Kamstrup ULTRAFLOW 54 DN150-300 Technical Description
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Kamstrup ULTRAFLOW 54 DN150-300 Technical Description

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Technical Description
ULTRAFLOW® 54 DN150-300

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Summary of Contents for Kamstrup ULTRAFLOW 54 DN150-300

  • Page 1 Technical Description ULTRAFLOW® 54 DN150-300...
  • Page 2 TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 3: Table Of Contents

    Electrical connection of Cable Extender Box ....................27 Connection of power supply ........................... 28 Battery supply ............................... 28 Mains supply modules ..........................28 Mains supply cable ............................29 Cable connections ............................30 Change of supply unit ........................... 30 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 4 Push-button functions ........................... 53 Using Pulse Tester ............................53 Spare parts ..............................54 Battery replacement ............................54 Sealing ..................................55 10 Software for Kamstrup heat/cooling meters ................57 11 Approvals ..........................58 11.1 MID and DK-BEK 1178 – 06/11/2014 ........................58 11.2 CE-Marking ................................

  • Page 5: General Description

    A three-wire signal cable is used to connect ULTRAFLOW® 54 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 –...

  • Page 6: Data

    (empty sensor) Pressure stage PN25, PS25 and PN16, PS16 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. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 7: Flow Data

    Signal cable (optional for separate ULTRAFLOW® 54) Silicone cable (3 x 0.5 mm Power supply cable 24/230 VAC (optional when selecting supply module) Cable with PVC-mantle (2 x 0.75 mm²) Housing, Cable Extender Box Base, cover Thermoplastic, ABS Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 8: Type Overview

    DN150x500 mm DN150x500 mm DN150x500 mm DN200x500 mm DN250x600 mm DN200x500 mm DN250x600 mm 1000 DN250x600 mm DN300x500 mm Flange facing type B, raised face according to EN 1092-1 Table 2. Type overview Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 9: Ordering Details

    65-5- FGDS -XXX 1000 2000 100:1 DN300 0.15 Stainless steel XXX - code for final assembly, approvals etc. - determined by Kamstrup. Table 3. Type numbers of ULTRAFLOW® 54 for MULTICAL®. Type numbers of separate ULTRAFLOW® 54 Dynamic Connection Length Material...

  • Page 10: Ordering Details Of Separate Ultraflow® 54

    ULTRAFLOW® is connected to other equipment/foreign calculators. For more information on electrical connection, please see paragraph 7.6 Electrical connections to MULTICAL®. Please note: Flow info cannot be read if output module with galvanic separation is used. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 11: Programming Options Of Meter Factor And Pulse Durations

    /h a meter factor of 100 liter/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 6 are programming values for ULTRAFLOW® 54 when connected to a Kamstrup MULTICAL® calculator.

  • Page 12: Accessories

    TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 Accessories Please note that not all article numbers can be directly ordered. Some articles must be ordered via Kamstrup service department. Note Article number Description (when ordering ULTRAFLOW®) 65-000-000-2000 D-cell lithium battery with two-pole connector...

  • Page 13: Cables

    Extender Box (Type 6699-036) must be ordered separately. Kamstrup offers signal cables in lengths of 2.5 m (Type 5000-333), 5 m (Type 5000-259) and 10 m (Type 5000-270), which can be ordered separately. In combination with the signal cables, which are typically delivered with ULTRAFLOW®, different total lengths of up to 20 m between ULTRAFLOW®...

  • Page 14: Dimensional Sketches

    Quantity Thread DN150 150 & 250 DN150 DN200 400 & 600 DN250 400 & 600 DN250 1000 DN300 1000 Flange facing type B, raised face according to EN 1092-1 Table 7 Figure 2 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 15: Cable Extender Box

    TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 Cable Extender Box Figure 3. Cable Extender Box seen from the front (a) and from the side (b). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 16: Pressure Loss

    1000 0.015 8160 4080 65-5- FGDS -XXX DN300 XXX - code for final assembly, approvals etc. - determined by Kamstrup. A few variants may not be available in national approvals. Table 8. Pressure loss table. Dp ULTRAFLOW ® 54 DN150-300...

  • Page 17: Installation

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

  • Page 18: Guidelines For Dimensioning Ultraflow® 54

    This means that the static pressure in water must be increased at a given temperature to avoid the steam phase that is shown in the lower right corner of the graph in Figure 5. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 19 Furthermore, it must be taken into account that the above static pressure is lower after a contraction than before (e.g. at cones). This means that the static pressure – when measured elsewhere in the installation– might be different from the pressure at the flow sensor outlet. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 20: Orientation Of Ultraflow® 54

    ULTRAFLOW® 54 can be mounted hanging from one of the two lifting rings depending on required flow direction. The enclosed distance piece can be used to secure optimal position of the electronics box. (See paragraph 7.3) Flow Flow Figure 7 Figure 8 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 21: Mounting Of Ultraflow® 54 Electronics Box

    By vertical mounting of ULTRAFLOW® 54 in a riser this can be secured by mounting the distance piece by means of the collar band as shown in Figure 11. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 22: Orientation Of Flow Sensor Electronics Box

    Furthermore, steel tube and wires 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 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 23: Straight Inlet

    Figure 14 For general information concerning installation see CEN report CEN CR 13582, Heat meter installation. Instructions in selection, installation and use of heat meters. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 24: Operating Pressure

    In order to prevent cavitation, the static pressure at the flow sensor outlet must be min. 1.5 bar at q and min. 2.5 bar at . This applies to temperatures up to approx. 80 °C. For further information on operating pressure see paragraph 7.1 Guidelines for dimensioning ULTRAFLOW® 54 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 25: Electrical Connections To Multical

    See paragraph 8.6.2 for electrical data on output module (Y=2 and 3). Note: Flow info cannot be read. Figure 15. Three-wire connection, MULTICAL® 602/603/801/803 via output module (Y=2). Figure 16. Three-wire connection, MULTICAL® 602/603/801/803 via output module (Y=3). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 26 PCB 66-99-045. Figure 19. Two-wire connection, MULTICAL® 602-D via output module (Y=2) and external 24 VDC supply. Figure 20. Two-wire connection, MULTICAL® 603-G via output module (Y=2) and external 24 VDC supply. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 27: Cable Length

    The example illustrates a default 2.5 m cable from ULTRAFLOW® to Cable Extender Box. In this case, the cable length between Cable Extender Box and MULTICAL® can be up to max 27.5 m Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 28: Connection Of Power Supply

    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 5510-408, ”Lithium batteries - Handling and disposal”).

  • Page 29: Mains Supply Cable

    Figure 25. 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. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 30: Cable Connections

    Please note that the supply type of some ULTRAFLOW® sensors appears from the label. If the original supply type is changed, it will no longer be in accordance with the label. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 31: Installation Examples (Electrical)

    ULTRAFLOW® 54 with galvanically separated output module (Y=2) and 230 VAC supply of its own is connected to MULTICAL® via a two-wire connection. See paragraph 7.6.2 for electrical wiring. Figure 27. ULTRAFLOW® connected to MULTICAL® 803 via a two-wire connection. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 32: Calculator With Two Flow Sensors

    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. Operational check Carry out an operational check when the complete meter (flow sensor, temperature sensors and calculator) has been installed and connected.

  • Page 33: Functional Description

    Within the heat, cooling and water meter industry, producers have been working on alternative techniques for the replacement of flow sensors based on the mechanical principle. Research and development at Kamstrup have proven that ultrasonic measuring is the most viable solution. Combined with microprocessor technology and piezo ceramics, ultrasonic measuring is not only accurate but also reliable.
  • Page 34 Reynolds numbers that characterize the flow, i.e. in practice for different flows (volume flow) and temperatures. To cover the various flow profiles in the best possible way with the ultrasound signal, Kamstrup uses a triangle sound path, as illustrated in Figure 29 from two perspectives, for large ULTRAFLOW® 54 flow sensor (q 3.5…100...
  • Page 35 When you look into the measuring tube (b), the signal is reflected along a triangular path. Figure 30. ULTRAFLOW® 54 (q 150…1000 m³/h). Two parallel sound paths at a slant in the measuring pipe. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 36: Function Of Ultraflow

    At flows exceeding the flow corresponding to pulse emission at max pulse frequency, the max pulse frequency will be maintained. Table 12 shows the saturation flow at a pulse frequency of 125 Hz for the different flow sizes and meter factors. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 37 (1h/day, 200 h/year), without exceeding max. permissible error. ULTRAFLOW® has no functional limitations during the period when the flow sensor operates above q Please note, however, that high flow velocities may cause cavitation, especially at low static pressure. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 38: Pulse Emission

    Supply voltage of ULTRAFLOW®: 3.6 VDC ±0.1 VDC The current consumption of ULTRAFLOW®: Max average 50 µA Max current 7 mA (max 40 ms) Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 39: Pulse Output Of Ultraflow

    Output impedance ~10 kΩ Concerning meter factor and pulse durations see paragraph 4.2.3 Figure 32. Block diagram of galvanically coupled output module (Y=1) in ULTRAFLOW® 54. Figure 33. Galvanically coupled output module (Y=1). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 40: Galvanically Separated

    Concerning meter factor and pulse durations, see paragraph 4.2.3 Figure 34. Block diagram of galvanically separated output module (Y=2) in ULTRAFLOW® 54. Figure 35. Galvanically separated output module (Y=2). Note the PCB number 5550-1062 in the encircled area. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 41 Concerning meter factor and pulse durations, see paragraph 4.2.3 Figure 36. Block diagram of galvanically separated output module (Y=3) in ULTRAFLOW® 54. Figure 37. Galvanically separated output module (Y=3). Note the PCB number 5550-1219 in the encircled area. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 42: Interface Connector/Serial Data

    External control of start/stop in connection with calibration The interface connector is constructed as shown in Figure 38. Meter interface Pin 1 Vcc Pin 2 Gnd Pin 3 Pulse out Pin 4 Access control Figure 38. Interface connector. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 43: Test Mode

    In the same way the lacking quantity is the water volume passing through the sensor during the time from the last accumulation until stop. The volume accumulated during the test can be stated as:    Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 44: Calibration Using Serial Data And Externally Controlled Start/Stop

    Communication with ULTRAFLOW® during test is not allowed. 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 monitored at intervals of 1 second. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 45: Accuracy

    ULTRAFLOW® will typically do better than half of the permitted tolerance according to EN 1434 class 2. Note: For further information regarding allowable test conditions such as water temperature and flow of the individual ULTRAFLOW®, see the approval of ULTRAFLOW® (see paragraph 11 Approvals). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 46 EN1434 cl.3 EN1434 cl.2 ½ EN1434 cl.2 1000 0,1x qp Flow [m³/h] Figure 41. Flow sensor tolerances specified as an example for a flow sensor with q 150 m³/h and q = 100:1. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 47: Calibrating Ultraflow

    2…100 ms depending on programming. Appears from type label. Meter factor: Depends on programming. Appears from type label. Start-up: It takes 16 seconds from start-up until true flow reading has been obtained and calibration can start. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 48: Electrical Connection

    39.2 kΩ Module Y=3 OC and OD Max input voltage Max input current 0.1 mA U ≤ 0.3 V @ 0.1 mA ON condition R ≥ 6 MΩ OFF condition Figure 44 Table 16 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 49: Suggested Test Points

    1000 pulses • Water volume at q corresponding to minimum 500 pulses These suggested test points can be optimized for the test benches as well as for the test purpose. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 50: Optimization In Connection With Calibration

    To avoid interference from the outside as well as to obtain an electrical interface to MULTICAL®, it is recommended to use a Pulse Tester (see paragraph 9.5) or to connect ULTRAFLOW® and the relevant test equipment that counts pulses via a galvanically separated output module. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 51: Pulse Tester

    The transmitter is a reed-switch, which is normally mounted on vane wheel and Woltmann meters, or the relay output of e.g. MID-meters. This type of transmitter should not be used as the quick pulse input of the Pulse Tester may regard bounce from the transmitter as pulses. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 52 TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 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)

  • Page 53: Hold-Function

    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). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 54: Spare Parts

    Current consumption with no sensors connected 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 (unplugged). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 55: Sealing

    Security seal or module D/F label (Depending on type label) Security seal. Covering screws Type label (as void label or with security seal D) Installation seal (wire and seal or sealing label) Figure 50. Sealing and marking of ULTRAFLOW® 54 DN150-300. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 56 TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 Figure 51. Sealing of Cable Extender Box seen from the front (a) and from the side (b). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 57: Software For Kamstrup Heat/Cooling Meters

    ULTRAFLOW® 54 DN150-300 10 Software for Kamstrup heat/cooling meters To adjust ULTRAFLOW® and to programme Pulse Divider, the software METERTOOL HCW 6699-724 is used. For more information, see the Technical description of METERTOOL HCW (5512-2097_GB). Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 58: Approvals

    2014/35/EU (when fitted with 230 VAC supply module) PE directive 2014/68/EU (DN150…DN300) category II 11.3 EU declaration of conformity With each ULTRAFLOW® 54 DN150-300 delivered from Kamstrup, an EU declaration of conformity is provided. See Kamstrup documentation No. 5518-309. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 59: Troubleshooting

    Air in sensor/cavitation Check installation angle. Check if there is air in the system or cavitation from valves and pumps. Increase the static pressure, if possible Flow sensor error Replace flow sensor/Send sensor for repair Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

  • Page 60: Disposal

    ULTRAFLOW® 54 DN150-300 13 Disposal Kamstrup A/S holds an environmental certification according to ISO 14001, and as part of Kamstrup’s environment policy, materials that can be recovered environmentally correctly are used to the greatest possible extent. Kamstrup A/S has climate accounts (Carbon footprint) for all meter types.

  • Page 61: Technical Documentation

    MULTICAL® 803 & ULTRAFLOW® 5512-2408 5512-2408 5512-2408 5512-2408 ULTRAFLOW® 54 DN150-300 5512-886 5512-887 5512-888 5512-889 Pulse Transmitter/Pulse Divider 5512-1387 5512-1421 5512-1422 Cable Extender Box 5512-2008 5512-2008 5512-2008 Table 20. Technical documentation for ULTRAFLOW®. Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...
  • Page 62 TECHNICAL DESCRIPTION ULTRAFLOW® 54 DN150-300 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 Kamstrup A/S · Technical description · 5512-876_M1_GB_12.2020...

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