Kamstrup MAXICAL III User manual

MAXICAL®III5511-229 GB/98.06/Rev. B1

MAXICAL®III

User’s Manual

5511-229/Rev. B1

ENGLISH

MAXICAL®III 5511-229 GB/98.06/Rev. B1

MAXICAL®III5511-229 GB/98.06/Rev. B1

1. Table of Contents

1. Table of Contents 3

2. Design and Areas of Application 5

2.1. Display 5

2.2. Calculation 7

2.3. Logging Peak Values 7

2.4. Measuring Temperature 7

2.5. Permanent Memory 8

2.6. Information Codes 9

2.7. Optical data acquisition 9

2.8. Voltage Supply and Back-up 10

2.9. Tariff Functions 10

2.10. Plug-in Modules 10

3. Panel Installation 11

4. Electrical Connection 11

4.1 General Installation Requirements 12

4.2 Voltage supply (27-28) 12

4.3 Temperature sensors (1-8) 13

4.3.1 Average Measurement 14

4.4 Flow Meter Input (9-11) 16

4.5 Flow Meter Input (75-76) 18

4.5.1 Flow Meter Connection 18

4.5.2 Flow meters with analogue output 20

4.6 Selecting flow meter inputs and pulse outputs 20

4.7 Pulse and Data Outputs (16-19) (62-64) 22

4.8 Analogue Outputs (80-87) 23

4.9 Relay Outputs (88-93) 24

5. Compiling the Type Number 25

6. Prog. Config and Data Summary 26

6.1 CCC-Table for MAXICAL®III 27

6.2 CCC-Table for MAXICAL®III 28

6.3 CCC-Table for MAXICAL®III 29

6.4 CCC-Table for MAXICAL®III 29

6.4 >DD< Configuration of Display Values 30

6.5 >E< Configuring Multi-Tariff 31

6.6 >H< Configuring Alarm Output 31

6.7 >J< Configuring analogue outputs 31

6.8 >K< Configuration of pulse dividers 31

MAXICAL®III 5511-229 GB/98.06/Rev. B1

7. Tariff Functions 32

8. Programming Tariff and Alarm Limits 36

9. Data Setup 39

10. Data Communication 40

10.1 Data Strings and Functions 41

10.2 Data Strings 41

10.3 Data Acquisition via Connection Terminals 43

11. Programming (Windows) software 66-99-210 44

11.1 Computer and Printer Requirements 44

11.2 Installing the Software 45

11.3 Connecting MAXICAL®III to the Computer 45

11.4 Reading MAXICAL®III’s Set-up 46

11.5 Partial Programming 46

11.6 Total Programming 46

11.7 Entering Data 46

11.8 Screen Menu 47

12. Sealing 48

13. Verification 49

13.1 Energy Calculation 49

13.2 SQuick-figure 51

13.3 Nominal quick-figure 53

14. Service 54

14.1 Trouble Shooting 54

14.2 Replacing Back-up Cell 55

14.3 Inserting Analogue and Relay Module 56

14.4 Reseting MAXICAL®III 56

15. Disposing of Energy Meters 57

MAXICAL®III5511-229 GB/98.06/Rev. B1

2. Design and Areas of Application

MAXICAL®III is designed for measuring, calculating and

registering energy consumption in large heat installations with

water as the heat transferring agent.

Typical applications include main heat metering at CHP

(cogeneration heat and power) suppliers, heat metering through

transmission nets or exchange stations.

In addition to energy metering, MAXICAL®III has various other

functions including; display of prevailing and peak values, relay,

pulse and analogue outputs, tariff registering, and data com-

munication. All of which make it the most obvious choice for

industrial management and regulation applications.

Thermal energy is calculated on the basis of the differential

temperature measured across the flow and return pipes and the

volume of water. The value is automatically corrected for density

and enthalpy.

4-wire technique is used for measuring and adjusting the

temperature, ensuring optimal accuracy and reliability.

The flow meter input comprises galvanically connected stages,

which can supply electronic pick-ups. Galvanically isolated stages

are used for flow meters with active outputs up to 5 or 10 kHz.

All operating parameters can be programmed by means of the

optical eye on the front of the meter and a computer equipped with

a Windows software package which facilitates quick and simple

startup.

2.1. Display

MAXICAL®III is equipped with a liquid crystal display with 8

numerical digits plus 3 alphanumerical characters. 7 digits indi-

cate the current and accumulated values. The last three alphanu-

merical characters indicate the relevant unit of measurement or

symbol.

Once the integrator has been connected to the mains, a discreet

background lighting will appear in the display, ensuring that

readings are clearly visible - even in areas with poor lighting.

MAXICAL®III 5511-229 GB/98.06/Rev. B1

Press the right or left key, as appropriate, to move from one

displayed value to another. Note that only values selected during

configuration can be displayed [DD].

1) The peak value displayed is the highest average of 1...120

minutes actual values recorded over the last 24 hour period.

The average period can be programmed. Depending on the

programming, either peak power or peak flow will be dis-

played.

2) The tariff or alarm type selected will be indicated by an

arrow at tF, tR, Dt, power or flow as appropriate.

N.B.:

The display will revert automatically to showing accumulated

energy consumption approx. 8 minutes after the key has been

depressed.

MAXICAL®III5511-229 GB/98.06/Rev. B1

2.2. Calculation

In MAXICAL®III, thermal energy is calculated after a given

amount of water has been recorded. The typical integration

interval is 10 litres with a Qn 1.5 m³/h flow meter and 1 m³, if a

Qn 120 m³/h to Qn 1400 m³/h flow meter is connected. The

thermal energy is derived by multiplying the volume of water by

the actual cooling and the relevant correction factor - derived from

Dr. Stuck’s k-factor table. Any remainder which cannot be dis-

played due to the resolution of the display will be saved and added

to the next integration. Pulse separation and the number of pulses

per litre, which ensure that the flow meter and the integrator tally,

is determined by the CCC program.

The current water flow and thermal power are calculated at 5

(CCC³ 100) or 30 (CCC<100) second intervals, depending on the

configuration selected, based on the no. of pulses emitted by the

flow meter during the given period of time. MAXICAL®III is

configured to an average flow and peak value, if a flow meter with

few volume pulses is connected, e.g. a mechancial meter with a

reed switch output (CCC<100).

2.3. Logging PeakValues

The highest thermal power - or the highest water flow - in each 24

hour period is stored in the memory, together with the date and

time for the measurement. The peak value for this period is the

highest average, determined over a period between 1 and 120

minutes as required, occuring between 2400 hours and 2400 hours

the next day.

The value is stored in the permanent EEPROM memory and - as

with all other data - covers the last 31 days.

2.4. MeasuringTemperature

MAXICAL®III can measure flow and return temperatures be-

tween 0.01°C and 182.00°C. Temperatures measured which

exceed these limits will be registered as sensor faults after 10-20

minutes - please refer to section 2.6. Information Codes.

MAXICAL®III 5511-229 GB/98.06/Rev. B1

The differential temperature is accurately calculated throughout

the whole measuring range - even with cooling down to 0.01°C.

Accuracy is, however, slightly affected below Dt=3°C. If a

negative differential temperature is registered, this will be per-

ceived as 0.00°C. Energy registering will then stop.

MAXICAL®III measures temperature every 5 seconds, updating

the display and analogue outputs with the new reading. Prior to

each temperature measurement, the A/D converters zero point and

span is adjusted automatically, based on the internal precision

resistors. Flow and return temperatures are then measured twice,

the second measurement being taken a number of 10 msec. after

the first to ensure optimal damping of 50 Hz mains interference.

Depending on the type of meter selected, a set of either Pt100 or

Pt500 sensors must be connected (according to IEC 751). The

sensors must always be matched and 4-wire screened cable used to

connect the sensors to MAXICAL®III, to ensure optimal preci-

sion. The cable screen must be connected at the MAXCIAL III

and not at the sensor housing.

In stand-by mode - i.e. when the supply is disconnected - tempera-

tures will be displayed without 4-wire compensation. Once the

supply has been connected, 4-wire compensation will eliminate

99% of the measuring error arising as a result of the length of the

cable.

When MAXICAL®III is connected to a pipe with a large diam-

eter, average measuring must be established to reduce the influ-

ence of temperature fluctuation in the water. Average measuring

can be built up with 5 Pt100 sensors connected in series to a Pt500

input or with 4-sensors connected in parallel/series (Please refer to

chapter 4.3.1).

2.5. Permanent Memory

MAXICAL®III has an electronic, erasable programmable, read-

only memory (EEPROM) which stores data independent of the

power supply. All accummulated values are stored in the memory

at hourly intervals. At midnight each night, the following data will

be stored in a 31-day datalogger:

Date, Energy, Water, TA2, TA3, Alarm

Peak time and Peak power/flow.

MAXICAL®III5511-229 GB/98.06/Rev. B1

2.6. Information Codes

During normal operation the information code will be 000. If one

or more of the following faults occurs, the letter “E” will be shown

in the current display, and the Infocode relay will be deenergized.

The information codes, which will be added together if more than

one is activated, can be displayed as required.

+2 Check the flow meter connection

Flow pulses have not been registered for a period of 48

hours, whilst Dt has been larger than 20°C.

+4 Check the temperature sensor in the return pipe

The return temperature has been less than 0°C or more

than 182°C for 10...20 minutes.

+8 Check the temperature sensor in the flow pipe

The flow temperature has been less than 0°C or more

than 182°C for 10...20 minutes.

+256 Check the flow meter code

The meter has registered an excess of water pulses,

corresponding to more than 1 integration per second.

Reseting information codes is described in chapter 14.4. If one or

more info codes are deselected under section 6.4 >DD<, these

codes will not deactivate the alarm relay, nor will “E” appear in

the display.

2.7. Optical data acquisition

An optical, infrared receiver/transmitter is situated in the bottom

left hand corner of MAXICAL®III’s front panel which communi-

cates with serial data in accordance with IEC 1107/EN61107.

MAXICAL®III 5511-229 GB/98.06/Rev. B1

A read-out head, type 66-99-102, with a 9-pole D-sub plug is used

for data acquistion and when configuring the meter from a compu-

ter.

Data acquisition is also possible with Kamstrup Energi’s hand-

held terminal, MULTITERM III. Kamstrup Energi’s software

package for MAXICAL®III, type 66-99-210, can be used to

configure via a standard computer.

2.8. Voltage Supply and Back-up

MAXICAL®III operates on 230 V AC, supplying the integrator

and the analogue module via two internal double isolated trans-

formers. Furthermore, an integrated 1 Ah lithium cell ensures that

the internal clock (with date) is continuously supplied, should the

power be cut off. In the even of a power cut, there is no back-up

on the frequency input (terminals 75-76). However there is a 5

minute back-up on the pulse input (terminals 10-11).

2.9. Tariff Functions

MAXICAL®III features several tariff functions. Regardless of the

tariff type, the total thermal energy will always be accumulated in

the primary register. Furthermore, tariff registers TA2 and TA3

accumulate the portion of the energy consumed in connection with

a specific condition. This condition, together with the relevant

limit values (TL2 and TL3), can be conveniently configured using

a Windows software package, type no. 66-99-210, which can

easily be installed on your computer.

2.10. Plug-in Modules

The facilities offered by MAXICAL®III can be extended by

means of plug-in modules. There is space for two modules, which

can be installed and configured on site.

The uppermost space can be used for 4 active analogue outputs

for flow, power, flow temperatures and return/differential tempera-

ture. Furthermore, the module has two relay outputs; a program-

mable limit switch and an information code switch.

The bottom space is designed for M-Bus, telephone modem or

EcheLon modules.

Table of contents

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