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: [phone] · [e-mail] · kamstrup.com

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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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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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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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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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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.
A
A
B
B
B
B
SECTION
B-B
SCALE
1 : 1

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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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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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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.
E
F
G
BC
D
A
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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MULTICAL® 403
3.3 Mounting of MULTICAL® 403 flow sensor
90° 90°
90° 90°
The flow sensor can be mounted horizontally, vertically, or at an angle.
90° 90°
The flow sensor should be mounted at 0° and can be turned downwards to 90°.

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MULTICAL® 403
3.4 Installation examples
Threaded meter:
Flow from the left Flow from the right
Flange meter:
Flow from the left Flow from the right
3.5 Humidity and condensation
If there is risk of condensation, e.g. in cooling
systems, a condensation-proof MULTICAL® 403,
type 403-T, must be used.

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MULTICAL® 403
4 Mounting the calculator
The MULTICAL® 403 calculator can be mounted in different ways; either direct on the flow sensor
(compact mounting), or on a wall (wall mounting).
4.1 Compact mounting
Compact mounting means that the calculator
is mounted directly on the flow sensor. Having
been mounted, the calculator is sealed
with seal and locking wire. If there is risk of
condensation (e.g. in cooling applications), the
calculator must be wall mounted. Furthermore,
MULTICAL® 403 in cooling applications must be
the condensation-proof version, type 403-T.
The construction of MULTICAL® 403 always
provides minimum installation depth in
connection with compact mounting. Due to the
design the mounting radius in critical places
remains 60 mm, both at 45° and 90° mounting
of the flow sensor.
90°
R60
45°
4.2 Wall mounting
MULTICAL® 403 can be mounted directly on an
even wall. Wall mounting requires a wall fitting
(3026-655), which is available as an accessory
to MULTICAL® 403. Use the fitting as a template
to mark and drill two 6 mm holes in the wall
and mount the fitting using the enclosed
screws and rawlplugs. Mount MULTICAL® 403
on the wall fitting by sliding the calculator
onto the fitting in the same way as it is done in
connection with compact mounting.
Note: For qp 3.5 flow sensors and larger it is
possible to demount the bracket from
the flow sensor and use it as a wall
bracket.
45

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MULTICAL® 403
4.3 Position of calculator
If the flow sensor is installed in a humid or
condensing environment, the calculator must
be wall mounted and positioned higher than the
flow sensor.

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MULTICAL® 403
5 Information codes ”INFO”
MULTICAL® 403 constantly monitors a number of important functions. If a serious error occurs in
the measuring system or the installation, a flashing “INFO” will appear in the display. The ”INFO”-
field keeps flashing as long as the error is present no matter which reading you choose. The
”INFO”-field is automatically switched off when the error has been corrected. The info code can be
displayed in in TECH loop reading 2-017-00, for indication of current errors in MULTICAL® 403. The
info code consists of 8 digits and each functionality has its own digit dedicated to the indication
of relevant information. For instance all information concerning temperature sensor t1 is shown in
the display as the second digit from the left.
Display digitDescription
1 2 3 4 5 6 7 8
Info t1t2 0 V1 0 In-A In-B
1 No voltage supply
2Low battery level
9 External alarm (e.g. via KMP)
1t1 Above measuring range or switched off
1t2 Above measuring range or switched off
2t1 Below measuring range or short-circuited
2t2 Below measuring range or short-circuited
9 9 Invalid temperature difference (t1-t2)
3 V1 Air
4 V1 wrong flow direction
6 V1 > qs for more than an hour
8 Pulse input A, leakage in system
9 Pulse input A, external alarm
8 Pulse input B, leakage in system
9 Pulse input B, external alarm
Example:
1 0 2 0 0 0 9 0

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MULTICAL® 403
6 Power supply
6.1 Battery supply
MULTICAL® 403 is available with battery supply using either two AA-cell batteries or one D-cell
battery. 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
lifetime of the battery (approx. 3.65 V). Therefore, it is not possible to determine the remaining
capacity of the battery by measuring the voltage. ”INFO” code ”2xxxxxxx” however, indicates low
battery level.
The battery cannot and must not be charged and must not be short-circuited. Used batteries
must be handed in for approved destruction, e.g. at Kamstrup A/S. Further details appear from
document on handling and disposal of lithium batteries (5510-408).

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MULTICAL® 403
6.2 Mains supply
MULTICAL® 403 is available with supply
modules for either 24 VAC or 230 VAC.
The modules are protection class II and are
connected via two-wire cable (without earth)
through the big cable bush, the second one
from the right, at the bottom of the connection
base. Use connecting cable with an outer
diameter of 5-10 mm and ensure correct cable
stripping as well as correct mounting of cable
relief.
If connecting to 230 VAC, it is important to
make sure that the whole installation complies
with current regulations. The supply cable
must not be protected by a fuse larger than
the one permitted for the given cable size, see
examples below.
Supply cable Max. Fuse
2 x 0.75 mm2
(accessory from Kamstrup A/S)
6 A
2 x 1.0 mm210 A
In connection with other types of installations
or requirements for larger fuses than the
ones listed above, it is necessary to consult a
certified electrician for an individual evaluation
of how the type of installation in question
should be carried out.
In addition please note that work on the fixed
installations, including any intervention in the
fuse box, must be carried out by an authorized
electrician.
Black
Red
61
60 97
98
24 VAC supply
24 VAC
3.6 V
24 VAC
E.g. transformer 230/24 V, type 66-99-403,
can be used.
Note: MULTICAL® 403 cannot be powered
by 24 VDC.
Black
Red
61
60
27
28
230 VAC supply
230 VAC
3.6 V
230 VAC
This module is used when the meter is supplied
directly by the mains.
Note: External supply must only be connected
to the supply module.

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MULTICAL® 403
7 Function check
Carry out an operational check when the energy meter has been fully mounted. Open
thermoregulators and valves to establish water flow through the system. Activate the left front key
(primary key) of MULTICAL® 403 to change display reading and check that the displayed values for
temperatures and water flow are credible values.
8 Electrical connection
The two matched two-wire sensors are
mounted in terminals 5 and 6 (t1) as well
as 7 and 8 (t2). The polarity of temperature
sensors t1 and t2 is without importance for the
functionality.
Please also see the position of the terminals in
the figure to the right:
Terminal no. Standard heat and
cooling measurement
t1 5-6 Sensor in inlet pipe
(red label)
t27-8 Sensor in outlet pipe
(blue label)

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MULTICAL® 403
9 Communication modules
MULTICAL® 403 can be extended by a wide range of extra functions by means of communication
modules. Below, pulse inputs/outputs and module types are briefly described.
Note: Before replacing or mounting modules, the supply to the meter must be switched off. The
same applies for mounting of an antenna.
9.1 Module overview
MULTICAL® 403 communication modules
Type No. Description
HC-003-10 Data + 2 pulse inputs (In-A, In-B)
HC-003-11 Data + 2 pulse outputs (Out-C, Out-D)
HC-003-20 M-Bus + 2 pulse inputs (In-A, In-B)
HC-003-21 M-Bus + 2 pulse outputs (Out-C, Out-D)
HC-003-30 Wireless M-Bus, configurable, 868 MHz + 2 pulse inputs (In-A, In-B), internal or
external antenna.
9.2 Pulse inputs
Pulse inputs A and B are used for connection of
extra meters with either Reed-switch output or
passive electronic pulse output.
Minimum pulse duration is 30 ms, max. pulse
frequency is 3 Hz.
If a module with pulse inputs is mounted in
MULTICAL® 403, the meter is automatically configured for pulse inputs. Please note that the pulse
figure (litres/pulse) must match the extra water meters and the configurations of inputs A and
B. After delivery the configurations of pulse inputs A and B (config FF and GG) can be changed by
means of the PC program METERTOOL HCW.
9.3 Pulse outputs
Pulse outputs for energy and volume are
made with darlington optocouplers, the pulse
outputs are available on a number of the
communication modules.
Max. voltage and current of the outputs are
30 VDC and 10 mA respectively.
When a module with pulse outputs is mounted in MULTICAL® 403, the meter is automatically
configured for pulse outputs. The pulse duration is ordered at 32 ms. or 100 ms. After delivery the
pulse duration can be changed by means of the PC program METERTOOL HCW.
The resolutions of the pulse outputs always follow the least significant digit displayed for energy
and volume respectively.
65 + Pulse input A
66 -
67 + Pulse input B
68 -
16 + Pulse output C
17 -
18 + Pulse output D
19 -

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MULTICAL® 403
9.4 Data + pulse inputs, type HC-003-10
The data terminals are used for connection of
e.g. a PC. The signal is passive and galvanically
separated by means of optocouplers.
Conversion to RS232 level requires connection
of data cable 66-99-106 (D-SUB 9F) or
66-99-098 (USB type A) with the following
connections:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
9.5 Data + pulse outputs, type HC-003-11
The data terminals are used for connection of
e.g. a PC. The signal is passive and galvanically
separated by means of optocouplers.
Conversion to RS232 level requires connection
of data cable 66-99-106 (D-SUB 9F) or
66-99-098 (USB type A) with the following
connections:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
9.6 M-Bus + pulse inputs, type HC-003-20
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 without importance for the
functionality.
The module is powered by the connected
master.