Kamstrup MULTICAL 41 Parts list manual

Technical description
MULTICAL® 41 Water meter
Kamstrup A/S
Industrivej 28, Stilling
DK-8660 Skanderborg
TEL: [phone]
FAX: [phone]
[email protected]
www.kamstrup.com

TECHNICAL DESCRIPTION MULTICAL®41
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TECHNICAL DESCRIPTION MULTICAL®41
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List of contents
1 General Description ..........................................................................................................5
1.1 Mechanical construction……………………………………………………………………………………………………………………….6
2 Technical Data ..................................................................................................................7
2.1 Approved meter data…………………………………………………………………………………………………………………………….7
2.2 Electrical data……………………………………………………………………………………………………………………………………….7
2.3 Mechanical data……………………………………………………………………………………………………………………………………7
2.4 Accuracy……………………………………………………………………………………………………………………………………………….8
2.5 Materials………………………………………………………………………………………………………………………………………………8
3 Type Overview ..................................................................................................................9
3.1 Type number, MULTICAL®41……………………………………………………………………………………………………………….10
3.2 PROG (A-B-CCC)…………………………………………………………………………………………………………………………………..11
3.3 CONFIG, DD-E-FF-GG…………………………………………………………………………………………………………………………….12
3.4 DATA…………………………………………………………………………………………………………………………………………………..13
3.5 Other functions……………………………………………………………………………………………………………………………………13
4 Dimensional Sketches ....................................................................................................14
5 Pressure Loss .................................................................................................................15
6 Installation .....................................................................................................................16
6.1 Installation requirements ……………………………………………………………………………………………………………………16
6.2 Installation angle for MULTICAL®41…………………………………………………………………………………………………….17
6.3 Straight inlet……………………………………………………………………………………………………………………………………….18
6.4 Installation example……………………………………………………………………………………………………………………………18
7 The Calculator.................................................................................................................19
7.1 Measurement and calculation…………………………………………………………………………………………………………….19
7.2 Push buttons………………………………………………………………………………………………………………………………………19
7.3 Display functions…………………………………………………………………………………………………………………………………20
7.4 Information codes……………………………………………………………………………………………………………………………….21
7.5 Reset functions……………………………………………………………………………………………………………………………………22
8 The Flow Sensor..............................................................................................................23
8.1 Ultrasound with piezo-ceramics…………………………………………………………………………………………………………..23
8.2 Principles……………………………………………………………………………………………………………………………………………23
8.3 The transit time method………………………………………………………………………………………………………………………23
8.4 Signal path………………………………………………………………………………………………………………………………………….25
8.5 Flow limits…………………………………………………………………………………………………………………………………………..25
8.6 Guidelines for dimensioning the MULTICAL®41…………………………………………………………………………………….25

TECHNICAL DESCRIPTION MULTICAL® 41
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9 Supply Modules ............................................................................................................. 26
9.1 Built-in D-cell lithium battery……………………………………………………………………………………………………………….26
9.2 Supply module 230 VAC………………………………………………………………………………………………………………………27
9.3 Supply module 24 VAC………………………………………………………………………………………………………………………..27
9.4 Exchanging the supply unit………………………………………………………………………………………………………………….27
9.5 Mains supply cables……………………………………………………………………………………………………………………………28
10 Plug-in Modules ............................................................................................................. 29
10.1 Data/pulse inputs (66-0R)…………………………………………………………………………………………………………………..29
10.2 M-Bus, EN 1434-3, EN 13757/pulse inputs (66-0P)
M-Bus, EN 1434-3/ pulse inputs (66-0S)…………………………………………………………………………………………….30
10.3 Radio (66-0L)………………………………………………………………………………………………………………………………………31
10.4 Radio (66-0M)…………………………………………………………………………………………………………………………………….32
11 Data Communication ...................................................................................................... 33
11.1 Optical reading……………………………………………………………………………………………………………………………………33
11.2 Optical data reading……………………………………………………………………………………………………………………………33
11.3 Data strings………………………………………………………………………………………………………………………………………….34
11.4 Communication driver…………………………………………………………………………………………………………………………35
12 Calibration and Verification............................................................................................ 36
12.1 Testing mode………………………………………………………………………………………………………………………………………37
12.2 Pulse Interface for MULTICAL®41…………………………………………………………………………………………………………38
13 Approvals....................................................................................................................... 39
13.1 Type approvals …………………………………………………………………………………………………………………………………..39
13.2 CE-Marking………………………………………………………………………………………………………………………………………….39
13.3 Measuring instrument directive …………………………………………………………………………………………………………..39
14 Trouble Shooting............................................................................................................ 41
15 Disposal......................................................................................................................... 42
16 Documents ..................................................................................................................... 43

TECHNICAL DESCRIPTION MULTICAL® 41
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1General Description
MULTICAL41 is a static water meter based on the ultrasonic principle. The water meter is based on experience
gained since 1991 of development and production of static ultrasonic meters.
The meter, which is intended for measurement of water comsumption in ”utility room environments”, has gone
through a very extensive OIML R 49 type test to secure a long-term stable, accurate and reliable meter. Some of
the many advantages of the water meter are among other things no wearing parts which improves the lifetime
significantly. Furthermore, the meter has a start flow of just 3 l/h which gives accurate measurements also at low
flow.
According to OIML R 49 the MULTICAL41 can be described as a ”complete water meter”. In practice this means,
that flow sensor and calculation unit must not be separated.
If flow sensor and calculation unit have been separated and the seals thereby broken, the meter will no longer be
valid for billing purposes, and the factory guarantee will not longer apply.
MULTICAL41 is based on ultrasonic measurement and a microprocessor technique. All circuits for calculation
and flow measurement are gathered in a single-board construction providing a compact and rational design, and
at the same time supreme measuring quality and reliability are achieved.
Volume measurement is carried out by means of bidirectional ultrasound technique according to the transit time
method which is a long-term stable and accurate measuring principle. Through two ultrasonic transducers the
sound signal is sent with and against the flow direction. The ultrasonic signal travelling in the flow direction will
reach the opposite transducer first, and the time difference between the two signals can subsequently be
converted into a flow velocity and thereby also a volume.
The accumulated water consumption is displayed in m3with seven significant digits and measuring unit. The
display is specially constructed to obtain a long lifetime and high contrast in a wide temperature range.
Other possible display indications are operating hour counter and current flow. MULTICAL41 can also be
configured to show peak flow, information code (info code), customer number and segment test.
MULTICAL41 is supplied from an internal lithium battery with a lifetime of up to 12 years. Alternatively, the
meter can be mains supplied, either from 24 VAC or 230 VAC.
In addition to the water meter’s own data, MULTICAL41 displays accumulated consumption for two extra meters
that supply a contact signal to MULTICAL41 via a Reed switch. The contact signals from the extra meters are
connected via the communication modules.
A multi-poled plug is placed under the top cover that is used partly for calibration and adjustment during
verification and partly in connection with communication modules. MULTICAL41 is supplied with
communication modules f.x. for radio, M-Bus and RS232.

TECHNICAL DESCRIPTION MULTICAL® 41
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1.1 Mechanical construction
1 Transparent top cover with front plate
2 Sealing screw for verification cover
3 Verification cover including push button. The lid of the supply unit can be opened without breaking
the verification
4 Supply: Battery, 24 VAC or 230 VAC. Can be replaced without breaking the verification
5 Case for electronics unit
6 Screws and rawlplugs for brackets – wall mounting
7 Brackets for wall mounting
8 Meter case
9 Strainer (accessory), see page 10
10 Prepared for current check valves (NF EN 13959)
4
3
1
2
5
6
7
8
9
Always delivered with the meter (article no. 3130-105)
10
Figur 1

TECHNICAL DESCRIPTION MULTICAL® 41
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2Technical Data
2.1 Approved meter data
OIML R 49 designation Accuracy class 2, environmental class B
Flow sensor types Q3 = 1.6 m3/h (see Table 1)
Media temperature in flow sensor 0.1C.…30C
Nom.
flow
Max.
flow
Min.
flow
Min. cut
off
Pressure
loss p
@ Q3
Connection
to sensor
Length
Type number m3/h m3/h l/hl/hbarmm
66-Zx-xx5-xxx Q3=1.6 Q4=2.0 Q1=16 3 0.28 G¾B 165
66-Zx-xx9-xxx Q3=1.6 Q4=2.0 Q1=16 3 0.28 G1B 190
Tabel 1
2.2 Electrical data
Supply voltage 3.6 V ± 5%
Battery 3.65 VDC, D-cell lithium
Replacement interval 12 years @ tBAT30°C
Mains supply 230 VAC +15/-30%, 50 Hz
24 VAC ±50%
Power consumption mains
supply
1W
Backup mains supply Integral super cap eliminates operational disturbances due to short-
term power cuts
EMC data Meets OIML R 49 class E1
2.3 Mechanical data
Metrological class 2
Environmental class Meets OIML R 49 class B
Electromagnetic environmental
class
Meets OIML R 49 class E1
Mechanical environment MID class M1
Ambient temperature 0…55°C
Protection class IP54
Medium temperature 0.1…30°C
Storage temperature, empty
meter
-25…60°C
Pressure stage (with thread) PN16
Flow sensor cable 1.4 m

TECHNICAL DESCRIPTION MULTICAL® 41
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2.4 Accuracy
MPE (Maximum Permissible Error).
MPE according to OIML R 49
5 % in the range Q1 Q Q2
2 % in the range Q2 Q Q4
Diagram 1: OIML R 49 requirements to water meters
2.5 Materials
Wetted parts
Housing, gland Enkotal (alpha brass)
Transducer AISI 316
Gaskets EPDM
Measuring pipe PES 30% GF
Reflectors AISI 304
Flow sensor housing
Wall/fittings PC + 20% glass
Calculator housing
Top PC
Base ABS with TPE gaskets (thermoplastic elastomer)
Internal cover PP
Flow sensor cable
Silicone cable with internal teflon insulation

TECHNICAL DESCRIPTION MULTICAL® 41
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3Type Overview
3.1 Type number
66-Z?-??X-???
Flow sensor
The type number of the flow sensor cannot be
changed after programming at the factory.
3.2 PROG (total programming)
A-B-CCC
3.3 CONFIG (partial programming)
DD-E-FF-GG
3.4 DATA (partial programming)
- Customer no.
- Target date
- Peak average time
-- Date/time
- Telephone numbers
- Preset VA and VB

TECHNICAL DESCRIPTION MULTICAL® 41
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3.1 Type number, MULTICAL41
Type 66-Z
 
0

Modules
No module 0
M-Bus/pulse inputs (secondary addressing) P
Data/pulse inputs R
M-Bus/pulse inputs (primary addressing) S
Radio/pulse output L
Radio with external antenna connection/pulse output M
Supply
No module 0
Battery, D-cell 2
230 VAC supply module 7
24 VAC supply module 8
Flow sensor
Q3 m3/hConnection Length mm
1.6 G¾B (R½) 165 5
1.6 G1B (R¾) 190 9
Country code 7XX
In addition, the country code can be used for:
Language and approval on type label
Flow sensor dynamic range (1:100)
Marking of PN class
Special verification, if any
Customer labels (2001-XXX) are integrated into the front label.
3.1.1 Accessories
Glands incl. gaskets
6561-323 Gland incl. gasket for DN15, (R½ x G¾), two
6561-324 Gland incl. gasket for DN20, (R¾ x G1), two
Gaskets
Gasket for gland
G¾ Type no. 2210-061
G1 Type no. 2210-062
Strainer for flow sensor inlet
6556-484 Strainer DN15 for G¾B (R½), 10 strainers, not for 110 mm housing
6556-485 Strainer DN20 for G1B (R¾), 10 strainers
Anti-pollution check valve (EN 13959) for flow sensor return, incl. PE gasket
6556-480 Anti-pollution check valve DN15 for G¾B, incl. strainer and two PE gaskets, not for
110 mm housing ( PE = Polyethylene)
6556-481 Anti-pollution check valve DN20 for G1B, incl. strainer and two PE gaskets
PE gasket for strainer and anti-pollution check valve
6556-494 DN15 (10 gaskets)
6556-495 DN20 (10 gaskets)

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3.2 PROG (A-B-CCC)
Programming number A - B - CCC
34
Flow sensor placing Internal value
Measuring unit Internal value
Flow sensor coding CCC
3.2.1 Standard CCC-codes
CCC-table for MULTICAL41
Number of decimals on the display
CCC no. m³ l/h Q3
m³/h
Type
66-Zx-xxX-xxx
119 2 0 1.6 5-9

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3.3 CONFIG, DD-E-FF-GG
3.3.1 >DD< CONFIGURATION OF DISPLAY
DD - codes >Primary<
Level 1 81 82
Volume 1 1
Hour counter 2 2
Actual flow 3 3
Peak flow (monthly) 4 4
Yearly peak flow
Allinfo.
All info., however (-2) 5 5
DD - codes >Secondary<
Level A 81 82
VA A
VB B
Readingdate1
Volume1
Yearly peak flow 1
Readingdate2
Volume2
Yearly peak flow 2
Monthly data 1-12 A C
Monthly volume B D
Monthly peak flow C E
Prog no.
Customer no. D F
Actualdate
Software edition E G
Segment test F H
Selection of peak power or peak flow for monthly data (/#5), see 11.3
NB: Info code 128 is automatically controlled in the factory/METERTOOL- configuration:
Type 66-Zx-2xx-xxx Info code 128 is active. In connection with other supply modules Info code 128 is not
active.
NBB: Remember that replacing of battery for power supply requires reconfiguration of the type number.
Yearly peak values are updated at the turn of the month.

TECHNICAL DESCRIPTION MULTICAL® 41
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3.3.2 >E< Configuration is not used for MULTICAL41
Set default at: 0
3.3.3 >FF< Input a, >GG< Input b, pulse separation (f 0.5 Hz)
Input a
Terminal 65-66 Input b
Terminal 67-68
FF Max. input
GG Max. input
Pre-counter l/pulse Measuring unit and decimal
point
00 OFF 00 OFF - - - -
01 50 m³/h 01 50 m³/h 1 100 m³a – m³b 000000.0
02 25 m³/h 02 25 m³/h 2 50 m³a – m³b 000000.0
03 12 m³/h 03 12 m³/h 4 25 m³a – m³b 000000.0
04 5 m³/h 04 5 m³/h 10 10 m³a – m³b 000000.0
05 2.5 m³/h 05 2.5 m³/h 20 5.0 m³a – m³b 000000.0
06 1 m³/h 06 1 m³/h 40 2.5 m³a – m³b 000000.0
07 0.5 m³/h 07 0.5 m³/h 100 1.0 m³a – m³b 000000.0
24 5 m³/h 24 5 m³/h 1 10 m³a – m³b 00000.00
25 2.5 m³/h 25 2.5 m³/h 2 5.0 m³a – m³b 00000.00
26 1 m³/h 26 1 m³/h 4 2.5 m³a – m³b 00000.00
27 0.5 m³/h 27 0.5 m³/h 10 1.0 m³a – m³b 00000.00
40 500 m³/h 40 500 m³/h 1 1000 m³a – m³b 0000000
NB: Electricity meters cannot be connected as 1 sec. pulse and pause are required.
3.4 DATA
Automatic To be stated when ordering Default
Serial no. (S/N) and year E.g. 2500000/2005 - -
Customer no. - Up to 11 digits Customer no. = S/N
Target date - MM=1-12 and DD=1-28 06.01 (1 June)
TL2 - - 0
TL3 - - 0
Peak average time - 1…120 min. 60 min.
Date/time YY.MM.DD/hh.mm.ss - -
Telephone number #1 - Max. 12 -
Telephone number #2 - Max. 12 -
3.5 Other functions
When making orders in BOS, select ”Locked M-Bus adr.” and all meters in one order are made with the same
customer number, e.g. 001. However, this requires customer label 2001-500 or higher.

TECHNICAL DESCRIPTION MULTICAL® 41
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4Dimensional Sketches
MULTICAL®41
Figur 2: Mechanical dimensions of the electronic unit
Figur 3: Flow sensor with G¾ and G1 thread connection
Thread L M H2 A B1 B2 H1
Approx.
weight
kg
G¾ (Q3=1.6) 165 L/2 92.5 20.5 42 28 47.5 1.7
G1 (Q3=1.6) 190 L/2 92.5 20.5 42 28 47.5 2.0
Tabel 2: Total weight excluding packing

TECHNICAL DESCRIPTION MULTICAL® 41
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5Pressure Loss
According to OIML R 49 the max. pressure loss must not exceed 1.0 bar in the range Q1 to Q4.
The pressure loss in a meter increases by the square of the flow and can be stated as:
pkvQ 
where:
Q =volume flow rate [m³/h]
kv=volume flow rate at a pressure loss of 1 bar [m³/h]
p=pressure loss [bar]
Q3 Nom. diameter Q@p 0.28 bar
Graph [m³/h] [mm] kv [m³/h]
A 1.6 DN15 & DN20 3 1.6
Tabel 3: Pressure loss table
Diagram 2: Pressure loss graph
p MULTICAL®
41
0,01
0,1
1
0,1 1 10
Flow [m³/h]
p [bar]
A

TECHNICAL DESCRIPTION MULTICAL® 41
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6Installation
6.1 Installation requirements
Before mounting MULTICAL®41, flush the system thoroughly with a fitting pipe mounted instead of the meter.
Then remove the protection caps from the input and the output of the meter and mount the flow sensor with
glands. Always use new packings in original quality.
In connection with mounting please make sure that the thread length of the glands does not prevent the sealing
surface from being sufficiently tightened, and that NP10 glands are used (PN16 threads/glands can be used as
well).
Correct position of the flow sensor. An arrow on the flow sensor indicates the flow direction.
The meter connection cables must be placed in such a way that condensed water cannot get into the meter.
Permitted operating conditions:
Ambient temperature: 0…55C
Medium temperature: 0.1…30C
System pressure: 1.5…16 bar (depending on gaskets/glands)
EMC conditions
MULTICAL®41 is intended for installation in residential houses as well as in light industrial environments and the
meter is CE marked according to OIML R 49 type test class E1 and the low-voltage directive.
Control cables from the meter must be drawn at a minimum distance of 25 cm from other installations.
Electrical installations
MULTICAL®41 is available for both 24 VAC and 230 VAC mains supply. The mains connection is made with a 2
wire cable without earth connection.
Use a strong connection cable with an outside diameter of max. 7 mm and ensure that the meter has a correct
cable retainer.
National regulations for electric installations must always be met, including e.g. a cable cross section used in
relation to the fuse size of the installation (short-circuit current). Max. fuse 6 A.
For installations made in Denmark, the information from ”Elråd” concerning ”installations for mains supplied
heat meters” applies to both direct 230 VAC supplied meters and 24 VAC meters supplied via a safety
transformer.
Service
When the meter has been mounted in the system neither welding nor freezing is permitted. Dismount the meter
from the system and disconnect the mains supply to the meter, if any, before the work is started.
To facilitate possible replacement of the meter, closing valves should always be mounted on both sides of the
meter.
Under normal operating conditions no strainer is required on the front of the meter.

TECHNICAL DESCRIPTION MULTICAL® 41
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6.2 Installation angle for MULTICAL®41
Figur 4
Figur 5
Figur 6
MULTICAL®41 can be installed horizontally,
vertically or at an angle.
Important!
MULTICAL®41 can be turned upwards to
max. 45° and downwards to max. 90° in
relation to the pipe axis.
Do not turn the plastic housing upwards.

TECHNICAL DESCRIPTION MULTICAL® 41
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6.3 Straight inlet
MULTICAL®41, DN15 (G¾) and DN20 (G1): No requirements
6.4 Installation example
Figur 7: Wall mounting of MULTICAL®41

TECHNICAL DESCRIPTION MULTICAL® 41
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7The Calculator
7.1 Measurement and calculation
MULTICAL41 uses time based integration, i.e. calculations of accumulated volume are carried out at fixed
intervals irrespective of the actual water flow. In normal mode MULTICAL41 has an integration interval of 28
sec., whereas in ”fast mode” it has an interval of 4 sec.
”Normal mode”
In normal mode MULTICAL41 passes through an integration sequence of 28 sec. Through this sequence the
water flow is measured at intervals of averagely 3.5 sec. All display values are updated at intervals of 28 sec. In
addition, the display showing actual flow is updated at intervals of 14 sec.
”Fast mode”
In fast mode MULTICAL41 passes through an integration sequence of 4 sec. Through this sequence the water
flow is measured at intervals of averagely 1 sec. At the end of the sequence the volume calculations are made.
All display values are updated at intervals of 4 sec.
7.2 Push buttons
MULTICAL41 has a front key for display change showing the main menu with primary registers. During normal
operation the display shows the accumulated volume in m3.
By activating the front key the display e.g. shows actual flow, peak flow (monthly), hour counter etc. (see section
3.1.1 Configuration of the display).
If the front key is activated for 4 sec., the display changes to a submenu showing secondary registers such as
Input A, Input B, tariffs and customer number (see section 3.1.1 Configuration af the display).
Figur 8
Under the transparent top cover an internal push button ”P” is found. This button is used during verification of
the meter (see section 12 Calibration and verification).
”P” button
Front key

TECHNICAL DESCRIPTION MULTICAL® 41
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7.3 Display functions
No matter which display has been selected in the main menu or submenu, the display will automatically change
into showing accumulated volume, when the front key has not been activated for 150 sec.
Figur 9
The contents of both main and submenus are determined by the configuration selected for the meter (see section
3.3.1 Configuration of the display). The display in MULTICAL41 includes both a main menu and a submenu. The
main menu includes accumulated volume, flow readings, hour counter and info codes (error codes). When the
front key is activated briefly, the display moves through the readings.
The submenu with secondary registers is activated by pressing the front key for 4 sec. Afterwards the front key
can be used to move through the submenu readings. When the submenu has been selected, An ”A” will appear in
the left side of the display.
Figur 10