INTEGRA Metering CALEC energy master User manual

Installation and operating instructions
CALEC® energy master
The benchmark for energy measurement technology
Firmware Version 1.00
VD 3-137e, 08.2018

2 CALEC®energy master installation and operating instructions
1 Contents
1Contents 2
2Information and references 4
2.1 Information 4
2.2 Documents 4
3Safety notices 5
3.1 Symbols used 5
3.2 Intended use 5
3.3 Inappropriate use 5
3.4 Installation guidelines 6
4Pattern approval, versions, marking 7
4.1 Pattern approval and conformity
assessment (Prot) 7
4.1.1European conformity assessment for
heating applications 7
4.1.2National approval for air-conditioning
applications 7
4.2 Device identification and labelling 7
4.3 Short text CALEC®energy master 8
5View of device with protective housing 9
6View of device without protective housing
(Mod) 10
7Mounting the device with protective housing
(Prot) 11
7.1 Scope of supply, tools and mounting
material (Prot) 11
7.2 Installation (Prot) 11
8Mounting the device without protective
housing (Mod) 15
8.1.1Rail mounting 15
8.1.2Connecting to mains power supply
230 VAC 15
8.1.3Connecting to low voltage supply 24
VDC 16
8.1.4Connecting signal cables 16
9Applications 17
9.1 Applications for energy calculator 17
9.1.1Overview of energy applications 17
9.1.2Heat meter application 18
9.1.3Cooling meter application 19
9.1.4Flow meter application 20
10 Mounting the device with protective
housing (Prot) 21
10.1 Scope of supply, tools and mounting
material (Prot) 21
10.2 Installation (Prot) 21
11 Mounting the device without protective
housing (Mod) 25
11.1.1 Rail mounting 25
11.1.2 Connecting to mains power supply
230 VAC 25
11.1.3 Connecting to low voltage supply 24
VDC 26
11.1.4 Connecting signal cables 26
12 Electrical connections 27
12.1 Connection instructions 27
12.2 Wiring diagram, module and signal
numbers 27
12.3 Numbering rules 28
13 Commissioning a measuring point 29
14 Operation 30
14.1 PC-Software AMBUS Win II 30
14.2 Display 30
14.2.1 Key functions 30
14.3 Right of access, security levels 31
15 Menu overview 32
15.1 Main display and main menu 32
15.2 Submenus 32
16 Use under operating conditions 35
16.1 The main display 35
16.2 The measured values submenu 36
16.2.1 Measured values 36
16.2.2 Meter readings 36
16.2.3 Current values 36
16.2.4 Billing date values 36
16.2.5 Logger values 36
17 Settings on commissioning 37
17.1 General settings 37
17.1.1 Display language 37
17.1.2 Date and time 37
17.1.3 Baud rate optical interface 37

CALEC®energy master installation and operating instructions 3
17.1.4 M-Bus address 38
17.2 Settings for the calculator function 38
17.2.1 Standard applications 38
17.2.2 Do not change settings in
programming mode 38
17.2.3 How does one recognize devices
with CE conformity assessment? 39
17.2.4 Calculator settings: Heat and
cooling calculator 39
17.2.5 Time settings: date, billing dates,
logger etc. 41
17.2.6 Settings of calculator function for
measuring transducer 41
18 Troubleshooting 42
18.1 Messages 42
18.2 Error message in the main display 42
18.3 Diagnosis submenu 42
18.3.1 Message submenu 43
18.3.2 Alarm / error submenu 43
18.3.3 Logbook submenu 43
18.3.4 Calibration log menu 43
18.4 Error messages 44
19 Maintenance, recalibration, disposal 46
19.1 Maintenance and recalibration 46
19.2 Dispatch 46
19.3 Disposal 46
20 Dimensional drawings and technical
specifications 47
20.1 Dimensional drawings of device with
protective housing Prot 47
20.2 Drawings of device without protective
housing (Mod) 47
20.3 Technical specifications 48
21 The module system 52
21.1 Arrangement and connection of the
modules 52
21.2 Number of modules in the protective
housing 52
22 The CALEC®master modules 53
22.1 The supply module 100-240 VAC 53
22.1.1 Safety instructions 53
22.1.2 Function and connections 53
22.2 The CPU module 2 x Pt100 54
22.2.1 Function and connections 54
22.2.2 Settings 54
22.2.3 Ordering a CPU module as spare 55
22.2.4 IrDA interface 55
22.2.5 Pt100 inputs 55
22.3 The display module 56
22.3.1 Function 56
22.3.2 Settings 56
22.3.3 Contents of the main display 56
22.4 The input module 2x pulse/analogue 57
22.4.1 Function and connections 57
22.4.2 Settings 58
22.4.3 Signal types 58
22.4.4 Digital signal types 59
22.4.5 Functions for digital input signals 59
22.4.6 Units of the pulse function 61
22.4.7 Analogue signal types 61
22.4.8 ‘Special’ signal type 62
22.5 The M-Bus module 63
22.5.1 Function and connections 63
22.5.2 M-Bus addressing 63
22.5.3 Other settings 64
23 EC declaration of conformity 65
24 Appendix 67
24.1 Terms, abbreviations, formula symbols67
24.1.1 Terms 67
24.1.2 Abbreviations 67
24.1.3 Symbols 68

4 CALEC®energy master installation and operating instructions
2 Information and references
2.1 Information
These installation and operating instructions describe the installation and commissioning of a stan-
dard device. The chapters describe the topics and tasks in the sequence in which they are needed
during commissioning.
•Safety instructions
•Information about the device
•Installation
•Electrical connections
•Operation
•Fault clearance
•Technical data
Always comply with the safety instructions.
2.2 Documents
The installation and operating instructions VD 3-135 vary in scope, depending on the version and
items covered by the delivery. The information required for ancillary modules and optional functions is
described in additional document extracts (VD 3-136).
Parameterisation software AMBUS Win II
The parameterisation software AMBUS Win II is available for setting the parameters. It can be
downloaded free of charge (see below).
Downloads
The current documents and AMBUS Win II are available as free downloads at
www.aquametro.com/downloads.

CALEC®energy master installation and operating instructions 5
3 Safety notices
3.1 Symbols used
Important information
Non-observance can lead to malfunction.
General warning
Non-observance can lead to damage or malfunction.
Warning of dangerous electric voltage
Non-observance can lead to physical injury!
3.2 Intended use
The device is used as an energy calculator for heating, cooling and air conditioning applications in
district heating or cooling, in building management services and in industrial energy metering.
It is part of a combined heating/cooling or air conditioning meter, consisting of a calculator, a pair of
temperature sensors and a flow meter, or as a transducer for a flow meter.
The environmental conditions described in the technical specifications, as well as the installation and
operating instructions must be complied with.
3.3 Inappropriate use
The device must not be used:
•In explosion-risk zones (no ex-risk protection!)
•In a wet environment (condensing, splashing or dripping water)
•Outdoors, without suitable protection
•In environmental conditions (temperature, humidity, vibrations, electromagnetic inter-
ference etc.) that do not comply with the technical specifications
•In all other instances that do not conform to its intended use
The device can be dangerous if it is not used as intended, or not in accordance with the installation
and operating instructions. In order to avoid this, it is essential that the safety instructions, operating
conditions (see technical specifications) and the relevant chapters of these instructions are strictly ad-
hered to.
The manufacturer accepts no liability for damage arising from inappropriate use.

6 CALEC®energy master installation and operating instructions
3.4 Installation guidelines
The installation should be performed by authorised, skilled personnel, in compliance with
the regulations in force (EN1434 part 6 Regulations and recommendations for installation
and operation) and the recommendations of the industry-specific associations (e.g. the
AGFW series of leaflets on district heating supplies).
The skilled personnel must have read and understood these instructions. The require-
ments in the instructions and the applicable regulations on electrical installations must al-
ways be observed.
Work on electrical circuits with hazardous voltages (> 24 VAC or >42 VDC) may only be
carried out by authorised, skilled people, in compliance with the locally applicable regula-
tions!

CALEC®energy master installation and operating instructions 7
4 Pattern approval, versions, marking
4.1 Pattern approval and conformity assessment (Prot)
4.1.1 European conformity assessment for heating applications
For custody transfer, all three component parts of a combined energy calculator must have pattern
approval and a conformity assessment. The device with protective housing complies with Directive
2004/22/EC (Measurement Instruments Directive, MID). If the device is approved according to MID,
then the conformity assessment replaces the initial calibration, which is the normal procedure for de-
vices with national approval.
The parts of the CE marking have the following meaning:
CE M 08 0102 CE: CE marking
M 08: Metrology mark and year of manufacture
0102: Identification number of the named body that was involved in the confor-
mity assessment (0102: PTB Germany).
A facsimile of the declaration of conformity is shown in chapter 23.
Calibration-relevant data can be changed with an authorisation code. This will result in the
invalidation of the calibration, and the action will be entered in the calibration log.
4.1.2 National approval for air-conditioning applications
The device has also a national aaproval for custody transfer according to the german PTB K7.2, (ap-
proval no, 22.75/08.01) for:
•Thermal energy metering in air-conditioning applications
•Thermal enegy metering in combined heating and air-conditioning applications ( BDE function).
•
4.2 Device identification and labelling
A basic unit consists of a minimum of 4 modules:
•Power supply (24 VDC or 100-240 VAC)
•CPU module with the device-specific function and 2 signal inputs
•Input module with 2 inputs
•Display module
The device can be expanded with additional modules (separate order).
A device is clearly identified by the following details (example):
Art. No. Short text Firmware Version (FWV)
CPU module Hardware No. (HW_No.) CPU module
94157 EM-101-Prot-AC[...I]C-T 1.00 1234567
Device type, fabrication number, fabrication date, firmware version, batch no., hardware no. and
checksum of the CPU module are displayed in the Diagnosis/System submenu.
An article number defines a basic device without ancillary modules. The short text indicates the de-
vice version and the module assembly at the time of delivery. This short text is printed on the wiring
diagram on the inside of the housing cover. If the module assembly is changed in the field, then this
identification will no longer correspond to the actual assembly.

8 CALEC®energy master installation and operating instructions
Marking „Prot“ected version „Mod“ule version Module
Type plate On the cover On the display module -
Wiring diagram Inside cover Enclosed in packaging On the side of the module
Terminal No. Above/below the terminals1) Above/below the terminals 1) Above/below the terminals 1)
1) The assignment of the signals to the terminals is displayed in the operating menus, on those pages where the
settings for the signals are performed.
4.3 Short text CALEC®energy master
The table below shows the key for the text used to order the CALEC®energy master:
Example: CALEC®energy master EM -101 Prot - AC [ M I ] C - T
CALEC®energy master EM
Flow calculator/transducer 1 0 0
Energy calculator for heating, air conditioning,
cooling 101
With protective housing („Prot“ected) IP 54 Prot
Module w/o protective housing („Mod“ule) IP 21 Mod
Voltage supply
Supply module 100 - 240 VAC AC
Connect module 24 VDC DC
All modules in sequence of assembly
Master Module Input 2xPulse/Analogue I
Master Module Input 2xPt100 * T
Master Module Output 2xRel.24V/Analogue O
Master Module Output 2xRel.240V * R
Master Module M-Bus M
CPU module with temp. measurement Pt100 C-T
*: Available on request

CALEC®energy master installation and operating instructions 9
5 View of device with protective housing
Device with closed protective housing
1 Housing cover
2 Operating keys
3 Dot-matrix LCD
4 Type plate with CE marking
5 IR interface on display module
(EN13757-2 / -3 M-Bus)
IrDA interface on CPU module
6 Housing screws, covered by security sealing
caps
Device with opened protective housing
2 Operating keys
3 Display, LCD dot matrix
5 IR interface (EN13757-2 / -3 M-Bus)
IrDA interface
7 Display module
8a Upper terminals, plug-in
8b Lower terminals, plug-in
9 Clip-on holder for modules
10 3 Fastening holes for wall mounting
11 Clip-on holder for rail mounting
12 Strain relief
13 Cover hinges
The wiring diagram is on the inside of the hous-
ing cover.
View of the protective housing from below
11 Clip for rail
14 Cable duct supply 14 mm
15 Cable ducts 10 mm
16 Cable ducts 14 mm

10 CALEC®energy master installation and operating instructions
6 View of device without protective housing (Mod)
The following diagram shows the device without protective housing.
2 Operating keys
3 Display, LCD dot matrix
5 IR interface (EN13757-2 / -3 M-Bus)
IrDA interface
7 Display module
8a Upper terminals, plug-in
8b Lower terminals, plug-in
9 Clip-on holder for modules
The Display can be installed at a remote location e.g. in a control panel by using the two Remote
Display Adapters:
11 Remote Display Adapter
RDA/CPU
12 Remote Display Adapter
RDA/Display
13 Network cable
11 12
13

CALEC®energy master installation and operating instructions 11
7 Mounting the device with protective housing (Prot)
7.1 Scope of supply, tools and mounting material (Prot)
Warning! Precision measuring devices! Protect against heat, humidity, dirt and vibra-
tion. Only unpack the device when ready to install. Non-observance can result in dam-
age or malfunction.
•One Installation and Operating In-
structions manual
1) Support rail optional
7.2 Installation (Prot)
Opening the housing
Mounting on support rail (DIN-EN 50222)
Choose the location for installation
•which is protected against humidity, heat, direct sunlight and damage
•with easy access for reading, operation and installation
•with sufficient distance from sources of electromagnetic interference

12 CALEC®energy master installation and operating instructions
1. Drill holes
2. Screw on support rail
3. Clip device onto sup-
port rail
Wall mounting
Remove clip-on holder to get
a stable support.
Only mount device on a flat
surface!

CALEC®energy master installation and operating instructions 13
Wiring diagram
The wiring diagram is on the in-
side of the housing cover.
Connecting to mains power supply 100 - 240 VAC
The mains supply must be connected via a two-pole separator and be adequately protected against
unauthorised interruption.
The mains supply 100 - 240 VAC may
only be connected to the following ter-
minals:
Terminals L, N (supply module)
Terminals 110, 115 (relay module 2x240 VAC)
The device must be protected by a 10 AT external fuse.
The device is fully isolated and requires no grounding connections.
Connection to other terminals is extremely dangerous and can permanently damage the
instrument!
Connecting to low voltage supply 24 VDC

14 CALEC®energy master installation and operating instructions
Connecting signal cables
1. Pierce sealing membrane with en-
closed awl
2. Insert cable
3. Attach cable to terminal screws
according to wiring diagram on the
inside cover
4. Affix strain relief clamp
Closing housing 1. Insert the cover into the hinge from
above and turn to close
2. Tighten the two fixing screws
3. Engage the security sealing caps
with the smooth side on the out-
side.
Once the caps ehave
been fitted, any unau-
thorised opening of the
device can be detected.
Removing the caps:
Insert a pointed tool and
lever out. The cap is
damaged as a result
and must be replaced.

CALEC®energy master installation and operating instructions 15
8 Mounting the device without protective housing (Mod)
8.1.1 Rail mounting
1. Drill fastening holes
2. Screw on support rail
3. Clip modules onto support
rail
8.1.2 Connecting to mains power supply 230 VAC
Refer to the wiring diagram before starting wiring!
The mains supply may only be connected to terminals L and N!
The device is fully isolated and requires no grounding connections.
All other terminals are only for low voltage (<50 V) and measuring signals. Connection
to these terminals is extremely dangerous and can permanently damage the instrument!
1. Strip the power cable as
shown in drawing.
2. Connect power cable to
supply module (see en-
closed wiring diagram)

16 CALEC®energy master installation and operating instructions
8.1.3 Connecting to low voltage supply 24 VDC
1. Strip cable as shown in
drawing
2. Attach cable to the con-
nect module (see en-
closed wiring diagram)
8.1.4 Connecting signal cables
1. Attach signal cables to
terminal screws accord-
ing to enclosed wiring
diagram
2. The terminal blocks can
be plugged in.

CALEC®energy master installation and operating instructions 17
9 Applications
9.1 Applications for energy calculator
9.1.1 Overview of energy applications
The wiring diagram S-EM1 on the inside of the upper section of the housing summarises all con-
nection variants of the device version for heat meters. The diagram shows the standard assembly
with the modules (left to right). The display module is not shown.
•CPU module
•Input module
•Supply or Connect Module (power supply)
Up to four additional input, output or communications modules can be fitted between the supply
and input modules.
Applications and the required signals:
Application Connected signals
Heat meter Qv Tc Th
Cooling meter Qv Tc Th
Combined cooling/heat meter (BDE) Qv Tc Th
Summer/winter operation Qv2 Qv1 Tc Th
Parallel flow meters (TWIN-V) Qv2 Qv1 Tc Th
Open systems (Twin-E) Qv2 Qv Tc Th
Flow direction (BDV) STA Qv Tc Th
Th, Tc: Thot: Temperature hot side, Tcold: Temperature cold side
Qv, Qv1, Qv2:Volume signal
STA: Flow direction indicator
These applications are grouped in one single wiring diagram:
Terminals
3… 6
Tc
Qv2, STA*
ThQv, Qv1230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
3… 6
Tc
Qv2, STA*
ThQv, Qv1230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
Connections:

18 CALEC®energy master installation and operating instructions
9.1.2 Heat meter application
When used as a heat meter, the transport of energy from a heat source to the consumer is meas-
ured in the supply and return flow of a transport duct. This requires signals measuring the supply
temperature and the return temperature, and signals from a flow sensor. The flow sensor should, if
possible, be mounted on the cold side to reduce thermal effects.
The supply temperature is higher than the return temperature, i.e. Tsupply = Th, Treturn = Tc
The following diagram illustrates the installation with the process signals, the modules with the ter-
minal assignments and the recorded meter readings.
Th
Tc Qv
hot
cold
E
E
S-EM1.1
M
V
E
M
V
E
3… 6
Tc
ThQv230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
3… 6
Tc
ThQv230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
Variants/special cases:
When installing the flow sensor on the hot side, the installation side of the flow sensor should be
set to Side Q Hot side in the Basic settings/input sub-menu,
The device provides the following meter readings:
E: Cumulative energy
V: Cumulative volume
M: Cumulative mass

CALEC®energy master installation and operating instructions 19
9.1.3 Cooling meter application
The following characteristics differentiate the cooling meter application from the heat meter appli-
cation:
•The supply temperature is lower than the return temperature, i.e. Tsupply = Tc, Treturn = Th.
•The temperature difference is in the range of 1 … 15 K. This means that, for the same energy
consumption, the flow rate is markedly higher than in heating applications.
•There is a risk of water condensing on the flow sensor, i.e. the sensor should be adequately
protected against ingress of water (e.g. IP 67).
•If the supply temperature is < approx. 3 °C, pure water cannot be used as the heat transfer me-
dium. The device is available with a selection of standard commercial heat transfer liquids for
this application.
With cooling meters, it is preferable to mount the flow sensor on the hot side in order to reduce
thermal effects. The installation side should be set correspondingly. In terms of sensor location,
this corresponds to installation in the return flow pipe.
Furthermore, suitable temperature sensors must be used. This can affect the test points, the mois-
ture resistance of the sensors and the cable sheath and the use of heat transfer barriers.
Required measuring signals: Supply and return temperature, flow rate signal.
M
V
E
M
V
E
3… 6
Tc
ThQv230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
3… 6
Tc
ThQv230 VAC
1212Sign.-Nr.
Pt100-InputInputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
The device provides the following meter readings:
E: Cumulative energy
V: Cumulative volume
M: Cumulative mass

20 CALEC®energy master installation and operating instructions
9.1.4 Flow meter application
As a flow meter/calculator, the signals from the flow sensors are converted into current values and
cumulative volumes. The measured liquid is also called a ‘heat transfer medium’ in this function,
although only the flow rate is measured.
A flow meter can be realised in each logical calculator. Up to three flow sensors can be connected
per device. The example below shows a flow meter application.
The volume of liquid and the current flow rate in two water pipes are transmitted via the M-Bus in-
terface to a billing system. The flow rate values are also transmitted as analogue signals to a build-
ing services management control system.
The following table summarises the input and output signals:
Signal transmitter Signal Physical variable Output control system Billing system
Water meter 1 Pulse Volume flow: 1: Qv 4 ... 20 mA M-Bus
Water meter 2 Pulse Volume flow: 2: Qv 4 ... 20 mA M-Bus
This produces the following application diagram:
M-Bus
4
M-Bus
Q1
1
Q2
2
Output
3
Output
5… 6
2: Qv
1: Qv230 VAC
12Sign.-Nr.
InputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
M-Bus
4
M-Bus
Q1
1
Q2
2
Output
3
Output
5… 6
2: Qv
1: Qv230 VAC
12Sign.-Nr.
InputSign.-Typ
12Mod.-Nr.
CPU 2 x Pt100InputSupplyMod.-Typ
This example can be implemented with one device, using calculators 1 and 2, which are both con-
figured as flow meters.
Meter readings
The device records the following meter readings.
Calculator 1 Calculator 2
VCumulative volume flow 2: V Cumulative volume flow