Kamstrup MULTICAL 602 User manual

www.kamstrup.com

Installation and User Guide for

MULTICAL® 602 &

ULTRAFLOW®

MID designations

Permissible operating conditions / measuring ranges:

Calculator q: 2°C…180°C DΘ: 3K…170K

Temperature sensor pair q: 10°C…150°C DΘ: 3K…140K

Flow sensor q: 15°C…130°C

Mechanical environment:

M1 (fixed installation with minimum vibration).

Electromagnetic environment:

E1 and E2 (housing/light industry and industry). The meter’s control cables must be

drawn at min. 25 cm distance to other installations.

Climatic environment:

Must be installed in environments with non-condensing humidity as well as in

closed locations (indoors). The ambient temperature must be within 5…55°C.

Maintenance and repair:

The district heating supplier can replace communication module, battery and

temperature sensor pair. The flow sensor is verified separately and can, therefore,

be separated from the calculator.

Other repairs require subsequent reverification in an accredited laboratory.

MULTICAL® 602, type 602-B/C/D must be connected to a temperature sensor pair

type Pt500.

MULTICAL® 602, type 602-A must be connected to a temperature sensor pair type

Pt100.

Battery for replacement: Kamstrup type 66-00-200-100.

MULTICAL® 602, type 602-A/B/C can be connected to flow sensor type

ULTRAFLOW®, electronic pick-up, or flow sensors with reed switch output.

MULTICAL® 602, type 602-D must be connected to a flow sensor with 24 V active

pulse output.

Irrespective of flow sensor type, “pulses/litre” must be identical in flow sensor and

calculator.

MULTICAL® 602 & ULTRAFLOW®

English

INSTALLATION

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

Contents

General information 4

Mounting of temperature sensors 4

Pocket sensor pair 4

Short direct temperature sensor pair 5

Mounting of flow sensor 5

Mounting ULTRAFLOW® ≤DN100 6

Mounting of ULTRAFLOW® 54 ≥DN150 7

Installation examples 7

Humidity and condensation 7

Mounting of calculator 8

Compact mounting 8

Separate/wall mounting 8

Panel mounting 8

Electrical connection, MULTICAL® and ULTRAFLOW® 8

Connection example 9

Heat meter with two flow sensors 9

Voltage supply of calculator/Pulse Transmitter 10

Battery supply 10

Mains modules 11

High-power supply modules 11

Isolated linear supply modules 11

Testing of function 11

Information codes ”INFO” 12

Plug-in modules 12

Base modules 12

Data + pulse inputs, type 67-00-10 12

M-Bus, type 67-00-20/27/28/29 13

Radio + pulse inputs, 67-00-21/25/26 13

Prog. data logger + RTC + 4…20 mA inputs + pulse inputs (67-00-22) 14

Analog outputs, type 67-00-23 14

Lon Works, type 67-00-24 14

Wireless M-Bus, type 67-00-30 14

ZigBee + pulse inputs, type 67-00-60 14

Metasys N2 + pulse inputs, type 67-00-62 14

SIOX module (Auto detect Baud rate), type 602-00-64 15

GSM/GPRS module (GSM6H), type 602-00-80 15

Ethernet/IP module (IP201), type 602-00-82 15

High-Power RadioRouter + 2 pulse inputs (VA, VB), type 602-00-84 15

Top modules 16

Electrical connection of MULTICAL®, ULTRAFLOW® and Pulse Transmitter 18

Setup via front keys 20

1. General information

Read this guide before installing the meter.

Kamstrup's guarantee obligations do not apply in case of incorrect mounting.

Please note that the following installation conditions must be obeyed:

- Pressure stage ULTRAFLOW®: PN16/PN25/PN40, see marking. Flow sensor

marking does not apply to enclosed accessories.

- Pressure stage Kamstrup

sensor pair type DS: PN16

- Pressure stage Kamstrup

stainless steel pockets: PN25/PN40 - depending on type

At medium temperatures above 90°C we recommend the use of flange meters as

well as wall mounting of MULTICAL® 602.

2. Mounting of temperature sensors

The temperature sensors used to measure flow and return temperatures re-

spectively are a matched sensor pair that must never be separated.

Temperature sensors are usually mounted in MULTICAL® 602 from the factory.

According to EN 1434 or OIML R75 the cable length must not be changed. If

necessary, sensors must always be replaced in pairs.

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 (see paragraph

5, page 8).

2.1 Pocket sensor pair

Preferably, sensor pockets must be mounted in tee-pieces or in 45° lateral Y-pieces.

The tip of the sensor pocket must point in the flow direction and should be placed

in the middle of the water flow.

The temperature sensors should reach the bottom of the pockets. If a short

response time is required, "non-hardening" heat conducting 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.

2.2 Short direct temperature sensor pair

The short direct sensors can be mounted in special ball valves or in special tee-

pipes, both with threads up to R1 and built-in M10 union for the short direct sensor.

For mounting in existing heating installations with standard angle tees Kamstrup

A/S can, furthermore, supply R½ and R¾ brass nipples fitting the short direct

sensors.

The short direct sensor can also be fitted directly into all Kamstrup's ULTRAFLOW®

variants with G¾ and G1 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.

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 (flow or return) appears from the front label of

MULTICAL® 602. The flow direction is indicated by an arrow on the side of the flow

sensor.

Gasket

Tightening app. 4 Nm

Glands and gaskets are mounted as shown in the above drawing.

Straight inlet: ULTRAFLOW® requires neither straight inlet nor straight outlet to meet

the Measuring Instruments Directive (MID) 2004/22/ EC, OIML R75:2002 and EN

1434:2007. A straight inlet section will only be necessary in case of heavy flow

disturbances before the sensor. We recommend to follow the guidelines of CEN CR

13582.

A Recommended flow sensor position

B Recommended flow sensor position

C Unacceptable position due to risk of

air build-up

D Acceptable 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 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 levels

In order to prevent cavitation the back pressure at ULTRAFLOW® must be min. 1.5

bar at qp and min. 2,5 bar at qs (4.5 bar for DN80). This applies to temperatures up

to approx. 80oC.

ULTRAFLOW® must not be exposed to lower pressure than the ambient pressure

(vacuum).

3.1 Mounting ULTRAFLOW® ≤DN100

90° 90°

ULTRAFLOW® can be mounted vertically,

horizontally or at an angle.

The electronics/plastic box

must be placed on the side (at

horizontal mounting).

Max.45°

ULTRAFLOW® may be turned up to ±45° in relation to the pipe axis.

ULTRAFLOW® must not be mounted with

the plastic case pointing upwards or

downwards.

3.2 Mounting of ULTRAFLOW® 54 ≥DN150

See installation instructions No. 5512-887.

3.3 Installation examples

Threaded meter with MULTICAL®/Pulse Transmitter mounted on ULTRAFLOW®.

Flow from the left Flow from the right

Flange meter with MULTICAL®/Pulse Transmitter mounted on ULTRAFLOW®.

Flow from the left Flow from the right

10190

45°

MULTICAL® 602 can be mounted in two positions

by means of an angle fitting.

Angle fitting type 30-26-252 is ordered separately.

3.3.1 Humidity and condensation

If ULTRAFLOW® is installed in moist environments, it must be turned 45° compared

to the pipe axis as shown in the drawing below.

45° If there is risk of condensation, e.g.

in cooling systems, a condensation

protected ULTRAFLOW® must be used.

4. Mounting of calculator

The MULTICAL® 602 calculator can be mounted in three different ways:

4.1 Compact mounting

The calculator is mounted direct on the flow sensor, e.g. via an angle fitting. Having

been mounted the calculator is sealed with seal and thread. In case of strong

condensation (e.g. cooling applications) we recommend wall mounting of the

calculator. Also see point 3.1" Mounting ULTRAFLOW® ≤DN100", page 6.

4.2 Separate/wall mounting

52 mm

In connection with mounting in condensing environments as well

as in order to prolong the battery lifetime, we recommend the use

of a wall fitting.

The wall fitting makes it possible to mount MULTICAL® 602 direct

on an even wall. Use the fitting as a template to mark and drill two

6 mm holes in the wall.

4.3 Panel mounting

MULTICAL® 602 can be mounted direct in panels and control panels, via Kamstrup's

panel mounting kit, No. 66-99-104 (192 x 144 mm).

5. Electrical connection, MULTICAL® and ULTRAFLOW®

The polarity of temperature sensors T1, T2 and T3 is unimportant.

For flow sensors V1 and V2 the below-mentioned colours are used

when connecting ULTRAFLOW® and electronic pick-up units.

Flow sensors with reed switch output are connected to terminals

11–10 and 11–69 respectively.

V1 V2

-11 11 Blue

+9 9 Red

SIG 10 69 Yellow

Terminal

no.

Standard heat and

cooling measurement

Heat measurement

and leak surveillance

Energy measurement

in open systems

T1 5-6 Sensor in flow (red) Sensor in flow (red) Sensor in flow (red)

T2 7-8 Sensor in return (blue) Sensor in return (blue) Sensor in return (blue)

V1 11-9-10 Flow sensor in flow or

return Flow sensor in flow Flow sensor in flow

V2 11-9-69 - Flow sensor in return Flow sensor in return

T3 51-52 - Tank/exchanger

temp., if any Reference sensor (grey)

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