dimensions and weight
 5

6. Accessories

7. Shipment

.2 Technical specifications

Table of Figures

Fig. 1: Presentation of the principle of ultrasonic flow measuring
Fig. 2: Installation position of Flowmeter
Fig. 3: Mounting examples for UltraFlo
Fig. 4: Mounting possibilities
Fig. 5: Mounting the UltraFlo
Fig. 6: UltraFlo with hot liquids
Fig. 7: Pin code: Connection plug / socket for 5-pin version
Fig. 8: Pin code: Connection plug / socket
Fig. 9: Operating with the key pad
Fig. 10: Menu organization for 5-pin version
Fig. 11: Menu organization for 8-pin version
Fig. 12: Function of the creeping suppression illustrated with 0.6 l/min
Fig. 13: Connecting Output Q1 to relay

20
20
21

20
21

02
03
05
05
06
06
07
08
10
11
12
14
16

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

General Safety Instructions

Please always observe the following safety instructions!
Please pay attention to the safety instructions with the following pictograms and signal words in

these operating instructions :

IMPORTANT! indicates situations or cases which, if not avoided, could result in

damage or failure of the UltraFlo 4000 equipment.

WARNING! indicates general hazardous situations or cases which, if not avoided,

could result in serious injury or death.

NOTICE

Is used to lead users to helpful information not related to personal injury.

INTENDED USE :

The flow meter UltraFlo 4000 should only be used for measuring the flow of pure,
homogeneous liquids.

The UltraFlo 4000 is not intended for use in medical applications.
The volume flow meter UltraFlo 4000 is built in accordance with industry standard EN 61010

regulations (corresponds to VDE 0411 “Safety specifications for electrical measurement,
control and laboratory devices”).

The manufacturer is not liable for any injury, damage or harm due to inappropriate or
unintended use or modifications of the flow meter. Conversions and/or changes to the flow
meter may only be made, if they are expressly performed in accordance with the operating
instructions in this operating manual.

Personnel for Installation, Commissioning and Operation

Assembly, electrical installation, commissioning and maintenance of the flow
meter must be carried out by qualified, trained personnel. The qualified
personnel must have read and understood the operating instructions in this
operating manual and must follow the operating instructions in this manual.

The installer has to ensure that the flow meter is correctly connected

ccording to the electrical connection diagrams in this operating manual.

WARNING!

a
Serious injury or death from electric shock may occur if wiring, installation,

disassembly or removal of wires is performed while electrical power is
energized

Technological Progress

The manufacturer reserves the right to revise, alter, or modify the flow meter to the most current
technology without special prior notice. Further information about the latest updates and potential
additions to these operating instructions are available from Truflo.

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01

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

1. Planning Information

1.1 Areas of application

The flow measurement device in the UltraFlo designed to measure dynamic flow in pipes and
tubes. This flow meter is suitable for liquids only. The UltraFlo can be used for the following:

Chemicals supply for controlling, logistics, monitoring
Filling machines in food industries
Cooling systems, logistics, monitoring
Process equipment for control and monitoring of formulas
Valve control for continuous release of liquid volumes
Supply with de-ionized water
Very dynamic liquid processes with dosing times of below 1 second

UltraFlo has the following features and benefits:

No movable parts, therefore no wear
High repeatability
Easy to clean
Safe operation
Compact design
Integrated detection of empty conduits
Integrated dosing function with pre-set and adjustable amounts
Chemical resistant
Integrated display with keypad

1.2 Measuring principle

The ultrasonic flow measurement is based on the phase-difference approach:
Two u
ultrasonic signals. If there is no liquid flow both sensors receive the transmitted ultrasonic signals in
the same phase, i.e. without phase difference. If liquid is flowing there is a phase shift. It differs
when measured in direction of the flow than when measured against the direction of the flow. This
phase difference is directly proportional to the flow rate.

ltrasonic-sensors located opposite from each other alternatively transmitting and receiving

L

D

wL

=

-

c - v

c

v

c-v

v

receiver /
sender

sender /
receiver

v

v

c

c+v

wL

=

+

c + v

L: length of measuring pipe
K: factor
D: diameter of measuring pipe

- +

v: flow velocity
c: sound velocity of the fluid

: phase with the flow

+

: phase against the flow

-

Fig. 1: Presentation of the principle of ultrasonic flow measuring

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02

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

1.3 Operational safety

Comprehensive self-tests ensure highest possible safety.
The protection class is IP 67.
UltraFlo meets the general EMC immunity requirements according to CE, EN 50081-2, and EN

50082-2.
UltraFlo meets the safety requirements according to EN 60601-1 concerning the low voltage

directive.

2. Assembly and Installation

2.1 Installation instructions

The housing of UltraFlo is labeled with an arrow symbolizing the direction of the flow
measurement. The flow meter has to be installed in a way so that the flowthrough is in the
same direction as the arrow symbol.

NOTICENOTICE

The housing of Flowmeter is labeled with an arrow symbolizing the direction of the flow. The
flowmeter must be installed in direction of the flow.

TOP -> outlet

Flow
Direction

DOWN -> inlet

Fig. 2: Installation position of Flowmeter

For fastest possible bubble detection it is important to keep the pipe distance to UltraFlo as
short as possible. Accurate measurement can only be assured, if the pipe is completely filled
and the liquid does not outgas. Notwithstanding it may be advantageous for dosing
applications to install
the U

ltraFlo as close as possible to the dosing equipment. Particles present in the flow stream

may result in measuring errors.

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03

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

When using pumps, UltraFlo must be installed in flow direction on the pressure side, on order to
ensure sufficient pressure.

Do not exceed the maximum pressure allowance for of the UltraFlo (see section 5.2
Technical specifications). Exceed the maximum pressure or the maximum torque

WARNING!

For correct volume flow measurements straight and unobstructed inflow and outflow distances have
to be observed. Starting from the connection thread these straight and unobstructed flow zones
must be:

can lead to destruction or rupture of the UltraFlo.

Nominal Diameter

Inflow Distance

Outflow Distance

Always make sure that the maximum torque of the nuts for the hydraulic connections is not
exceeded. Use the delivered seals and the maximum torque depending on the diameter:

Nominal Diameter

Inflow Distance

Due to the material characteristics of PSU UltraFlo has a limited resistance against UV
rays.

DN10

3/8"

10cm

3,94"

0 cm

0.0"

DN10

3/8"

2Nm

1.5 ft-lbs

DN15

1/2"

30cm

11,81"

0 cm

0.0"

DN15

1/2"

3Nm

2.2 ft-lbs

DN20

3/4"

40cm

15,75"

20 cm

7.9"

DN20

3/4"

4Nm

3.0 ft-lbs

DN25

1"

40cm

15,75"

20 cm

7.9"

DN25

1"

6Nm

4.4 ft-lbs

2.2 Assembly of the flow meter

The flow meter is mounted into a pipe system by using the mechanical connection.
UltraFlo should be mounted vertically into the pipe for the best measuring performance. Do
not install the flow meter after a dosing valve where the flow meter can run empty. Placing
the flow meter after a dosing valve and allowing it to run empty will cause a measuring
deviation at the next measurement. To avoid bubbles in the liquid, UltraFlo should be

NOTICE

installed on the pressure side of the pump.

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04

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

UltraFlo

Valve

Container

Valve

UltraFlo

Pump

Fig. 3: Mounting examples for UltraFlo

If it is not possible to mount the flow meter vertically, then mount the instrument in a location where
the pipe will be filled at all times. The best measuring result is achieved if bubbles do not pass
through UltraFlo.

Valve Valve

UltraFlo

Fig. 4: Mounting possibilities

UltraFlo

For applications with a “clean design“ for which it is necessary to completely drain the pipe system,
we recommend mounting the flow meter in the vertical position. Residual liquid may remain inside
the device if flow meter is mounted horizontally.

Vibrations or mechanical forces may decrease measuring accuracy. Mounting the flow meter using
two clamps will reduce vibrations or movements. Use the clamps as seen in the figure below at the
inlet and outlet connections of UltraFlo.

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05

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Fig. 5: Mounting the UltraFlo

UltraFlo must be installed without mechanical tensions on the existing pipe system. The flow meter
may be damaged if there is tension on the existing pipe system. Set the axial channel offset to
5mm when mounting the flow meter (For details see section 5.1 Dimensions and weight on page 22
/ latter F).

Non-compliance of the installation instructions may result in tearing of the housing,

WARNING!

liquid may leak out.

Applications with hot liquids:

If UltraFlo is used in applications with liquid temperatures hotter than 60°C and mounted
horizontally then the flow meter should be mounted with the electronic housing on the
underside to reduce exposure to rising heat. If UltraFlo is mounted vertically, heat damage
is not an issue.

Fig. 6: UltraFlo with hot liquids

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06

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

2.3 Electrical Wiring

Serious injury or death from electric shock may occur if wiring, installation,
disassembly or remove of wires is performed while electrical power is energized.

Always shut off or disconnect electrical power at service panel and lock switch or
breaker and tag to prevent energizing electrical power during work or while

WARNING!

Flowmeter is not assembled and installed.

Wiring installation, disassembly and removal must be performed by qualified
persons experienced and knowledgeable about electrical work.

4

3

5

1

2

4 3

5

1

2

socket for 5-pin versionFig. 7: Pin code: Connection plug /

Connector cable pin configuration defined by manufacturer
The outlets may be re-programmed for specific applications

Pin Function Description

1 L+ Power supply: 18...30 VDC
2 Pulse output O1 alternative:

1. Empty-pipe output

2. Dosing output

3. Upper or Lower Limit output

4. Negative flow

3 GND Ground : 0 V

Digital Output Q1
Freely a
ml/pulse steps, npn-Transistor, max. load 30V/100mA.
Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Configurable o
lower limit
Configurable output of 0V or 24V when liquid flows in

egative direction

n

djustable ranging from 0.1 to 3000 ml/pulse in 0.1

utput of 0V or 24V when reaching upper or

4 Communication Communication interface
5 Analog output QA 4….20mA ; 0….20mA

Example: 0L/min => 4mA
60L/min => 20mA
Empty pipe Alert => 3.5mA
(4-20mA depending on the configured limits)

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

6

1

5

4

87 3

2

6

1

5

4

87 3

2

plug / socketFig. 8: Pin code: Connection

Connector cable pin configuration defined by manufacturer
The outlets may be re-programmed for specific applications.

Pin Function Description

1 L+ Power supply: 18...30 VDC
2 Pulse output O1 alternative:

1. Empty-pipe output

2. Dosing output

3. Upper or Lower Limit output

4. Negative flow

Digital Output Q1
Freely a
ml/pulse steps, npn-Transistor, max. load 30V/100mA.
Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Configurable o
lower limit
Configurable output of 0V or 24V when liquid flows in

egative direction

n

djustable ranging from 0.1 to 3000 ml/pulse in 0.1

utput of 0V or 24V when reaching upper or

3 GND Ground : 0 V
4

5 Analog Output QA 4….20mA ; 0….20mA

6 Communication Communication Interface
7

Digital output Q2 Functions:

1. Empty pipe output

2. Dosing output

3. Pulse output

4. Upper or Lower Limit output

5. Negative flow

Digital input I1

1. Dosing output

2. Set offset

3. Reset counter

4. Creeping flow off

Digital output Q2
Configurable npn- or pnp-Transistor, max. Load 30V/
100mA. Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Freely a
ml/pulse steps.
Configurable o
or lower limit.
Configurable output of 0V or 24V when liquid flows in

Example: 0L/min => 4mA
60L/min => 20mA
Empty pipe Alert => 3.5mA
(4-20mA depending on the configured limits)

Digital input I1
Starts the dosage by a rising edge of 24V.
The Offset is set by a rising edge of 24V.
Reset of the counter by a rising edge of 24V.
Creeping suppression is deactivated as long as there are
24V at the input.

djustable ranging from 0.1 to 3000 ml/pulse in 0.1

utput of 0V or 24V when flow reaches upper

8 Shielding EMC safety

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08

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Attention: Only operate the flow meter UltraFlo within the operating limits
stipulated on the product label and the operating manual / data sheet. Use of the
UltraFlo outside these conditions will lead to overloads which cause permanent
damage.

3. Commissioning

NOTE : While commisioning run the Basic Trim (SoftFlo medium) when is filled. Repeat

NOTICE

3.1 Operation

If SoftFLo is used as a volume flow meter for water or water-like liquids it will not require on-site
calibration. Parameters for water are calibrated at the factory. The UltraFlo may also be ordered
with customized settings, but customized settings must be requested when SoftFLo is ordered.

this action until amplifier stage and receiving amplitude reach a steady value.

NOTE : If necessary, e.g. if viscosity and/or speed of sound deviate significantly from
water, the pre-set parameters can be adjusted with the help of the hardware interface and
the SoftFLo service software. It is always necessary to adjust the manufacturer pre-set

NOTICE

parameters when using the SoftFLo as a dosing device according to section 3.2 Dosing
function on page 19. Adjusting the manufacturer pre-set parameters requires a display or
the “USB Converter 2”.

The following parameters may be changed to settings suitable for the individual
conditions: for 5-pin version

Digital output Q1, function and behavior
Analog output QA, function and behavior
Flow range, for which shall apply 4...20 mA
Pulse value
Creeping suppression
Optimization of measurement curve with up to 8 interpolation values (medium matrix)

The following parameters may be changed to settings suitable for the individual
conditions: for 8-pin version

Digital output Q1, function and behavior
Digital output Q2, function and behavior
Digital input I1, function and behavior
Analog output QA, function and behavior
Flow range, for which shall apply 4...20 mA
Pulse value
Creeping suppression
Optimization of measurement curve with up to 8 interpolation values (medium matrix)

Also reference the SoftFlo operating instructions

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09

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

3.2 Functionalities of flow meter and default settings

Flowmeter is equipped with a display to visualize actual measurement values and to change
parameters of the flow meter. Menu navigation and parameter changes are controlled by the four
keys on the keypad.

Fig. 9: Operating with the key pad

Press the "Set" key to display the main menu. Different menu options can be selected by using the
two arrow keys.
To enter e.g. analog limits "Analog output - Upper limit" use the arrow keys to change values and
press "Set" to confirm. To switch back to the last menu level press the "Esc" key. As soon as the
operator tries to change values the user will be prompted to enter a password. Password protection
is used to ensure changes to values or configurations are done by authorized personnel. The
default password for Flowmeter is 41414. The password can be changed with Programmtool. The
user level will remain active for 5 minutes after the last press on any button.

The Password should only be shared with personnel authorized to make
changes to setting.

NOTE : Always the first parameter of the menu appears in the display.This need not be the

adjusted enabled parameter. The enabled parameter appears inverted and possibly visible
by scrolling.

NOTICE

NOTE : Functions marked with asterisk (*) are only available for the Flowmeter 8-pin version.

Flowmeter without user display supports the same functions as the display-version. The
display and programming unit Programmtool is needed to change configurations of

NOTICE

Flowmeter without user display.

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10

Creeping Flow

ml/s

l/min + m

3

Gal/min + Gal

l/min + l

Dosing Quantity

Dosing Time

Start
Stop

Units

Filter

Media

Set Offset

Basic Trim

Reset Counter

Language

Dosing

Start Screen

Diagnostic

Options output

Digital Output Q1

Analog Output QA

Version

Values

Configuration

Status

Pulse Output

Off

Dosing

Negative Flow

Upper Limit
Lower Limit

Empty Pipe

NPN normal open

NPN normal closed

PNP normal open

PNP normal closed

Flow

Temperature

Off
0-20mA
4-20mA

max Range

min Range

Output Value

Function

Pulse Value
Upper Limit
Lower Limit

Function

Logic

Off

Strong

Selection

Correction

Deutsch

English

Medium

Soft

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Fig. 10: Menu organization for 5-pin version

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Fig. 11: Menu organization for 8-pin version

Digital Output Q1

Analog Output QA

Creeping Flow

Units

Filter

Media

Set Offset

Basic Trim

Reset Counter

Language

Start

min Range

max Range

Function

Pulse Output

Off

Dosing

Negative Flow

Upper Limit

Flow

Temperature

Off
0-20mA
4-20mA

Lower Limit
Empty Pipe

PNP normal open

NPN normal closed

NPN normal open

PNP normal closed

Logic

Output Value

Function

Dosing Quantity

Dosing Time

Start
Stop

Version

Values

Configuration

Status

Off

Dosing

Reset Counter

Creeping Flow Off

Set Offser

Pulse Value
Upper Limit
Lower Limit

Function

Logic

ml/s + l

l/min + m

3

Gal/h + Gal

l/min + l

Off

Strong

Medium

Soft

Selection

Correction

Deutsch

English

Dosing

Diagnostic

Digital Input I1

Options Output

Digital Output Q2

Pulse Output

Off

Dosing

Negative Flow

Upper Limit
Lower Limit
Empty Pipe

PNP normal open

NPN normal closed

NPN normal open

PNP normal closed

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Set Offset

In the sub menu “Set Offset” it is possible to set the actual offset of the flow meter. Use this function
only when UltraFlo is completely filled with liquid, and there is no flow. If the offset is set while flow
is present or when the pipe is empty it will cause an offset drift what results in a faulty
measurement.

A small offset change, e.g. caused by variable temperatures, is automatically done by the flow
meter. It is also possible to set the offset via the configurable digital inputs.

Language

The language of the display can be changed. Available languages are English and German.

Filter

The function ”Filter“ averages the analog output signal. Possible settings: Soft, Medium, Strong,
Off. The analog output signal reacts faster to signal changes when average determination is set to
“soft”. Whereas the analog output signal reacts slower when average determination is set to
“strong”.

Units

UltraFlo is able to show actual flow or the volume in different units. Following units can be selected:
ml/s + l , Gal/min +Gal , l/min + l , l/min + m³.

The first letters correspond to the unit of the flow value. The letters after the + correspond to the
unit of the volume value.

Reset Counter

The volume counter of UltraFlo can be reset. Note, once reset, counter values cannot be restored.
After a reset the counter works normally.

Basic Trim

The “Basic Trim” function insures that the flow meter is conforming to the media specific
characteristics. To execute this function, UltraFlo runs a selfdiagnostic function which
optimizes all important parameters. This process lasts approximately 1 minute.

To make sure the basic trim is correctly done, the flow meter has to be filled with liquid without
a flow.

NOTICE

When there is an error detected while performing the basic trim function, the display shows
“Error”. After successfully finishing the basic trim function, the display will show “Done”.

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13

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Creeping suppression

The creeping suppression excludes flow measurements that result from convection in a narrow
band around zero, even with a closed valve. At the factory, the creeping suppression is set at a
standard value in relation to the cross-section of the flow meter. Changes to a smaller value of the
parameter may cause an offset drift what results in a faulty measurement.

There are higher tolerances below the standard default settings, see also section 5.2 measurement
errors!

Setting range : 0.0...20 l/min, in 0.006 l/min steps
Default settings : 0.3 l/min for DN10
 0.9 l/min for DN15
 3.5 l/min for DN20
 5.0 l/min for DN25

The creeping suppression works with a hysteresis of - 25%.

Flow [l/min]

1.2

1.05

0.9

0.75

0.6

-25%

0.45

1

0.3

0.15
0

Pulse/Analog output active inactive active inactive active

1. Creeping Suppression switch on

2. Creeping Suppression switch off

2

1

2

Fig. 12: Function of the creeping suppression illustrated with 0.6 l/min

Example : Creeping suppression = 0.6 l/min
If the flow rate is lower than 0.45 l/min the pulse output/analog output becomes inactive. If the flow
rate exceeds 0.6 l/min a pulse is output again and added to the totalizer. Similarly, a value is
transmitted to the analog output again.

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14

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Diagnostic

The sub menu "Diagnostic" shows the software/hardware version and other helpful values for
analysis. Actual values and the instrument´s present status are important to analyze the
measurement or failure by the manufacturer service

NOTICE

Analog output QA

The analog output is available as current output 4-20mA or 0-20mA. This is selected with the
purchase order. As a standard it comes with current output 4- 20mA. It can also be switched off by
using the device menu or SoftFlo operating software.

The current output ranges from 0 to 22.6mA measuring the flow rate or the condition of the flow
measurement.

The values here signify for 4-20mA configuration:

20 mA the upper limit of the relevant measurement
4 mA the lower limit of the relevant measurement

3.5 mA empty pipe

Upper and lower limit parameters can be set within the type-specific measurement of the device. By
default, zero flow is set at 4 mA and the maximum flow is set at 20 mA.

Set point ranges : 0-20mA, 4-20mA, off
Output value : Flow, Temperature

When current output is used, the load must not be higher than 500Ohm. A higher load
prevents the device from providing the maximum current of 22.6mA.

Pulse value

The pulse value determines the flow volumes for which an output pulse will be emitted. Choose a
configuration which will neither exceed the maximum output frequency of the UltraFlo (10kHz) nor
the maximum input frequency of the control. If the maximum frequency is exceeded the UltraFlo will
not output pulses correctly.

This means : a pulse is emitted every 2.0 ml.
Setting range : 0.1...3000.0 ml/Pulse, in 0.1 ml/Pulse steps
Default setting : 1.0 ml/Pulse

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15

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Dosing

The UltraFlo can be configured for manually dosing by choosing the dosing function via the user
display. The Volume “Dosing Batch“ and the “Dosing Time“ are freely adjustable. When the “Dosing
Time“ is set to zero, the timer control is inactive. A dosage can be started and stopped with the
menu function keys “Start“ and “Stop“.

Setting range “Dosing Batch” : 0 – 3500 Liters
Setting range “Dosing Time” : 0 –30000 Seconds
Default setting “Dosing Batch” :
Default setting “Dosing Time” :

0 Liters
3 Seconds

Digital output Q1

Digital output Q1 may be used as pulse output, empty pipe detection, for switching dosing valve or
limit control. By using Programmtool the user can switch between npn and pnp-transistor logic. In
case of inductive load a diode has to be connected parallel to the coil.

24V

GND

24V

pnp

Relay

Output

npn

Fig. 13: Connecting Output Q1 to relay

Setting area : off, pulse output, empty pipe, dosing output, lower limit, upper limit, negative flow

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Digital output Q2 *

Digital output Q2 may be used as pulse output, empty pipe detection, for switching dosing valve,
limit control or flow direction control. See chapter 2.3 table connection plug 8-pins.
The npn or pnp logic can be selected. When the output is connected to an inductive load a diode
has to be installed parallel to the load.

Inductive load on the digital outputs without an installed diode may cause damage on the
UltraFlo electronics.

Dosing function

Dosing can be determined in different ways :

1. Flowmeter as dosing device (dosing control via Flowmeter)
Flowmeter controls the complete dosing function. The dosing quantity (e.g. 400 ml) is pre-set in the

Flowmeter via the display or Programmtool. Dosing starts, as soon as the digital input is wired to
24V, e.g. via a pushbutton. Flowmeter will open the dosing valve via the output configured for it.
When the pre-set dosing quantity is released, the dosing valve is closed via the above output. The
dosing procedure can also be started and stopped by using the dosing user menu. The second
output can be used independently for signaling empty pipe, limit control or flow direction.

2. UltraFlo as dosing device (dosing control via SoftFlo)
UltraFlo controls the complete dosing function. The dosing quantity (e.g. 400 ml) is pre-set in the

UltraFlo via the diital interface (RS4B5) with the operating software “Flowsoft”. Dosing starts via the
dosing-menu in the operating software. UltraFlo will open the dosing valve via the output configured
for it. When the pre-set dosing quantity is released, the dosing valve is closed via the above output.

3. UltraFlo as flow meter (dosing control via dosing equipment)
The dosing equipment controls the entire dosing function. The dosing quantity is fixed in the dosing

equipment control during commissioning by pre-selecting the meter pulses. Dosing starts, when the
relevant pushbutton of the dosing equipment is pushed. The control will open the dosing valve.
Once the button is pushed UltraFlo will send a voltage pulse to release the metered volume (e.g.
per 1ml). Once the pre-selected metered volume is released, the control closes the dosing
valve. In this case, output 1 is used to send out pulses.

The customer has to provide an emergency stop and an overfilling stop to prevent
hazardous situations. Both functions must perform safety shut down of pumps and

WARNING!

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closing of valves.

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17

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Media

UltraFlo comes with a medium matrix with up to 8 interpolation values. Different media can be managed
in the sub menu “Media”. By using the sub menu point “Correction” it is possible to correct flow
measurement in percent.

Digital input I1*

UltraFlo has a digital input that is programmable for the following functions: dosing input, set offset,
creeping suppression inactive and reset counter. In order to start a dosing process, 24V DC power is
required. The status of the dosing parameters or modifications can be done via user display or FlowSoft
service software via the “USB Converter2”.

The dosing input is locked so that a re-start is not possible during a running dosing process. After
changing configurations via Flowsoft a restart of the device is necessary to activate the doing input
function.

Not all of the following functions are adjustable via the user display. See chapter 3.2 Fig. 10 and 11;
Menu organization.

3.3 Overview of default settings

Function

Digital output Q1
Digital output Q2*
Digital input I1*
Current output QA

Pulse value
Creeping suppression

Default settings

Pulse output as 24V normal open
Empty pipe detection as 24V normal open
No function assigned
Flow as 4-20mA signal

20mA -> 3 l/min at DN5
6 l/min at DN7
24 l/min at DN10
60 l/min at DN15

1 ml/pulse

0.024 l/min at DN5

0.09 l/min at DN7

0.3 l/min at DN10

0.9 l/min at DN15

3.4 General Information

Please check the following before powering the flowmeter for the first time:

Check the electrical connections and cable allocations
Check the installation position of the flowmeter. Are the direction of the arrow on the name plate
and the actual flow direction in the pipe congruent?
Is the measurement pipe completely filled with fluid?

heck the back pressure in the system

C

When everything has been checked, switch on power. After 30 minutes with power running the measuring
device reaches the maximum accuracy.

Now, UltraFlo is operational!

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

4. Exchange of Measuring Device

Switch off power before disconnecting the electrical connections!
Wiring installation, disassembly and removal must be performed by qualified persons
experienced and knowledgeable about electrical work.

WARNING!

If the device requires a configuration change, the display and programming unit SoftFlo or the
SoftFlo programming software and a “USB Converter 2” as well as a PC are required (see section

6. Accessories).

Serious injury or death from electric shock may occur if wiring, installation,
d

isassembly or remove of wires is performed while electrical power is energized

Please note that after replacing the flowmeter

a) the programming of the previous flowmeter should be saved and copied on
the new flowmeter
b) when using the dosing function, set a quantity

Repair, Hazardous Substances

Before sending the flowmeter Flowmeter for repair, the following precautions must be taken:

Clean all process chemicals from the device. Fully rinse the flow path. Please
pay close attention to the process fittings. All media must be removed before
returning. This is particularly important, if the medium to be measured is health

WARNING!

Devices judged to be insufficiently cleaned will be returned to sender. No inspection of device will
be done until proper cleaning is completed by user.

Costs due to inadequate cleaning of the instrument for possible disposal or injury (burns, etc.) will
be charged to the sender of the meter into account.

WARNING!

In order to be able to process your repair order quickly and smoothly it is important that you provide
a technical contact person including phone and fax number as well as e-mail address.

hazardous.

With the flowmeter send a detailed report describing the failure, the application
and the physical-chemical properties of the medium parameters. (e.g. a
decontamination declaration).

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19

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

5. Technical specifications

5.1 Dimensions and weight

Nominal

Diameter

DN10 3/8"
DN15 1/2"
DN20 3/4"
DN25 1"

Connection

½ G,NPT
¾ G,NPT

1 G,NPT

1 ¼ G,NPT

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Lengths

A [mm]

147.0

147.0

160.0

168.0

Widths
B [mm]

84.0

84.0

84.0

84.0

Height

C [mm]

83.0

84.5

94.2

98.5

Height axis

D [mm]

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70.5

71.1

77.6

77.6

Plug

E [mm]

15.0

15.0

15.0

15.0

Parting line

F [mm]

5.0

5.0

5.0

5.0

Weight

[g]

332
344
414
454

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

5.2 Technical Specifications

Housing

Nominal diameters

Connection

Medium temperature 0...+80°C
Protection class IP 67

Pressure nominal

Material

DN10 - 3/8”, DN15 - 1/2", DN20- 3/4”, DN25 - 1”
inch thread G, inch threat NPT, clamp connection

DIN11864-3 BKS-Clamp Form A

16 Bar / 232Psi for DN10 – 3/8” and DN15 – 1/2"
10 Bar / 145Psi for DN20 – 3/4" and DN25 – 1”

all parts in contact with medium made of PSU (Polyphenylsulfone)
Electronics housing made of PSU (Polyphenylsulfone)

Electronics

18...30VDCPower supply
Power input at 24V DC = 3.6W
Connection Plug 5 pins, option plug 8 pins

Ambient temperature 0....+60°C

Storage temperature 0....+70°C

0/4...20 mA

Current output QA

Digital output Q1/2

Data interface Data interface for parameterize

Measuring deviation

Measuring range

Repeatability 0.5%

Lower- and upper limit adjustable,
Ground connected to supply ground
Error Signal according to NAMUR NE43

via transistor npn- and pnp-logic
max. 30V/100mA
output voltage according to DIN 19240:
5V means Low
12V means HIGH
Short cut resistant

Frequency 0....10kHz

± 2% of reading ± 3mm/s (± 6mm/s for DN10 – 3/8”)
Option: ± 1% of reading ± 3mm/s (± 6mm/s for DN10 – 3/8”)
Reference conditions (VDE/VDI 2642)

0.3 – 21 l/min for DN10 – 3/8”

0.9 – 36 l/min for DN15 – 1/2"

3.5 – 60 l/min for DN20 – 3/4"

5.0 – 240 l/min for DN25 – 1”

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21

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Digital outputs

All outputs switch over to high resistance when the supply is smaller than 18V. When overload or
short circuit is detected the digital outputs are switched off after 100 s for a period of 2s. When time
is up the outputs get applied again.

Empty pipe output

Empty pipe
NPN normal closed High resistant
NPN normal open 0V
PNP normal closed High resistant
PNP normal open 24V High resistant

Filled, no flow

0V

High resistant

24V

Pulse output

Empty pipe
NPN normal closed 0V
NPN normal open 0V
PNP normal closed High resistant
PNP normal open High resistant High resistant

Filled, no flow

0V
0V

High resistant

Filled, flow

OV Pulse

OV Pulse
24V Pulse
24V Pulse

Lower limit output

NPN normal closed High resistant High resistant
NPN normal open OV
PNP normal closed High resistant

0V

High resistant

PNP normal open 24V 24V

OV

High resistant

24V

High resistant

Higher limit output

Below lower limit
NPN normal closed 0V
NPN normal open High resistant
PNP normal closed 24V
PNP normal open High resistant 24V

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Between the limits

High resistant

OV

High resistant

Above upper limit

High resistant

OV

High resistant

24V

22

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Dosing output

Startup of device
NPN normal closed High resistant
NPN normal open High resistant
PNP normal closed High resistant
PNP normal open High resistant 24V

While dosing

High resistant

0V

High resistant

Before/after dosing

0V

High resistant

24V

High resistant

Important! When using the dosing function the output should not be configured as
normal closed!
If the dosing output is configured as normal closed the valve will stay open after the
dosing batch.

Characteristic curves analog output

The analog output is available as current output 4-20mA or 0-20mA. This is selected with the
purchase order. As a standard it comes with current output 4-20mA. It can also be switched off by
using the device menu or Programmtool.

0 - 20mA

For the following graphic "min Range" is used for 0% and "max Range" is used for 100%.

24
22
20

Current [mA]

-20-100102030405060708090100 110

18
16
14
12
10

8
6
4
2
0

Current output 0...20mA

120

Value [%]

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23

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Value

Smaller 0%
0% (min Range)
Between 0% and 100%
100% (max Range)
Bigger 100%
Bigger max Value

Linear interpolation from 0 to 20 mA

Current [mA]

0
0

20
20
20

0 - 20mA

For the following graphic "min Range" is used for 0% and "max Range" is used for 100%

24
22
20
18

Current [mA]

16
14
12
10

8
6
4
2
0

-20-100102030405060708090100 110

Current output 4...20mA

Value [%]

120

Value

Empty pipe
Smaller -1.2%
Between -1.2% and 0%
0% (min Range)
Between 0% and 100%
100% (max Range)
Between 100% and 103%
Bigger 103%

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Linear interpolation from 3.8 to 4mA

Linear interpolation from 4 to 20mA

Linear interpolation from 20 to 20.5mA

Current [mA]

3.5

3.8

4

20

22.6

24

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Behavior of the Temperature Sensor

The integrated temperature sensor has no direct contact to the liquid and is used to calculate the
expansion of the housing. The environment temperature greatly influences the actual temperature
of the temperature sensor. The response time of temperature changes relates to the mounting
position of the temperature sensor inside the housing.

Step-Response Time

Step-response time after a significant temperature change. (Filter "Off")

100

80

60

Temperature [%]

40

20

0

0 5 10 15 20 25 30 35 40 45

Step-response time

Filter Configurations for Temperature Sensor

Filter
Off
Soft
Medium
Strong 4min

100%
1s
16s
1min

Step-response with filter

100

80

60

40

Value [%]

20

0

0 1 2 3 4

Time [min]

Off
Soft
Medium
Strong

Time [s]

Influence of the environment temperature
In the table below some examples of the temperature influence are shown.

Liquid Temp

40
40
40
60

X

0.7

X
X
X
X

0.7

0.7

0.7

0.7

+

Environment temp.

+
+
+

20°C
20°C
20°C

0.3

X

0.3

X

0.3

X

0.3

X

0.3

X

=

=
=
=
=

Measured temp.

34°C
37°C
40°C
48°C+ 20°C

In case of an error :

In case of a short circuit of the temperature sensor -50°C are shown.
In case of a cable brake between temperature sensor and electronic -30°C are shown.

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ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Filter options for analog output

Response time analog output

Wert [%]

100

80

Filter
off
soft
medium
strong

60

40

20

0

0 1 2 3 4

100%
16ms

0,3s

1s

4,2s

Off
Soft
Medium
Strong

TIme [i]

Digital input

When input setting is changed a device restart is required. After restart the changes are activated.
Available input functions:

40
40

40

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Set offset

­Rising edge:

0->24V
Set offset

Creeping flow off

­State:

deactivating creeping
flow

only use when there is currently no flow

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Dosing

­Rising edge:

0->24V
start dosing

Reset counter
20°C

Rising edge:
0->24V
counter is reset

off

-

-

26

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

Possible error text UltraFlo*

Display text

Empty Pipe

Low Voltage

Short Circuit

Lower Limit

Upper limit

Sonic Speed Actual sonic speed out of specified value. Run basic trim! Only text

When "Empty Pipe" is detected, no flow measurement
When power supply is less than 18V the outputs are

inactive.
When over load of the digital outputs is detected

(>100mA), outputs are inactive.
When the flow is less than an adjustable limit and the

output is configured for limit control.
When the flow is more than an adjustable limit and the

output is configured for limit control.

Pulse value

Behavior

Display flashing + text

Display flashing + text

Only text

Only text

Only text

6. Accessories

FloVu 100

Evaluation and management unit for up to 10 ultrasonic volume flow meter UltraFlo. Flovu 100 is
based on a compact SPS-control with integrated touch screen.
Order code 909765

Truflo connection socket

Truflo connection socket is used to power and connect UltraFlo 4000 to an external control unit.
Order code 507321 (Socket 5 pins)
Order code 800845 (Socket 8 pins)

FloCon 200

External display and programming unit for use in combination with ultrasonic flow measuring
devices UltraFlo. FloCon 200 can also be installed as separate display for UltraFlo.
Order code 908873

USB-toRS485-Converter

Interface converter from USB to RS485 with spring terminal connection for quick-connection
of UltraFlo and SoftFlo / part 1, PC software for configuration of ultrasonic volume flow meter
UltraFlo.
Order code 908728

7. Shipment

The device UltraFlo delivered without additional material like connection socket or cable. We
recommend ordering a connection socket (Ordercode 507321) to supply the measuring device.

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27

ULTRAFLO 4000

Multi-Function Ultrasonic Flow Meter

UltraFlo4000

Specifications may be modified without notice in advance.

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