Kamstrup MULTICAL 803 User manual

Installation and user guide

MULTICAL® 803 & ULTRAFLOW®

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

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MULTICAL® 803 & ULTRAFLOW®

Information

Permissible operating conditions / measuring ranges

Heat meter with approval according to MID and EN1434:

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

ULTRAFLOW® (temperature of medium) qq: 15 °C…130 °C

Cooling meter with approval according to DK-BEK 1178 and EN1434:

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

ULTRAFLOW® (temperature of medium) qq: 2 °C…130 °C

MID designation

Mechanical environment

MULTICAL®: Class M1 and M2

ULTRAFLOW®: Class M1 (M2 for ULTRAFLOW® type 65-5-XXHX-XXX)

Electromagnetic environment

Class E1 (housing/light industry) and class E2 (industry).

The meter’s control cables must be drawn at min. 25 cm distance from other installations.

Climatic environment

Condensing, closed location (installation indoors), ambient temperature 5…55 °C.

Maintenance and repair

The district heating supplier can replace temperature sensor pairs, ﬂow sensor as well as supply

and communication modules. Other repairs require subsequent reveriﬁcation in an accredited

laboratory.

Selection of temperature sensor pair

MULTICAL® 803-A: Pt100/Pt500 - EN 60751, 4-wire connection

Battery for replacement

Kamstrup type HC-993-10

Communication modules

An overview of available modules is found in the paragraph “Communication modules”.

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MULTICAL® 803 & ULTRAFLOW®

Contents

1 In general 4

2 Mounting of temperature sensors 5

2.1 Short direct sensor (DS) 5

2.3 Pocket sensor with connection head (PL) 6

2.2 Pocket sensor (PL) 6

3 Mounting of ﬂow sensor 7

3.1 Mounting of couplings and short direct sensor in ﬂow sensor 7

3.2 Mounting of ULTRAFLOW® ≤ DN125 8

3.3 Mounting of ULTRAFLOW® 54 ≥ DN150 8

3.4 Flow sensor position 9

3.5 Installations with two ULTRAFLOW® sensors 10

4 Mounting the calculator 11

4.1 Wall-mounting 11

4.2 Compact mounting 11

5 Electrical connection 12

5.1 Connection of temperature sensors 12

5.2 Connection of ULTRAFLOW® 13

5.3 Connection of other ﬂow sensors 13

6 Connection of power supply 14

6.1 Mains supply 14

6.2 Backup battery 15

7 Testing of function 15

8 Info code 16

9 Communication modules 17

9.1 Module overview 17

9.2 Pulse inputs 17

9.3 Pulse outputs 18

9.4 Data + pulse inputs, type HC-003-10 18

9.5 Data + pulse outputs, type HC-003-11 18

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

9.7 M-Bus + pulse outputs, type HC-003-21 19

9.8 M-Bus + Thermal Disconnect, type HC-003-22 19

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

9.10 Wireless M-Bus + pulse outputs, type HC-003-31 20

9.11 Analog outputs, type HC-003-40 20

9.12 Analog inputs, type HC-003-41 21

9.13 PQT Controller, type HC-003-43 21

9.14 LON TP/FT + pulse inputs, type HC-003-60 22

9.15 BACnet MS/TP + pulse inputs, type HC-003-66 22

9.16 Modbus RTU + pulse inputs, type HC-003-67 22

9.17 2G/4G network module + pulse inputs, type HC-003-80 23

9.18 Modbus/KMP TCP/IP + pulse inputs, type HC-003-82 23

10 Setup via front keys 24

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MULTICAL® 803 & ULTRAFLOW®

1 In general

Please read this guide carefully before installing the energy meter.

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

By connecting to 230 V supply, there is a risk of electric shock.

When working on the ﬂow sensor in the installation, there is a risk of outﬂow of (hot)

water under pressure.

At a media temperature higher than 60 °C, the ﬂow sensor should be shielded from

unintended contact.

Please note that the following installation conditions must be obeyed:

- Pressure stage ULTRAFLOW®: PN16/PN25, see marking

- Pressure stage Kamstrup sensor pair, type DS: PN16/PN25

- Pressure stage Kamstrup pocket sensors, type PL: PN25

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

MULTICAL®.

At media temperatures below the ambient temperature, MULTICAL® must be wall-mounted, and

the ﬂow sensor/ULTRAFLOW® must be a condensation-proof version.

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MULTICAL® 803 & ULTRAFLOW®

2 Mounting of temperature sensors

The temperature sensors used for measuring inlet and outlet temperatures respectively,

constitute a matched sensor pair, which must never be separated. 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 inlet pipe. The other sensor, marked with

a blue sign, is to be installed in the outlet 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 and heat/cooling installations.

2.1 Short direct sensor (DS)

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

tee-pieces. Kamstrup A/S can supply R½ and R¾ brass nipples that ﬁt the short direct sensors.

The short direct sensor can also be mounted directly in selected ﬂow sensors from Kamstrup A/S.

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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MULTICAL® 803 & ULTRAFLOW®

2.2 Pocket sensor (PL)

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 be placed in the middle of the ﬂow. Push the temperature sensors as

deep as possible into the pockets. If a short response time is required, “non-hardening” 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

A-A

SCALE

1 : 1

SECTION

B-B

SCALE

1 : 1

SECTION

B-B

SCALE

1 : 1

2.3 Pocket sensor with connection head (PL)

See Installation and user guide no. 5512-2272.

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MULTICAL® 803 & ULTRAFLOW®

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 position of the ﬂow sensor appears either from the calculator’s type label or from the

display where indicates the position in inlet, whereas indicates the position in outlet.

The ﬂow direction is symbolised by an arrow on the ﬂow sensor.

3.1 Mounting of couplings and short direct sensor in ﬂow sensor

Flow sensor and any mounted blind plug can be

used in connection with both PN16 and PN25.

The ﬂow sensor is available with either PN16

or PN25 marking as required. Any provided

extensions and glands can be used for both

PN16 and PN25.

In connection with ﬂow sensors with the

nominal dimensions G¾Bx110 mm and

G1Bx110 mm, it must be checked if the thread

run-out is sufﬁcient.

Couplings and gaskets are mounted as shown

in the ﬁgure. Make sure to position the gasket

correctly in the recess of the gland as shown in

the details excerpt in the ﬁgure. Gasket

Moment

approx. 4 Nm

Gasket

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MULTICAL® 803 & ULTRAFLOW®

3.2 Mounting of ULTRAFLOW® ≤ DN125

90°

90° 90°

90°90°

90° 90°

The ﬂow sensor can be mounted horizontally, vertically or at an angle.

Max. 45°

The ﬂow sensor should be mounted with the plastic casing placed

on the side (at horizontal mounting).

The ﬂow sensor (65-5-XXHX-XXX) may be turned up to 45°

downwards in relation to the pipe axis as shown above, if required1.

1Flow sensor types 65-5-XXAX-XXX, 65-5-XXCX-XXX and 65-5-XXJX-XXX may also be turned 45°

upwards.

Note: In installations in which the media temperature is below the ambient temperature,

ULTRAFLOW® in a condensation-proof version must be used. At the same time,

ULTRAFLOW® must not be mounted with the plastic casing turned to below 0°. It is

recommended to turn the plastic casing 45° upwards.

3.3 Mounting of ULTRAFLOW® 54 ≥ DN150

See Installation and user guide no. 5512-887.

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MULTICAL® 803 & ULTRAFLOW®

3.4 Flow sensor position

Kamstrup ﬂow sensors require neither straight inlet nor straight outlet to meet the Measuring

Instruments Directive (MID) 2014/32/EU, OIML R75:2002 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.

A Recommended position.

B Recommended position.

C Unacceptable position due to risk of air

build-up.

D Acceptable position in closed systems.

E 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 Ought not to be placed immediately before

or after a pump.

G Ought not to be placed immediately 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 pressure

lower than the ambient pressure (vacuum).

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MULTICAL® 803 & ULTRAFLOW®

3.5 Installations with two ULTRAFLOW® sensors

MULTICAL® can be used in various applications

with two ULTRAFLOW® sensors, including leak

surveillance and open systems. As a main rule,

when two ULTRAFLOW® sensors are installed

with one MULTICAL®, a close electric coupling

between the two pipes ought to be carried out

on which the two ﬂow sensors are mounted. If

the two pipes are installed in a heat exchanger,

close to the ﬂow sensors, however, the heat

exchanger will provide the necessary electric

coupling.

ULTRAFLOW®

MULTICAL®

ULTRAFLOW®

• Inlet and outlet pipes are closely electrically coupled.

• The parts of the pipe installation that are electrically connected to the ﬂow sensors must both

be subjected to soldering.

In installations where the electric coupling is

not possible or welding1can occur in the pipe

system, the cable from one ULTRAFLOW®

must be led through a Pulse Transmitter to

obtain galvanic separation before the cable is

connected to MULTICAL®.

1Electric welding must always be carried out

with the grounding connection closest to

the welding point. Damage to meters due

to welding is not comprised by the factory

guarantee.

ULTRAFLOW®

MULTICAL®

ULTRAFLOW®

Pulse

Transmitter

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