Kamstrup MULTICAL 602 User manual

Installation and User Guide
MULTICAL® 602 & ULTRAFLOW®

2 Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
MID designtions
Permissible operting conditions / mesuring rnges
Clcultor q: 2 °C…180 °C DΘ: 3K…170K
Temperture sensor pir q: 10 °C…150 °C DΘ: 3K…140K
Flow sensor q: 15 °C…130 °C
Mechnicl environment
M1 (fixed instlltion with minimum vibrtion).
M2 (significnt or high level of vibrtion nd shock - Flow sensor type 65-5-XXHX-XXX only).
Electromgnetic environment
E1 nd E2 (domestic/light industry nd industry). The meter’s control cbles must be drwn t min.
25 cm distnce to other instlltions.
Climtic environment
Must be instlled in environments with non-condensing humidity s well s in closed loctions
(indoors). The mbient temperture must be within 5…55 °C.
Mintennce nd repir
The district heting supplier cn replce communiction module, bttery, temperture sensor pir
nd flow sensor. The flow sensor is verified seprtely nd cn, therefore, be seprted from the
clcultor.
Other repirs require subsequent reverifiction in n ccredited lbortory.
MULTICAL® 602, type 602-B/C/D must be connected to  temperture sensor pir type Pt500.
MULTICAL® 602, type 602-A must be connected to  temperture sensor pir type Pt100.
MULTICAL® 602, type 602-A/B/C cn be connected to flow sensor type ULTRAFLOW®, electronic
pick-up, or flow sensors with reed switch output.
MULTICAL® 602, type 602-D must be connected to  flow sensor with 24 V ctive pulse output.
Irrespective of flow sensor type, “pulses/litre” must be identicl in flow sensor nd clcultor.
Bttery for replcement
Kmstrup type 1606064.

Installation and User Guide
MULTICAL® 602 & ULTRAFLOW®

4 Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
Contents
1 Generl informtion 4
2 Mounting of temperture sensors 5
2.1 Pocket sensor pir 5
2.2 Short direct temperture sensor pir 6
3 Mounting of flow sensor 7
3.1 Mounting ULTRAFLOW® ≤ DN125 9
3.2 Mounting of ULTRAFLOW® 54 ≥ DN150 9
3.3 Instlltion exmples 10
4 Mounting of clcultor 11
4.1 Compct mounting 11
4.2 Seprte/wll mounting 11
4.3 Pnel mounting 11
5 Electricl connection, MULTICAL® nd
ULTRAFLOW® 12
5.1 Connection exmple 13
5.2 Het meter with two flow sensors 14
5.3 Electricl connection of
Pulse Trnsmitter 15
6 Voltge supply of clcultor/
Pulse Trnsmitter 15
6.1 Bttery supply 15
6.2 Mins modules 15
7 Testing of function 16
8 Informtion codes ”INFO” 17
9 Plug-in modules 18
9.1 Top modules 18
9.2 Bse modules 20
9.3 Module overview 24
10 Setup vi front keys 25
1 Generl informtion
Red this guide before instlling the meter.
Kmstrup’s wrrnty obligtions do not pply in cse of incorrect mounting.
Plese note tht the following instlltion conditions must be obeyed:
- Pressure stge ULTRAFLOW®: PN16/PN25/PN40, see mrking. Flow sensor mrking does not
pply to enclosed ccessories.
- Pressure stge Kmstrup
sensor pir type DS: PN16
- Pressure stge Kmstrup
stinless steel pockets: PN25/PN40 - depending on type
At medium tempertures bove 90 °C we recommend the use of flnge meters s well s wll
mounting of MULTICAL® 602.

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MULTICAL® 602 & ULTRAFLOW®
2 Mounting of temperture sensors
The temperture sensors used to mesure inlet nd outlet tempertures respectively re 
mtched sensor pir tht must never be seprted.
Temperture sensors re usully mounted in MULTICAL® 602 from the fctory. According to EN
1434 or OIML R75 the cble length must not be chnged. If necessry, sensors must lwys be
replced in pirs.
The sensor mrked with  red sign is to be instlled in the inlet pipe. The other sensor mrked with
 blue sign is to be instlled in the outlet pipe (see prgrph 5, pge 12).
Note: The sensor cbles must not be pulled. Be wre of this in cse of binding the cbles.
2.1 Pocket sensor pir
Preferbly, sensor pockets must be mounted in tee-pieces or in
45° lterl Y-pieces. The tip of the sensor pocket must be plced
in the middle of the wter flow.
The temperture sensors should rech the bottom of the
pockets. If  short response time is required, “non-hrdening”
het conducting pste cn be used.
Push the plstic sleeve on the sensor cble into the sensor
pocket nd secure the cble by mens of the enclosed M4
seling screw. Fsten the screw with your fingers only. Sel the
pockets using sel nd locking wire.

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MULTICAL® 602 & ULTRAFLOW®
2.2 Short direct temperture sensor pir
The short direct sensors cn be mounted in specil bll vlves or
in specil tee-pipes, both with threds up to R1 nd built-in M10
union for the short direct sensor.
For mounting in existing heting instlltions with stndrd
ngle tees Kmstrup A/S cn, furthermore, supply R½ nd R¾
brss nipples fitting the short direct sensors.
The short direct sensor cn lso be fitted directly into ll
Kmstrup’s ULTRAFLOW® vrints with G¾ nd G1 thred on the
meter cse. Fsten the sensors’ brss unions lightly (pprox.
4 Nm) using  12 mm fce wrench nd sel the sensors with
sel nd locking wire.

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MULTICAL® 602 & ULTRAFLOW®
3 Mounting of flow sensor
Prior to instlltion of the flow sensor, the
system should be flushed nd protection
plugs/plstic diphrgms removed from the
flow sensor.
Correct flow sensor position (inlet or outlet)
ppers from the front lbel of MULTICAL® 602.
The flow direction is indicted by n rrow on
the flow sensor.
Fittings, if supplied, cn only be used for PN16.
For PN25 instlltions, fittings suitble for
PN25 should be used.
In connection with G¾x110 mm nd G1x110
mm it shll be checked tht the thred run-out
is sufficient. See the figures to the right.
Tightening pp. 4 Nm
Gsket
10 mm
Type 65-5-XXAX-XXX
Gsket
Tightening pp. 4 Nm
12 mm
Type 65-5-XXHX-XXX
Couplings nd gskets re mounted s shown in the bove figures.
Stright inlet: ULTRAFLOW® requires neither stright inlet nor stright outlet to meet the
Mesuring Instruments Directive (MID) 2004/22/ EC, OIML R75:2002 nd EN 1434:2007. A stright
inlet section will only be necessry in cse of hevy flow disturbnces before the sensor. We
recommend to follow the guidelines of CEN CR 13582.

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MULTICAL® 602 & ULTRAFLOW®
A Recommended flow sensor position.
B Recommended flow sensor position.
C Uncceptble position due to risk of ir build-
up.
D Acceptble in closed systems. Uncceptble
position in open systems due to risk of ir
build-up in the system.
E A flow sensor ought not to be plced
immeditely fter  vlve, with the exception
of block vlves (bll vlve type) which must
be fully open when not used for blocking.
F A flow sensor should not be plced t the
suction side of  pump.
G A flow sensor ought not to be plced fter 
double bend in two levels.
A
BC
D
E
F
G
In order to prevent cvittion the bck pressure (the pressure t the flow sensor outlet) t
ULTRAFLOW® must be min. 1.5 br t qpnd min. 2.5 br t qs. This pplies to tempertures up to
pprox. 80 °C.
ULTRAFLOW® must not be exposed to lower pressure thn the mbient pressure (vcuum).

9Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
3.1 Mounting ULTRAFLOW® ≤ DN125
90° 90°
ULTRAFLOW® cn be mounted verticlly, horizontlly or t n ngle.
Mx. 45°
Mx. 45°
The electronics/plstic box
must be plced on the side
(t horizontl mounting).
ULTRAFLOW® my be turned up to ±45° round the pipe xis.
ULTRAFLOW® must not be mounted with the plstic
cse pointing upwrds or downwrds.
3.2 Mounting of ULTRAFLOW® 54 ≥ DN150
See instlltion instructions No. 5512-887.

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MULTICAL® 602 & ULTRAFLOW®
3.3 Instlltion exmples
Threded meters with MULTICAL® mounted on ULTRAFLOW®.
Flow from the left
Type 65-5-XXAX-XXX
Flow from the right
Type 65-5-XXHX-XXX
Flnge meter with MULTICAL® mounted on ULTRAFLOW®.
Flow from the left Flow from the right
MULTICAL® 602 cn be mounted in two positions
by mens of n ngle fitting.
Angle fitting type 30-26-252 is ordered seprtely.
3.3.1 Humidity nd condenstion
If ULTRAFLOW® is instlled in moist environments, it must be turned 45° round the pipe xis s
shown in the drwing below.
If there is risk of condenstion, e.g. in
cooling systems,  condenstion protected
ULTRAFLOW® must be used.
45°

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MULTICAL® 602 & ULTRAFLOW®
4 Mounting of clcultor
The MULTICAL® 602 clcultor cn be mounted in three different wys:
4.1 Compct mounting
The clcultor is mounted direct on the flow sensor, e.g. vi n ngle fitting. Hving been
mounted the clcultor is seled with sel nd thred. In cse of strong condenstion (e.g.
cooling pplictions) we recommend wll mounting of the clcultor. Also see point 3.1 Mounting
ULTRAFLOW® ≤ DN125, page 9.
4.2 Seprte/wll mounting
In connection with mounting in condensing
environments s well s in order to prolong the
bttery lifetime, we recommend the use of 
wll fitting.
The wll fitting mkes it possible to mount
MULTICAL® 602 direct on n even wll. Use the
fitting s  templte to mrk nd drill two 6 mm
holes in the wll. 52 mm
4.3 Pnel mounting
MULTICAL® 602 cn be mounted direct in pnels nd control pnels, vi Kmstrup’s pnel
mounting kit, No. 66-99-104 (192 x 144 mm).

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MULTICAL® 602 & ULTRAFLOW®
5 Electricl connection, MULTICAL® nd ULTRAFLOW®
The polrity of temperture sensors T1, T2 nd
T3 is unimportnt.
For flow sensors V1 nd V2 the below-
mentioned colours re used when connecting
ULTRAFLOW® nd electronic pick-up units.
Flow sensors with reed switch output re
connected to terminls 11–10 nd 11–69
respectively.
V1 V2
- 11 11 Blue
+ 9 9 Red
SIG 10 69 Yellow
Terminl no. Stndrd het nd cooling
mesurement
Het mesurement nd lek
surveillnce
Energy mesurement in
open systems
T1 5-6 Sensor in inlet (red) Sensor in inlet (red) Sensor in inlet (red)
T2 7-8 Sensor in outlet (blue) Sensor in outlet (blue) Sensor in outlet (blue)
V1 11-9-10 Flow sensor in inlet or outlet Flow sensor in inlet Flow sensor in inlet
V2 11-9-69 - Flow sensor in outlet Flow sensor in outlet
T3 51-52 - Tnk/exchnger temp., if ny Reference sensor (grey)

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MULTICAL® 602 & ULTRAFLOW®
5.1 Connection exmple
Exmples of connection of ULTRAFLOW® nd
MULTICAL® (bttery supplied).
ULTRAFLOW® 54 (H)
MULTICAL® 602
ULTRAFLOW® 54
DN150-DN250
MULTICAL® 602

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MULTICAL® 602 & ULTRAFLOW®
5.2 Het meter with two flow sensors
MULTICAL® 602 cn be used in vrious pplictions with two flow sensors, including lek
surveillnce nd open systems. When two ULTRAFLOW® re direct connected to one
MULTICAL® 602,  close electric coupling between the two pipes ought to be crried out s  min
rule. If the two pipes re instlled in  het exchnger close to the flow sensors, however, the het
exchnger will provide the necessry electric coupling.
ULTRAFLOW® 54 (H)
MULTICAL® 602
Electricl connection
ULTRAFLOW® 54 (H)
• Inlet nd outlet pipes re closely electriclly coupled.
• No electric welding occurs.
In instlltions where the electric coupling is not possible or welding in the pipe system cn occur,
the cble from one ULTRAFLOW® must go through  Pulse Trnsmitter with glvnic seprtion
before the cble enters MULTICAL® 602.
ULTRAFLOW® 54 (H)
MULTICAL® 602
Pulse Trnsmitter
ULTRAFLOW® 54 (H)
• Inlet nd outlet pipes re not necessrily closely coupled.
• Electric welding* cn occur.
* Electric welding must lwys be crried out with the erth pole closest to the welding point.
Dmge to meters due to welding is not comprised by our fctory wrrnty.

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MULTICAL® 602 & ULTRAFLOW®
5.3 Electricl connection of Pulse Trnsmitter
If ULTRAFLOW® 54 is used for other equipment, connection must be mde through 
Pulse Trnsmitter or Pulse Divider. See instlltion instructions No. 5512-1421 for further
informtion.
6 Voltge supply of clcultor/Pulse Trnsmitter
MULTICAL® 602 cn be powered by  built-in lithium bttery or n integrl 24 VAC or 230 VAC mins
module.
The bttery or mins module is mounted vi  two-pole plug in the clcultor terminl.
For Pulse Trnsmitter the supply module/bttery is connected vi  two-pole plug. See instlltion
instructions No. 5512-1421 for further informtion.
6.1 Bttery supply
MULTICAL® 602 is connected to  lithium bttery, D-cell. The bttery is mrked with instlltion
yer, e.g. 2014, s well s production dte.
Optiml bttery lifetime is obtined by keeping the bttery temperture below 30 °C, e.g. by wll
mounting.
The voltge of  lithium bttery is lmost constnt throughout the lifetime of the bttery (pprox.
3.65 V). Therefore, it is not possible to determine the remining cpcity of the bttery by
mesuring the voltge.
The bttery cnnot nd must not be chrged nd my only be short-circuited briefly (mx. 2
seconds). Used btteries must be hnded in for pproved destruction, e.g. t Kmstrup A/S.
6.2 Mins modules
The modules re protection clss II. They re connected by mens of  two-wire cble (without
erth) through the cble bush of the clcultor plced in the right side of the connecting bse. Use
connecting cble with 5-10 mm outer dimeter nd ensure correct dismntling s well s correct
mounting of cble relief.
Mx. permitted fuse: 6 A.
Ntionl regultions for electric instlltions must be observed.
6.2.1 High-power supply modules
These modules re glvniclly seprted from the mins supply. The modules include  Switch
Mode Power Supply (SMPS), which fulfils double-isoltion requirements when the clcultor top is
mounted. The modules re vilble in two vrints with either 24 VAC or 230 VAC connection.

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MULTICAL® 602 & ULTRAFLOW®
6.2.2 Isolted liner supply modules
Blck
Red
61
60 97
98
24 VAC supply
24 VAC
3.6 V
Blck
Red
61
60 27
28
230 VAC supply
230 VAC
3.6 V
24 VAC
For instnce 230/24 V trnsformer,
type 66-99-403, cn be used.
Note: MULTICAL® 602 cnnot be
powered by 24 VDC.
230 VAC
This module is used in connection with direct
mins connection.
Note: Externl supply shll only be connected
to the supply module.
7 Testing of function
Crry out n opertionl check when the energy meter hs been fully mounted. Open
thermoregultors nd vlves to estblish wter flow through the heting system. Activte the top
key of MULTICAL® 602 nd check tht the displyed vlues for tempertures nd wter flow re
credible vlues.
Importnt notice for the instlltion:
When the instlltion hs been completed nd there is volume flow in the system, it is necessry
to ctivte the front key until the info code is displyed, nd then wit for 15-20 seconds for the
info code sttus of the connected flow sensor(s) to be updted. When the meter is left t info code
disply reding, the meter will continue to updte the meter sttus every 10 seconds, for  period
of 4 min., before returning to the first disply reding. This updting sequence cn be ctivted
mximum 25 times pr. dy (24 h.), but the sequence will only strt if the meter is kept t the info
code reding for more thn 15-20 seconds.
If this is omitted, the sttus of the connected flow meter(s) cnnot be (remotely) red until the dy
fter the meter ws instlled (i.e. fter 00:00:10 meter time).

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MULTICAL® 602 & ULTRAFLOW®
8 Informtion codes ”INFO”
MULTICAL® 602 constntly monitors  number of importnt functions. In cse of  serious error in
mesuring system or instlltion, “INFO” is displyed nd n info-code cn be red by ctivting
the top front key until the mesuring unit sys “INFO”. The info code is only displyed when the
error is present.
Info code Description Response time
0 No irregulrities -
1 Supply voltge hs been interrupted -
8 Temperture sensor T1 outside mesuring rnge 1…10 min.
4 Temperture sensor T2 outside mesuring rnge 1…10 min.
32 Temperture sensor T3 outside mesuring rnge 1…10 min.
64 Lek in cold wter system 24 hours
256 Lek in heting system 24 hours
512 Burst in heting system 120 s.
ULTRAFLOW® info (ctive when CCC=4XX)
16 Flow sensor V1, communiction error After one dy (t 00:00)
1024 Flow sensor V2, communiction error After one dy (t 00:00)
2048 Flow sensor V1, wrong pulse figure After one dy (t 00:00)
128 Flow sensor V2, wrong pulse figure After one dy (t 00:00)
4096 Flow sensor V1, signl too wek (ir) After one dy (t 00:00)
8192 Flow sensor V2, signl too wek (ir) After one dy (t 00:00)
16384 Flow sensor V1, wrong flow direction After one dy (t 00:00)
32768 Flow sensor V2, wrong flow direction After one dy (t 00:00)
If  number of info codes pper t  time, the sum of info codes is displyed. If e.g. both
temperture sensors re outside mesuring rnge, info code 12 is displyed.

18 Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
9 Plug-in modules
MULTICAL® 602 cn be extended by  wide rnge of extr functions by mens of plug-in modules.
The individul modules re briefly described below.
9.1 Top modules
Type 67-02: ∆Energy clcultion nd hourly dt logger
This top module clcultes the difference between inlet nd outlet
energy, whereby n expression of the tpped energy in open
systems is obtined.
Differentil energy dE=E4-E5.
The module lso includes n hourly dt logger.
The connection terminls of this module re not used.
Type 67-03: PQT-limiter + hourly dt logger
The module hs two pulse outputs which cn be used for UP/
DOWN control of  low-speed three-point motor-operted vlve
vi n externl solid-stte rely, type S75-90-006 nd  230/24 V
trnsformer, type 66-99-403. The required power nd flow limits re
entered into MULTICAL® 602 by mens of the PC-progrm METERTOOL.
Also see instructions: 5512-498.
The module includes n hourly dt logger too.
Type 67-05: Dt output + hourly dt logger
The module hs  glvniclly seprted dt port which functions
together with the KMP protocol. The dt output cn be used for
e.g. connection of externl communiction units or other hrdwired
dt communiction which it is not expedient to crry out vi opticl
communiction on the meter’s front.
62: DATA (brown)–63:REQ (white)–64: GND (green). Use dt cble type
66-99-106 with 9-pole D-sub or type 66-99-098 with USB connector.
The module includes n hourly dt logger.
Only current nd ccumulted dt cn be red. Hourly/dily/monthly/
yerly dt loggers cnnot be red through the dt port of top module
67-05.
DAT
REQ
GND
GND
Type 67-07: M-Bus
M-Bus cn be connected in str, ring nd bus topology. Depending
on M-Bus Mster nd cble length/cross section, up to 250 meters
with primry ddressing cn be connected, nd even more using
secondry ddressing.
Cble resistnce in network: < 29 Ohm
Cble cpcity of network: < 180 nF
The connection polrity of terminls 24-25 is un-importnt.
Usully the primry ddress is identicl with the lst digits of the
customer number (000-250). However, it cn be chnged by mens of
the PC progrm, METERTOOL.

19Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
Type 67-09: ∆Volume clcultion nd hourly dt logger
This top module clcultes the difference between inlet nd outlet
volume, whereby n expression of the tpped volume in open systems
is obtined.
Differentil volume dV=V1-V2.
The module lso includes n hourly dt logger.
The connection terminls re not used in this module.
Type 67-0A: 2 pulse outputs for CE nd CV + hourly dt logger +
scheduler
The top module hs the sme functions s top module 602-0C.
Furthermore, the module cn simulte  cold wter temperture
ccording to  progrmmed scheduler, in which T2, T3 or T4 cn be
progrmmed with up to 12 individul dtes/tempertures per yer.
Type 67-0B: 2 pulse outputs for CE nd CV + prog. dt logger
The RTC nd pulse output functions of this top module re identicl
with the functions described for top module 602-0C (see below).
The top module is prepred for use in  Kmstrup rdio network
together with High Power RdioRouter bse module 6020084, red
dt being trnsferred to the system softwre vi the network unit RF
Concentrtor.
Type 602-0C: 2 pulse outputs for CE nd CV
This top module hs two configurble pulse outputs, which re
suitble for volume nd energy pulses for het meters, cooling meters
nd combined het/cooling meters.
The pulse resolution follows the disply (determined by the CCC-
code). E.g. CCC=119 (qp1,5): 1 pulse/kWh nd 1 pulse/0.01 m3.
The pulse outputs re optoisolted nd withstnd 30 VDC nd 10 mA.
Normlly energy (CE) is connected to 16-17 nd volume (CV) to 18-19,
but other combintions cn be selected by mens of the PC progrm
METERTOOL, which is lso used for selecting the pulse durtion t
either 32 or 100 ms.

20 Kamstrup A/S • 5512952_C6_GB_07.2015
MULTICAL® 602 & ULTRAFLOW®
9.2 Bse modules
9.2.1 Dt + pulse inputs, type 67-00-10
The dt terminls re used for connection of
e.g.  PC. The signl is pssive nd glvniclly
seprted by mens of optocouplers.
Conversion into RS232 level requires
connection of dt cble 66-99-106 (D-Sub
9F) or 66-99-098 (USB) using the following
connections:
62 Brown (DAT)
63 White (REQ)
64 Green (GND)
The pulse inputs cn be used for connection of electricity nd wter meters.
Plese py ttention to mximum pulse frequency s well s correct pulse coding (l/imp. nd
Wh/imp.), which is selected by mens of the FF nd GG configurtion.
65 - 66 Input A
67 - 68 Input B
9.2.2 M-Bus + pulse inputs, type 67-00-20/27/28/29
M-Bus cn be mounted in str, ring or bus topology. Up to 250 meters cn be connected
depending on the M-Bus Mster’s power supply nd the totl cble resistnce.
Cble resistnce < 29 Ohm
Cble cpcity < 180 nF
The M-Bus network is connected on terminls
24 nd 25. The polrity is unimportnt.
M-Bus comes with pulse inputs.