Sontex Supercal 5 User manual

Supercal 5
Installation guide
Installationsanleitung
Guide d‘installation
Guida d‘installazione

2Installation guide | Supercal 5

3Installation guide | Supercal 5
Installation guide Englisch 04 – 39
Installationsanleitung Deutsch 40 – 75
Guide d‘installation Français 76 – 111 FR
DE
EN
Guida d‘installazione Italiano 112 – 147 IT
In the case of divergences, the Englisch version takes precedence.
Bei Abweichungen hat die englische Version des Inhalts Vorrang
En cas de divergences du contenu, la version anglaise prévaut.
In caso di divergenze del contenuto, la versione inglese prevale.

4Installation guide | Supercal 5
Contents
Installation guidelines for thermal energy meter Supercal 5 6
General 6
Before installation 6
Remarks on the correct installation:
Conditions to comply with the directive 2014/32/EU (MID) 7
Cable connection 8
Grounding 9
Power supply modules 9
Power Supply at the calculator 9
The electrical connection of the mains power supply modules 9
Backup battery 10
Safety instructions 10
Function test 10
Pressure Loss Curve 11
Temperature sensors mounting 12
List of sensor pockets 12
Temperature sensors connections 13
Temperature sensor installation with cooling applications 13
Error messages 14
Communication options 15
Cooling liquids (Glycols) 15
Display 15
LCD control concept 16
LCD (Standard-Anzeige) 16
Dimension 17
Map Menu 18
Commissioning Menu 20

5Installation guide | Supercal 5
EN
Confuguration Menu 21
Main Menu 26
Metrotological Menu 29
Service Menu 31
Dimension Flow Sensor Superstatic 440 32
Technical Data Flow Sensor Superstatic 440 33
Horizontal Mounting Position 36
Vertical mounting position 36
General notice for mounting 36
Conditions to comply with the directive 2014/32/EU (MID) 37
Security seals 38
Sealing 39
Technical support 148
Hotline Sontex 148
Declaration of conformity 148

6Installation guide | Supercal 5
Installation guidelines for thermal energy
meter Supercal 5
General
The static ow sensor and its calculator may only be operated within the con-
ditions outlined on the identication plate, as well as within the technical spec-
ication! In the case of ignoring these default conditions, the manufacturer’s
responsibility is void and null.
The manufacturer is not liable for inappropriate installation and operation. Seals
may not be removed and/or only by authorized persons. The country-specic,
local regulations, as well as the manufacturer instructions, must be respected!
If the manufacturer’s seal has been broken or damaged, the manufacturer cannot
be made responsible for the change of the veried and meas-uring relevant data.
When using several heat meters in an installation unit, fair heat consumption
measurement muss be chosen. All of them in the same types of device and in-
stallation positions
Before installation
Check the design layout data of the installation.
The pulse value of the calculator and the installation location must match
the values indicated on the ow sensor, consult the identication plate!
The permissible ambient temperature range of the calculator is 5–55ºC.
The installation and project prescriptions must be followed.
 The readability of the calculator and also the identication plates must be
followed.

7Installation guide | Supercal 5
EN
Remarks on the correct installation:
Conditions to comply with the directive
2014/32/EU (MID)
The calculator is delivered as a heat meter as standard. If it is to be used as
a cooling meter or as a combined cooling/heat meter, this must be specied
when ordering. Other metrological parameters such as installation position
or pulse value (Supercal 5 I only) as well as non-metrological parameters
such as M-Bus address can be parameterised with the Superprog software
before sealing. Please note that metrological parameters can no longer be
changed after the calculator has been sealed.
 The cable between the ow sensor and the calculator cannot be extended.
All wiring must be installed with a minimum distance of 300 mm from heavy
voltage and high frequency cables.
 Radiated heat and interfering electrical elds close to the calculator must
be avoided.
In general, the calculator should be installed away from the cooling pipes.
It has to be ensured that no condensed water can run along the wires into
the calculator.
If the danger of vibrations in the piping system exists, the calculator should
be installed separately on the wall.
For temperatures over 90°C the calculator must be installed apart from
the ow unit.
 The ow sensor should be installed between two shut-off valves.
 The ow sensor must be mounted with the measuring head to the side
 The ow direction of the ow sensor must be respected (arrow on the
ow sensor).
 Flush the pipe system before installing the ow sensors. To guarantee that
no foreign particles remain in the pipe.
The ow sensor should be mounted BEFORE any control valve to exclude
any potential parasitic inuences.

8Installation guide | Supercal 5
During commissioning the pipe system must be purged. Air in the system of
the ow sensor may affect the measurement.
Use only new and appropriate sealing material.
 Water tightness of the different connections should be veried.
The Supercal 5 is a compact calculator and consists of the following two partial
units:
Measuring and calibrating-relevant upper part
Lower part
The pulse values of the calculator and of the ow unit, as well as the resistance
value of the temperature sensors (Pt500) must match. Compare the labels of the
devices!
Terminal connection type
5, 6 2-wire direct connection, temperature high
1, 2 and 5, 6 4-wire, temperature high
7, 8 2-wire direct connection, temperature low
3, 4 and 7, 8 4-wire, temperature low
10 (+) pulse inputs ow sensor 440 (white cable)
11 (-) pulse inputs ow sensor 440 (green cable)
9Power supply of the ow sensor 440 (brown cable)
50 (+) Pulse input, additional pulse input 1
51 (-) Pulse input, additional pulse input 1
52 (+) Pulse input, additional pulse input 2
53 (-) Pulse input, additional pulse input 2
16 (+) Open collector-output 1
17 (-) Open collector output 1 +2
18 (+) Open collector output 2
24 M-Bus
25 M-Bus
Cable connection
To connect the inputs and outputs the calculator’s upper part must be removed.
Shielded cables must be grounded with a strain relief!

9Installation guide | Supercal 5
EN
Grounding
It has to be guarantied that all grounding connections (line and power mains and
chassis of the ow sensor) of the total installation are equipotential.
Power supply modules
The power supply modules are connected by means of a plug-in connector to
the main board.
Power Supply at the Calculator
The Supercal 5 can be supplied with either battery or mains modules: D Battery
3,6 V, mains 24 V (12 VAC to 36 VAC or 12VDC to 42 VDC), mains 230 VAC (110
VAC to 230 VAC, 50/60 Hz). These can be converted and retrotted at any time.
The mains module is equipped with a backup battery already installed.
The electrical connection of the mains power supply modules
The electrical connection has to be done in accordance with valid standards,
under consideration of local safety regulations and by an authorized person. The
electrical main is to be made in such way that no hot parts (pipes etc. over 80°C)
can be touched (danger with damaged isolation). Water contact of the electrical
connection must be avoided.
Cable connections
Mains supply
110 ... 230 VAC
Cable connections
Mains supply
12...36 VAC / 12...42 VDC

10 Installation guide | Supercal 5
Backup battery in the calculator upper part
The upper part of the calculator, which is relevant for calibration and measure-
ment, is equipped with an A-cell battery. This serves as power supply for the LCD
display when the upper part of the calculator is removed from the lower part
or when no power supply is available. The battery has a service life of about 10
years in the backup function.
Safety instructions
The calculator is manufactured and tested according to EN 61010 safety control
for measuring units and left the factory in perfect safety tech-nical condition. To
maintain this status and to guarantee the safe operation of the calculator, the
user must respect the instructions contained in this document. When opening
covers or removing parts, parts under power can be accessed. Further connec-
tion terminals can be under power. All repair and maintenance work may be
only implemented by a trained and authorized specialist. If the housings and/or
the connect-ing cable show any damage, the calculator unit should be discon-
nected and secured against accidentally reset up – put in operation. General-ly,
avoid an installation situation with an accumulation of heat above average. An
above-average heat build-up affects substantially the lifetime of the electronic
components.
Heat meters are measuring devices and must be handled with care.
To protect the unit against damage and contamination, the packing should be
only removed at the moment of installation.
For cleaning just use water moistened cloth and no solvent.
The connecting and connection cable may not be fastened on the pipe and under
no circumstances be isolated together with the pipe.
Function test
After opening the shut-off valves, the system must be checked for leaks.
Then, by repeatedly pressing the user button, various operating param-
eters such as ow rate, output and ow and return temperature can be read
on the LCD display of the calculator. If modules are installed, this is also
shown on the LCD display (M1:,M2:). With the Superprog Windows and Su-
perprog Android software, you can read additional information from the unit.

11Installation guide | Supercal 5
EN
All parameter displays are used to check the thermal energy meter or to adjust
the system. It must be checked that the regulated ow of the system does not
exceed the maximum permitted ow of the meter. A commissioning protocol via
the optical interface with the readout software is recommended for a compre-
hensive functional check.
Pressure Loss Curve

12 Installation guide | Supercal 5
Temperature sensors mounting
The temperatures indicated on the identication plate of the temperature
sensors are to be observed. The temperature sensors are always paired. Only
matched pairs are supplied and may not be separated, extended or shortened,
since this affects the measuring accuracy. With temperature sensor pairs with
a cable length longer than 3 m, we exclusively recommend the use of shielded
temperature sensor pairs. In this case, the shields must be installed correctly.
Temperature sensors with protection pockets must be inserted up to the stall –
and xed afterwards. With unequal cable lengths or longer than 6 m we recom-
mend exclusively the use of four-wire technology. The temperature sensors can
be installed alternatively in protection pockets or directly in the heating and/or
cooling agent however always both in the same way. Asymmetrical mounting,
one sensor direct the other with pockets, isn’t permitted. The measuring tip of
the temperature sensor part must be positioned in the center of the cross section
of the pipe.
Temperature
sensor
Versions Pocket Part number Material Temperature
range
Ø 6x 31mm Pt500 G3/8" 0460A202 Brass 0 …100°C
Ø 6x 31mm Pt500 G1/2" 0460A206 Brass 0 …100°C
Ø 6x 85mm Pt500, DIN G1/2" 0460A207 Stainless 0…150°C
Ø 6x 134mm Pt500, DIN G1/2" 0460A208 Stainless 0… 150°C
Ø 6x 174mm Pt500, DIN G1/2" 0460A209 Stainless 0… 150°C
The resonance frequencies of the protection pockets are outside of the ow velocities at
maximum ow (qs).
List of sensor pockets
Installation in T-tting
Temperature sensor perpendicularly to
the axis of the piping in the same level
Installation with welding sleeve 90º
Temperature sensor axle coincide with
the tubing axle
Installation with welding sleeve 45º
Temperature sensor measuring element
sub-merged onto the tubing axle
Installation in pipe
Temperature sensor axle perpendicular-
ly to the tubing axle.

13Installation guide | Supercal 5
EN
Temperature sensors connections
Wire cross section for head sensors ≥ 0,5 mm2(EN 1434-2)
Temperature sensor installation with cooling applications
The isolation may be made only up to the temperature sensor screw
connection.
The screw connection of the temperature sensors may in no case be
isolated with. This applies even if the temperature sensor is installed
directly in the ow sensor.
GEFAHR
1
5
2
6
r
r
w
w
3
7
4
8
r
r
w
w
12
rw
34
rw
5678
r w r w
2 wires cable sensor
5/6 temperature high
7/8 temperature low
4 wires sensor with
2 wires integrator
1/2 temperature high
3/4 temperature low
4 wires sensor with
4 wires integrator
1/5 + 2/6 temperature high
3/7 + 4/8 temperature low

14 Installation guide | Supercal 5
Error messages
The Supercal 5 indicates occurring errors by displaying on the LCD the Err-sign
together with a numbered code. If several errors occur at the same time, the
numbers of the error codes are added.
1
Temperature reference 1 A/D: A cable of
the temperature sensor is interrupted or not connected.
2
Temperature reference 2 A/D: A cable of the temperature sensor is interrupted
or not connected.
4
Temperature reference 1 A/D: A cable of the temperature sensor is conected
but its value can not be read out.
8
Temperature reference 2 A/D: A cable of the temperature sensor is connected
but its value can not be read out
16
Temperature sensor 1 < = min. Range error
32
Temperature sensor 1 > = max. Range error
64
Temperature sensor 2 < = min. Range error
128
Temperature sensor 2 > = maxß. Range error
512
The ow rate is higher than 1,5 qs
1024
The SC5 is open
2048
Power outage
4096
M1 Power Supply / M1 Unsupported / Slot left error: Error in module 1:
Details must be found into specic module error
8192
M2 Power Supply / M2 Unsupported / Slot right error : Error in module 2:
Details must be found into specic module error
Errors will be registered in the error register with its date and time (beginning) and duration
(in minutes).

15Installation guide | Supercal 5
EN
Communication options
The Supercal 5 can be tted with up to two different optional communication
modules. The optional communication modules can be equipped afterwards,
without damaging the verication. The optional modules have no inuence
on the veried relevant part in the cover of the inte-grator unit. At the latest
6 seconds after the installation, the calculator unit recognizes the plugged-in
optional modules and the functions are freely available. When connecting the
communication modules, the installation guidance - supplied with the unit - is
to be considered.
Cooling liquids (Glycols)
In the calculator Supercal 5 more than 70 cooling liquids are programmed and
many additional mixtures can be specied by software.
The feature of the calculator Supercal 5 for cooling applications with cooling
liquids water mixtures is exclusively to be used with the ow sensor Superstatic
440 (Not to be used with mechanical ow sensors).
The feature cooling liquid (Glycol) water mixture is enabled with the Superprog
windows and Superprog android.
Note: If cooling liquids are used, the calculator or thermal energy meter loses
its MID approval.
Display
The calculator Supercal 5 has the following display sequence:
Main menu (Billing relevant data)
Metrological
 Conguration
Service
Test Radio

16 Installation guide | Supercal 5
The Right key has two functions:
One single press and it selects next menu.
Press it for Two Seconds in the “Overview Menu”
and you can enter to the highlighted menu.
➔
➔
LCD control concept
Left key is designated to select previous menu.
If you are in any of the menus and you press both key, LEFT and
RIGHT for two seconds, you get back to the “Overview Menu”.
After 3 minutes the display of the calculator switches automatically back to the
main menu.
LCD (Standard-Anzeige)
The control key can be used to select and conrm the various menus, parame-
ters, or other selection options within the display.
►Menu's name
►M1: Module installed in slot 1
►M2: Module installed in slot 2

17Installation guide | Supercal 5
EN
Dimension Supercal 5
Supercal 5 LowerPart
159.6
163.6
136.3
138.3
49
5.5
23.2
175.1
95.08
143
158
53.5
3.9

18 Installation guide | Supercal 5

MainMenu
Errors
CumulatedEnergy/
Cumulatedvolume
CumulatedEnergy
Tariff1 /Cumulated
volume Tariff 1
Cumulated Energy
Tariff2/Cumulated
volume Tariff 2*
 
 

  

Metrological
Configuration
Service

 
   
 
  


  
Set day 2 Date /
Power Volume
Totalyzer

Set day 1 Date /
Power Volume
Totalyzer
Thermal Power /
Flow
Temperatures High-
Low / Temperature
difference
Cumulated value
IN5
Cumulated value
IN6 **
Cumulated value
IN3
Cumulated value
IN4 **
Cumulated value
IN1
Cumulated value
IN2
Supercal 5 Menu Overview

MainMenu
Metrological
Mounting

Position/Pulse
Factor
AccuracyClass/
DN***
Pn/Ps***
qp/qs***
qi/ThetaQ***
Flowmeter
type/Flo

 
FluidType/
Concentration
Configuration
Service
TestRadio
Cumulated
Volume
Cumulated
Energy
Flowmeter ID***
*Active-Only in Heating-Cooling mode & Cooling mode
** Active-Only when modules Input / Output Relay modules are installed in the proper slot.
***Active-Only in Supercal 5S version.

19Installation guide | Supercal 5
EN

MainMenu
Metrological
Configuration
Address baudrate
/Identification
number
Currentdate/
Currenttime
UnitPulseIN1/
PulsefactorIN1
UnitPulseIN2/
PulsefactorIN2
UnitPulseIN3/
PulsefactorIN3
UnitPulseIN4/
PulsefactorIN4*
UnitPulseIN5/
PulsefactorIN5*
UnitPulseIN6/
PulsefactorIN6*

Pulse Factor OUT1

 
Multiplier OUT1
   

   
 
Service
TestRadio
-
PulseFactorOUT5/
PulseFactorOUT6
Multiplier OUT2
Multiplier OUT3*
Pulse Factor OUT2
Pulse Factor OUT3
   
 Multiplier OUT5*
Pulse Factor OUT5
   
 Multiplier OUT4*
Pulse Factor OUT4
   
 Multiplier OUT6*
Pulse Factor OUT6
   
 Multiplier OUT3*
Pulse Factor OUT3
The menues are detaileds below

MainMenu
Metrological
Configuration
Service
Fabrication
Number 

FirmwareVersion
/Firmware CRC32
RunningHours/
RunningYears
Days
TestRadio
Display pixel test

 

Customer
 
configurable 
message 1 & 2
  
Errors 
* Active only when modules Input / Output Relay modules
are installed in the proper slot

20 Installation guide | Supercal 5
Commissioning:
commissioning menu
 Conguration via NFC
1× short press on the right
button
 Seal conguration
SEAL: seals the conguration and
switches to Default Menu
1× long press (> 2 seconds) on the
left button
Cumulated energy
Cumulated volume
Commissioning Menu