Kamstrup MULTICAL 403 Installation and operating instructions

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Installation & Maintenance Instructions

MULTICAL® 403

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Installation and user’s guide

MULTICAL® 403

Kamstrup A/S · Industrivej 28, Stilling · DK-8660 Skanderborg · T: +45 89 93 10 00 · info@kamstrup.com · kamstrup.com

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Reading

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ABLE Instruments & Controls Ltd

Cutbush Park, Danehill, Lower Earley,

Reading, Berkshire, RG6 4UT. UK.

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2 Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

Information

Permissible operating conditions / measuring ranges

Approved heat meter in accordance with MID and EN1434:

Temperature Range q: 2 °C…180 °C DΘ: 3 K…178 K

Flow sensor (temperature of medium) qq: 2 °C…130 °C

Approved cooling meter in accordance with DK-BEK 1178 and EN1434:

Temperature Range q: 2 °C…180 °C DΘ: 3 K…178 K

Flow sensor (temperature of medium) qq: 2 °C…130 °C

MID designation

Mechanical environment

Class M1 and M2

Electromagnetic environment

Class E1 (housing/light industry). The meter’s control cables must be drawn at min. 25 cm

distance from other installations.

Climatic environment

Non-condensing, closed location (installation indoors), ambient temperature 5…55 °C.

Maintenance and repair

The district heating supplier can replace temperature sensor pair, battery and communication

module. The ﬂow sensor must not be separated from the calculator. Other repairs require

subsequent reveriﬁcation in an accredited laboratory.

Selecting a temperature sensor pair

MULTICAL® 403-W - Pt500

MULTICAL® 403-T - Pt500

MULTICAL® 403-V - Pt100

Battery for replacement

Kamstrup type 403-0000-0000-200 (1 x D-cell)

Kamstrup type 403-0000-0000-100 (2 x AA-cell)

Communication Modules

For an overview of available modules we refer to section 9, page 18.

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Reading, Berkshire, RG6 4UT. UK.

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3Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

Contents

1 General information 4

2 Mounting of temperature sensors 5

2.1 Direct sensors 5

2.2 Pocket sensors 6

2.3 Temperature sensor compatibility with ﬂow sensors 7

3 Mounting of ﬂow sensor 8

3.1 Mounting of couplings, and short direct sensor in MULTICAL® 403 ﬂow sensor 8

3.2 Flow sensor position 9

3.3 Mounting of MULTICAL® 403 ﬂow sensor 10

3.4 Installation examples 11

3.5 Humidity and condensation 11

4 Mounting the calculator 12

4.1 Compact mounting 12

4.2 Wall mounting 12

4.3 Position of calculator 13

5 Information codes ”INFO” 14

6 Power supply 15

6.1 Battery supply 15

6.2 Mains supply 16

7 Function check 17

8 Electrical connection 17

9 Communication modules 18

9.1 Module overview 18

9.2 Pulse inputs 18

9.3 Pulse outputs 18

9.4 Data + pulse inputs, type HC-003-10 19

9.5 Data + pulse outputs, type HC-003-11 19

9.6 M-Bus + pulse inputs, type HC-003-20 19

9.7 M-Bus + pulse outputs, type HC-003-21 20

9.8 Wireless M-Bus + pulse inputs, type HC-003-30 20

10 Set-up via front keys 21

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4 Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

1 General information

Please read this guide carefully before mounting the energy meter.

In case of incorrect mounting, Kamstrup's guarantee obligations no longer apply.

Please note that the following installation conditions must be obeyed:

- Pressure stage: PN16/PN25, see marking. The meter marking does not apply

to enclosed accessories.

- Pressure stage, Kamstrup

sensor pair type DS: PN16

- Pressure stage, Kamstrup

pocket sensors type PL: PN25

At medium temperatures above 90 °C we recommend ﬂange sensors as well as wall-mounting of

calculator.

At medium temperatures below ambient temperature, MULTICAL® 403 must be wall mounted and

the condensation-proof version, type 403-T, must be used.

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Reading, Berkshire, RG6 4UT. UK.

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5Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

2 Mounting of temperature sensors

The temperature sensors used for measuring forward and return temperatures respectively,

constitute a matched sensor pair, which must never be separated. Temperature sensors are

usually mounted in the calculator from the factory. According to EN 1434/OIML R75 the cable

length must not be changed. Should replacement be necessary, both sensors must be replaced.

The sensor marked with a red sign is to be installed in the ﬂow pipe. The other sensor, marked with

a blue sign, is to be installed in the return pipe. For mounting in the calculator, see the paragraph

”Electrical connection”.

Note: The sensor cables must neither be exposed to jerking nor pulling. Please be aware of this

when binding the cables, and be careful not to pull the binders unnecessarily tight as this

may damage the cables. Please also note that temperature sensors must be mounted from

below in cooling or heat/cooling installations.

2.1 Direct sensors

The short, direct sensors up to DN25 can be mounted in special ball valves with built-in M 10

socket for the short direct sensor. They can also be mounted in installations with standard angle

tee-pipes. Kamstrup supply R½ and R¾ brass nipples, which ﬁt our short, direct sensor. Make sure

that the tip of the temperature sensor reaches at least the center of the ﬂow pipe. The short direct

sensor can also be direct mounted in all Kamstrup ﬂow sensors with G¾B, G1B, G5/4B and G2

thread on the meter case. Fasten the sensors’ brass unions lightly (approx. 4 Nm) using a 12 mm

face wrench and seal the sensors with seal and locking wire.

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Reading, Berkshire, RG6 4UT. UK.

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6 Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

2.2 Pocket sensors

The sensor pockets can be mounted in e.g. a welding sleeve or in a 45° lateral Y-piece. The tip

of the sensor pocket must at least reach the center of the ﬂow pipe. Push the temperature

sensors as deep as possible into the pockets. If a short response time is required, “nonhardening”

thermally conductive paste can be used. Push the plastic sleeve on the sensor cable into the

sensor pocket and secure the cable by means of the enclosed M4 sealing screw. Fasten the screw

with your ﬁngers only. Seal the pockets using seal and locking wire.

SECTION

B-B

SCALE

1 : 1

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Reading, Berkshire, RG6 4UT. UK.

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7Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

2.3 Temperature sensor compatibility with ﬂow sensors

The size of the ﬂow sensor determines which temperature sensors you can use and how they are

mounted. The below table shows which temperature sensor types to use with which ﬂow sensor.

Flow sensor Temperature sensor

Can be mounted in ﬂow

sensor.

Cannot be mounted in ﬂow

sensor.

qpDN G DS 27.5 DS 38 Ø5.8 mm pocket

0.6-1.5 15 G¾BX

0.6-1.5 20 G1B X

3.5-6 25 G5/4B X

10 40 G2B X

15 50 - X

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Reading, Berkshire, RG6 4UT. UK.

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MULTICAL® 403

3 Mounting of ﬂow sensor

Prior to installation of the ﬂow sensor, the system should be ﬂushed and protection plugs/plastic

diaphragms removed from the ﬂow sensor.

Correct ﬂow sensor position (inlet or outlet) appears from the display of MULTICAL® 403. Mounting

in inlet pipe is symbolised by , whereas mounting in outlet pipe is symbolised by . The

ﬂow direction is indicated by an arrow on the ﬂow sensor.

3.1 Mounting of couplings, and short direct sensor in MULTICAL® 403 ﬂow sensor

The short direct sensor from Kamstrup may be

installed in PN16 installations only. The blind

plug which is mounted in the MULTICAL® 403

ﬂow sensor from the factory can be used in

connection with both PN16 and PN25.

The ﬂow sensor can be used in both PN16 and

PN25 installations and is available with either

PN16 or PN25 marking as required.

Enclosed couplings, if any, are only intended for

PN16. Suitable PN25 couplings must be used in

PN25 installations.

Gasket

Torque ~4 Nm

Straight inlet: MULTICAL® 403 neither requires straight inlet nor straight outlet to meet the

Measuring Instruments Directive (MID) 2004/22/EC, 2014/32/EC, OIML R75:2002, EN 1434:2007

and EN 1434:2015. A straight inlet section will only be necessary in case of heavy ﬂow

disturbances before the meter. It is recommended to follow the guidelines of CEN CR 13582.

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Reading, Berkshire, RG6 4UT. UK.

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9Kamstrup A/S • 55121739_A3_GB_04.2016

MULTICAL® 403

3.2 Flow sensor position

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.

E A ﬂow sensor ought not to be placed

immediately after a valve, with the

exception of block valves (ball valve type)

which must be fully open when not used for

blocking.

F A ﬂow sensor must never be placed on the

inlet side of a pump.

G A ﬂow sensor ought not to be placed after a

double bend in two planes.

In order to avoid cavitation, the back pressure at the ﬂow sensor (the pressure at the ﬂow sensor

outlet) must be minimum 1.5 bar at qp (nominal ﬂow) and minimum 2.5 bar at qs (maximum ﬂow).

This applies to temperatures up to approx. 80 °C.

The ﬂow sensor must not be exposed to lower pressure than ambient pressure (vacuum).

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