Integra CALEC ST II Installation And Operation Manual
Installation and operation manual
CALEC® ST II
Table of contents
1 Safety 2
2 Structure of a measuring point 4
3 Scope of delivery, installation accessories 5
4 Installation 6
5 Controls and operation 32
6 Maintenance and repair 49
7 Disposal 49
8 Technical specifications 50
9 CE Declaration of Conformity 54
10 Appendix 55
VD 3-126e 01.2018
1 Safety
1.1 Intended use
CALEC® ST II is a high precision instrument designed for the collection, analysis, presentation and transmission
of information. Improper or non-intended use of the device may compromise operational safety. We accept no
liability for any resulting damages.
1.2 Notes on safety instructions and symbols
The device has been designed to fulfil modern safety requirements. It has been tested and delivered in a condition
that ensures safe operation. However, improper or non-intended use of the device may result in it becoming
dangerous. Please always pay attention to the safety instructions in this manual which are accompanied by the
following symbols:
2
CALEC® ST II
WARNING!
WARNING indicates an action or measure which, if performed incorrectly, can cause
potentially life-threatening injuries and lead to a high safety risk. Always follow the
instructions and proceed with caution.
NOTE!
NOTE indicates an action or measure which, if performed incorrectly, may have an
indirect effect on the operation of the device, or trigger an unexpected response.
COMMENT!
COMMENT provides information and recommendations for efficient and trouble-free
operation.
CAUTION!
CAUTION indicates an action or measure which, if performed incorrectly, can cause
minor injuries and/or incorrect operation or destruction of the device. Always follow the
instructions.
REFERENCE!
REFERENCE refers to additional documents.
3
CALEC® ST II
1.3 Installation, startup and operation
General hazards and warnings
This device is intended for permanent installation with a fixed electrical connection. The installation, connection
to the electricity supply, startup and maintenance must be carried out by trained, qualified personnel who are
authorised to perform this type of work. The respective specialist personnel must have read and understood this
installation and operation manual, and follow the instructions contained therein. The operator must ensure that
the measuring system is wired correctly in accordance with the wiring diagrams. Contact protection is deactivated
when the cover is removed (risk of electric shock). The housing may only be opened by qualified personnel.
Disconnect the power supply prior to electrical installation, and ensure that it cannot be reconnected
without your consent.
Pay attention to the following points during installation:
• Voltage, operating data
• Maximum transmission length
• Cable cross-section and length
• Ambient temperature and installation position
1.4 Technical progress
We reserve the right to modify the technical specifications without prior notice.
WARNING!
Danger of electrocution!
Touching or gripping live electrical parts can cause an electric shock, which may
result in burns, paralysis or death.
• The device should only be opened, installed or repaired when the power has
been switched off.
• Only specialist technicians are authorised to work on or with mains voltage.
They must comply with the applicable regulations.
• Only the intended terminals should be used to connect the device to the mains
supply.
REFERENCE!
Latest version of this manual!
The latest version of this manual is available at:
http://www.aquametro.ch/qr/prod/calec-st/11111.html
4
CALEC® ST II
2 Structure of a measuring point
A complete measuring point for thermal energy consists of the CALEC® ST II energy calculator, paired temperature
sensors and flow sensor.
The applicable regulations and recommendations for installation and operation must also be complied with,
e.g. Section 6 of EN 1434, and the recommendations of professional associations such as the „Merkblätter der
Fernwärmeversorgung“ [fact sheets for district heating] issued by the German Energy Efficiency Association for
District Heating, Cooling and CHP (AGFW). The installation of control immersion sleeves is mandatory in some
countries (e.g. in France after FDE 39-007).
NOTE!
Type of temperature sensor, pulse value, installation side!
Check whether the temperature sensor type (e.g. Pt100), pulse value and installation
side (cold, hot) of the flow sensor match the nameplate on the CALEC® ST II.
NOTE!
Calibrated device!
Depending on the version, the CALEC® ST II is a calibrated measuring device
(see calibration markings on the nameplate).
Calibration is rendered invalid if any changes are made to the calibration parameters.
The parameters can only be accessed once the verification seal has been destroyed.
Parameters related to the calibration of calibrated devices can only be adjusted by
the manufacturer or by a designated calibration centre. The commissioning of a calibrated
measuring point must be made by an authorized organisation according to the valid regulations.
After commissioning of the meter, the components (the calculator, the flow meter and two
temperature sensors) must be sealed.
5
CALEC® ST II
3 Scope of delivery,
installation accessories
The supplied assembly and connection accessories
are located on the top of the housing:
The yellow piercing awl 1) can be used to pass the
cables through the membrane seals easily
The strain on the wire can be eased using the
white strain-relieving discs 2).
The two red plugs 3) are used to secure the two screws in the front cover.
Unauthorised opening of the device can be detected if these safety caps have been installed.
Removing the protective caps:
Pierce with a sharp tool and lever them out. This damages the cap, which needs to be replaced.
NOTE!
Calibrated device!
The unit can be damaged if not stored correctly!
This precision measuring device can be damaged by heat, moisture, dirt and vibration,
which can cause malfunctions.
The device must be stored in accordance with the specifications and only removed from
the packaging immediately prior to installation.
6
CALEC® ST II
4 Installation
The CALEC® ST II can be mounted on a mounting rail or on a flat wall. Suitable mounting rails are available as
an accessory (article number 19838). Please refer to the last page of this document for a hole template for both
installation types.
Device dimensions
Hole dimensions for wall mounting Clear height
(for clipping on the housing cover)
7
CALEC® ST II
Tools, assembly materials
(Not included in the scope of delivery)
Opening the housing
3 x Ø
4
3 x Ø6
Torx T15
Ø6
3 x 4.3 x 12
3.5 x 0.6
8
CALEC® ST II
Unit design
À
The front cover can be locked into the lower section of the housing
Á
The connection diagram is located on the inside of the front cover
Â
The motherboard can be accessed by removing the plug-in totaliser
Ã
Motherboard with terminals and microswitches for configuring inputs and outputs
Ä
Clip-on holder for mounting rail
À
Á
Â
Ã
Ä
9
CALEC® ST II
4.1 Installation
Installation instructions
Select the installation point:
• protected from moisture, heat, direct sunlight and damage
• easily accessible for reading, operation and installation
• at a sufficient distance from sources of electromagnetic interference
Mounting on rail DIN-EN 50222
À
Drill holes Ø6
Á
Screw in the mounting rail
Â
Clip the device onto the
mounting rail
Wall mounting
Only mount the device on
a flat surface!
À
Drill holes Ø6
Á
Screw in the device
10
CALEC® ST II
4.2 Electrical connection
Hazard warning
Connection diagram
The connection diagram is located on the inside of the front cover.
Sample connection diagram:
Analogue outputs in socket #1 and M-Bus
in socket #2.
WARNING!
Danger of electrocution!
Touching or gripping live electrical parts can cause an electric shock, which may
result in burns, paralysis or death.
• The device should only be opened, installed or repaired when the power has been
switched off.
• Only specialist technicians are authorised to work on or with mains voltage.
They must comply with the applicable regulations.
• Only the screw-type terminals in the separated area on the left in the terminal
compartment should be used to connect the device to the mains supply.
11
CALEC® ST II
Terminal technology
The CALEC® ST II is equipped with direct plug-in terminal connectors based on the “push-in” principle. Stripped
rigid conductors or flexible conductors with crimped ferrules (AEH) can be plugged directly into the spring terminal
to create a reliable, vibration-resistant and gas-tight connection. The release button has to be pressed for finestranded conductors, or to release the conductors.
Connectable conductors:
Single-conductor connection:
• Single-wire mm2: 0.50…1.50
• Finely stranded mm2: 0.50…1.50
• Finely stranded with AEH mm2: 0.25…1.50
• AEH with plastic collar mm2: 0.25…0.75
Stripping length mm: 8.0 + 1.0
AWG: 24-16
Functionality of connections
Connection diagram
The functionality of different connections can be configured with microswitches S1 - S5. The original factory
status is documented on the connection diagram. If required, the alternative functionality shown in the connection
diagram can be made available by switching the corresponding microswitch.
Sample connection diagram:
Analogue outputs in socket #1
and M-Bus in socket #2.
Overview of configuration options using microswitches
Terminals Switch Left function position Right function position
100 - 101 S1 OUTPUT#1 INPUT#2
102 - 103 S2 OUTPUT#2 INPUT#3
10 - 11 S3 INPUT#1: Active transmitter signal INPUT#1: Passive transmitter signal
(5 - 48 VDC) (e.g. reed)
108 - 109 S4 Sensor supply voltage Note: Consider section low voltage
supply (page 13)
106 - 107 S5 OUTPUT #1C Sensor supply voltage
3.6 V DC
Supply voltage 100 - 240 V AC 50/60 Hz
l
Connections: L and N The supply voltage is connected via the two screw terminals in
accordance with on-site regulations.
The cable is passed through the diaphragm seal using
the enclosed piercing awl.
Voltage range: 100 - 240 V AC
Frequency range: 50/60 Hz
Power requirements: max. 15 VA
Connection cross-section: max. 2.5 mm
2
Cladding diameter: max. 8 mm
Heat resistance: min. 65°C
Connection to circuit with protection of max. 10A and
double-pole isolating element.
Low voltage supply 12 - 42 V DC or 12 - 36 V AC 50/60 Hz or 24 VDC ± 20%
l
Connections: 108 and 109 Switch S4 (24 V ~ )
The CALEC® ST II can be supplied with safe extra-low voltage via these
terminals.
Voltage range: 12 - 42V DC / 12 - 36V AC
Frequency range: 50/60 Hz
Power requirements: max. 1 VA
With adapter « insulated supply 24V-24V» (Art. no. 80828))
Voltage range: 24VDC ± 20%
Frequency range: 50/60 Hz
Performance range: max 1 W
12
CALEC® ST II
13
CALEC® ST II
NOTE!
In low voltage applications of CALEC® ST II, in which a multiple grounding (PE) exists in field
installation, the adapter “insulated supply 24V-24V» (Art. no. 80828) must be positioned
upstream.
Examples for grounding:
• Grounded pulse input (e.g. pulser AMFLO® MAG Basic)
• Grounded sensor supply 3.6V and / or 24V
• Grounded pole of the low voltage supply
Procedure:
1. Disconnect CALEC® ST II from power supply
2. Set switch S4 from left to right
3. Connect adapter:
108+ from adapter to clamp 108 on CALEC® ST II
109- from adapter to clamp 109 on CALEC® ST II
IN+ and IN- from adapter to the external measuring point supply
Additionally the low voltage and sensor supply is possible with the adapter “insulated supply
24V-24V». Therefore the sensor shall be connected with OUT2+ and OUT2- (max. 150 mA).
If the switch is not correctly set, the device is later may not working properly or getting
destroyed.
The function low voltage supply shall only be used with the switch S4 in the position “right”!
14
CALEC® ST II
4-wire temperature sensor
l
Connections: 1 to 8
Check that the temperature sensor type (e.g. Pt500) corresponds to
the specifications of the CALEC® ST II.
Connection cross-sections: min. 0.22 mm
2
Cable length: max. 100 m
2-wire temperature sensor
l
Connections: 1, 2 and 3, 4
Check that the temperature sensor type (e.g. Pt500) corresponds to the
specifications of the CALEC® ST II.
Connection cross-sections:
Head sensor: min. 0.8 mm
2
Cable sensor: min. 0.22 mm
2
Cable length: shorter than 50 m (recommended)
Please note that the following maximum cable lengths are permitted for
2-wire technology, according to EN 1434-2:
Cable cross-section: Cable length:
Pt100 Pt500
min. 0.22 mm2 2.5 m 12.5 m
min. 0.50 mm2 5.0 m 25.0 m
min. 0.75 mm2 7.5 m 37.5 m
min. 1.5 mm2 15.0 m 75.0 m
NOTE!
Please check the connections carefully and ensure that the sensors are not reversed.
T
hot
terminals 1/5 and 2/6
T
cold
terminals 3/7 and 4/8
Temperature sensor cables must not be routed near power lines or electromagnetic inter-
ference sources (min. 50 cm distance).
NOTE!
The length of signal cable supplied by the manufacturer must not be changed.
Please check the connections carefully and ensure that the sensors are not reversed.
T
hot
terminals 1 and 2
T
cold
terminals 3 and 4
Temperature sensor cables must not be routed near power lines or electromagnetic inter-
ference sources (min. 50 cm distance).
15
CALEC® ST II
Sensor supply voltage 24 V DC
l
Connections: 108 and 109 Switch S4 (PS1)
When switch S4 is in the left-hand position (PS1), terminals 108/109
have a 24 V DC power supply for supplying a flow transmitter, e.g.
AMFLO® MAG Smart.
Output voltage: 24 VDC, electrically isolated
from all other outputs
Load: max. 150 mA
Electrical isolation: max. 48 VDC
Sensor supply voltage 3.6 V DC
l
Connections: 106 and 107 Switch S5 (PS2)
When switch S5 is in the right-hand position (PS1), terminals 106/107
have a 3.6 V DC power supply for supplying a flow transmitter, e.g.
AMFLO® SONIC UFA113.
Output voltage: 3.6 VDC, not electrically isolated
Load: max. 2 mA
NOTE!
When the sensor power supply is not needed, it can also be used for the active supply
of the current outputs (optional). If multiple current outputs are supplied, please note
that these are no longer electrically isolated from each other.
NOTE!
Terminal 107 is connected to terminal 11 and establishes the reference potential
for the flow transmitter.
16
CALEC® ST II
Flow transmitter with passive signal on pulse input #1
l
Connections: 10 and 11 Switch S3 (PASSIVE)
When switch S3 is set to the right-hand position (PASSIVE), a flow
transmitter with passive pulse signals, such as a reed relay or SSR
(solid state relay), can be connected to terminals 10 and 11.
The pulse signal from the flow transmitter must comply with the
following specifications:
Open-circuit voltage: 8 V
Short-circuit current: 8 mA
Switching level: <1.5 mA, >2.1 mA
Input capacity: 20 nF
Frequency range: 0…20 Hz 0…200 Hz
Min. OFF (toff): 20 ms 2 ms
Min. ON (ton): 3 ms 300 μs
The programming options for this input are described in the “InPutS”
of chapter „Operation“.
Diagram of input circuit
NOTE!
Flow transmitter cables must not be routed near power lines or electromagnetic interfe-
rence sources (min. 50 cm distance).
17
CALEC® ST II
Flow transmitter with active signal on pulse input #1
l
Connections: 10 and 11 Switch S3 (ACT)
Switch S3 must be moved to the left-hand position (ACT) for flow
transmitters with an active signal.
The pulse signal from the flow transmitter must comply with the
following specifications:
Voltage range: 3...48 VDC
Current signal: > 2 mA
Reverse polarity protection: -48 V
Electrical isolation: 48 V
Frequency range: 0…20 Hz 0…200 Hz
Min. OFF (toff): 20 ms 2 ms
Min. ON (ton): 3 ms 300 μs
The programming options for this input are described in “InPutS”
of chapter „Operation“.
Diagram of input circuit
NOTE!
Flow transmitter cables must not be routed near power lines or electromagnetic interfe-
rence sources (min. 50 cm distance).
Loading...