5 691

SUPERSTATIC / SUPERCAL

STATIC ENERGY METER SS440…

FLUIDIC OSCILLATOR SC…

SuperStatic 440 flow meters and SuperCal integrator units for the measurement
of energy & volume and flow monitoring in heating or cooling systems.
Featuring:
• No moving parts so therefore low wear
• Long term measurement stability means ensured revenue
• Suitable for dirty water, pure water, glycol applications
• Low pressure loss
• A selection of integrator units dependant on reading or output requirement
• Manufactured in accordance with EN 1434 Class 3.0

Applications

Metering of consumption and demand data:

• heat energy & demand
• cooling energy & demand
• volume & flow
Typical users:
• apartment complexes
• commercial buildings
• district heating schemes
• industrial processes

Typical Metering Data

• total energy (kWh) • instantaneous power & flow (kW &

• total volume (m³) m³/h)
• maximum demand (kW MD) • instantaneous supply & return temp.
• maximum flow rate (Q MD) • instantaneous ∆t
• maximum supply & return temp. • date & time
• annual ‘set-day‘ values • customer number
• statistical data
Ordering

When ordering it is necessary to order a set of items to make up the metering set.
Depending on the requirements, it is necessary to order the following items:

• Flow tube SS440…

• Integrator unit SC…
• Temperature sensor pair 460R…
• Sensor mounting accessories 460A… or 460A…
• Welding sleeve WZT…

For flow-only metering, only the flow tube and the integrator unit are required.

Additional to the basic order codes , it is necessary to provide the factory with
configuration instructions. This information can be detailed using the SONTEX
Production Specification (SPS) tool which is available from product management.

The SPS will assist in creating the order codes for each item and should be forwarded
to the factory at the time of ordering.

SS440 Flow Tubes - Overview

The SuperStatic 440 flow measuring unit consists of a flow tube and fluidic oscillator
measuring chamber. From DN 25 up to DN 40 the flow tube is constructed from brass.
From DN 50 up to DN250 they are stainless steel. The DN 500 version is normal steel.

In the smaller sizes the flow is directed entirely through the oscillation chamber
whereas in the larger sizes, a portion of the flow is shunted through the oscillation
chamber.

The oscillation chamber is of a specially designed geometry that utilises a natural

physical response whereby the water flow oscillates within the chamber at a frequency
that is proportional to the total flow of water through the flow tube.

A piezo electric transducer senses the change in pressure caused by the oscillation
and emits an equivalent frequency pulse. This pulse is shaped and amplified before
being made available at the connection cable. The connection cable is then connected
to the selected integrator which logs the output pulses for further calculation depending
on the application required (flow/volume metering or additionally, energy metering with
associated temperature sensors).

• In the smaller meters – as pictured - all of the flow is passed

into the oscillation chamber at point 11. In the larger meters
a proportion of the flow is shunted through the chamber at
this point
• The water flows through the nozzel, 5, and passes back out
through points 7 & 8.
• Two feedback loops, 9 & 10, channel water over and under
the piezo transducer. The feedback loops meet the main
flow at point 5.
• The feedback loop with the higher pressure influences the
balance of water flow through 7 & 8, thereby changing the
relative pressure of 7 to 8 and leading to a change in
relative pressure between 9 & 10. Therefore the feedback
loop relative pressure relationship swaps position.
• The cycle repeats, producing an alternating pressure
differential across the transducer at a frequency
proportional to the rate of flow of water.

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SS440 Size Range

Type Nominal Nominal Mounting Length of Sensor

Reference flow rate Connection Pressure Length Sensor Cable
(ASN) (m³/h) (bar) (mm) (mm) (m)

SS440-0A25 1.0 T 1“ 16 190 26 2

SS440-0B25 1.5 T 1“ 16 190 26 2

SS440-0C25 2.5 T 1“ 16 190 26 2

SS440-0A32 3.5 T 1 ¼“ 16 260 31 2

SS440-0B32 6.0 T 1 ¼“ 16 260 31 2

SS440-0040 10 DN 40 16 300 85 2

SS440-0050 15 DN 50 16 270 85 2

SS440-0065 25 DN 65 16 300 85 2

SS440-0080 40 DN 80 16 300 134 2

SS440-0100 60 DN 100 16 360 134 2

SS440-0125 100 DN 125 16 250 134 2

SS440-0150 150 DN 150 16 300 174 2

SS440-0200 250 DN 200 10 350 174 2

SS440-0250 400 DN 250 10 450 174 2

SS440-0500 1500 DN 500 10 500 174 2

SS440 Key Flow Points

As defined in the EN 1434 standard for energy meters, the main flow points to consider
when selecting a flow tube are as follows:

Reference Alt. Description Comment

Reference
Nominal flow; the flow rate at which the It is this value that should be used
QNom qp flow unit will operate within class when selecting a flow tube. The flow
accuracy continuously without tube should not be selected based on
exceeding 250mBar pressure loss the pipe size
Maximum flow; 2.qp – the flow rate that The short time reference relates more
QMax qs the flow unit can endure for a short to mechanical meters (<1 hr/day or
time while remaining in accuracy class. 200 hrs/yr). Static meters will operate
up to qs continuously but the
associated pressure loss should be
considered.
Minimum flow; the flow rate by which For SS440:
QMin qI time the meter must be operating within - Up to qp 25 1:100
class accuracy. Typically expressed as - From qp 40 to qp 400 1:50
a ratio to qp - qp 1500 1:10
Starting flow; the flow rate by which For SS440:
QStart qa flow should be registered. No accuracy Up to qp 3.5 1:250
requirement. Typically expressed as a - From qp 6.0 to qp 25 1:200
ratio to qp - From qp 40 to qp 400 1:100
- qp 1500 1:50

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SC… Integrator Units - Overview

The SuperCal integrators perform the data collection and processing function, making
the measured data available for billing, statistical, monitoring or control purposes.
Retrieval of the data is via LCD register, impulse outputs, analogue outputs or via
communication bus. The type of outputs available is dependant on the type of
integrator selected.

The integrator is programmed according to the size of SS440 flow tube that will be
connected to it. Each SS440 has a impulse/litre value marked on it and the integrator
unit must have the same value for correct operation. Because the SS440 and integrator
are ordered together, the integrator will be preset for it’s associated flow tube’s impulse
rate at the time of manufacture. Should it be necessary, there is a programming tool
available for the SC431 and SC437. The SCM03 can be programmed via the two
display navigation buttons on the front.

If energy measurement is required then Pt500 sensor pairs must be ordered also. If the
integrator is only to indicate volume and flow then the temperature sensors are not
required (for flow-only with analogue output, the integrator type SCM03… is
necessary). Power options are dependant on the data collection requirement:

Manual reading/impulse outputs Analogue outputs (upto 4) c/w M-BUS Flow only c/w Analogue
(SC431…) (SC437…) output
(SCM03…)
• Battery, 5 years • 230Vac • 230Vac
• 230Vac

The integrators provide the following data:

• Accumulated energy (kW) • Instantaneous power (kW) • Supply temperature

• Accumulated volume (m³) • Instantaneous flow (l/h) • Return temperature
• Maximum demand power (kW MD) • 12 monthly readings (automatic) • Diff. Temperature
• Maximum demand flow (Q MD) • Annual ‘set-day‘ reading (user date) • Date/time

The integrator receives the flow proportional impulses from the SS440 and makes the
instantaneous flow rate available at the LCD or analogue outputs. Based on the flow
rate, the accumulated volume and flow maximum demand is calculated and recorded.

If temperature sensors are connected, a calculation is made based on the flow rate (Q),
the differential temperature and the coefficient for the medium used for the energy
transfer (water – 1.15, glycol – dependant on the ratio). From this calculation, the power
(kW) is derived and consequently the energy and power MD can be calculated and
recorded:

kW = Q * ∆t * 1.15

The power calculation is typically based on the flow unit being positioned in the return
pipe. If necessary, the programming can be made for supply pipe mounting. This must
be informed at the time of ordering.

Depending on the integrator type and the flow unit size, the metering set can be used
for metering energy relating to Heating systems, Cooling systems or combined
Heat/Cool.

The Heat/Cool application is typically used for 2 pipe systems operating in heating or
cooling mode dependant on the time of the year. The heat energy is registered in the
normal energy register. The cooling energy is registered in a tariff register; the cooling
tariff is active when the measured temperature falls below a preset threashold – in this
case, 20°C.

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SC431… Local Reading & Impulse Outputs

The SuperCal 431 is used for applications that simply require that the metering data is
manually read from the LCD registers or if impulse outputs are required.

Impulse Outputs Two impulse output transistors are available that can be configured for Energy (n
kW/imp.) & Volume (n litres/imp.) , Energy & Alarm or Heat Energy & Cool Energy.

Impulse Inputs Two impulse inputs are available that allow up to two other devices having an impulse
output to be connected to the integrator whereby the integrator acts as a data logger,
saving the impulse counts in auxilliary registers. This facility allows reading of two other
meters (water, gas, electricity for instance) from a common point.

It should be noted that if the meter is required to register Heat/Cool then only one
auxilliary input register is available as one of these registers is utilised for the Cooling
Tariff register.

Flow only The SC431 may be ordered for use without temperature sensors and therefore, used
for metering flow/volume only
Standard Types

ASN Order Code Application Power Supply

SC431-10012W0BE Heat or Cool Battery

SC431-10012W0NE Heat or Cool 230Vac

SC431-10013W0BE Heat/Cool Battery

SC431-10013W0NE Heat/Cool 230Vac

SC437… Analogue Outputs, M_BUS, Local Reading, Impulse Outputs

The SuperCal 437 is similar to the SC431 except that additionally there are 2 or 4
analogue outputs available and M-BUS communication output for networked reading of
multiple meters via two-wire bus.

Analogue Outputs The analogue outputs give a real-time indication of power, flow, supply temperature &
return temperature. Two versions are available:

SC437-2… Power & Flow

SC437-4… power, flow, supply temperature & return temperature

The outputs can be 0…20mA, 4…20mA or 0-10Vdc

The output maximums are derived as follows:

Output Type Value at output maximum

A01 Power qs * ∆t25°C * 1.15

A02 Flow qs

A03 Supply temperature Heating 150°C, Cooling 30°C, Heat/Cool 150°C

A04 Return temperature Heating 150°C, Cooling 30°C, Heat/Cool 150°C

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Standard Types

ASN Order Code Application Power Supply

SC437-20012W0NE Heat or Cool, 2 analogue outputs, 230Vac

M-BUS output
Heat/Cool from qp 3.5 only
SC437-40012W0NE Heat or Cool, 4 analogue outputs, 230Vac
M-BUS output
Heat/Cool from qp 3.5 only
SC437-90012W0NE Heat or Cool, M-BUS output 230Vac
Heat/Cool from qp 3.5 only

SCM03… Flow only, Local Reading, Impulse Output, Analogue Output

For flow only applications requiring an analogue output, the SCMO3… should be used.

Standard Types

ASN Order Code Application Power Supply

SCM03-90012W0NE Only for SS440 from qp 3.5 230Vac

Sensors

The sensors are Pt500, ordered as a separate item and supplied as a matched pair.
One order number indicates a pair of sensors.

Sensor Pair Length Immersion Pocket Welding Sleeve

ASN (mm) ASN
Pipe (DN) ASN
460R538 26 None (direct immersion) 25 WZT-G10

460R030 31 460A206 32 Out sourced (G ½“)

460R531 85 460A207 40…50 WZT-G12

65 WZT-GLG

460R532 134 460A208 80…100 WZT-G12

125 WZT-GLG

460R533 174 460A209 150 WZT-G12

200…500 WZT-GLG

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Installation Notes – SS440…/SC…

Before Installation
• Check system layout data
• The pulse value and mounting location (return or supply side) of the flow sensor
must match the values specified on the integrator. Please note identification plate!
• The permissible ambient temperature range in the case of the integrator is 5 -
55 ºC
• Make sure the integrator is in a position that can be read easily
• The integrator is designed for wall mounting
• With regard to the flow tube, please note direction of flow (arrow on flow sensor)
• Radiated heat and electrical interference fields close to the integrator should be
avoided

Flow Unit Positioning

• Avoid positioning where air locks may occure. Do not mount in the highest point of
a system or the highest point in a segment of piping. Systems should always be
purged correctly
• If in vertical pipe-work, position the flow tube in ascending pipe rather than
decending
• If installing in pipe-work with open in-flow or out-flow, the flow tube should be
placed in the low point of a siphon formation
• Balancing and control valves should be positioned after the flow tube
• Pumps should be positioned before the flow tube

Integrator
• Ensure the pulse value noted on the integrator matches that noted on the flow tube
• Cables must be clear of any hot parts (>100°C)
• Where cables are shielded, ensure shields are correctly fastened under the cable
clamps
• Electrical connections should be according to local regulations
• The integrator cover should be sealed upon completion of connections (subject to
local regulation)

Sensors
• Matched pairs should be used
• If a sensor is damaged and must be replaced, replace both sensors with a new
matched pair
• Never lengthen or shorten the sensor cables
• The sensor should penetrate to at least half the pipe diameter.
• Where the sensor is not mounted perpendicular to the pipe, then the sensor should
be positioned such that it points into the direction of flow

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LCD Operation

SC431 / SC437

Main Menu Service Menu (press button for 5 seconds)

kum. = Cumulative Temperaturfühler = Temperature sensor

Energie = Energy Impulswertigkeit = Pulse value
Volumen = volume Identitätsnummer = Serial number
Segmenttest = Segment Test Typenbezeichnung = Type designation
Zusatzzähler = Supplementary meter Stichtag = Set Day
Vorlauftemperatur = Supply flow temperature Datum = date
Rücklauftemperatur = Return flow temperature Zeit = Time
Temperaturdifferenz = Differential temperature
Betriebsstunden = Operating hours
aktueller Durchfluss = Current flow rate
aktuelle Leistung = Current output
Fehler = Error
Prozessor rechnet = Processor computing
Batterie ersetzen = Replace battery

NB: Although not shown above, the maximum demand values are also available.

Error Error description Remedial actions, instructions

001 Return flow sensor faulty Check sensor and connections. Replace if necessary
002 Supply flow sensor faulty Check sensor and connections. Replace if necessary
003 Err 1 and Err 2 present Connect sensors
004 Sensors or flow reversed Correct system
008 Calib. error in temp. meas. cycle Return to service point
016 Flow volume too high Correct system
032 Fault in pulse input A Pulse rate too high (max. 1.5 Hz)
064 Fault in pulse input B Pulse rate too high (max. 1.5 Hz)
Battxxx Batteries drained Return to service point

SCM03 Please refer the separate Operating Manual

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Terminations

SS440 Fly lead to integrator:

Brown: +ve (to integrator terminal 9)

White: Flow signal output (to integrator terminal 10)
Green: -ve (to integrator terminal 11)

SC431
Hinweis
Die Klemmen sind nur
1 2 3 4 9 10 11 16 17 181950 51 52 26 27 28 bestückt, wie die
N P im Typ enthalten
O
Volumen Belegung der Netz
messtei gemäss 230V /

Volumenmessteil = Volumetric flow meter

Belegung der gemäss… = Allocation of terminals as per table
Netz = Mains power supply

Note: Terminals are only allocated according to model selected.

1 Higher temperature sensor 19 Pulse output - volume (0V)

2 Higher temperature sensor
3 Lower temperature sensor
4 Lower temperature sensor
9 SS440 flow meter power supply
10 SS440 flow meter input signal
11 SS440 flow meter ref. potential
16 Pulse output - energy
17 Pulse output - energy (0V)
18 Pulse output - volume
26 Power supply earth
27 Power supply neutral
28 Power supply phase
50 Supplementary input A
51 Supplementary input A (0V)
52 Supplementary input B
53 Supplementary input B (0V)
54 Error pulse output
55 Error pulse output

SC437

Volumetric flow meter = Volumetric flow meter

Zusatzzähler = Supplementary meter
energy/Volumen Option Transistorausgang = Energy/volume optional transistor output
aktiv = active
Option aktive Analogausgänge = Optional active analogue outputs
Netz = Mains power supply

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 1 Higher temperature sensor 19 Volume pulse output (0V) 62 Data interface RS232 GND
2 Higher temperature sensor 26 Power supply earth 63 Data interface RS232 RXD
3 Lower temperature sensor 27 Power supply neutral 64 Data interface RS232 TXD
4 Lower temperature sensor 28 Power supply phase 65 Data interface RS232 DTR
5 Higher temperature sensor(4-wire) 50 Supplementary input A 70 Analogue output 1+
6 Higher temperature sensor(4-wire) 51 Supplementary input A (0V) 71 Analogue output 1-
7 Lower temperature sensor (4-wire) 52 Supplementary input B 72 Analogue output 2+
8 Lower temperature sensor (4-wire) 53 Supplementary input B (0V) 73 Analogue output 2-
9 SS440 flow meter power supply 54 Error pulse output 74 Analogue output 3+
10 SS440 flow meter input signal 55 Error pulse output (0V) 75 Analogue output 3-
11 SS440 flow meter ref. potential 56 Alarm pulse output 76 Analogue output 4+
16 Pulse output energy 57 Alarm pulse output (0V) 77 Analogue output 4-
17 Pulse output energy (0V)
18 Pulse output volume

Note: Terminals are only allocated according to model selected.

SCM03 Please refer to the Operation Manual - O5696A061En1.

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Technical data

SC431/SC437 Power supply 230V ac

110V ac
Lithium battery
Frequency 50/60 Hz
Temperature sensors Pt500 matched pair, 2 wire
Range 0°C – 180°C
Differential 0 – 150 K
Display units
Energy KWh, MWh, MJ, GJ or BTU
Volume m3
Impulse outputs
Type Transistorised
Max. voltage 40V (externally powered)
Max. current 10mA
Impulse width 400ms
Auxiliary Volume inputs
Compatibility Reed impulse
Maximum frequency 1.5hz
Impulse weighting 1 – 10 – 100 – 1000 l/imp.
Analogue outputs (only SC437) 0 – 10V dc
0/4…20mA
Data storage Non-volatile EEPROM
Power consumption 9 VA
Maximum ambient temperature
transport and storage -10...+60°C
operation 5...50°C
Standards Product standards
Energy Meters EN1434
Temperature sensors IEC 751
Electromagnetic compatibility As per the requirements of EN 1434
Housing protection class IP65 as per DIN VDE 0470
Safety test EN 61010

SCM03 Please refer to the Operation Manual - O5696A061En1

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 Dimensions

SS440 – to DN32

qp G PN Fig. B (mm) H (mm) L (mm)

1.0 1“ 16 1 125 79 190
1.5 1“ 16 1 125 79 190
2.5 1 ¼“ 16 2 78 105 260
3.5 1 ¼“ 16 2 78 105 260

SS440 – DN40 to
DN250

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 qp DN PN L D d
10 40 16 300 150 42
15 50 16 270 165 53
25 65 16 300 185 69
40 80 16 300 200 81
60 100 16 360 220 107
100 125 16 250 250 132
150 150 16 300 285 159
250 200 10 350 340 207
400 250 10 450 405 260
1500 500 10 500 670 497

SC431

SC437

190

77
144

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Pressure Drop

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Typical Data

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Notes

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