Kamstrup MULTICAL 402 Installation and operating instructions

Installation & Maintenance Instructions
MULTICAL® 402
Reading Office
Cutbush Park, Danehill, Lower Earley,
Reading, Berkshire. RG6 4UT. UK.
Tel: [phone]
Email: [email protected]
Aberdeen Office
Unit 6 Airside Business Park, Kirkhill Industrial Estate,
Dyce, Aberdeen. AB21 0GT. UK.
Tel: [phone]
Email: [email protected]
Internet: www.able.co.uk
e-procurement: www.247able.com
Registered in England No: 01851002
VAT No: GB 417 2481 61

MULTICAL® 402
Energy Measurement
MULTICAL® 402 functions in the following way:
The flow meter registers the amount of district heating water in
m³ (cubic metres) circulating through the heating system.
The temperature sensors placed in inlet and outlet pipes
register the cooling, i.e. the difference between input and
output temperatures.
MULTICAL® 402 calculates consumed energy based on volume
of district heating water and cooling.
Readings
When the top front key is activated, a new reading
appears.
The lower front key displays historical readings and
average values.
Four min. after the latest activation of the front key the meter
automatically switches to consumed energy.
www.kamstrup.com

MULTICAL® 402
English
USERS GUIDE
Kamstrup A/S
Industrivej 28, Stilling, DK-8660 Skanderborg
Tel: [phone] · Fax: [phone]
[e-mail] · www.kamstrup.com

MID designations
Permissible operating conditions / measuring ranges
Calculator : 2 °C…160 °C : 3K…150K
Temperature sensor set : 10 °C…150 °C : 3K…140K
Flow sensor (heat meter) : 15 °C…130 °C
Also available as cooling meter with temperature range 2...50°C or as
combined heat/cooling meter with temperature range 2...130°C, with-
out MID approval however.
Mechanical environment
M1 (fixed installation with minimum vibration).
Electromagnetic environment
E1 (housing/light 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, bat-
tery and temperature sensor set. The flow sensor must not be separated
from the calculator
Other repairs require subsequent reverification in an accredited labora-
tory.
MULTICAL® 402, type 402-W and 402-T must be connected to a tem-
perature sensor set type Pt500.
MULTICAL® 402, type 402-V must be connected to a temperature sensor
set type Pt100.
Battery for replacement
Kamstrup type 402-000-2000-000 (D-cell) or 402-000-1000-000
(2 x AA-cells).
2

Contents
1 General information 4
2 Mounting of temperature sensors 4
2.1 Pocket sensor set 5
2.2 Short direct sensor set 6
3 Information codes ”INFO” 6
4 Mounting of flow sensor 7
4.1 Mounting of glands and short direct sensor mounted in
MULTICAL®402 flow part 7
4.2 Mounting of MULTICAL® 402 10
4.3 Installation examples 11
5 Mounting the calculator 12
5.1 Compact mounting 12
5.2 Wall mounting 12
6 Power supply 13
6.1 Battery supply 13
6.2 Mains modules 13
7 Testing the function 14
8 Electrical connection 14
9 Plug-in modules 15
9.1 Pulse inputs 15
9.2 Pulse outputs 15
9.3 Data + pulse inputs, type 402-0-10 16
9.4 Data + pulse outputs, type 402-0-11 16
9.5 M-Bus + pulse inputs, type 402-0-20 17
9.6 M-Bus + pulse outputs, type 402-0-21 17
9.7 M-Bus module with MULTICAL® III data package + pulse inputs,
type 402-0-29 17
9.8 Wireless M-Bus, type 402-0-30, 402-0-35 and 402-0-37 18
9.9 Radio, type 402-0-40 and 402-0-41 18
9.10 Radio+ pulse inputs, type 402-0-42 and 402-0-44 18
9.11 Radio+ pulse outputs, type 402-0-43 and 402-0-45 19
9.12 Module overview 20
10 Setup via front keys 21
3

1. General information
Read this guide before installing the 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 flow
sensor marking does not apply to
enclosed accessories
- Pressure stage, Kamstrup
sensor set type DS: PN16
- Pressure stage, Kamstrup
stainless steel pockets: PN25
At medium temperatures above 90°C in flow sensor, use of flange me-
ters is recommended, and the calculator should be wall-mounted.
2. Mounting of temperature sensors
The temperature sensors used to measure inlet and outlet temperatures
are a matched sensor set that must never be separated.
MULTICAL® 402 is by default supplied with mounted temperature sen-
sors. According to EN 1434 the cable length must not be changed. If
necessary, sensors must always be replaced in pairs.
One sensor is marked with a red sign and must be installed in the inlet
pipe. The other sensor is marked with a blue sign and must be installed
in the outlet pipe (see paragraph 8, page 14).
Note: The sensor cables must not be pulled. Be aware of this in case of
binding the cables.
4

2.1 Pocket sensor set
Preferably, sensor pockets must be mounted in tee-pieces or in 45° lat-
eral Y-pieces. The tip of the sensor pocket must point against the flow
direction and be placed in the middle of the water flow.
Temperature sensors should be inserted to 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 with the enclosed M4 sealing screw. Fasten the screw
with your fingers only. Seal the pockets using seal and locking wire.
5

2.2 Short direct sensor set
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 supply R½ and R¾ brass nipples fitting the short
direct sensors.
Short direct sensors can also be fitted directly into all Kamstrup’s
ULTRAFLOW® variants with G¾ and G1 threads on the meter case.
Fasten the brass unions of the sensors lightly (approx. 4 Nm) using a 12
mm face wrench and seal the sensors with seal and locking wire.
3. Information codes ”INFO”
MULTICAL® 402 constantly monitors a number of important functions. If
there is a serious error in the measuring system or installation, a flash-
ing “INFO” is displayed, and an info code can be read by activating the
top front key until the measuring unit displays “INFO”. The info code is
visible as long as the error exists, unless the meter has been specially
configured for ”manual reset of info codes”. When an info code has
existed for an hour, it is saved in the info log.
6

Info
Code
Description Response time
0 No irregularities -
1 Supply voltage has been interrupted -
8 Temperature sensor T1 outside measur-
ing range
 30 sec.
4 Temperature sensor T2 outside measur-
ing range
 30 sec.
4096 Flow sensor V1, signal too weak (air)  30 sec.
16384 Flow sensor with wrong flow direction  30 sec.
If several info codes appear at a time, the sum of the info codes is dis-
played. If e.g. both temperature sensors are outside measuring range,
info code 12 is displayed.
4. 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 pipe) appears from the front
label of the MULTICAL® 402. The flow direction is indicated by an arrow
on the side of the flow sensor.
4.1 Mounting of glands and short direct sensor mounted in
MULTICAL®402 flow part
The short direct sensor from Kamstrup can only be mounted in PN16
installations. The blind plug mounted in the MULITCAL® 402 flow part
can be used in connection with both PN16 and PN25.
7

The flow meter can be used in both PN16 and PN25 and can be sup-
plied marked either PN16 or PN25 as desired.
Possibly supplied glands can only be used for PN16. For PN25 installa-
tions shall be used suitable PN25 glands.
In connection with G¾x110 mm and G1x110 mm it shall be checked
that 10 mm thread run-out is sufficient. See the figure below.
Straight inlet: MULTICAL® 402 requires neither straight inlet nor straight
outlet to meet the Measuring Instruments Directive (MID) 2004/22/
EC and EN 1434:2007. A straight inlet section will only be necessary in
case of heavy flow disturbances before the meter. We recommend to
follow the guidelines of CEN CR 13582.
Gasket
Gasket
Tightening approx. 4 Nm
Gasket
Gasket
Tightening approx. 4 Nm
10
8

In order to prevent cavitation the operating pressure at
MULTICAL® 402 must be min. 1.5 bar at qp and min. 2.5 bar at qs. This
applies to temperatures up to approx. 80 °C.
MULTICAL® 402 must not be exposed to pressure lower than the ambi-
ent pressure (vacuum).
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 sys-
tems 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 should not be placed at the suction side of a pump
G A flow sensor ought not to be placed after a double bend in two
levels.
9

4.2 Mounting of MULTICAL® 402
90° 90°
MULTICAL® 402 can be mounted
vertically, horizontally or at an angle
MULTICAL® 402 must not be mounted
with the plastic box pointing upwards
MULTICAL® 402
may be turned up
to max. 45° and
downwards for max.
90° in relation to the
pipe axis.
10

4.3 Installation examples
Threaded meter:
Flange meter:
4.3.1 Humidity and condensation
If MULTICAL® 402 is installed in moist environments, it must be turned
45° relative to the pipe axis as shown in the drawing below.
Flow from the left Flow from the right
Flow from the left Flow from the right
45° If there is risk of condensation,
e.g. in cooling systems, a condensation protected
MULTICAL® 402 must be used.
11

5. Mounting the calculator
The MULTICAL® 402 calculator can be mounted in two different ways:
5.1 Compact mounting
The calculator is mounted direct on the flow sensor. After mounting the
calculator is sealed with seal and locking wire. In case of strong conden-
sation (e.g. cooling applications) we recommend wall mounting of the
calculator. Furthermore, MULTICAL® 402 must be the condensation pro-
tected version.
5.2 Wall mounting
If minimum installation depth (G¾ and G1) is re-
quired, the flow sensor is mounted with the plastic
case pointing downwards and the calculator on
the side
60 mm
The wall fitting makes it possible to mount
MULTICAL® 402 direct on an even wall. Use the
fitting as a template for marking and drilling
two 6 mm holes in the wall
41 mm
12

6. Power supply
MULTICAL® 402 can be powered by a built-in lithium battery or by an
integral 24 VAC or 230 VAC mains module.
The two wires from battery or mains module are mounted in the calcula-
tor via a two-contacts connector.
6.1 Battery supply
MULTICAL® 402 is connected to a lithium battery, D-cell or
2 x AA-cells.
Optimal battery lifetime is obtained by keeping the battery temperature
below 30 °C, e.g. by wall mounting.
The voltage of a lithium battery is almost constant throughout the life-
time of the battery (approx. 3.65 V). Therefore, it is not possible to de-
termine the remaining capacity of the battery by measuring the voltage.
The battery cannot and must not be charged and must not be short-
circuited. Used batteries must be handed in for approved de-struction,
f.inst. at Kamstrup A/S.
6.2 Mains modules
The modules are protection class II and are connected via a two-wire
cable (without earth) through the cable bush of the calculator placed
in the right side of the connecting base. Use connecting cable with an
outer diameter of 5-10 mm and ensure correct dismantling as well as
correct mounting of cable relief.
Max. permitted fuse: 6 A
National installation regulations must be obeyed.
13

24 VAC Supply
Black
Red
230 VAC Supply
Black
Red
24 VAC
F.inst. transformer 230/24 V, type
66-99-403, can be used.
Note! MULTICAL® 402 cannot be
supplied by 24 VDC.
230 VAC
This module is used for direct
mains connection.
Note! External supply must be con-
nected to the supply module
7. Testing the function
Carry out an operational check when the energy meter has been fully
mounted. Open thermoregulators and cocks to establish water flow
through the heating system. Activate the top key on
MULTICAL® 402 and check that the displayed values for temperatures
and water flow are credible values.
8. Electrical connection
The two pairede 2-wire sensors must be mounted in terminals 5 and 6
(T1), and 7 and 8 (T2). The polarity of temperature sensors T1 and T2 is
unimportant.
See the position of the terminals below:
Terminal no. Standard heat and cooling
measurement
T1 5–6 Sensor in inlet pipe (red)
T2 7–8 Sensor in outlet pipe (blue)
T1
T2
5
6
7
8
14

9. Plug-in modules
A number of extra functions can be added to MULTICAL® 402 by means
of plug-in modules. The individual modules are briefly described below.
9.1 Pulse inputs
Pulse inputs (VA) and (VB) are used for the connection of extra water
meters with either Reed switch output or passive electronic pulse
output. Min. pulse duration is 30 msec. and max. pulse frequency is 0.5
Hz.
If a module with pulse inputs is mounted in MULTICAL® 402, the meter
is automatically configured for pulse inputs.
Please note that the pulse figure (litres/pulse) must match between the
extra water meters and the configuration of VA and VB. After delivery the
configuration of VA and VB (config FF and GG) can be changed by means
of the PC program METERTOOL.
65 + (VA) Pulse input
66 -
67 + (VB) Pulse input
68 -
9.2 Pulse outputs
Pulse outputs for energy (CE) and volume (CV) are designed with
darlington optocouplers and are available with many of the plug-in
modules. Max. voltage and current is 30 VDC and 10 mA.
If a module with pulse outputs is mounted in MULTICAL® 402, the meter
is automatically configured for pulse outputs. The pulse duration is
ordered at 32 msec. or 0.1 sec. After delivery the pulse duration can be
changed by means of the PC program METERTOOL.
The resolutions of the pulse outputs always follow the least significant
digits of energy and volume respectively in the display.
16 + (CE) Pulse output for energy
17 -
18 + (CV) Pulse output for volume
19 -
15

9.3 Data + pulse inputs, type 402-0-10
The data terminals are used for connection of
e.g. a PC. The signal is passive and galvani-
cally separated by means of optocoup-lers.
Conversion into RS232 level requires connec-
tion of data cable 66-99-106
(D-Sub 9F) or 66-99-098 (USB) with the fol-
lowing connections:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
9.4 Data + pulse outputs, type 402-0-11
The data terminals are used for connection of
e.g. a PC. The signal is passive and galvani-
cally separated by means of optocoup-lers.
Conversion into RS232 level requires connec-
tion of data cable 66-99-106
(D-Sub 9F) or 66-99-098 (USB) as follows:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
Mounting an external antenna it must be secured that the antenna
cable does not become caught between the PCB and the stay of
the cover.
Replacing or mounting modules the meter must be without current.
The same applies when mounting an external antenna.
16

9.5 M-Bus + pulse inputs, type 402-0-20
M-Bus module with primary, secondary and
enhanced secondary addressing.
The module is connected to an M-Bus master
via terminals 24 and 25 using a twisted pair.
The polarity is unimportant.
The module is powered by the connected
master.
9.6 M-Bus + pulse outputs, type 402-0-21
M-Bus module with primary, secondary and
enhanced secondary addressing.
The module is connected to an M-Bus master
via terminals 24 and 25 using a twisted pair.
The polarity is unimportant.
The module is powered by the connected
master.
9.7 M-Bus module with MULTICAL® III data package + pulse
inputs, type 402-0-29
The M-Bus module 402029 comprises the
same data packet as M-Bus module 6604
for MULTICAL® III/66-C and module 660S for
MULTICAL® Compact/MULTICAL® 401.
The module can e.g. be used together with the
old M-Bus master with display, old regulators
and old reading systems not supporting the
newer M-Bus modules.
Mounting an external antenna it must be secured that the antenna
cable does not become caught between the PCB and the stay of
the cover.
Replacing or mounting modules the meter must be without current.
The same applies when mounting an external antenna.
17

9.8 Wireless M-Bus, type 402-0-30, 402-0-35 and 402-0-37
The radio module has been designed to form
part of Kamstrup’s hand-held Wireless M-Bus
Reader system, which operates in the licence-
free frequency band in the
868 MHz area.
The radio module comes fitted with internal
antenna as well as connection for external
antenna.
9.9 Radio, type 402-0-40 and 402-0-41
These radio modules are your first choice for
reading via Kamstrup’s hand-held reading sys-
tems, e.g. USB Meter Reader and hand-held
terminal MT Pro, which operate in the licence-
free frequency band in the 434 MHz area.
The radio module comes fitted with internal
antenna.
9.10 Radio+ pulse inputs, type 402-0-42 and 402-0-44
The radio modules have been optimized to
form part of a Kamstrup radio network system,
which operates in the licence-free frequency
band in the 434 MHz area, but can also be
used for the hand-held reading systems in the
same frequency area.
The radio module comes fitted with internal
antenna as well as connection for external
antenna and two pulse inputs.
Mounting an external antenna it must be secured that the antenna
cable does not become caught between the PCB and the stay of
the cover.
Replacing or mounting modules the meter must be without current.
The same applies when mounting an external antenna.
18