Kamstrup ULTRAFLOW 54 DN15-125 Technical Description Download | Manualshive

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ULTRAFLOW® 54 DN15-125

82

Kamstrup A/S · Technical description · 5512-2464_D1_GB_09.2021

8.5.5

Spare parts

Description

Type No.

Battery D-cell

1606-064

Cable retainer (secures the battery)

1650-099

2-pole plug (female)

1643-185

3-pole plug (female)

1643-187

Base PCB (66-R)

5550-517

Table 34. Spare parts for Pulse Tester.

8.5.6

Battery replacement

If Pulse Tester is used continuously, it is recommended to replace the battery once a year.

The battery connector is cut and the cable insulation is removed before the battery is connected to the terminals marked

“Batt”, the red wire to + and the black

wire to -.

Current consumption:

Current consumption with no sensors connected

400



A

Max current consumption with two ULTRAFLOW® connected

1.5 mA

<

If the base unit is fitted with battery or externally supplied, the Pulse Tester’s integral supply must be disconnected

(unplugged).

8.6

Adjustment of ULTRAFLOW® flow sensors with Kamstrup software

Adjusting of ULTRAFLOW® flow sensors is supported from Kamstrup for authorized laboratories. The adjustment is
performed through

Kamstrup’s software LabTool. Please contact the

Kamstrup Product Service in Denmark

[email protected]

) for additional information.

<

To prevent any attempt of fraud, LabTool is exclusively distributed to workshops/laboratories with national legal

authorization and partnership with Kamstrup.

8.7

Calibration and adjustment with NOWA

NOWA describes a standardized interface between the heat meter laboratory test equipment (e.g. flow bench) and is
mainly used in laboratories in Germany and Austria. NOWA test and adjusting of ULTRAFLOW® 54 DN15-125 (q

p

0.6…100

m³/h) is supported in combination with MULTICAL® 601/602/603. For more information about test and adjusting of
ULTRAFLOW® with NOWA, see Kamstrup documentation 5585-703 (Hardware) and 5585-706 (Software). NOWA does
not support calibration of ULTRAFLOW® 54 DN150-300 (q

p

≥

150 m

3

/h). Verification of ULTRAFLOW® 54 DN150-300 (q

p

≥

150 m

3

/h) is instead carried out via counting of pulses.

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Summary of Contents for ULTRAFLOW 54 DN15-125

Page 1: ...Kamstrup A S Industrivej 28 Stilling DK 8660 Skanderborg T 45 89 93 10 00 info kamstrup com kamstrup com Technical description ULTRAFLOW 54 DN15 125 ...

Page 2: ...ULTRAFLOW 54 DN15 125 2 Kamstrup A S Technical description 5512 2464_D1_GB_09 2021 ...

Page 3: ...composition of Pulse Transmitter and Pulse Divider 16 4 3 3 Output module and supply module 16 4 3 4 Pulse Divider configuration CCC DD E MMM 17 4 3 5 Accessories for Pulse Transmitter and Pulse Divider 20 4 3 6 Cables 20 4 3 7 Cable Extender Box 20 5 Dimension sketches 21 5 1 Threaded meters 21 5 1 1 ULTRAFLOW 54 Type 65 5 XXHX XXX G B and G1B 21 5 1 2 ULTRAFLOW 54 Type 65 5 XXJX XXX G1 B G1 B an...

Page 4: ...al 46 6 10 1 MULTICAL 603 mounted on ULTRAFLOW 54 Type 65 5 XXHX XXX 46 6 10 1 1 Installation in an ascending pipe 46 6 10 1 2 Installations at or above eye level 46 6 10 1 3 Installation at ground level 47 6 10 1 4 Mounting of angle bracket 3026 858 48 6 10 2 MULTICAL 603 mounted on ULTRAFLOW 54 Type 65 5 XXJX XXX and Type 65 5 XXCX XXX 49 6 10 3 MULTICAL 803 mounted on ULTRAFLOW 50 6 10 4 Pulse ...

Page 5: ...71 7 10 Externally controlled start stop 71 7 11 Calibration using serial data and externally controlled start stop 72 7 12 Accuracy 73 8 Calibration adjustment and sealing of ULTRAFLOW 75 8 1 Technical data for ULTRAFLOW 75 8 2 Electrical connection 76 8 3 Suggested test points 77 8 4 Optimization in connection with calibration 78 8 5 Pulse Tester 79 8 5 1 Technical data for Pulse Tester 79 8 5 2...

Page 6: ...ULTRAFLOW 54 DN15 125 6 Kamstrup A S Technical description 5512 2464_D1_GB_09 2021 ...

Page 7: ...ICAL 403 ensuring equally proven accuracy durability and serviceability For further information about our compact meters MULTICAL 303 and MULTICAL 403 please consult Kamstrup doc no 5512 2701_GB and 5512 1689_GB 1 3 General description The flow sensor program ULTRAFLOW 54 DN15 125 is particularly designed for heat meters in combination with MULTICAL 603 and MULTICAL 803 and a set of TemperatureSen...

Page 8: ... VDC Battery Pulse Transmitter Pulse Divider 3 65 VDC D cell lithium Battery lifetime replacement interval 6 years tBAT 30 C With output module Y 3 Mains supply Pulse Transmitter Pulse Divider 230 VAC 15 30 50 Hz 24 VAC 50 50 Hz Power consumption mains supply 1 W Backup mains supply Integral SuperCap eliminates interruptions due to short term power failures Cable length Flow sensor Pulse Transmitt...

Page 9: ... See paragraph 6 Installation Medium in flow sensor Water recommended water quality as described in CEN TR 16911 and AGFW FW510 Temperature of medium ULTRAFLOW 54 15 130 C or narrower range depending on configuration see marking At medium temperatures above 90 C the use of flange meters is recommended At medium temperatures above 90 C or below the ambient temperature the calculator and Pulse Trans...

Page 10: ...1 7 5 5 3 5 50 100 1 2 1 9 7 6 25 100 1 2 1 18 12 10 15 100 1 2 1 30 20 15 10 100 1 2 1 45 30 25 6 100 1 2 1 75 50 40 5 100 1 2 1 90 80 60 2 5 100 1 2 1 180 120 100 1 5 100 1 2 1 300 200 1 The meter factor appears from the type label 2 Saturation flow 125 Hz Max pulse frequency is maintained at higher flow Nom flow qp Meter factor 1 Dynamic range Flow 125 Hz 2 Min cutoff Table 1 Flow data ...

Page 11: ...d Polyethersulfone PESU 30 GF Electronics housing ULTRAFLOW 54 Base flow sensor Thermoplastic 30 glass fibre reinforced Polyethersulfone PESU 30 GF only flow sensor type 65 5 XXHX XXX Thermoplastic 10 glass fibre reinforced Polycarbonate PC 10 GF Top cover flow sensor Thermoplastic 10 glass fibre reinforced Polycarbonate PC 10 GF only flow sensor type 65 5 XXHX XXX Thermoplastic 20 glass fibre rei...

Page 12: ...G5 4Bx260 mm DN25x260 mm G5 4Bx135 mm G5 4Bx150 mm 6 G5 4Bx260 mm G1 Bx260 mm DN25x260 mm DN32x260 mm G5 4Bx135 mm G5 4Bx150 mm 10 G2Bx300 mm DN40x300 mm G2Bx200 mm 15 DN50x270 mm DN50x250 mm 25 DN65x300 mm 40 DN80x300 mm DN80x350 mm 60 DN100x360 mm DN100x400 mm 100 DN100x360 mm DN125x350 mm Country specific variants Installation dimensions Table 2 Type overview of ULTRAFLOW 54 Thread EN ISO 228 1...

Page 13: ... 6 0 06 12 G5 4B R1 260 16 25 25 Brass 65 5 CHJH XXX 6 0 06 12 G1 B R5 4 260 16 25 25 Brass 65 5 CHCB XXX 6 0 06 12 DN25 260 25 25 Stainless steel 65 5 CHCC XXX 6 0 06 12 DN32 260 25 25 Stainless steel 65 5 CJJ8 XXX 10 0 1 20 G2B R1 200 16 25 15 Brass 65 5 CJJJ XXX 10 0 1 20 G2B R1 300 16 25 15 Brass 65 5 CJCD XXX 10 0 1 20 DN40 300 25 15 Stainless steel 65 5 CKC4 XXX 15 0 15 30 DN50 250 16 25 10 ...

Page 14: ...147 G1 2210 062 DN25 2210 133 G5 4 2210 063 DN32 2210 217 G1 2210 064 DN40 2210 132 G2 2210 065 DN50 2210 099 DN65 2210 141 DN80 2210 140 DN100 1150 142 DN125 1150 153 Gaskets for couplings PN16 PN25 Gaskets for flange meters PN25 Table 5 Separate gaskets for the couplings and flange meters PN16 PN25 2101 147 Blind plug for ULTRAFLOW Excl o ring 1150 132 1150 132 O ring for blind plug 2101 147 221...

Page 15: ...ore than 10 m is required between MULTICAL and ULTRAFLOW 2 For flow sensor no 2 in connection with MULTICAL If two flow sensors are used together with MULTICAL and an equipotential connection between the two flow sensors cannot be carried out one typically V2 should be galvanically separated For further information see paragraph 6 12 3 Calculator with two flow sensors 3 If ULTRAFLOW is connected t...

Page 16: ...e Transmitter and Pulse Divider are available with one of two different galvanically separated output modules Output module Y 2 is used when extra long cables are required When connecting to MULTICAL a DC supply is required as shown in Figure 33 to Figure 36 pages 53 and 54 See also the Technical description of MULTICAL Flow sensor with active 24 V pulse output For output module Y 2 battery supply...

Page 17: ...150 63 100 2 5 10 600 34 100 3 5 151 50 3 9 Default 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 6 137 25 3 9 Default 6 1 25 33 20 50 6 2 5 62 5 63 100 6 10 250 34 100 6 25 625 64 100 10 178 15 3 9 Default 10 1 15 33 20 50 10 10 150 34 100 10 25 375 64 100 15 120 10 3 9 Default 15 1 10 33 20 15 10 100 34 50 100 15 25 250 64 100 15 100 1000 35 100 25 179 6 3 9 Default 2...

Page 18: ... duration E for Pulse Divider for ULTRAFLOW X4 qp 40 100 m3 h Default values in Table 8 and Table 9 indicate meter factors and pulse durations of ULTRAFLOW X4 qp CCC m h pulses l l pulse Divider DD ms E 1 ms E 4 ms E 5 ms E 6 0 6 116 300 70 3 9 Standard 0 6 0 0167 5 41 3 9 0 6 0 02 6 51 3 9 0 6 0 04 12 12 3 9 1 5 119 100 31 3 9 Standard 1 5 0 02 2 51 3 9 1 5 0 04 4 12 3 9 1 5 0 1 10 32 3 9 2 5 198...

Page 19: ...dard 3 5 0 02 1 51 3 9 6 137 25 12 3 9 Standard 6 0 04 1 12 3 9 10 178 15 22 3 9 Standard 10 0 0667 1 22 3 9 15 120 10 32 3 9 Standard 15 0 1 1 32 3 9 25 179 6 42 3 9 Standard 25 0 1667 1 42 3 9 40 158 5 52 3 9 Standard 40 0 2 1 52 3 9 60 170 2 5 13 3 9 Standard 60 0 4 1 13 3 9 100 180 1 5 23 3 9 Standard 100 0 6667 1 23 3 9 Meter factor Pulse duration Table 11 Configuration variants for meter fac...

Page 20: ...when ordering Pulse Transmitter Pulse Divider 1 Obligatory when changing from mains supply module to battery supply 2 Including 5000 290 Table 12 Accessories for Pulse Transmitter and Pulse Divider 4 3 6 Cables Pulse Transmitter and Pulse Divider are available with signal cable lengths 2 5 5 or 10 m The signal cable is mounted from the factory If 24 230 VAC supply module is selected Pulse Transmit...

Page 21: ...W 54 threaded meters type 65 5 XXHX XXX Thread EN ISO 228 1 Thread L M H2 A B1 B2 H1 Approx weight kg G B qp 0 6 1 5 110 L 2 86 8 37 32 55 0 41 G1B qp 1 5 110 L 2 86 12 37 32 55 0 46 G1B qp 0 6 1 5 130 L 2 86 12 37 32 55 0 51 G1B qp 2 5 130 L 2 86 12 40 35 55 0 53 G B qp 1 5 165 L 2 86 8 37 32 55 0 51 G1B qp 0 6 1 5 190 L 2 86 12 37 32 55 0 61 G1B qp 2 5 190 L 2 86 12 40 35 55 0 67 Table 13 Dimens...

Page 22: ...SO 228 1 EN 10226 1 Nominal diameter Length L Length L1 Weight of couplings 2 pcs Thread DN mm mm kg G B R 15 110 189 0 2 G B R 15 165 244 0 2 G1B R 20 110 208 0 3 G1B R 20 130 228 0 3 G1B R 20 165 262 0 3 G1B R 20 190 288 0 3 G1B x 130 mm with couplings including adapter 1330 023 and extra gasket Table 14 Length of ULTRAFLOW 54 threaded meters type 65 5 XXHX XXX with and without couplings and wei...

Page 23: ...XX Thread EN ISO 228 1 Thread L M H2 A B1 B2 H1 Approx weight kg G5 4 qp 3 5 6 0 135 63 89 14 58 20 55 0 9 G5 4 qp 3 5 6 0 150 71 89 14 58 20 55 1 0 G5 4 qp 3 5 260 L 2 89 16 58 20 55 1 5 G5 4 qp 6 0 260 L 2 89 16 60 20 55 1 6 G1 qp 6 0 260 L 2 89 31 60 24 55 1 7 G2 qp 10 200 85 89 33 63 29 55 1 8 G2 qp 10 300 L 2 89 40 2 63 29 55 2 5 Table 15 Dimensions and weight of ULTRAFLOW 54 threaded meters ...

Page 24: ...nnection Flow sensor Installation ISO 228 1 EN 10226 1 Nominal diameter Length L Length L1 Weight of couplings 2 pcs Thread DN mm mm kg G5 4B R1 25 135 253 0 6 G5 4B R1 25 150 268 0 6 G5 4B R1 25 260 378 0 6 G1 B R5 4 32 260 376 0 8 G2B R1 40 200 328 1 0 G2B R1 40 300 428 1 0 Table 16 Length of ULTRAFLOW 54 threaded meters type 65 5 XXJX XXX with and without couplings and weight of couplings ...

Page 25: ...eight diameter L M H2 B1 D H k Number Thread d2 kg DN20 qp 1 5 190 L 2 89 58 105 95 75 4 M12 14 3 2 DN20 qp 2 5 190 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 DN32 260 L 2 89 D 2 140 128 100 4 M16 18 5 2 DN40 250 L 2 89 D 2 150 136 110 4 M16 18 7 9 DN40 300 L 2 89 D 2 150 136 110 4 M16 18 8 3 DN50 250 155 89 D 2 165 145 125 4 M16 18 9 8 DN50 270 155 89 D 2 165 145 ...

Page 26: ...th EN 1092 1 PN25 Nom Diameter Bolts Approx weight L M H2 B1 D H k Number Thread d2 kg DN65 300 170 89 H 2 185 168 145 8 M16 18 13 2 DN80 300 170 89 H 2 200 184 160 8 M16 18 16 8 DN80 350 170 89 H 2 200 184 160 8 M16 18 18 6 DN100 360 210 89 H 2 235 220 190 8 M20 22 21 7 DN100 400 210 89 H 2 220 210 180 8 M16 18 22 8 DN125 350 212 89 H 2 270 260 220 8 M24 26 28 2 Table 18 Dimension and weight of U...

Page 27: ...se Transmitter and Pulse Divider Figure 7 Pulse Transmitter Pulse Divider seen from the front Figure 8 Pulse Transmitter Pulse Divider seen from the side Figure 9 Wall mounted Pulse Transmitter Pulse Divider Figure 10 Pulse Transmitter Pulse Divider mounted on ULTRAFLOW 54 Type 65 5 XXHX XXX ...

Page 28: ...ULTRAFLOW 54 DN15 125 28 Kamstrup A S Technical description 5512 2464_D1_GB_09 2021 5 4 Cable Extender Box a b Figure 11 Cable Extender Box seen from the front a and from the side b ...

Page 29: ... to the Danish Standard organization s web shop https webshop ds dk en gb frontpage CurrencyCode EUR Alternatively you can find your national standardization organization here https www iso org members html Consider the following general risks and advice By connecting to 230 VAC supply there is a risk of electrical shock When working on the flow sensor in the installation there is a risk of outflo...

Page 30: ... 90 C or below the ambient temperature calculator and Pulse Transmitter Pulse Divider must not be mounted on the flow sensor Instead wall mounting is recommended See Table 12 Accessories for Pulse Transmitter and Pulse Divider Mechanical environment MID M1 applies to instruments used in locations with vibration and shocks of low significance e g for instruments fastened to light supporting structu...

Page 31: ...this means that the IP class is higher than required by EN 1434 for other enclosures which are not to be installed in pipe work Note that it is the responsibility of the installer to ensure proper mounting of the cable screw connections as otherwise the IP classification is not valid Flow sensor and Cable extender box are not protected against periodically or permanently wet conditions and must no...

Page 32: ...sk of these factors affecting accuracy is reduced by maintaining a suitable pressure in the system In relation to the recommended static pressure the steam pressure at the current temperature must also be considered The recommended static pressure applies to temperatures up to approx 80 C The steam pressure is the pressure where steam and liquid are in equilibrium at the current temperature boilin...

Page 33: ...is increased in a contraction and the static pressure decreases 𝑞 𝐴1 𝑣1 𝐴2 𝑣2 𝐴𝑖 𝑣𝑖 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 Continuity equation When dimensioning a flow sensor you must take the above into consideration especially if the sensor is used within the scope of EN 1434 between qp and qs and in case of major pipe contractions In general the maximum design flow in the system must NOT exceed the nominal flow qp of the fl...

Page 34: ...5 CHJG XXX G5 4B R1 260 65 5 CHJH XXX G1 B R5 4 260 65 5 CJJ8 XXX G2B R1 200 65 5 CJJJ XXX G2B R1 300 65 5 CJCD XXX DN40 300 65 5 CKC4 XXX DN50 250 65 5 CKCE XXX DN50 270 G 25 65 5 CLCG XXX DN65 300 0 06 102 51 65 5 CMCH XXX DN80 300 65 5 CMCJ XXX DN80 350 65 5 FACL XXX DN100 360 65 5 FAD5 XXX DN100 400 65 5 FBCL XXX DN100 360 65 5 FBCM XXX DN125 350 1 XXX code for final assembly approvals etc det...

Page 35: ...LOW 54 DN15 125 Kamstrup A S Technical description 5512 2464_D1_GB_09 2021 35 0 01 0 1 1 0 1 1 10 100 1000 Δp bar Flow m h Δp ULTRAFLOW 54 A B B1 C D E F G H J Figure 13 Pressure loss diagram of ULTRAFLOW 54 ...

Page 36: ...gaskets up to and including DN80 are suitable for both PN16 and PN25 Flange gaskets DN100 and DN125 are suitable for PN25 only due to their physical dimension Couplings and gaskets are mounted as shown in Figure 14 See Table 4 and Table 5 for ordering details of suitable couplings and gaskets In connection with G1Bx110 mm it must be checked that the thread run out is sufficient Type 65 5 XXHA XXX ...

Page 37: ...4 260 Ok Ok 65 5 CHCB XXX 6 DN25 260 65 5 CHCC XXX 6 DN32 260 65 5 CJJ8 XXX 10 G2B R1 200 Ok 65 5 CJJJ XXX 10 G2B R1 300 Ok 65 5 CJCD XXX 10 DN40 300 65 5 CKC4 XXX 15 DN50 250 65 5 CKCE XXX 15 DN50 270 65 5 CLCG XXX 25 DN65 300 65 5 CMCH XXX 40 DN80 300 65 5 CMCJ XXX 40 DN80 350 65 5 FACL XXX 60 DN100 360 65 5 FAD5 XXX 60 DN100 400 65 5 FBCL XXX 100 DN100 360 65 5 FBCM XXX 100 DN125 350 1 XXX code...

Page 38: ...a cable length of more than 10 m between ULTRAFLOW and MULTICAL see 4 3 Pulse Transmitter Pulse Divider and Cable Extender Box 6 3 Flow sensor position Inlet Outlet Correct flow sensor position inlet or outlet appears from the front label or display of MULTICAL where indicates the position in inlet and indicates the position in outlet When ULTRAFLOW is connected to another calculator ULTRAFLOW can...

Page 39: ...ures up to the temperature of the thermal energy conveying liquid as thermal balance to the environment is prohibited This might be critical to some components in particular to sensitive electronics Predominantly in cooling installations humidity from the warm environment will condense on comparatively colder pipes This is why they are often permanently wet Insulation therefore requires temperatur...

Page 40: ...low installation recommendations into consideration A Recommended flow sensor position B Recommended flow sensor position C Unacceptable position due to risk of air build up D Acceptable position in closed systems Unacceptable position in open systems due to risk of air build up in the system E A flow sensor ought not to be placed immediately after a valve with the exception of shut off valves ful...

Page 41: ...le If Kamstrup flow sensors are vertically mounted they can be turned 360 around the pipe axis The plastic box should be placed on the side at horizontal mounting See below for additional details Figure 16 Separate mounting of Kamstrup flow sensors Vertically horizontally or at an angle At horizontal mounting Kamstrup s flow sensors can be turned around the pipe axis Acceptable angles of rotation ...

Page 42: ...t horizontal mounting a Threaded meter housings with qp 2 5 m3 h b Threaded meter housings with qp 3 5 m3 h and flange meters The orientations marked with are conditionally accepted when the assumptions below are fulfilled 1 District heating cooling water must be clean and must not contain any kind of dirt Dirt can otherwise be deposited on the transducers of the flow sensor which affects their ab...

Page 43: ...lange meters a b Figure 18 Recommended orientation of Kamstrup flow sensors around the pipe axis at horizontal mounting for cooling and combined heat cooling installations a Threaded meter housings with qp 2 5 m3 h b Threaded meter housings with qp 3 5 m3 h and flange meters District heating and cooling water must be free of air Air bubbles will interfere severely with the ultrasound signal If the...

Page 44: ...tion These recommendations for temperature sensor installation comply with the recommendations for flow sensor installation illustrated in Figure 17 and Figure 18 However while a temperature sensor can well be directly installed in a flow sensor for cooling installation mounted in an ascending pipe it must not be mounted in a flow sensor for cooling installation mounted in a descending pipe 6 7 Mo...

Page 45: ...e prepared for mounting screws 6 9 Maintenance and service during operation The flow sensor is verified separately and can therefore be separated from the calculator See the sealing drawings of the connected calculator such as MULTICAL 603 5512 2029_GB or MULTICAL 803 5512 2360_GB Due to the sealing levels of Pulse Transmitter Pulse Divider see Figure 69 it is also permitted to replace the supply ...

Page 46: ...5 5 XXHX XXX 6 10 1 1 Installation in an ascending pipe Figure 22 MULTICAL 603 mounted on ULTRAFLOW 54 mounted in an ascending pipe When installing ULTRAFLOW in an ascending pipe it can be of advantage to turn ULTRAFLOW 360 around the pipe axis to optimize the readability of the MULTICAL display at direct mounting of MULTICAL on ULTRAFLOW 6 10 1 2 Installations at or above eye level Figure 23 MULT...

Page 47: ... the ground When installing near the ground MULTICAL can with advantage be mounted directly on ULTRAFLOW 54 type 65 5 XXHX XXX by means of the supplied angle bracket 3026 858 ULTRAFLOW 54 type 65 5 XXHX XXX can be turned downwards to optimize the readability of the MULTICAL display At installation in humid environments the plastic housing of ULTRAFLOW 54 type 65 5 XXHX XXX must be positioned on th...

Page 48: ...pe label is fairly robust it must be handled with care if the angle bracket is to be mounted on this side The signal cable on the other side is flexible enough to be inserted between the electronics case and the angle bracket B Move the angle bracket around the side edge towards the electronics case C Press the angle bracket against the electronics case cover at the indicated positions and click i...

Page 49: ...ons near the ground MULTICAL can with advantage be mounted directly on ULTRAFLOW by means of angle bracket 3026 252 see Figure 26 b The angle bracket 3026 252 must be ordered separately a b Figure 26 MULTICAL 603 mounted on ULTRAFLOW 54 a The flow sensor can be turned around the pipe axis to optimize the readability of the MULTICAL display b In some cases the angle bracket 3026 252 can optimize th...

Page 50: ...cks By compact mounting the calculator is mounted directly on ULTRAFLOW using the mounting bracket 3026 857 If there is risk of condensation e g in cooling installations the calculator must always be wall mounted Furthermore ULTRAFLOW in cooling installations must be a condensation proof version Figure 27 MULTICAL 803 with bracket 3026 857 mounted on ULTRAFLOW 54 Type 65 5 XXHX XXX 6 10 4 Pulse Tr...

Page 51: ...ive electronics flow sensor PCB which must NOT be exposed to high temperatures Furthermore insulation of the plastic casing at a medium temperature above 110 C can severely damage the plastic casing itself because the temperatures inside the insulation get close to the glass transition temperature of the plastic casing Figure 30 Insulation of ULTRAFLOW 54 DN15 125 in a heat installation ...

Page 52: ...e connected via Pulse Transmitter ULTRAFLOW is galvanically separated from MULTICAL and the cable length between ULTRAFLOW and MULTICAL can be extended up to 110 m Flow info is not possible if Pulse Transmitter Pulse Divider is used If ULTRAFLOW is connected to other equipment than MULTICAL always connect ULTRAFLOW via Pulse Transmitter or Pulse Divider For connection of Pulse Transmitter and Puls...

Page 53: ...99 045 MULTICAL 602 603 801 803 Table 24 Maximum allowable cable length depends on the output module in Pulse Transmitter Pulse Divider and how the MULTICAL calculator is connected Using long signal cables careful consideration is required in connection with installation With respect to EMC there must be a distance of at least 25 cm between signal cables and all other cables Recommended cable cros...

Page 54: ... 045 Cable length 100 m Figure 35 Two wire connection of Pulse Transmitter with output module Y 2 to MULTICAL 602 D and external 24 VDC supply 1 Cable length 100 m Figure 36 Two wire connection of Pulse Transmitter with output module Y 2 to MULTICAL 603 G and external 24 VDC supply 1 Cable length 100 m 1 External 24 VDC supply is not part of the calculator Examples of connection of Pulse Transmitt...

Page 55: ...fore 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 must be replaced by a corresponding lithium battery with connector from Kamstrup A S Used batteries must be handed in for approved destruction e g to Kamstrup A S see chapter 12 Disposal 6 11 2 2 2 Mains supply mo...

Page 56: ...dividual installations which are supplied by a separate 230 24 V safety transformer in the main electrical panel The module includes a double chamber safety transformer which fulfils double insulation requirements when the cover is mounted on Pulse Transmitter Pulse Divider Power consumption is less than 1 W or 1 VA National regulations for electric installations must be observed The 24 VAC module...

Page 57: ...g torque Maximum 4 Nm traction relief minimum 40 N according to EN 61558 In connection with battery supply the unused cable screw connection must be sealed off as shown in Figure 43 page 59 6 11 2 2 5 Change of supply unit The supply unit of Pulse Transmitter Pulse Divider can be changed from mains supply to battery or vice versa as the needs of the utility company change Thus it can be an advanta...

Page 58: ... of up to 27 5 m with the same wire diameter and of the same quality as the cable from ULTRAFLOW and connect the 3 wires to the other terminal in Cable Extender Box Connect the opposite end of the extension cable to the terminal V1 or V2 in MULTICAL Connect the cables according to the following combination 10 Yellow 9 Red and 11 Blue This colour combination applies to both Cable Extender Box and M...

Page 59: ...5 XXHX XXX connected to MULTICAL 603 See also paragraph 6 11 1 Electrical connection of ULTRAFLOW and MULTICAL 6 12 2 Example of connection of Pulse Transmitter Figure 43 ULTRAFLOW 54 Type 65 5 XXHX XXX connected to Pulse Transmitter with battery supply MULTICAL 603 is connected to the Pulse Transmitter s output module Y 3 If battery supplied the right cable screw connection of Pulse Transmitter i...

Page 60: ...ential connection electric low impedance connection between the two pipes should be carried out as a main rule to protect the meter electronics against transients and potential differences If the two pipes are installed in a heat exchanger close to the flow sensors however the heat exchanger will provide the necessary electric connection Figure 45 Direct electric connection of two ULTRAFLOW flow s...

Page 61: ...LTICAL calculator terminal blocks while the welding is being performed For meters with two ULTRAFLOW flow sensors connected to the calculator both ULTRAFLOW signal cables must be disconnected Damage to meters due to welding is not comprised by Kamstrup s factory guarantee 6 13 Operational check Carry out an operational check when the complete meter flow sensor temperature sensors and calculator ha...

Page 62: ...nt changes when exposed to an electric field voltage and thereby it functions as a transmitter of ultrasound When the element is mechanically influenced it generates a corresponding electric voltage and thus functions as a receiver of ultrasound 7 2 Signal path flow calculation and flow profiles As proven by the calculations below the average flow velocity is directly proportional to the transit t...

Page 63: ...seconds Therefore the time difference is measured as a phase difference between the two 1 MHz sound signals in order to obtain the necessary accuracy Furthermore the influence of the temperature of the sound velocity of water must be taken into account In ULTRAFLOW the velocity of ultrasound 𝑐 is measured by means of a number of absolute time measurements between the two transducers As the geometr...

Page 64: ... 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 triangular sound path as illustrated in Figure 48 from two perspectives for large MULTICAL 403 ULTRAFLOW 44 and ULTRAFLOW 54 flow sensors qp 3 5 100 m3 h a b Figure 48 Triangular signal path shown...

Page 65: ...s working range from min cut off to saturation flow there is a linear connection between the flow rate and the number of pulses being emitted The diagram below shows an example of the connection between flow and pulse frequency for ULTRAFLOW qp 1 5 m h Figure 49 0 20 40 60 80 100 120 140 0 5 0 5 1 5 2 5 3 5 4 5 Pulse frequency Hz Flow m h Pulse frequencyand flow qp 1 5 m h Min cutoff Saturation fl...

Page 66: ...ted at 1 second intervals 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 there will be a tra...

Page 67: ...chnical description 5512 2464_D1_GB_09 2021 67 7 6 Pulse output of ULTRAFLOW ULTRAFLOW Type Push Pull Output impedance 10 kΩ Pulse duration 2 6 ms Duration of pause Depending on actual pulse frequency Figure 50 Block diagram for ULTRAFLOW ...

Page 68: ...lator Type Open collector Connection Can be connected as two wire or 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 UCE 2 5 V 12 mA OFF condition R 6 MΩ R 6 MΩ Table 26 Concerning meter factors and pulse durations see paragraph 4 3 4 Pulse Divider configuration CCC DD E MMM Figure 51 Bloc...

Page 69: ...r Type Open collector Connection Three wire connection is possible 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 27 Concerning meter factors and pulse durations see paragraph 4 3 4 Pulse Divider configuration CCC DD E MMM Figure 53 Block diagram for galvanically separated output module Y 3...

Page 70: ...by means of METERTOOL Because of different physical PCB layouts the connecting cables of the interfaces in ULTRAFLOW 54 type 65 5 XXHX XXX are slightly different from those of other types of ULTRAFLOW 54 The interface connector is constructed as shown in Figure 55 Note that the general functions of the connection are identical but the location of the individual functions is different a b Figure 55...

Page 71: ...connection with calibration by means of serial data e g in connection with NOWA ULTRAFLOW 54 can be monitored by an external signal when it is in verification mode see paragraph 7 9 Test mode This is done by grounding pin 4 of the internal plug 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 ...

Page 72: ...place at the same time as the master meter starts accumulating pulses or the diverter of the weight is changed Then ULTRAFLOW accumulates the water volume until pin 4 is disconnected to terminate the test Subsequently the volume accumulated during the test can be read in consideration of start and stop From the test has been completed and until the accumulated quantity of water can be read minimum...

Page 73: ...qs for ULTRAFLOW To render probable that the sensors meet the tolerance requirements EN 1434 5 specifies calibration requirements in connection with verification of sensors It is required that flow sensors are tested at the following 3 points qi 1 1 x qi 0 1 x qp 0 11 x qp and 0 9 x qp qp During test the water temperature must be 50 C 5 C for ULTRAFLOW as a heat meter For ULTRAFLOW as a cooling me...

Page 74: ..._D1_GB_09 2021 6 4 2 0 2 4 6 0 01 0 1 1 10 Tolerances Flow m3 h Flow sensor tolerances qp qi 100 1 qp 1 5 m3 h EN1434 cl 3 EN1434 cl 2 EN1434 cl 2 qs qp 0 1x qp qi Figure 58 Flow sensor tolerances specified as an example for a flow sensor with qp 1 5 m h and qp qi 100 1 ...

Page 75: ...s recommended to use galvanic separation via Pulse Transmitter or Pulse Divider qp Meter factor m h p l 0 6 300 1 5 100 2 5 60 3 5 50 6 25 10 15 15 10 25 6 40 5 60 2 5 100 1 5 Table 28 Output signal Output ULTRAFLOW Type Push Pull Output impedance 10 kΩ Pulse duration 2 6 ms Duration of pause Depending on actual pulse frequency Figure 59 Block diagram for ULTRAFLOW From start up it takes minimum 1...

Page 76: ...ng Pulse Transmitter Pulse Divider with galvanically separated output module Y 2 Type Open collector Two wire or three wire connection is possible via the built in 56 2 kΩ pull up resistor 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 UCE 2 5 V 12 mA OFF condition R 6 MΩ R 6 MΩ Table 29 Figure 60 Block diagram for galvanically sep...

Page 77: ... 25 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 6 300 20 60 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 200 600 100 1 5 100 1 10 3 20 6 5000 333 1000 Test quantities Test duration Test point Table 31 Table for ULTRAFLOW including suggested test points tes...

Page 78: ...ion with bends etc there should be a minimum distance of 10 x DN If tests are made at low flow with a bypass at right angles to the pipe it will be an advantage to mount an absorber of pressure fluctuations caused by the perpendicular inlet This can be a flexible tube on the bypass In addition it will be an advantage to mount a flow straightener before the first distance piece Flow disturbances su...

Page 79: ...ssive signal Internal pull up 680 kΩ Internal supply 3 65 V lithium battery Depending on the connecting base used there will be one or two pulse inputs outputs Figure 62 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 flow sensor M1 and terminals 69 and 11 for flow sensor M2 The leak current of...

Page 80: ...output and integral supply Flow sensors with active signal output are connected as shown in Figure 62 The signal level must be between 3 5 and 5 V Higher signal levels can be connected via a passive voltage divider e g 47 kΩ 10 kΩ at signal level 24 V Pulse outputs M1 M2 Pulse duration 4 ms Duration of pause Depending on the actual pulse frequency Two wire connection Voltage 24 V Load 1 5 kΩ Three...

Page 81: ...utton 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 65 The left push button The right push button resets both counters M1 and M2 Figure 66 The right push button 8 5 4 Use of Pulse Tester Pulse Tester can be used as follows Standing start stop of the flow sensor using the integra...

Page 82: ... flow sensors with Kamstrup software Adjusting of ULTRAFLOW flow sensors is supported from Kamstrup for authorized laboratories The adjustment is performed through Kamstrup s software LabTool Please contact the Kamstrup Product Service in Denmark service kamstrup com for additional information To prevent any attempt of fraud LabTool is exclusively distributed to workshops laboratories with nationa...

Page 83: ...broken the sensor must be reverified before being installed in a location demanding verification Figure 67 Sealing and marking of ULTRAFLOW 54 Type 65 5 XXHX XXX In the drawings sealing is divided into the following groups D Security seal or module D F label depending on type label S Laboratory marking Sealing of screws T Type label as void label or with security seal D I Installation seal wire an...

Page 84: ...5 5 XXCX XXX and 65 5 XXJX XXX In the drawings sealing is divided into the following groups D Security seal or module D F label depending on type label S Laboratory marking Sealing of screws T Type label as void label or with security seal D I Installation seal wire and seal or sealing label R Re verification marking suggested position ...

Page 85: ...gure 70 Sealing of Cable Extender Box seen from the side a and from the front b In the drawings sealing is divided into the following groups S Laboratory marking Sealing of screws T Type label as void label or with security seal S I Installation seal wire and seal or sealing label Sealing requirements may vary as a consequence of national regulations ...

Page 86: ...justment is performed through Kamstrup s software METERTOOL HCW 6699 724 or LabTool Please contact the Kamstrup Product Service in Denmark service kamstrup com for additional information To program Pulse Divider the software METERTOOL HCW 6699 724 is used For more information see the Technical description of METERTOOL HCW 5512 2097_GB To adjust ULTRAFLOW 54 see 8 6 Adjustment of ULTRAFLOW flow sen...

Page 87: ...AFLOW 34 and ULTRAFLOW 54 qp 150 m3 h MID certification according to Module D DK 0200 MID D 001 Please contact Kamstrup A S for further details on type approval and verification 10 2 CE marking In addition ULTRAFLOW is marked according to the following directives EMC directive 2014 30 EU LV directive 2014 35 EU when connected to mains supplied Pulse Transmitter or Pulse Divider PE directive 2014 6...

Page 88: ...ection Check flow sensor connection Check with PULSE TESTER if necessary Flow sensor is inverted Check flow sensor direction Air in sensor cavitation Check installation angle Check if there is air in the system or cavitation from valves and pumps If possible try to increase the static pressure Flow sensor error Replace the flow sensor send meter for repair Erroneous accumulation of m Erroneous pro...

Page 89: ...nclose a copy of this page in order to inform the recipient of the contents Lithium cells and meters including lithium cells must be packed marked and forwarded as dangerous goods see also Kamstrup document 5510 408 Lithium batteries Handling and disposal Batteries must NOT be subjected to mechanical shock and the cables must NOT be able to be short circuited during transport Meter part Material R...

Page 90: ... Data sheet ULTRAFLOW 54 DN15 125 ULTRAFLOW 44 DN15 125 ULTRAFLOW 54 DN150 300 5810 1546 5810 1753 5810 834 5810 1547 5810 1751 5810 835 5810 1548 5810 1754 5810 836 5810 1549 5810 837 Installation guide MULTICAL 603 ULTRAFLOW MULTICAL 803 ULTRAFLOW ULTRAFLOW 54 DN150 300 Pulse Transmitter Pulse Divider Cable Extender Box 5512 2231 5512 2408 5512 886 5512 1387 5512 2008 5512 2231 5512 2408 5512 88...

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