Hamworthy Superstatic 449 Installation, Commissioning, Operation & Service Instructions
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Hamworthy Superstatic 449 Installation, Commissioning, Operation & Service Instructions

Hamworthy Superstatic 449 Installation, Commissioning, Operation & Service Instructions

Solar heat meter for rhi
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Solar Heat Meter For RHI
Installation, Commissioning,
Operation & Service Instructions
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING THIS EQUIPMENT

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  • Page 1 Solar Heat Meter For RHI Installation, Commissioning, Operation & Service Instructions IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING THIS EQUIPMENT...
  • Page 2 Site Assembly Hamworthy offer a service of site assembly for many of our products where plant room access is restricted. Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
  • Page 3 UNDERSTOOD BEFORE INSTALLING & COMMISSIONING THIS HEAT METER. HEAT METER SUPERSTATIC 449 WITH INTEGRATOR SUPERCAL 531 COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. HEAT METER SUPERSTATIC 449 & INTEGRATOR SUPERCAL 531 SOLD BY HAMWORTHY HEATING LTD IS A REGISTERED TRADEMARK OF SONTEX SA. PUBLICATION NO. 500001294 ISSUE ‘B’...
  • Page 4 CONTENTS SECTION INSTALLATION GUIDELINES FOR HEAT METER SUPERSTATIC 449 ........1 OPERATIONS MANUAL FOR INTEGRATOR (SUPERCAL 531) SOLD WITH HEAT METER SUPER STATIC 449 ................2 SPARE PART NUMBERS FOR HEAT METER SUPERSTATIC 449 & INTEGRATOR SUPERCAL 531 ....................3...
  • Page 5 SECTION 1 Installation Guidelines For Heat Meter Superstatic 449 Page HAMWORTHY HEATING LTD SOLAR HEAT METER FOR RHI 500001294/B...
  • Page 6 Einbau- und Betriebsanleitung statischer Wärmezähler Superstatic 449 Installation guidelines Static Heat Meter Superstatic 449 Allgemeines General Der statische Durchflusssensor und das Rechenwerk dürfen nur innerhalb The static flow sensor and the integrator may only be operated within the der auf dem Typenschild sowie in der technischen Spezifikation conditions outlined on the identification plate, as well as within the technical aufgeführten Bedingungen betrieben werden! Bei Missachtung dieser...
  • Page 7 Schutzfilm montiert werden, der die Batterie vor der frühzeitigen to remove the protective film before commissioning. Entladung schützt. Es ist sicher zu stellen, dass der Schutzfilm vor der Inbetriebnahme entfernt wird. Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 8 überschreitet. Zur umfassenden Funktionsprüfung wird ein the startup protocol by means of the optical interface and reading Inbetriebnahmeprotokoll über die optische Schnittstelle mit der software Auslese-Software empfohlen. Druckverlustkurve Pressure Loss Curve Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 9 Fall mit isoliert werden. Dies gilt auch, wenn der Tempera- in no case be isolated with. This applies even if the turfühler direkt im Durchflusssensor montiert ist. temperature sensor is installed directly in the flow sensor. Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 10 Cooling liquids (Glycols) Für Kälteanwendungen mit Kühlmittel-Wassergemischen ist aus- For cooling applications with cooling liquids water mixtures exclu- schliesslich der Kältezähler Superstatic 440 zu verwenden. sively use the Superstatic 440. Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 11 Anzeigeziffern Rahmen Nachkommastellen Display figures Frame for decimal figures Index für die Menüführung Index for menu guidance Statischer Wärmezähler Supestatic 449 Static Heat Meter Superstatic 449 Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 12 Further values within the menu available: 3 - 15 monthly values 3 - 32 average values 3 - 32 maximum values Glykol Kurve Einbauort Glycol curve Mounting position 88888.888 Segmenttest Segment test Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 13 - Recommendations for sealing Ab Werk plombiert - Ex factory seals Ab Werk plombiert - Ex factory seals 1: Klebeplombe / Sticker seal 2: Drahtplombe / Wire seal Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 14 Konfiguration Service Prüfprogramm Configuration Service Test mode Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 15 0D für / for : L=190mm Verbindung zwischen Durchflusssensor und Rechenwerk 0.8 m; fest / fix Connection between flow sensor and integrator Superstatic 449: Max. 140 x 110 x 112 [mm] Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 16 * In Vorbereitung / under way Der Superstatic 449 kann ab 0.8 bar Rohrdruck eingesetzt werden. The flow sensor Superstatic 449 can be operated from 0.8 bar pipe pressure. Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 17 The detailed declaration of conformity can be found and downloaded on our homepa The detailed declaration of conformity can be found and downloaded on our homepage www.sontex.ch Installation Superstatic 449 DE EN 24-11-2010 Sontex SA, 2605 Sonceboz, Schweiz, Switzerland Sontex SA, 2605 Sonceboz, Schweiz, Switzerland...
  • Page 18 SECTION 2 Operations Manual For Integrator (Supercal 531) Sold With Heat Meter Superstatic 449 Page HAMWORTHY HEATING LTD SOLAR HEAT METER FOR RHI 500001294/B...
  • Page 19 Manual Integrator Integrator Supercal Supercal Issue: Rev. 121109 Document: Manual Integrator Supercal 531 12 Manual Integrator Supercal 531 12-11-2009 Manufacturer: Sontex SA 2605 Sonceboz, Switzerland itzerland Phone: +41 32 488 30 00 Fax: +41 32 488 30 01 Email: sontex@sontex.ch Internet: www.sontex.ch Technical modifications subject to change...
  • Page 20 Revision Issue Date Author Description of Modification 030909 03.09.09 Data copied, layout adapted 151009 15.10.09 English Translation 121109 12.11.09 Completely reviewed Manual Integrator Supercal 531 12-11-2009.docx...

  • Page 21: Table Of Contents

    Table of Contents Introduction ................... 6 Brief description ......................6 Advantages of the Supercal 531 ................. 6 Concept of the Heat Meter ..............7 Measuring concept ...................... 7 Integrator ........................7 Flow sensors ....................... 7 Temperature sensor ....................8 2.4.1 2-Wire-cable sensor .......................
  • Page 22 6.1.2 Pulse input for volume measurement ................... 26 6.1.3 Two additional pulse inputs ....................26 6.1.4 Two open-collector pulse outputs ..................26 6.1.5 M-bus communication ......................26 6.1.6 Timing of M-Bus communication ..................27 Optional communication modules ................28 6.2.1 Analogue module with two outputs ..................
  • Page 23 11.2.1 Mains module with backup-battery ..................61 11.2.2 Battery module ........................61 11.3 Communication features ................... 62 11.3.1 Standard version ........................62 11.3.2 Options of standard setting ....................64 11.3.3 Optional communication modules ..................65 Identification Plate Supercal 531 ............69 Mounting and Dimensional Drawing ..........

  • Page 24: Introduction

    1. Introduction 1.1 Brief description This Supercal 531 convinces by using state-of-the-art multi-functional technologies and by its modular concept. It can easily be adapted to our customer‘s requirements such as e.g. simplified system integration, tariff functions, data logger functions, universal data transfer or connection to existing process sys- tems.

  • Page 25: Concept Of The Heat Meter

    2. Concept of the Heat Meter 2.1 Measuring concept The energy of a heat transfer medium is always calculated with its flow rate and the difference between „temperature high“ and „temperature low“. The heat capacity and the density of the heat transfer medium are also considered in this cal- culation.

  • Page 26: Temperature Sensor

    In general, the flow sensor is installed at a place where the temperature of the medium is nearer to the ambient temperature. In heating systems, this is the return line and in cooling systems, this is the supply line. Thus a higher measuring precision and a longer service life of the flow sensor are achieved. 2.4 Temperature sensor Please be careful when choosing and installing the temperature sensors.

  • Page 27: 4-Wire-Cable Sensor

    EN1434-2 2004 stipulates the following maximum cable lengths for 2-wire temperature sensors: Wire cross section Maximum cable length Pt100 Pt500 0.22 mm2 2.5 m 12.5 m 0.50 mm2 5.0 m 25.0 m 0.75 mm2 7.5 m 37.5 m 1.50 mm2 15.0 m 75.0 m 2.4.2 4-wire-cable sensor...

  • Page 28: Installation Guideline Of Temperature Sensor Acc. To En1434

    2.4.2.1 4-wire-cable sensor with 2-wire integrator 1 / 2 3 / 4 temperature high temperature low 2.4.3 Installation guideline of temperature sensor acc. to EN1434 2.4.3.1 Adherence to the operating conditions acc. to MID for temperature sensors The temperature sensors have to be installed symmetrically in the supply and return pipe and pref- erably directly.

  • Page 29: Installation Guidelines

    Furthermore, attention has to be paid that the integrator is electrically compatible with the tempera- ture sensors: Pt100-temperature sensors must not be connected to an integrator which is designed for Pt500- temperature sensors (and vice versa). To avoid unauthorized access, the installations points have to be sealed after installation. 2.4.3.2 Interfering factors If there is a risk of electric or electro-magnetic interferences, temperature sensors in 2- and 4-wire technology with shielded cables or shielded cables on the connection heads have to be used.

  • Page 30: The Integrator Supercal 531

    3. The Integrator Supercal 531 3.1 The modular concept The integrator Supercal 531 consists of: Measuring- and calibration-relevant upper part Base part Thanks to the modular concept of the integrator storing costs can be kept very low and replace- ment of the meter after expiry of the validity of the calibration is simple and reasonably-priced. In this case only the integrator upper part is replaced.

  • Page 31: Integrator Base Part

    3.1.2 Integrator base part The following elements are incorporated in the base part of the integrator: main board connection point for M-Bus or radio module mounted at the factory (below b, not visible) EEPROM, non-volatile memory for data storage terminals strain reliefs for connection cables and grounding Bar code label Optional mains- / battery supply...

  • Page 32: Wiring Diagram

    3.2 Wiring diagram The integrator upper part has to be removed to connect the inputs and outputs. The wiring has to be done as follows: Terminal Description 1, 2 2-wire technology, temperature high 1, 2 and 5, 6 4-wire technology, temperature high 3, 4 2-wire technology, temperature low 3, 4 and 7, 8...

  • Page 33: Calculation Of Flow

    3.4 Calculation of flow The calculation of flow bases upon the volume pulses detected and cumulated within a certain time interval. For the first flow calculation, the integrator always requires two volume pulses to be able to calcu- late the actual flow. Depending on the configuration the internal flow calculations are carried out and the actual flow is indicated immediately on the LCD-display.

  • Page 34: Tolerated Errors And Limit Values

    high measuring resolution and high measuring reliability. To improve the measuring reliability, a coherence test (check of the logical sequences of the values) has been implemented. The mains-supplied integrator Supercal 531 measures the „temperature high“ and „temperature low“ every 3 seconds. The battery-supplied (battery type C or D) integrator measures the temperatures every 30 sec- onds.

  • Page 35: Cooling Energy - Combined Cold-/Heat Meter

    3.6.3 Cooling energy – combined cold-/heat meter The combined cold-/heat meter (tariff function cooling/heat tariff) calculates the cooling energy as soon as the two following conditions are fulfilled at the same time: temperature difference (∆t) < - 0.2 K „temperature high“ < 18 ° C The threshold value of 18 °...

  • Page 36: Possible Parameterisations

    3.8 Possible parameterisations The Supercal 531 is parameterised with the software Prog531 over the optical interface or the ex factory M-Bus module. Each integrator is manufactured after order and parameterised in the fac- tory in accordance with the customer’s specifications. Adaptations and modifications of the factory parameterisation can be carried out by authorized centres (e.g.

  • Page 37: Data Storage

    4. Data Storage 4.1 Data storage over EEPROM The Supercal 531 has two non-volatile EEPROMs for storing data. The data are updated every hour in the non-volatile EEPROM of the upper part of the Integrator (MET). Thus, the data backup is kept even in case of power supply failure. All data are updated and stored automatically.

  • Page 38: Data Storage With Backup-Batteries In The Mains Modules

    4.2 Data storage with backup-batteries in the mains modules The mains modules: 230 VAC - 45/60 Hz (115 VAC - 45/60 Hz on request) 24 VAC - 45/65 Hz 12..24 VDC By default, each mains module is supplied with a backup-battery which guarantees the current supply in case of a power failure.
  • Page 39 In backup-battery mode, the following functions of the Supercal 531 are still active: Temperature and flow measurement, energy calculation Tariff- and alarm functions Inputs A1 and A2 Outputs B1 and B2 Optical interface In battery-saving mode, all communication options are deactivated. The measuring cycle is re- duced to 30 seconds.

  • Page 40: Operational Concept

    5. Operational Concept When designing the Supercal 531, main importance was placed on the user-friendliness. Thus, the integrator features an extremely large and clearly structured LCD-display. It has only two operator buttons to display the measuring data and for the menu navigation thus adding to the user- friendliness.

  • Page 41: The Display Menu

    5.2 The display menu The display sequences are divided into the following menus: Main menu Set day values 15 monthly values 32 average values 32 maximum values Configurations Service information Favourites menu (optional) *1234567 Error menu 1234567 Verification menu The display sequence can be set according to your requirements: The menu „favourites“...

  • Page 42: The Operator Buttons

    5.3 The operator buttons The two operator buttons enable simple and customer-friendly handling of the Supercal 531. Pressing control key, you move on the actual menu level. Pressing enter key, you go to the next sub-menu, one level down Pressing enter key and control key simultaneously, you go one level up in the menu tree.

  • Page 43: The Communication Concept

    6. The Communication Concept For instructions on the installation and the parameterisation of the modules, we refer to „Start-up and Applications“ (point 8), as from page 50 The terminal lay-out can be taken from the „wiring diagram Supercal 531“ (point 3.2.), page 15. The specifications of the below mentioned communication configurations are stated in „Technical Data “...

  • Page 44: Pulse Input For Volume Measurement

    Alarm signal: 0101010101… Transmission time: 2.2 seconds +/- 0.1 Total transmission time: If the time > 40 seconds or if X > 138 ms, a new wake up is sent. 6.1.2 Pulse input for volume measurement The Supercal 531 allows the connection of slow and fast flow sensors. To this end, two specific filters have been integrated (normal- or fast mode) which can be selected over the software Prog531.

  • Page 45: Timing Of M-Bus Communication

    6.1.6 Timing of M-Bus communication Manual Integrator Supercal 531 12-11-2009.docx...

  • Page 46: Optional Communication Modules

    6.2 Optional communication modules The two free module connection points in the integrator base part can be used to retrofit the below mentioned optional communication modules without infringing the validity of the calibration. See „The modular concept“ (point 3.1.), page 13 After installation of the modules, they are identified automatically within 30 seconds by the Super- cal 531.

  • Page 47: Relay Module

    6.2.1.2 Analogue module with two outputs 0...20 mA, 4...20 mA or 0...10 VDC Application identical to point 6.2.1.1 For each circuit, a separate flip switch allows the independent switchover of the analogue outputs to the range 0..10 VDC. The two red LEDs are only on if the current does not correspond to the set value of the analogue signal, e.g.

  • Page 48: Module Rs-232 With Two Relay Outputs

    6.2.3 Module RS-232 with two relay outputs The optional module RS-232 with two relay outputs allows the connection of the integrator Super- cal 531 to a control system, a system processor, a modem or a PC. Thus, it is possible to readout the data of the heat meter and to transmit them via RS-232 inter- faces.

  • Page 49: Combined Module

    6.2.5 Combined module RS-232 interface with three relay outputs and four freely programmable outputs 0...20 mA, 4...20 mA, 0...10 VDC or 2…10 VDC. The optional combined module with RS-232, three relay outputs and four freely programmable outputs 0..20 mA, 4..20 mA, 0..10 VDC or 2…10 VDC combines at the same time: The communication over the serial interface RS-232 (with a control system or all kinds of con- troller or remote readout systems) with the transmission of status messages, alarm and/or er- rors as relay output...

  • Page 50: M-Bus Module With Two Relay Outputs

    6.2.6 M-Bus module with two relay outputs The optional M-Bus module with two relay outputs allows the integration of the integrator Supercal 531 into a M-Bus-, control- or process system. Thus it is possible to readout the data of the heat meter and to transmit them via M-Bus. Therefore the M-Bus module combines the advantages of the communication via M-Bus with a data processing centre (or any kind of controller, control system and remote readout system) with the transmission of status messages, alarm and/or errors as relay output.

  • Page 51: The Display Menus

    7. The Display Menus 7.1 Menu control Press the enter key and the control key simultaneously. The last occurred error is displayed. Press the control key: The first display of the main menu, the cumulated energy is indicated. The index for the menu navigation is above the „1“. 7.2 Main menu Confirm menu 1 = main menu by pressing the enter key: The index for the menu navigation flashes.
  • Page 52 Cumulated Volume Possible volume units: , US-gallon Default parameterisation ex works: Maximal displayed volume: 99'999’999 The number of digits after the decimal point can be set at the factory or by an authorized laboratory. The displays of the cumulated volumes for tariff 1 and tariff 2 are identical.

  • Page 53: Menu Set Day Values

    7.3 Menu set day values Two set days are possible: set day 1 = S1, set day 2 = S2. Values recorded on set day: energy, volume, tariff values and additional pulse inputs. The first display of the display sequence indicates the date of the set day, if occurred. Display and presentation of the cumulated set day values are identical with those of the main menu.
  • Page 54 Volume on set day 01 Energy tarif 1 on set day 01 Further data are displayed by repeatedly pressing the control key. Selecting of set day 02: Press enter key: The index „S1“ for set day 01 flashes. Press the control key: The index goes to „S2“.

  • Page 55: Menu Monthly Values

    7.4 Menu monthly values The Supercal 531 records 15 monthly values, in the order 01 to 15. Every month, the cumulated values for energy, volume, additional pulse inputs and tariffs are re- corded. Index „01“ refers to the last monthly value, index „02“ refers to the month before last, the indices „03“...
  • Page 56 Then the first display of the display sequence for month 01 turns up, the cumulated energy. By repeatedly pressing the control key, display after display for month 01 can be called: cumulated volume, cumulated values of the additional pulse inputs and tariffs. Selecting of the monthly values 02 to 15: Press enter key: The index „01“...

  • Page 57: Menu Average Values

    7.5 Menu average values With the Supercal 531 a maximum of 32 average values can be readout and recorded. The aver- age time can be set between 1 minute and 45 days. The average values for the current power, flow, „temperature high“ and „temperature low“, tem- perature difference, flow A1 and flow A2 are recorded and displayed with the index „avg“.
  • Page 58 To address the average values 02 to 32: Please press the enter key The index „01“ for average value „01 avg“ flashes. Now you can proceed in two different ways: Press the control key constantly. Thus the indices of all further average values (02 to 32, flashing) can be called.

  • Page 59: Menu Maximum Values

    7.6 Menu maximum values The time window for 32 maximum values can be selected freely between 1 hour and 1 year. The maximum values for performance, flow, „temperature high“ and „temperature low“, temperature difference and pulse inputs A1 and A2 are supplemented by the index „max“. Date and time of the recorded maximum values are also displayed.
  • Page 60 By repeatedly pressing the control key all further recorded data of maximum value 01 can be called: flow, supply and re- turn temperature, temperature difference, pulse input A1 and pulse input A2. To select all further maximum values 02 to 32: Press the enter key The index „01“...

  • Page 61: Menu Configuration

    7.7 Menu configuration Here, the configuration values of the Supercal 531 can be checked and altered if required. Main menu Menu maximum values Max. value 01 current power Menu configuration Date Ttime Pulse factor Pulse units for Pulse factor for etc.
  • Page 62 Pulse units of the additional pulse inputs A1 and A2 (indi- ces A1 and A2) Pulse factors of the additional pulse inputs A1 and A2 (indices A1 and A2) Pulse units of the additional pulse outputs B1 and B2 (indices B1 and B2) Pulse factors of the additional pulse outputs B1 and B2 (indices B1 and B2) Integration period for calculating the average value...

  • Page 63: Menu Service

    7.8 Menu service Here, the configuration values of the Supercal 531 can be checked and altered if required. Main menu Menu configuration Time Menu service Customer etc. Manufactur- Software- Customer number er’s number version number (index Cn) (index SW) upper part base part (index MFn) (index CFn)
  • Page 64 Manufacturer’s number MIO (index CFn) Software version (index SW) Hardware version (index HW) Options (index Opn) Decoding of the options (positions numbered from left to right): Pos 1 power supply 0 = battery 1 = mains Pos 2 basic version 0 = standard 1 = M-Bus factory-mounted 2 = radio module...
  • Page 65 Operating hours of the Supercal 531 (index rh); indication of the operating time in hours Number of days without flow (index DF) Number of days without energy measurement (index DE) Display of current error (Err, error number) Duration of current error in minutes (index Erm) Error messages 1 –...
  • Page 66 Date (DA)beginning of error Time (Hr) beginning of error By pressing the control key again, the display goes back to the identification number / customer number (index Cn) mentioned above. To access the data of the recorded errors 02 to 10, repeat the procedure until reaching the error with index „01“.

  • Page 67: Start-Up And Applications

    8. Start-up and Applications As already mentioned in 2.5, the installation of a heat metering point may only be carried out by authorized personnel and the directives of installation as well as the local rules have to be taken into account. The same applies for the start-up of the metering point where an expert has to check its proper functioning.

  • Page 68: Supercal 531

    8.1.2 Supercal 531 8.1.2.1 Checking of date and time The correct setting of date and time is important so that the recorded data of the Supercal 531 can be allocated chronologically. They can be set with the service software Prog531 over the optical interface. 8.1.2.2 Flow check If the pulse factor of the flow sensor has been adjusted correctly to the Supercal 531, an existing flow will immediately be displayed (see flow indicator, point 5.1, page 21).

  • Page 69: The Supercal 531 In Combination With Standard (Slow) Flow Sensors

    8.2.1.1 Response time and accuracy of the flow calculation The time period during which the Supercal 531 carries out a new flow calculation is called re- sponse time. At the same time, the value of the current flow is updated on the LCD-display in the M-Bus protocol (if existing) by pulse- or analogue output (if existing)
  • Page 70 Example 3: Water meter: Qn 25 m3/h, 100 litre/pulse Configuration 531: requested precision 4 % (25 pulses) Minimum holding time 10 seconds Maximum holding time 480 seconds flow frequency period response specification precision [m3/h] [Imp/sec] [sec/pulse] time [sec] parameter achieved precision 0.0694 14.4 maximum period...

  • Page 71: The Supercal 531 In Combination With The Flow Sensor Superstatic 440

    8.2.3 The Supercal 531 in combination with the flow sensor Superstatic 440 Oscillating beam flow sensor Superstatic 440 The electronic output signal of the Superstatic 440 represents the oscillation frequency of the hy- draulic fluid oscillator. In the table below, please find the typical frequency at Qn (qp) as function for different nominal flows (DN): DN [mm] Qn (qp) [m3/h]...

  • Page 72: The „Cut Off"- Function Of The Superstatic 440

    basic configuration minimum values precision minimum period 5 sec. (10 sec. battery-operated) 5 sec. (10 sec. battery-operated) maximum period 200 sec. 5 sec. For specific applications, the minimal values of the holding time are reduced: Minimum holding time: 1 second Maximum holding time: 2 seconds Attention: When configuring the parameter of the maximum holding time, attention has to be paid that this...
  • Page 73 Remark: The threshold values of the „cut off“- function have to be regarded as autonomous from the other two additional threshold values. Table with the factory-set threshold values acc. to PTB metrological class C Table with the factory-set threshold values acc. to OIML R75 1988 Manual Integrator Supercal 531 12-11-2009.docx...

  • Page 74: Special Functions

    9. Special Functions The special functions of the Supercal 531 can either be activated at the factory or with the service software Prog531. 9.1 Status message of the transistor outputs The Supercal 531 allows the transmission of the status messages to the transistor outputs. The displayed statuses can be defined over the threshold values.

  • Page 75: Open System (In Development)

    9.5 Open System (In development) In open heating systems one flow sensor is installed in the supply- and one in the return pipe. The Supercal 531 (Supercal 533) calculates the heat energy consumption with the temperature differ- ence and the two flow volumes. 9.6 Power Supply Batteries or power supply modules can be used.

  • Page 76: Seals And Operating Modes

    10. Seals and Operating Modes Seals and Operating Modes Seals and Operating Modes Generally, the Supercal 531 is set to normal is set to normal mode. Apart from normal mode, the integrator sof m normal mode, the integrator soft- ware allows the following operating modes the following operating modes: Test mode (Damaging the seal amaging the seal A)

  • Page 77: Calibration Mode

    10.3 Calibration Mode The Supercal 531 may only be switched over to calibration mode by authorized personnel. To ac- cess the calibration mode, the seal (C) on the back side of the integrator cover has to be removed. As soon as the seal is damaged or removed, the validity of the official calibration test and the warranty from Sontex are void.

  • Page 78: Technical Data

    11. Technical Data 11.1 Integrator Supercal 531 CE-Conformity: EMC-directive 89/336/EEC Electro-magnetic immunity acc. to EN 50082-1 Electro-magnetic emission acc. to EN 50081-1 Low voltage directive 73/23/EEC for power supply units protection class *) Mains 230 VAC II acc. to EN 61558 Mains 24 VAC III acc.

  • Page 79: Mains Module With Backup-Battery

    11.2.1 Mains module with backup-battery 230 VAC – 45 / 60 Hz (on request 115 VAC) Type protection class II Frequency 45 / 60 Hz Voltage tolerance + 10 / - 15 % Relative humidity > 93 % Fuse protection T 200 mA 24 VAC –...

  • Page 80: Communication Features

    Lithium D - cell Nominal voltage 3.6 V Service life up to 11 + 1 years (in combination with autarkic flow sen- sors) Maximum ambient temperature 55° C 11.3 Communication features The features of the Supercal 531 (in the integrator lower part) mentioned in point 11.3.1 are stan- dard features ex factory and the features mentioned in point 11.3.2 can be installed additionally in our factory.
  • Page 81 Circuit diagram pulse k t i v Normal mode: t1 = t2 min. 100 ms (pulse duty factor = 50%) Fast mode (mains operation): t1 = t2 min. 0.04 ms (pulse duty factor = 50%) Vin max. < 30 V quiescent, 0.5 V active Vin min.

  • Page 82: Options Of Standard Setting

    Circuit diagram: Control of outputs Zähler 1 Zusatzzähler Ausgänge Iout Zähler 2 Vout Control of pulse 1 / f Ruhend Aktiv Normal mode: t1 = t2 100 ms (pulse duty factor = 50%) Fast mode: t1 = t2 0.04ms (pulse duty factor = 50%) Vout max.

  • Page 83: Optional Communication Modules

    Radio module (factory-assembled) Method FM, bidirectional Frequency 433.82 MHZ Transmission power ≤ 10 mW Operating range on average 30m, depending on the local conditions and the structural engineering conditions Radio telegram: The radio telegram of the integrator Supercal 531 is structured in accordance with the M-Bus pro- tocol to EN1434-3.
  • Page 84 Analogue module with two outputs 0...20 mA, 4..20 mA or 0..10 VDC (see 6.2.1) 2 inputs: 2 (external voltage supply) Voltage supply 12 VAC or 12...24 VDC (external) Tolerances 12 VDC (0 %), 24 VDC (+ 35%) 2 outputs Analogue signal 0...20 mA, 4..20 mA (in overflow 3,5..24 mA) Voltage signal 0...10 VDC, 2…10 VDC...
  • Page 85 Module RS-232 with two relay outputs (see 6.2.3) RS-232: Baud rate 300..38'400 baud Data transmission full duplex Protocol M-Bus acc. to EN 1434 (half-duplex) Relays: Outputs Max. switching voltage, peak 60 V AC/DC Max. constant current 400 mA Surge current (100 ms) 1'000 mA Max.
  • Page 86 M-Bus module with two relay outputs (see 6.2.6) M-Bus: Definition of interface acc. to EN 1434-3 Interface potential-free, protected against reverse polarity Transmission rate 300...9’600 baud Data structure variable Relay: see specification relay module Connection diagram: M-Bus module (see 6.2.7) Definition of interface acc.

  • Page 87: Identification Plate Supercal 531

    12. Identification Plate Supercal 531 In accordance with PTB / MID the following data are stated on the identification plate or on the integrator upper part: Manufacturer’s logo Sontex standard Ownership or metering point number optional Product description Supercal 531 integrator upper part CE-designation integrator upper part...

  • Page 88: Mounting And Dimensional Drawing

    13. Mounting and Dimensional Drawing The integrator Supercal 531 can be installed in different ways: Wall-mounting Compact mounting on a flow sensor Top hat rail mounting Manual Integrator Supercal 531 12-11-2009.docx...

  • Page 89: Error Messages

    14. Error Messages The Supercal 531 indicates an existing error on the LCD display with the designation „Err“ and a numerical code: In case several errors occur at the same time, the numbers of error codes are listed and displayed. Description of error messages Err0 no error detected (service level)

  • Page 90: Project Planning

    15. Project Planning Security The integrator Supercal 531 features state-of-the-art technology and is in compliance with EN1434. If the integrator is operated outside the specifications defined in this manual or is not operated in accordance with the regulations, all service and warranty claims toward Sontex are null and void. Local regulations The following regulations have to be taken into consideration: Local regulations for electric installations...

  • Page 91: Annexe

    16. Annexe 16.1 Nowa / Unicon „NOWA“ stands for „NOrmierter Wärmezähler-Adapter“ (standardized heat meter adapter). In accordance with the latest standard, it should rather say „UNICON“ (UNIversal Signal- CONverter). The NOWA-interface is a standardised interface, which over the interface of a modern integrator, provides the connection to the control of the official calibration test rig.
  • Page 92 The interfaces of the NOWA-adapter Prüfstand NOWA (optional) ∆ϑ ∆ϑ - Simulation ∆ϑ ∆ϑ (optional) ∆ϑ ∆ϑ ∆ϑ ∆ϑ ∆ϑ ∆ϑ ∆ϑ ∆ϑ Wärme- Wärme- zähler zähler Over the interface S1 the test rig communicates the NOWA-function on the basis of defined speci- fications.

  • Page 93: Sontex Nowa.exe V1.03

    16.1.1 SONTEX NOWA.EXE V1.03 16.1.1.1 Key data Manufacturer abbr.: Type of meter: Integrator Supercal: SUPERCAL, SUPERCAL531 or SC Volume measuring part: SUPERSTATIC or SS440 Supported NOWA-test modes: V, RKS, RTS, TK,TT Adjustment options: Parallel capability (With the respective Nowamux-hardware): Special features: To ensure a reliable communication, it is necessary to know if optical probes are used with or with- out echo.
  • Page 94 (Command ‚l’: parameter flow + tv/tr of the test items), resp. the locally defined test duration (pa- rameter time). For all test modes TK/TT/RKS/RTS the corresponding parameters are extracted from the com- mand ‚r’ in case the test rig PC does not send any CURRENT parameters (‚l’). Checking of several test points before carrying out the calibration: Measuring method V (volume): minimum flow distance of the test points: 50% Qnenn Maximum volume error of the test item: 50%...
  • Page 95 Overview of the test sequence integrator (simulated flow) ‚RKS / RTS’: Entry of the number of measurements of simulation pulses (1 temperature measurement per s) in the meter NowaStart NowaStop Readout of measuring data, interim storage and transmission to test rig Errors received by test rig No calibration possible.

  • Page 96: Tariff Functions

    16.2 Tariff Functions Manual Integrator Supercal 531 12-11-2009.docx...
  • Page 97 Notes Manual Integrator Supercal 531 12-11-2009.docx...
  • Page 98 Technical Support For technical support, please contact your local Sontex representative or Sontex SA directly. Hotline Sontex: sontex@sontex.ch +41 32 488 30 04 Manual Integrator Supercal 531 12-11-2009.docx...
  • Page 99 SECTION 3 Spare Part Numbers For Heat Meter Superstatic 449 & Integrator (Supercal 531) Page HAMWORTHY HEATING LTD SOLAR HEAT METER FOR RHI 500001294/B...
  • Page 100 SPARE PART NUMBERS 553001073 - Flow & Return Sensors For Heat Meter Superstatic 449 Page HAMWORTHY HEATING LTD SOLAR HEAT METER FOR RHI 500001294/B...
  • Page 102 Wessex House, New Fields Business Park, Stinsford Road, Poole, Dorset, BH17 0NF Telephone: 01202 662500 Fax: 01202 662522 Email: service@hamworthy-heating.com Website: www.hamworthy-heating.com Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

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