When it comes to accurate, reliable, and non-invasive liquid flow measurement, ultrasonic flow meters have become the go-to solution across countless industries. Whether you’re managing chemical processing, water treatment, HVAC systems, or industrial utilities, selecting the right flow meter can dramatically impact efficiency, safety, and cost. In this blog, we explore one of the most versatile and high-performing options available today: the UF500 Clamp-On Ultrasonic Flow Meter from Icon Process Controls.
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We’ll walk you through the principles of ultrasonic flow measurement, explaining the difference between transit-time and Doppler technology and how clamp-on designs work without cutting into your pipe system. You’ll discover why ultrasonic meters are ideal for applications where clean or dirty liquids must be monitored without introducing potential leak paths or flow disruption, and how they provide accurate measurements of liquid velocity without the need for moving parts.
Next, we’ll break down the technical features of the UF500, including its accuracy, repeatability, installation options, supported pipe sizes, and output signals. We’ll also compare ultrasonic flow meters vs. other technologies like magnetic and turbine meters, so you can confidently evaluate which fits your needs best.
You’ll also find real-world application examples in industries like chemical, water/wastewater, food & beverage, and data centers—with insight into how the UF500 is helping plant operators reduce downtime, improve safety, and streamline operations. We’ll answer common questions about ultrasonic technology, share best practices for installation, and highlight important certifications that make this flow meter suitable for demanding industrial environments.
By the end of this post, you’ll understand why the UF500 Clamp-On Ultrasonic Flow Meter is a top-tier choice for both new installations and retrofit projects. Ready to explore the UF500’s specifications, certifications, and ordering options? Visit the UF500 product page for full details and purchasing.
An ultrasonic flow meter is a non-invasive device used to measure the flow rate of liquid flowing inside a closed pipe using high-frequency sound waves. Unlike mechanical or intrusive meters, ultrasonic meters rely on acoustic signals rather than moving parts, making them ideal for applications requiring low maintenance, high accuracy, and chemical compatibility.
Ultrasonic flow meters work by transmitting sound waves through the pipe and the liquid inside. Two transducers—mounted either inside the pipe or externally in a clamp-on configuration—act as both transmitters and receivers. These transducers send ultrasonic pulses upstream and downstream. The difference in travel time between the two directions is used to calculate the velocity of the flowing liquid. With known pipe dimensions and liquid properties, the meter determines the volume flow rate.
There are two primary ultrasonic measurement methods:
The clamp-on configuration, used in the UF500 from Icon Process Controls, offers several unique advantages of clamp-on flowmeters:
Ultrasonic flow meters are commonly used in industries such as chemical processing, water treatment, food and beverage, power generation, and HVAC. Their non-intrusive operation makes them especially valuable where process fluids are corrosive, hazardous, or require strict hygiene standards.
Whether you’re working with clean water, greywater, slurries, or aggressive chemicals, the UF500 Clamp-On Ultrasonic Flow Meter delivers accurate, real-time flow data with zero interruption to your system.
Want to skip ahead and learn more about the UF500’s full capabilities, certifications, and pricing? Visit the UF500 product page for detailed specifications and purchasing options.
Ultrasonic flow meters rely on two core technologies: Transit Time and Doppler. While both use sound waves to measure flow, their operating principles and ideal applications are quite different. Understanding the distinction is key to selecting the right meter for your system.
The UF500 Clamp-On Ultrasonic Flow Meter from Icon Process Controls uses transit time technology, which is the gold standard for measuring clean, acoustically conductive liquids such as water, chemicals, or oils.
How it works: Transit time meters have two transducers that alternately send and receive ultrasonic signals both upstream and downstream. When liquid is flowing, sound waves traveling with the flow move faster than those traveling against it. The meter calculates the difference in travel time to determine the flow velocity. Because the time shift is directly proportional to the flow rate, the result is a highly accurate and repeatable measurement.
Key advantages of Transit Time:
Doppler ultrasonic meters are designed for fluids that contain entrained gases, suspended solids, or bubbles—such as wastewater, sludge, or slurries.
These meters transmit a continuous ultrasonic signal into the fluid. That signal reflects off particles or bubbles, and the frequency shift between the transmitted and received signal (known as the Doppler Effect) is used to calculate flow velocity.
If you’re working with clean or moderately clean liquids, transit time technology is the superior choice. The UF500 Clamp-On Ultrasonic Flow Meter delivers:
Its transit time design ensures performance across a wide range of industries—from chemical and water treatment to HVAC and food processing—where precision and reliability are essential.
Ready to see if the UF500 fits your application? Visit the UF500 product page for detailed specs, documentation, and ordering options.
The UF500 Clamp-On Ultrasonic Flow Meter from Icon Process Controls delivers accurate, non-invasive liquid flow measurement using advanced transit time technology. It’s engineered for simplicity, speed, and performance—whether used for permanent monitoring or temporary verification.
The UF500 installs outside the pipe, eliminating the need to cut or modify piping. Two precision transducers are clamped onto the exterior of the pipe using a coupling gel to ensure proper acoustic contact. This approach allows for rapid installation with no shutdown, no pressure loss, and no contamination risk.
Once installed, the UF500 works by sending ultrasonic signals between the two transducers—one in the upstream direction and one in the downstream direction.
Here’s how the process works:
The UF500’s transducers are designed to auto-calibrate, adapting to different pipe diameters and wall materials. Built-in diagnostics continuously verify signal strength and alignment to ensure reliable long-term performance—even in challenging environments.
Whether used for water, chemicals, or process fluids, the UF500 delivers dependable data without interfering with your system. Want to explore the technical specs, outputs, and pipe compatibility of the UF500? Visit the UF500 product page for detailed information and purchasing options.
The UF500 Clamp-On Ultrasonic Flow Meter is trusted across a wide range of industries that demand accuracy, reliability, and minimal intrusion into their process systems. Its non-invasive design, fast installation, and high precision make it ideal for everything from utility water monitoring to aggressive chemical applications.
The UF500 is widely used to monitor flow in:
Its clamp-on design ensures there’s no risk of contamination, while its ability to measure without pressure loss makes it perfect for regulated water systems.
In chemical plants, fluid compatibility and safety are critical. The UF500 provides:
Operators benefit from leak-free installation, and there’s no contact with the chemical, protecting both the sensor and the process.
The UF500 supports energy efficiency initiatives by tracking:
It enables thermal energy monitoring and system diagnostics without disrupting the HVAC loop.
Sanitary environments benefit from:
The UF500’s non-intrusive setup meets stringent hygiene standards without compromising production.
Power plants rely on the UF500 for:
Its rugged design handles fluctuating temperatures and high system pressures—common in these demanding environments. Additionally, the UF500 can determine the molecular weight and mass flow rate of gases, which is crucial for providing accurate flow data in various industrial applications.
Applications include:
Monitoring water supply to processing equipment
Flow balancing in industrial distribution systems
Pump performance verification
Even in high-vibration or remote environments, the UF500 remains reliable and maintenance-free.
Why it works across so many industries:
Installs without downtime
No risk of contamination or corrosion
Accurate with clean or moderately clean fluids
Works with various pipe materials and sizes
Integrates easily into existing systems
Want to explore whether the UF500 is a fit for your specific industry? Visit the UF500 product page or speak with an Icon representative for application-specific support.
One of the standout features of the UF500 Clamp-On Ultrasonic Flow Meter is how easy it is to install—without cutting pipes, shutting down systems, or altering process flow. However, to ensure the most accurate and reliable results, proper installation is critical. This section outlines best practices that help maximize performance from day one.
Straight Pipe Lengths Matter
Select a location with at least 10 pipe diameters of straight run upstream and 5 pipe diameters downstream of the transducers. This minimizes flow disturbances from elbows, valves, or pumps.
Avoid Pipe Irregularities
Stay clear of weld seams, pipe joints, or heavily corroded areas that could interfere with ultrasonic signals.
Full Pipe Condition Required
Make sure the pipe is completely full of liquid at the measurement point. Partial fill conditions will compromise accuracy.
Clean and Smooth
Remove rust, paint, or debris using sandpaper or a wire brush. A clean surface ensures solid coupling between the transducers and the pipe wall.
Apply Coupling Gel
Use the recommended ultrasonic gel to eliminate air gaps between the transducers and pipe. Air is a poor conductor of sound—this step is critical for signal strength.
Proper Alignment
Install the transducers exactly as shown in the UF500 installation guide—typically in a V-path configuration, where signals reflect once off the inside wall before reaching the opposite transducer.
Correct Spacing
Use the built-in spacing guide or measurement scale to position the transducers at the exact distance specified for your pipe diameter and material.
Consistent Pressure
Secure the clamps so that both transducers maintain even, stable contact with the pipe throughout operation.
Input Pipe Data
Enter the correct pipe material, wall thickness, and internal diameter into the UF500’s setup menu. This allows the system to calculate flow based on acoustic velocity and transit time.
Verify Signal Strength
During setup, check the UF500’s real-time signal quality indicators. Aim for the highest possible signal-to-noise ratio (SNR) for stable readings.
Test and Confirm
Run a system verification or compare readings against a known reference point. This helps confirm proper installation before full operation.
Protect from Vibration
While the UF500 is built tough, excessive vibration can reduce accuracy. Mount transducers on stable pipe sections when possible.
Temperature Awareness
Make sure ambient and pipe surface temperatures are within the specified range for the transducers and electronics enclosure.
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Cable Management
Secure cables to prevent stress on connectors and avoid electromagnetic interference near power sources or high-voltage equipment.
Bonus Tip: For temporary flow checks or audits, the UF500 can be installed, commissioned, and removed within minutes—making it perfect for spot measurements and diagnostics in the field.
Need help with your UF500 setup? Our team offers installation support, guides, and training. Visit the UF500 product page for manuals, videos, and more.
Product Page | Data Sheet | Manual
The UltraFlo 500 offers high accuracy and reliability for small to medium pipes, making it suitable for municipal water systems.
The Truflo® UF500 series Clamp-On Ultrasonic Flow Meter Sensor redefines simplicity and efficiency in liquid flow measurement. These cutting-edge meters boast a remarkable feature set that eliminates the need for any pipe modification, ensuring a hassle-free installation process. Emphasizing user convenience, these flow meters enable fast setup, remove flow restrictions, and offer unparalleled ease of installation.
A standout trait of Truflo® UF500 Ultrasonic Flow Meter Sensor is its remarkable adaptability to diverse scenarios, showcasing exceptional versatility. The flow meters are designed with a wide dynamic flow range, spanning from 0.1 to 5 m/s (0.3 to 15 ft/s). This versatility makes them suitable for a diverse range of applications, including low-pressure systems. The flow meter’s ultrasonic transducer sends 50+ pulses/sec, ensuring accurate measurement of liquid flow rates in full pipes.
The rugged construction of these flow meter sensors is another testament to their quality and reliability. Available in Teflon® Epoxy Coated Aluminum body, they strike a perfect balance between being lightweight and possessing excellent external corrosion resistance. This ensures longevity and durability, contributing to an extended lifecycle with virtually no maintenance requirements.
What truly sets the Truflo® UF500 series apart is its efficiency in installation. Install these ultrasonic flow meter sensors seamlessly in under two minutes without altering existing piping configurations. This not only saves valuable time but also enhances the overall user experience.
Truflo® UF500 Ultrasonic Flow Meter Sensors merge advanced technology, sturdy construction, and unparalleled ease of use for optimal performance. Ideal for low-pressure systems or industrial use, these flow meters provide exceptional value, ensuring accurate and hassle-free liquid flow measurement.
The UF500 is designed for clean or mildly contaminated liquids that are acoustically conductive. It performs best with water, oils, chemicals, and process fluids without excessive air bubbles or solids.
The UF500 is compatible with most metal and plastic pipes, including stainless steel, carbon steel, PVC, CPVC, and HDPE. Avoid use on lined pipes or those with air gaps or heavy scaling, as this can interfere with signal transmission.
The UF500 delivers typical accuracy of ±1% of reading, provided it is installed correctly with proper straight-run lengths and pipe data.
No. The UF500 uses a clamp-on, non-invasive design, so there’s no cutting, welding, or system shutdown required during installation.
Yes. The UF500 is ideal for both permanent and temporary installations, making it a great tool for flow verification, troubleshooting, or system commissioning.
The UF500 supports standard industrial outputs, including:
4–20mA analog
Pulse/frequency
RS485 Modbus
This allows seamless integration into SCADA, PLC, or BMS systems.
It works with a wide range of pipe sizes, from ½” – 10″.
No. The UF500 uses transit time technology, which is optimized for clean liquids. For liquids with heavy solids or air bubbles, a Doppler-style meter may be more appropriate.
Yes. The UF500 features a durable, weather-resistant enclosure and is built to withstand harsh industrial settings. It is also suitable for installation in outdoor, wet, or corrosive environments.
Minimal tools are required—just a measuring tape, mounting brackets, and acoustic coupling gel. No formal training is needed, but Icon offers detailed manuals, installation videos, and technical support to assist you.
Still have questions? Contact Icon Process Controls or visit the UF500 product page to access resources, datasheets, and expert assistance.
The UF500 from Icon Process Controls is engineered for precision, flexibility, and rugged performance in industrial flow monitoring. Below is a breakdown of its key specifications:
Magnetic mounting brackets
Remote display and data logging kits
Pipe wrap insulation kits for outdoor use
Calibration certificate (NIST-traceable)
The UF500 delivers dependable, high-resolution flow measurement for professionals who require fast setup, low maintenance, and long-term performance.
Need a datasheet or want to request a quote? Visit the UF500 product page for documentation, accessory options, and order inquiries.
Choosing the right flow meter is critical for ensuring operational efficiency, system reliability, and process control. The UF500 Clamp-On Ultrasonic Flow Meter from Icon Process Controls delivers a winning combination of high accuracy, flexible installation, and zero process disruption.
Built on reliable transit time technology, the UF500 is ideal for clean liquid applications in industries such as water treatment, chemical processing, HVAC, power generation, and food and beverage. Its clamp-on design allows for quick installation without cutting pipes, halting production, or exposing technicians to hazardous fluids.
With advanced diagnostics, a broad range of pipe compatibility, and multiple output options—including 4–20mA, pulse, and Modbus—the UF500 integrates seamlessly into new and existing systems. Whether you’re installing it permanently or using it for spot checks and system verification, this meter delivers dependable performance every time.
Backed by Icon’s engineering support, industry expertise, and commitment to quality manufacturing, the UF500 is a future-ready solution for today’s flow monitoring challenges.
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Visit the UF500 product page for full specifications, manuals, and purchasing options—or contact us today to speak with a technical expert.
It is important to know the thickness of the plates for the manufacture of aluminium plates. The non-contact profile measuring system measures the profile of the plates using a capacitive sensor. At the same time, the width of the plate is determined during the measurement. The reversing rolling stand and the following roller stands can be better adjusted using the data obtained. The system is integrated in the existing roller track. Installed directly before the cropping shear where the plate is stationary for the cut, the production process is not impaired.
In the production of battery separators the in-line monitoring of the profile thickness is an important measurement task within the framework of quality assurance. A measurement system with high spatial resolution and a high sampling rate is needed for the determination of the profile structure. This task represents one of the classical fields of application for the laser-based triangulation sensor in the Series ILD . The battery separator is manufactured in an extrusion process. For the thickness measurement the optical sensors are mounted on a welded C-frame. This traverses on air bearings without making physical contact on a hard rock base. In this way the vibration of the top belt is minimized and a precise measurement facilitated.
It is often the case for sheet machining that sheets must be transported individually in machines. Therefore, it is essential that only one sheet gets into the machine. If two sheets are on top of each other, the process will be halted. This task is resolved in a simple way using thickness measurement. If the current measured value is different from the thickness of one sheet, an error is detected. The measurement is independent of the absolute position of the sheet in the measuring gap. Depending on the requirement, laser, optical, capacitive or eddy current sensors can be used for this.
optoNCDT ILR-100 laser distance sensors from Micro-Epsilon measure the coils based on the phase comparison method. For this measurement task, a sensor is mounted at a distance of 0.2 to 10 m facing the radius of the coil. It continuously measures the distance to the coil. As the diameter of the steel strip coil is constantly reduced by the unwinding process, the distance between the coil and the sensor consequently increases. The sensor reliably detects this change in distance and transmits it as a measurement value via the RS422 serial interface to the production process control system. An early warning message can now be issued via the control system, even before the material has been completely unwound.
When producing potato crisps, factors such as consistency, quality and taste depend to a significant degree on the thickness of the potato slices used. Depending on the process parameters and the condition of the tools used, the thickness of the cut slices changes slowly but steadily during the production time. This is why it is important to continuously monitor the thickness during production by using the scanCONTROL -50BL sensor. The sensor projects a laser line onto a conveyor belt, which continuously guides sample slices along it.
A special measuring system has been developed for the quality control of display glass. The glass pane is placed on a measuring table by a robot. A measuring arm with several confocal sensors traverses the glass pane there. If any thickness discrepancies are found, the pane is marked as NOK and rejected. The scanCONTROL laser scanner simultaneously circumnavigates the edges and checks these for defects and dimensions. After the check has been completed successfully, the pane is lifted back into the production process and the next measurement is started.
The thickness of manufactured films is frequently a decisive quality criteria in production. Specially developed thickness measurement systems are used as early as possible in the production for the check of the thickness. Dual sensors consisting of two sensors with different measuring principles measure the thickness across the complete width of the film from one side without contact. A thickness profile of the flat film is thus produced using which the production systems can be regulated extremely precisely. The dual sensors are compiled differently depending on the type of film.
A consistent yarn thickness is a prerequisite in the textile industry for high quality products. Therefore, the naturally occurring yarn thickness fluctuations must be eliminated. The yarn is drawn to a constant thickness using a stretching tool. The measured data for controlling the stretching tool are provided by an eddy current sensor which indirectly measures the thickness. The thickness is transmitted to the eddy current sensor using sensing rollers. After the stretching, the result of the processing operation is also checked by an eddy current sensor.
A special measuring system has been developed for the quality control of glass. The glass pane is placed on a measuring table by a robot. A measuring arm with several confocal sensors traverses the glass pane there. If any thickness discrepancies are found, the pane is marked as NOK and rejected. The scanCONTROL laser scanner simultaneously circumnavigates the edges and checks these for defects and dimensions. After the check has been completed successfully, the pane is lifted back into the production process and the next measurement is started.
The specification of the thickness of glass panes is an optimization process between a required mechanical strength and efficient use of materials. In the manufacturing process the glass thickness is measured and the conformance to prescribed tolerances is monitored. The measurement is carried out with displacement sensors working on the eddy-current principle. Here, the sensor hovers over the glass surface and measures through the glass to a metal plate situated behind it. The values can be read off directly on the device; an analog output voltage facilitates further evaluation.
Inner liners are used in every tyre to prevent the air from escaping. As the inner liner is a characteristic relevant to safety of every tyre, there are high requirements for compliance with the target data. An important criterion is the layer thickness. The system for measuring the thickness of inner liners operates without contact and wear-free. The inner liner is routed through the measuring system immediately after the calender roller. A measuring head traverses above the surface. An eddy current sensor measures the distance to the reference roller while an optical micrometer measures the distance to the rubber surface. The system can be integrated in the heating circuit of the calender roller for better temperature compensation.
In the manufacturing of plastic panels, thickness profile measurements must be carried out due to the necessary quality assurance. For this purpose two laseroptical displacement sensors are mounted on a traversing device, one underneath and one above the panel which passes along a defined path. The preprogrammed measuring points are sampled consecutively. Irrespective of the exact height position of the panels, the accurate material thickness is obtained by simple coupling of the synchronously measured distance values from both sensors. The output of the desired measurement log is realized with the aid of a PC system in the fully automatic sequence of the profile measurement table.
In order to protect PCBs from environmental influences such as humidity, they are coated with a protective clear varnish. This ensures error-free operation. The automotive industry in particular demands a minimum thickness for this protective coating.
Up to now, it was not possible to perform a measurement without destroying the target. Confocal sensors from Micro-Epsilon solve this measurement task without making contact with the target and therefore in a non-destructive manner. They providethe thickness values in real time.
confocalDT IFS confocal sensors with a measuring range of 1 mm are used. These sensors are characterized by their extremely small measuring spot size of only 8 µm and excellent precision for measuring thin layers.
When optical data carriers are produced, the data are initially transferred to a master. Depending on the number of copies, different dies made of nickel are produced from the master by galvanisation. These dies must show a thickness of 297 µm ± 3 µm for faultless production. It is checked several times during the galvanisation that this dimension is complied with. The company ISEDD GmbH from Bielefeld has developed a measuring device for this which enables fast and accurate inspections of the dies. Capacitive sensors from Micro-Epsilon are used for the thickness measurement.
Thickness measurement using displacement sensors is a wide application area. Basically there are distinctions between non-destructive/destructive, non-contact/with contact and one-side/two-sided thickness measurement. The Micro-Epsilon measuring techniques for thickness measurement are all emission-free whereby no emissions regulations of any kind have to be complied with.
Thickness measurements must be performed both with contacting as well as with non-contact sensors whereby non-contact measuring techniques show advantages as regards accuracy and measuring speed.
There is also a distinction between one-sided and two-sided thickness measurement. Two-sided thickness measurements are carried out with at least one pair of sensors which are installed together on one axis. This pair of sensors measures the target synchronously. The difference between the measurement results (C-A-B) produces the thickness of the measuring object.
One-sided thickness measurements must only be performed with non-contact sensors. In doing so, the target is only measured with one sensor and either only a part of the target thickness (e.g. layer thickness) or the complete measuring object thickness is measured.
Thickness measurements are mainly used in process control and quality assurance, e.g. for the control of extrusion systems or 100% checking of tube diameters.
Precise thickness specifications are assigned for the manufacture of rubber film which is rolled using calender rollers. Random-sample manual measurements, as previously carried out, are no longer sufficient for today’s demands on quality assurance. Consequently, a system with three fixed tracks has been adapted for in-line inspection of the thickness. For each track an eddy current sensor of Type U6 is built into a jockey follower system which measures against an stainless steel roller. Controllers of the range multiNCDT series 100 are employed for the evaluation electronics. The stainless steel roller represents the reference system for the measurement.
The oil film thickness for combustion engines describes the gap and thus the quantity of oil between piston and cylinder wall. Thus it is sometimes a determining factor for smooth operation and durability. As the oil film can only be integrated and really measured in the firing condition, it is extremely difficult to manufacture sensors for these environmental conditions and then also find space for them. Specially miniaturised eddy current sensors from Micro-Epsilon are capable for this. The smallest with only 2.4 mm external diameter is integrated directly into the cylinder wall and ground to its shape. There, it measures the distance from sensor to piston or the space available for the engine oil for lubrication in every stroke.
To prevent damage, laser-based optical displacement sensors are employed in front of the inlet for profiled sheets in presses to enable the detection of double sheets. The sensors are mounted opposite one another, above and below the passing sheets. Irrespective of the actual position of the sheets, the material thickness is obtained by
simple coupling of the distance signals from both sensors. For adjustment a master sheet for each type of sheet is inserted into the measuring gap and the resulting signal set to zero. The zero value is monitored within a tolerance. The sensors are operated in special protective housings because of the harsh ambient.
Layer thickness measurement belongs to the group of one-sided, non-contact thickness measurement. Basically, only the layer thickness of electrical insulators can be measured for opaque objects. An eddy current sensor penetrates the insulating layer without damage and measures the distance to a layer underneath it. At the same time, a second sensor, a laser triangulator measures the insulating layer. The layer thickness is obtained by offsetting both signals. This method of measuring with two sensors using different principles is called the dual sensor technique by Micro-Epsilon.
A second possibility is the layer thickness measurement of transparent materials using confocal measurement technology. The emitted white light penetrates the measuring object and provides a peak in the signal graph at every material transition. For example, the film thickness between two glass panes can be easily measured in this way.
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