Kamstrup MULTICAL 601 User manual

Installation
and User’s Guide
MULTICAL® 601 &
ULTRAFLOW®
www.kamstrup.com

MID designations
Rated operation conditions/measuring ranges:
Calculator q: 10°C…180°C DΘ: 3K…170K
Temperature sensor pair q: 10°C…150°C DΘ: 3K…140K
Flow sensor q: 15°C…130°C
Mechanical environment:
M1 (fixed installation with minimum vibration).
Electromagnetic environment:
E1 and E2 (Domestic, light industrial and industrial). Signal cables from the meter
must be separated by at least 25cm distance to other installations.
Maintenance and repair:
The heat supplier is allowed to change communication module, battery,
temperature sensor pair and flow sensor. Sensor pair and flow sensor are
separately verified and can, therefore, be separated from the calculator. All repairs
require a following re-verification on an accredited laboratory.
Climatic environment:
The installation shall be made in non-condensing environments and in closed
location (indoor). The ambient temperature must be within 5…55°C.
MULTICAL® 601, type 67-B/C/D is suitable for temperature sensors type Pt500
MULTICAL® 601, type 67-A is suitable for temperature sensors type Pt100
Battery for replacement: Kamstrup type 66-00-200-100
MULTICAL® 601, type 67-A/B/C can be connected to flow sensor type ULTRAFLOW®,
electronic pick-up unit or flow sensor with reed switch output.
MULTICAL® 601, type 67-D must be connected to a flow sensor with 24 V active
pulse output.
Irrespective of flow sensor type, ”pulse/litres” must be identical on flow sensor and
calculator.

MULTICAL® 601 & ULTRAFLOW®
English
INSTALLATION
Kamstrup A/S
Industrivej 28, Stilling, DK-8660 Skanderborg
Tel: [phone] · Fax: [phone]
[e-mail] · www.kamstrup.com

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Contents
General information 4
Mounting of temperature sensors 4
Pocket sensor pair 4
Short direct temperature sensor set 5
Information codes “INFO” 5
Mounting of flow sensor 6
Mounting of ULTRAFLOW® ≤DN125 7
Mounting of ULTRAFLOW® 54 ≥DN150 7
Mounting of ULTRAFLOW® 65 ≥DN150 7
Installation examples 8
Mounting of the calculator 9
Compact mounting 9
Separately/wall mounting 9
Panel mounting 9
Power supply for calculator/Pulse Transmitter 10
Battery supply 10
Mains modules 10
Operational check 11
Electrical connection for MULTICAL® and ULTRAFLOW® 11
Connection example 11
Calculator with two flow sensors 12
Plug-in modules 13
Data + pulse inputs, type 67-00-10 13
M-Bus, type 67-00-20/27 13
Radio + pulse inputs, type 67-00-21/25/26 14
Prog. data logger + RTC + 4…20 mA inputs + pulse inputs (67-00-22) 14
Analog outputs 15
Lon Works 15
Wireless M-Bus, type 67-00-30 15
ZigBee + pulse inputs, type 67-00-60 15
Metasys N2 + pulse input, type 67-00-62 15
Top modules 16
Electrical connection for MULTICAL®, ULTRAFLOW® and Pulse Transmitter 19

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1. General information
Read this guide before installing the energy meter. If the meter is installed
incorrectly, Kamstrup’s guarantee obligations will no longer apply.
Please note that the following installation conditions must be obeyed:
- Pressure stage ULTRAFLOW®: PN16/PN25/PN40, see marking. Marking of flow
part does not cover included accessories
- Pressure stage Kamstrup
sensor set type DS: PN16
- Pressure stage Kamstrup
stainless steel pockets: PN25/PN40 - depending on type
If the medium temperature exceeds 90°C we recommend to use flange meters and
to mount MULTICAL® 601 on the wall.
2. Mounting of temperature sensors
Temperature sensors used to measure flow and return temperatures make
up a matched pair of sensors and must never be separated.
Usually, MULTICAL® 601 is supplied with mounted temperature sensors. According
to EN 1434 or OIML R75 the cable length must not be changed. Replacement of
sensors, if required, must always be made in pairs.
One sensor is marked with a red sign, and must be installed in the flow pipe.
The other sensor is marked with a blue sign, and must be installed in the return
pipe (see paragraph 8 on page 11).
2.1 Pocket sensor pair
Preferably, sensor pockets must be mounted in tee-pieces or in 45°C lateral
Y-pieces. The tip of the sensor pocket must be placed pointing towards the
flow direction and in the middle of the water flow.
Temperature sensors should be inserted to the bottom of the pockets. If a quick
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 supplied M4 sealing screw. Fasten the screw with your fingers only.
Seal the pockets using seal and sealing wire.

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2.2 Short direct temperature sensor set
The short direct sensor can be mounted in special ball valves or in special
angle 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 also supply R½ and R¾ brass nipples which fit the short direct sensors.
The short direct sensor can also be fitted directly into all ULTRAFLOW® variants from
Kamstrup A/S with G¾ and G1 thread on the meter case. Fasten the brass unions of
the sensors lightly (approx. 4 Nm) by means of a 12 mm face wrench, and seal the
sensors with seal and wire.
3. Information codes “INFO”
MULTICAL® 601 constantly monitors a series of important functions. If a serious
error occurs in the measuring system or in the installation, an “INFO” appears in the
display and an info code can be read by activating the upper front plate button until
the measuring unit shows an “INFO” in the display. The info code is only visible
while the error exists.
Info code Description Response time
0 No irregularities -
1 Supply voltage has been cut off -
8 Temperature sensor T1 outside measuring
range
1…10 min.
4 Temperature sensor T2 outside measuring
range
1…10 min.
32 Temperature sensor T3 outside measuring
range
1…10 min.
64 Leak in the cold-water system 24 hours
256 Leak in the heating system 24 hours
512 Burst in the heating system 120 sec.
ULTRAFLOW® 54 info (if activated CCC=4XX)
16 Flow sensor V1, Datacomm error,
signal too low or wrong flow direction
After reset and 1 day (00:00)
1024 Flow sensor V2, Datacomm error,
signal too low or wrong flow direction
After reset and 1 day (00:00)
2048 Flow sensor V1, Wrong meter factor After reset and 1 day (00:00)
128 Flow sensor V2, Wrong meter factor After reset and 1 day (00:00)
4096 Flow sensor V1, Signal too low (Air) After reset and 1 day (00:00)
8192 Flow sensor V2, Signal too low (Air) After reset and 1 day (00:00)
16384 Flow sensor V1, Wrong flow direction After reset and 1 day (00:00)
32768 Flow sensor V2, Wrong flow direction After reset and 1 day (00:00)
If several info codes appear at the same time the sum of the info codes is shown. E.g. if
both temperature sensors are outside measuring range, info code 12 will appear.

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4. Mounting of flow sensor
Before mounting the flow sensor, flush the system thoroughly and remove pro-
tection plugs/plastic membranes from the flow sensor. Correct flow sensor position
(flow or return pipe) appears from the front label placed on the MULTICAL® 601. The
flow direction is indicated by an arrow on the side of the flow sensor.
Glands and gaskets must be mounted as shown on the above drawing.
Straight inlet: ULTRAFLOW® requires neither straight inlet nor outlet to meet the
Measuring Instruments Directive (MID) 2004/22/EEC, OIML R75:2002 and EN
1434:2007. Only in case of heavy flow disturbances before the meter will a straight
inlet section be necessary. We recommend to follow the guidelines in CEN CR
13582.
To prevent cavitation, the operating pressure at the ULTRAFLOW® must be min. 1.5
bar at qp and min. 2.5 bar at qs. This applies to temperatures up to approx. 80°C.
ULTRAFLOW® must not be exposed to pressures below ambient pressure (vacuum).
Tightening approx. 4 Nm
Gasket
Gasket
A Recommended position of flow meter
B Recommended position of flow meter
C Unacceptable position due to risk of
air build-up
D Acceptable in closed systems.
Unacceptable position in open
systems due to risk of air build-up
E A flow meter ought not to be placed
immediately after a valve, except from
closing valves (ball check valve type),
which must be completely open when
not used for closing
F Never place a flow meter on the inlet
side of a pump
G A flow meter ought not to be placed
after a double bend, in two levels.

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4.1 Mounting of ULTRAFLOW® ≤DN125
4.2 Mounting of ULTRAFLOW® 54 ≥DN150
See Installation Guide No. 5512-887.
4.3 Mounting of ULTRAFLOW® 65 ≥DN150
With ULTRAFLOW® ³DN150 (150 m3/h) the box containing electronics must be
placed on the top of the meter when it is installed horizontally.
ULTRAFLOW® may be turned up to ±45° in relation to the pipe axis.
90° 90°
ULTRAFLOW® must be mounted vertically,
horizontally or at any angle in between.
Electronics/plastic case must
be placed on the side (when
installed horizontally).
Max. 45°
Max. 45°
ULTRAFLOW® may be turned up to
±45° in relation to the pipe axis.
The ULTRAFLOW® housing must not be
mounted facing upwards or downwards.
90° 90°
Max. 45° Max. 45°

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4.4 Installation examples
Threaded meter with MULTICAL®/Pulse Transmitter mounted on ULTRAFLOW®.
Flange meter with MULTICAL®/Pulse Transmitter mounted on ULTRAFLOW®.
4.4.1 Humidity and condensation
When installed in humid environments ULTRAFLOW® must be turned 45° in
relation to the pipe axis as shown below.
Flow from the left Flow from the right
Flow from the left Flow from the right
By means of the angle bracket MULTICAL®
can be mounted in two positions.
Angle bracket type 3026-252 must
be ordered separately.
10190
91
27
45°
81
63
45° If condensation is likely, e.g. in cooling
systems, an ULTRAFLOW® which is protected
against condensation must be used.

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5. Mounting of the calculator
The MULTICAL® 601 calculator can be mounted in three different ways:
5.1 Compact mounting
The calculator is fitted directly onto the flow sensor, by means of an angle bracket,
if necessary. Once the calculator has been mounted it must be sealed with seal
and wire. In connection with heavy condensing (e.g. cooling applications) we
recommend to mount the calculator on the wall. See also section ”4.1 Mounting of
ULTRAFLOW®£DN125” on page 7.
5.2 Separately/wall mounting
5.3 Panel mounting
MULTICAL® 601 can be mounted directly into panels by means of Kamstrup’s panel
mounting kit, no. 66-99-104 (192 x 144 mm).
The wall bracket gives you the opportunity of
mounting MULTICAL® 601 directly on an even wall.
Use the bracket as a template to mark and drill two
holes with a diameter of 6 mm in the wall.
52 mm

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6. Power supply for calculator/Pulse Transmitter
MULTICAL® 601 can be power supplied by means of a built-in lithium battery, an
internal 24 VAC mains module or an internal 230 VAC mains module.
The two wires from the battery or mains module are mounted in terminals 60 and
61 of the calculator.
The polarity has to be correct; connect the red wire to terminal no. 60 (+)
and the black wire to terminal no. 61 (-).
6.1 Battery supply
MULTICAL® 601 is connected to a lithium battery, D-cell. The battery is marked with
installation year, e.g. 2009, as well as production date.
Optimal battery life 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 whole lifetime of
the battery (approx. 3.65 V). Therefore, it is not possible to determine the remaining
capacity 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 destruction, e.g. at Kamstrup’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 a connecting cable with an outer diameter of
5–10 mm and ensure correct dismantling as well as correct mounting of the cable
relief.
Max. permitted fuse: 6 A
National installation regulations must be obeyed.
Black
Red
Black
Red
24 VAC
E.g. transformer 230/24 V,
type 66-99-403 can be used.
NB! MULTICAL® 601 cannot be
supplied from 24 VDC.
230 VAC
This module is used for direct mains
connection.
NB! External supply must only be
connected to the supply module.

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7. Operational check
Carry out a operational check when the energy meter has been fully mounted. Open
the thermo-regulators and cocks in order to establish a water flow through the
heating system. Activate the upper push button on the MULTICAL® 601 and check
that the display values for temperature and water flow are reliable.
8. Electrical connection for MULTICAL® and
ULTRAFLOW®
The polarity of the temperature sensors T1, T2 and T3 is
unimportant. Use below colours at the flow sensors V1 and V2
when connecting the ULTRAFLOW® and electronic pick-up units.
Flow sensors with Reed switch output must be connected to
terminals 11-10 and 11-69, respectively.
V1 V2
-11 11 Blue
+9 9 Red
SIG 10 69 Yellow
Terminal
No.
Standard
measurement of
heat and cooling
Heat measurement
and leak surveil-
lance
Energy
measurement
in open systems
T1 5–6 Sensor in flow pipe
(red)
Sensor i flow pipe
(red)
Sensor in flow pipe
(red)
T2 7–8 Sensor in return pipe
(blue)
Sensor in return pipe
(blue)
Sensor in return pipe
(blue)
V1 11–9–10 Flow sensor in
flow or return pipe
Flow sensor
in flow pipe
Flow sensor
in flow pipe
V2 11–9–69 - Flow sensor
in return flow pipe
Flow sensor
in return pipe
T3 51–52 - Tank/heat exchanger
temperature
Reference sensor
(grey)
8.1 Connection example
Example of connection between ULTRAFLOW® and MULTICAL® (battery supply).
ø4...6 mm
M16, ø4...9 mm

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8.2 Calculator with two flow sensors
MULTICAL® 601 can be used in various applications with two flow sensors, e.g. leak
surveillance or open systems. When two ULTRAFLOW® are direct connected to one
MULTICAL® 601, a close electric coupling between the two pipes ought to be carried
out as a main rule. 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.
• Forward and return pipes are closely electrically coupled
• No welded joints occur
In installations where the electric coupling cannot be carried out, or where welding
in the pipe system can occur, the cable from one ULTRAFLOW® must be routed
through a Pulse Transmitter with galvanic separation before the cable enters
MULTICAL® 601.
• Forward and return pipes are not necessarily closely coupled
• Electric welding *) can occur
*) Electric welding must always be carried out with the earth pole closest to the
welding point. Damage to meters due to welding is not comprised by our factory
guarantee.
ULTRAFLOW® 54
MULTICAL® 601
Electric coupling
ULTRAFLOW® 54
MULTICAL® 601
Pulse Transmitter

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9. Plug-in modules
MULTICAL® 601 can be extended with a number of extra functions in the form
of plug-in modules. Below is a short description of the individual modules.
9.1 Data + pulse inputs, type 67-00-10
Data terminals are e.g. used for connecting a PC.
The signal is passive and galvanically separated
through optocouplers. Conversion into RS232 level
requires connection of data cable 66-99-106 (D-Sub 9F)
or 66-99-098 (USB) with the following connections:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
NB! If data reading must be compatible with
MULTICAL® 66-CDE, top module 67-06 must
be used in MULTICAL® 601.
The pulse inputs can be used for connecting electricity and water meters. Please
note the maximum pulse frequency and correct pulse coding (l/pulse and Wh/
pulse) which are selected by means of the FF and GG configuration.
65 - 66 Input A
67 - 68 Input B
9.2 M-Bus, type 67-00-20/27
M-Bus can be mounted in star, ring or bus topology. Depending on the power
supply of the M-Bus Master as well as the total cable resistance, up to 250 meters
can be connected.
Cable resistance <29 Ohm
Cable capacity <180 nF
The M-Bus network is to be connected to
terminals 24 and 25. The polarity is unimportant.
M-Bus is supplied with pulse inputs.

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9.3 Radio + pulse inputs, type 67-00-21/25/26
The radio module is used for wireless communication via a
license-free radio frequency and is available for internal or
external antenna.
For further information on radio please refer to
Technical Description for Radio (5512-013).
The pulse inputs in this module are identical with
the ones described earlier.
NB! Type 67-00-21 includes radio and router funtions.
The RadioRouter module (67-00-21) must be used with
mains supply.
9.4 Prog. data logger + RTC + 4…20 mA inputs + pulse inputs (67-00-22)
The module has connection possibility for two pressure
transmitters on terminals 57, 58 and 59 and can be
adjusted for current reading or pressure ranges of 6, 10 or
16 bar.
The module is prepared for remote reading, data from
meter/module being transferred to the system software
via the connected external GSM/GPRS modem on
terminals 62, 63 and 64.
Furthermore, the module has two extra pulse inputs, VA
and VB.
The module must always be powered by 24 VAC.

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9.5 Analog outputs
Type 67-00-23, see Installations manual 5512-369 (DK-GB-DE).
9.6 Lon Works
Type 67-00-24, see Installations manual 5512-396 (DK) or 5512-403 (GB).
9.7 Wireless M-Bus, type 67-00-30
The radio module has been designed to form part of the hand-held Wireless M-Bus
Reader systems of Kamstrup A/S using license-free radio frequency (868 MHz).
The module fulfils the C-mode specifications of prEN13757-4 and can, thus, also be
part of other systems using wireless M-Bus C-mode communication.
The module comes with internal antenna and connection for external antenna as
well as two pulse inputs, which are identical with the previously described pulse
inputs.
9.8 ZigBee + pulse inputs, type 67-00-60
The ZigBee module is used for wireless communication and can form part of a
remote reading system, enabling several units to communicate with each other.
The pulse inputs of this module are identical with the previously described pulse
inputs.
The ZigBee module (67-00-60) requires mains supply.
9.9 Metasys N2 + pulse input, type 67-00-62
The N2 module is used for data communication between meters and N2 Masters in
a Johnson Controls System.
The RS485 port is galvanically separated from the meter.
The pulse inputs of this module are identical with the previously described pulse
inputs.
The N2 module (67-00-62) requires mains supply.

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9.10 Top modules
Type 67-01: RTC (Real Time Clock)
The top module consists of real time clock and
battery backup.
When the MULTICAL® 601 calculator top is placed
in the connecting bracket and is powered, current
date and time is transferred from the top module to
the calculator.
The top module is recommended for applications in
which correct date/time in data loggers as well as in
time-controlled tariff is considered important.
Real time clock and battery backup are standard
features in all other top modules.
Terminal screws are not used in this module.
Type 67-02: RTC + Denergy calculation and time
data logger
This top module calculates the difference between
forward and return energy, whereby an expression
of the tapped energy in open systems is obtained.
The module also comprises a time data logger.
Terminal screws are not used in this module
Type 67-03: RTC + PQ-limiter + hourly data logger
The module has two pulse outputs which can be
used for UP/DOWN control of a low-speed three-
point motor-operated valve via an external solid-
state relay, type S75-90-006 and a 230/24 V trafo,
type 66-99-403.
The required power and flow limits are entered into
MULTICAL® 601 via the PC-program METERTOOL.
Also see instructions: 5512-498.
The module also includes an hourly data logger.
Type 67-05: RTC + data output + hourly data logger
The module has a galvanically separated data port
which functions together with the KMP-protocol.
The data output can be used for e.g. connection of
external communication units or other hardwired
data communication which it is not expedient to
carry out via the optical communication on the
meter’s front.
62: DATA (Brown) – 63: REQ (White) – 64: GND
(Green). Use data cable type 66-99-106 with 9-pole
D-sub or type 66-99-098 with USB connector.
The module also includes an hourly data logger.
Only current and accumulated data can be read.
Data loggers for time/days/months/years cannot
be read through the data port of top module 67-05.

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Type 67-06: RTC + 66-C
compatibility + pulse outputs
The top module makes MULTICAL® 601 data
compatible with MULTICAL® 66-C making it
possible to use many of the previous base modules
for MULTICAL® 66-C in MULTICAL® 601 too.
Furthermore the top module has two pulse outputs
for energy (CE) and volume (CV) respectively. The
pulse resolution follows the display (determined in
the CCC-code). E.g. CCC=119 (qp 1.5): 1 pulse/kWh
and 1 pulse/0.01 m3. The pulse width is 32 ms.
The pulse outputs are optoinsulated and stand
30 VDC and 10 mA.
Type 67-07: RTC + M-Bus
M-Bus can be connected in star, ring and bus
topology.
Depending on the M-Bus Master and the cable
length/cross section, up to 250 meters can be
connected with primary addressing, and even more
if secondary addressing is used.
Cable resistance in network: <29 Ohm
Cable capacity in network: < 180 nF
The connection polarity of terminals 24-25 is
unimportant.
Normally the primary address consists of the last
digits of the customer number (000-250), but it
can be changed via the PC program METERTOOL.
Type 67-08:
RTC + hourly data logger + pulse outputs
This top module has two configurable pulse
outputs, which are suitable for volume and
energy pulses for heat meters, cooling meters and
combined heat/cooling meters.
The pulse resolution follows the display
(determined in the CCC-code). E.g. CCC=119
(qp 1.5):
1 pulse/kWh and 1 pulse/0.01 m3.
The pulse outputs are optoinsulated and stand
30 VDC and 10 mA.
Normally energy (CE) is connected to 16-17 and
volume (CV) to 18-19, but other combinations can
be selected via the PC program METERTOOL which
is also used for selecting pulse widths 32 or
100 ms.
Furthermore, the module includes a hourly data
logger.

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Type 67-09: RTC + Dvolume calculation and hourly
data logger
This top module calculates the difference between
forward and return volume, whereby an expression
of the tapped energy in open systems is obtained.
Differential volume dV=V1-V2.
The module also comprises a hourly data logger.
Terminal screws are not used in this module.
Type 67-0A: RTC + 2 pulse outputs for CE and
CV + hourly data logger + scheduler
The top module has the same functions as the 67-
08 top module and furthermore the module is able
to simulate a cold water temperature according to
a programmed scheduler, where the programmed
temperature for T2, T3 or T4 can be programmed
with up to 12 individual dates/temperatures per
year.
This function is available for T3 and T4 of all
MC601 models, but the scheduler function of T2 is
restricted for the 67-E only.
Type 67-0B: RTC + 2 pulse outputs for CE and
CV + prog. data logger
The RTC and pulse output functions of this top
module are identical with the functions described
under top module 67-08.
The top module is prepared for use in a Kamstrup
radio network together with the Radio Router
base module 6700210003xx, read data being
transferred to the system software via network unit
RF Concentrator.