Sontex Supercal 5 Thermal Energy Meter User Manual
- August 31, 2024
- Sontex
Table of Contents
Sontex Supercal 5 Thermal Energy Meter User Manual
Installation guidelines for thermal energy meter Supercal 5 General
The static flow sensor and its calculator may only be operated within the
conditions outlined on the identification plate, as well as within the
technical specification! 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 or only by authorized persons. The country-specific, 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 verified and measuring relevant data. When using several heat meters in an installation unit, fair heat consumption measurement must be chosen. All of them are in the same types of devices and installation 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 flow sensor, consult the identification 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 identification plates must be followed.
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 specified 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 parameterized 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 flow 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 fields 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 flow unit.
- The flow sensor should be installed between two shut-off valves.
- The flow sensor must be mounted with the measuring head to the side
- The flow direction of the flow sensor must be respected (arrow on the flow sensor).
- Flush the pipe system before installing the flow sensors. To guarantee that no foreign particles remain in the pipe.
- The flow sensor should be mounted BEFORE any control valve to exclude any potential parasitic influences.
- During commissioning the pipe system must be purged. Air in the system of the flow sensor may affect the measurement.
- Use only new and appropriate sealing material.
- The water tightness of the different connections should be verified. 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 the flow unit, as well as the
resistance value of the temperature sensors (Pt500), must match. Compare the
labels of the devices!
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!
Grounding
It has to be guaranteed that all grounding connections (line and power mains
and chassis of the flow sensor) of the total installation are equipotential.
Power supply modules
The power supply modules are connected using 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 12 VDC to 42 VDC), mains 230 VAC (110
VAC to 230 VAC, 50/60 Hz). These can be converted and retrofitted 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 by valid standards, under consideration of local
safety regulations, and by an authorized person. The electrical main is to be
made in such a way that no hot parts (pipes etc. over 80°C) can be touched
(dangerous with damaged isolation). Water contact with the electrical
connection must be avoided.
Backup battery in the calculator’s upper part
The upper part of the calculator, which is relevant for calibration and measurement, is equipped with an A-cell battery. This serves as a power supply for the LCD 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 and technical
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 connection 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 connecting cable shows any damage, the calculator unit should be disconnected and secured against accidentally resetting in operation. Generally, 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 parameters such as
flow rate, output, and flow and return temperature can be read on the LCD of
the calculator. If modules are installed, this is also shown on the LCD (M1:
M2:). With the Superprog Windows and Superprog Android software, you can read
additional information from the unit. All parameter displays are used to check
the thermal energy meter or to adjust the system. It must be checked that the
regulated flow of the system does not exceed the maximum permitted flow of the
meter. A commissioning protocol via the optical interface with the readout
software is recommended for a comprehensive functional check.
Pressure Loss Curve
Temperature sensors mounting
The temperatures indicated on the identification 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 fixed afterward. With unequal cable lengths or longer than 6 m, we recommend 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 to 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.
List of sensor pockets
The resonance frequencies of the protection pockets are outside of the flow velocities at maximum flow (qs).
Temperature sensors connections
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. This applies even if the temperature sensor is installed directly in the flow sensor.
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. Errors will be registered in the
error register with their date time (beginning) and duration (in minutes).
Communication options
The Supercal 5 can be fitted with up to two different optional communication
modules. The optional communication modules can be equipped afterwards,
without damaging the verification. The optional modules have no influence on
the verified relevant part in the cover of the integrator 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 specified by software. The feature of the
calculator Supercal 5 for cooling applications with cooling liquids water
mixtures are exclusively to be used with the flow sensor Superstatic 440 (Not
to be used with mechanical flow sensors).
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
- Configuration
- Service
- Test Radio
LCD control concept
The control key can be used to select and confirm the various menus,
parameters, or other selection options within the display.
The Right key has two functions:
- One single press and it selects the next menu.
- Press it for Two Seconds in the “Overview Menu” ➔ and you can enter the highlighted menu.
- The left key is designated to select the previous menu.
- If you are in any of the menus and you press both keys, 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)
Commissioning Menu
- Commissioning: commissioning menu
- Configuration via NFC
The sealing can be performed via NFC with the Superprog Android application or via optical head or M-Bus with the Superprog Windows application. To perform the configuration with Superprog Android proceed as follows: Open the application on the phone, select the ‘‘INSTALL/CONFIGURE’’ option, and follow the instructions on the screen. Once the installation assisted by Superprog Android is finished, Superprog Android will ask you to Seal the calculator. Select ‘‘YES’’. Remember that Superprog Windows has more options to configure the Supercell 5. To perform the configuration with Superprog Windows proceed as follows: Start Superprog Windows on the computer Connect to Supercal 5 via the selected interface.
Configure all the desired values. Once you have configured the desired values, press the ‘‘WRITE’’ button to confirm the changes and when you are requested to confirm the changes, you can check the checkbox to Seal the Supercell 5. If at this point, after configuring the device, you have not yet sealed the Supercal 5, you can do so manually as indicated in the following menu display.
- 1× short press on the left button
- Seal configuration
- SEAL: seals the configuration and switches to Default Menu
- 1× long press (> 2 seconds) on the left button
- Cumulated energy
- Cumulated volume
Dimension Supercal 5
Supercal 5 Lower Part
Conditions to comply with the directive 2014/32/EU (MID)
- The temperature sensors have to be mounted symmetrically in flow and return preferably without pockets. If using pockets they must be by the conformity declaration. Flow and return sensors must be mounted to the bottom of the pockets. Installation places in the flow sensor can be used with the symmetrical installation of the temperature sensor pair. Asymmetrical mounting of the temperature sensor isn’t permitted.
- In the case of permanently mounted temperature sensor pairs the connecting cables must not be shortened. In the case of exchangeable temperature sensor pairs according to MID, the maximum equal length is 15 m. Wire cross sections according to EN 1434-2. Connection to the calculator according to terminal connection on page 2 by respecting the electrical compatibility Pt 500 of the calculator.
- Straight sections of piping of 3 DN in flow and return of any flow meter or heat meter must be respected. For the Superstatic 440 up to DN 40 (qp10), the straight sections of piping of 3 DN are already included in the length of the flow sensor.
- The selection of the battery has to take place in such a way that it permits at least a supply of auxiliary energy throughout the application plus 1 year storage period.
- Information about the measuring stability is described in the conditions for water measurement by AGFW requirements FW 510. In case of deviating compositions, the thermal energy meter must be submitted to periodic control according to the guidelines of Sontex.
- If a customer-specific correction curve is applied, a sticker must be placed on the cover of the calculator and completed with the serial number of the sensor head. Replacement of the sensor head, as it is described in the homologation, isn’t possible in this case.
Security seals
Seals are country-specific; the local regulations must be respected. Against
possible manipulation or unauthorized dismantling, the thermal energy meters,
the screw connections, as well as the temperature sensors and pockets must be
protected with user seals. The seals may be removed only by authorized
persons. By neglecting this precaution the guarantee obligation is void. The
seal wires must be kept as short as possible and are well strained towards the
seals. Only this way, the seal is protected against unauthorized interference.
Manufacturer’s notice
The heat/cooling meter Superstatic 5 S is configured and adjusted ex-factory
to the different sizes of fluid oscillator flow sensors. An optimal measuring
accuracy and stability according to EN 1434 class 2 is guaranteed and a free
swapping of the sensor head is possible. Sontex declines all responsibility
for specific correction curves of the fluid oscillator flow sensors that we’re
not defined by Sontex.
Sealing
The sealing concept is subject to country-specific regulations. The sealing
points shown here were included in the construction of the Supercal 5.
Once the Supercal 5 is manufactured, it comes out from the factory as unsealed. It means it has to be installed at least with the following operations:
- Fixing it to its operable and definitive location.
- Installing the two temperature sensors.
- Installing the power supply if required
The calculator of the Supercal 5 S is then closed and mounted. It is then necessary to seal the calculator either via the menu on the display or Superprog Android/Windows. If the installer needs to change other metrological parameters, this can be done using the Superprog Android or Superprog Windows software. (Android version is recommended). From this moment on, and if at any time it is necessary to return to commissioning mode or the “Unsealed” state, the seal shown in the following image must be broken: In the case of divergences, the Englisch version takes precedence. Bei Abweichungen hat die englische Version des Inhalts Vorrang.
Further information
Technical support
For technical support contact your local Sontex agent or Sontex SA directly.
Declaration of conformity
The detailed declaration of conformity can be found and downloaded on our
homepage www.sontex.ch
Hotline Sontex
support@sontex.ch
+41 32 488 30 04
Technical modifications are subject to change without notice.
Sontex SA
Rue de la Gare 27
CH-2605 Sonceboz
Tel. +41 32 488 30 00
sontex@sontex.ch
www.sontex.ch
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