Gossen MetraWatt R2500 Operating Instructions Manual

3-349-374-03

19/6.18

R2500

Compact Controllers and Temperature Limiters

Operating Instructions

Contents Page Contents Page

GMC-I Messtechnik GmbH R2500–3

Safety Features and Precautions .........................................................4

Maintenance .....................................................................................5

Repair and Replacement Parts Service ................................................5

Product Support Industrial Division ......................................................5

Device Identification ..........................................................................6

Mechanical Installation / Preparation ..................................................8

Electrical Connection ........................................................................8

Operation .......................................................................................10

Disabling Modifications ....................................................................11

Performance After Activating Auxiliary Voltage ..................................11

Operating Flow Chart ......................................................................12

Automatic Operation / Off ................................................................13

Manual / Automatic Selection ..........................................................13

Controller Types ..............................................................................19

Conversion of Parameter Sets ..........................................................20

Backup Functions ............................................................................20

PI Performance ................................................................................20

Extra derivative action for cooling ......................................................20

Configuring the Switching Outputs and the Continuous Output ...........21

Relay Outputs for Actuating Signals ..................................................21

Actuator Output for Contactor ...........................................................22

Water Cooling .................................................................................22

Configuration of the Controller with Continuous Output ......................22

Setpoint Ramps ...............................................................................23

Suppression of Periodic Disturbances .............................................. 23

Adaptive Measured Value Correction ................................................ 24

Hot-Runner Control ......................................................................... 25

Feed-Forward Control ..................................................................... 26

Parameters Configuration ................................................................ 27

Program Controller .......................................................................... 29

Program Entry ................................................................................ 31

Manual Optimization ....................................................................... 33

Self-Tuning ................................................................................... 37

Balancing ....................................................................................... 38

Limit Value Monitoring ................................................................... 39

Limiter ........................................................................................... 39

Heating Current Monitoring .............................................................. 40

Heating Circuit Monitoring ............................................................... 41

Alarm History .................................................................................. 42

Data Logger ................................................................................... 42

Error Messages .............................................................................. 43

Error Acknowledgement .................................................................. 44

Error mask ..................................................................................... 45

Replacing an R2400 Controller with an R2500 Controller .................. 47

Technical Data ................................................................................ 49

CompactConfig Configuration Tool ................................................... 50

GMC-I Messtechnik GmbH R2500–4

Meanings of Symbols on the Instrument Safety Features and Precautions

The R2500 controller is manufactured and tested in accordance with safety
regulations IEC 61010-1 / DIN EN 61010-1 / VDE 0411-1. If used for its
intended purpose, the safety of the user and the device is assured.

Read the operating instructions completely and carefully before
using the device, Follow all instructions contained therein. Make
sure that the operating instructions are available to all users of the
instrument.

Observe the following safety precautions:

– The device may only be connected to an electrical system which

complies with the specified nominal range of use (see circuit diagram and
serial plate), and which is protected with a fuse or circuit breaker with a
maximum nominal current rating of 16 A.

– The installation must include a switch or a circuit breaker which serves

as a disconnecting device.

The controller may not be used:

– If it demonstrates visible damage
– If it no longer functions flawlessly
– After long periods of storage under unfavorable conditions (e.g.

humidity, dust or extreme temperature)
In such cases, the instrument must be removed from operation and
secured against unintentional use.

Continuous doubled or

Warning concerning a point of danger

Indicates EC conformity

reinforced insulation

Attention: observe documentation!

Functional earth terminal,
earthing for functional purposes only
(no safety function)

The device may not be disposed of with the trash. Further
information regarding the WEEE mark can be accessed on
the Internet at www.gossenmetrawatt.com by entering the
search term WEEE.

GMC-I Messtechnik GmbH R2500–5

Maintenance

Housing

No special maintenance is required for the housing. Keep outside
surfaces clean. Use a slightly dampened cloth for cleaning. Avoid the use
of solvents, cleansers and abrasives.

Repair and Parts Replacement

Repair and replacement of parts conducted at a live open instrument may
only be carried out by trained personnel who are familiar with the dangers
involved.

Return and Environmentally Sound Disposal

The R2500 is a category 9 product (monitoring and control instrument) in
accordance with ElektroG (German electrical and electronic device law).
This device is subject to the RoHS directive. Furthermore, we make reference
to the fact that the current status in this regard can be accessed on the Inter­net at www.gossenmetrawatt.com by entering the search term WEEE.
We identify our electrical and electronic devices in accor­dance with WEEE 2012/19/EU and ElektroG with the symbol
shown at the right per DIN EN 50419.
These devices may not be disposed of with the trash. Please
contact our repair and replacement parts service department regarding
the return of old devices.

Repair and Replacement Parts Service

If required please contact:

GMC-I Service GmbH
Service Center
Beuthener Straße 41
90471 Nürnberg, Germany
Phone [phone]
Fax [phone]
E-Mail [e-mail]
www.gmci-service.com

This address is only valid in Germany. Please contact our representatives
or subsidiaries for service in other countries.

Product Support Industrial Division

If required please contact:

GMC-I Messtechnik GmbH
Product Support Hotline – Industrial Division
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

GMC-I Messtechnik GmbH R2500–6

Device Identification

Feature Designation
Compact controller, 48 x 48 mm, IP 67, with self-tuning, 2

nd

setpoint and 2 alarms,

hot-runner functions, data logger, alarm history, program controller, infrared interface

R2500

Controller Type Outputs

Two-step, three-step, step-action controller 2 transistor, 2 relay A1
Two-step, three-step, step-action controller 2 transistor, 3 relay A2
Continuous, split range controller, discontinuous action controller 1 continuous, 1 transistor, 3 relay A5

Measuring Ranges

Configurable measurement input

B1

Thermocouple Type J, L 0 ... 900 C / 32 ... 1652 F

Type K, N 0 ... 1300 C / 32 ... 2372 F
Type R, S 0 ... 1750 C / 32 ... 3182 F
Type B 0 ... 1800 C / 32 ... 3272 F
Type C 0 ... 2300 C / 32 ... 4172 F
Type E 0 ... 700 C / 32 ... 1292 F
Type T 0 ... 400 C / 32 ... 752 F
Type U 0 ... 600 C / 32 ... 1112 F

Resistance thermometer Pt100 – 200 ... 600 C / –328 ... 1112 F

Ni100 – 50 ... 250 C / –58 ... 482 F
Ohm 0 ... 340 

Linear 0 ... 50 mV

GMC-I Messtechnik GmbH R2500–7

Measurement input: configurable standard signal

B2

0 / 2 ... 10 V or 0 / 4

... 20 mA

Auxiliary Voltage

85 ... 265 V AC, 48 ... 62 Hz C1
20 ... 30 V DC C2

Extras

Heating current monitoring E0
RS 485 data interface E1

Configuration

Default settings K0
Configured per customer requirements K9

Operating Instructions

German L0
English L1
Italian L2
French L3
None L4

Feature Designation

GMC-I Messtechnik GmbH R2500–8

Mechanical Installation / Preparation

Figure 1: Housing Dimensions and Panel Cutout

The R2500 controller is intended for installation to a control panel. The
installation location should be vibration-free to the greatest possible
extent. Aggressive vapors shorten the service life of the controller.
Requirements set forth in VDE 0100 must be observed during the
performance of all work. Work on the device may only be carried out by
trained personnel who are familiar with the dangers involved.

Set the housing into the panel cutout from the front, and secure it from

behind at the top and bottom with the two included snap retainers.
Several devices can be mounted next to each other without separators at
the side.

In general, unobstructed air circulation must be assured when one or
several devices are installed. The ambient temperature underneath the
devices may not exceed 50 C.
In order to assure IP 67 protection, an appropriate seal must be installed
between the device and the panel.

Electrical Connection

Figure 2: Connector Terminal Positions

48

48

45

+0.6

45

+0.6

104

119

5

12
12
14
15
15
16
17
18
19
20

1
2
3
4
5
6
7
8
9

10

Connectors: screw terminals for wire with 1.5 square mm cross-section
or two-core wire-end ferrules for 2  0.75 square mm

GMC-I Messtechnik GmbH R2500–9

Attention: to ensure radio interference suppression, the protective conductor and/or control cabinet grounding must be connected to terminal 13.

Binary Input

Transistor Output Cont.

Output

Auxiliary Voltage

A1, A2, A5 A5 C1 C2

1111

2 ––2 – 12

3 + out1 3

+

13

4 + out2 + out2 414

5515

6616

7717

8 A 818

9 B 919

10 C 10 20

B1 B2 E0 E1

Relay

Outputs

A2, A5

Sensor

Heating
Current

Transformer

RS 485

Relay

Output

110 / 230 V AC

N

L

24 V DC
–

+

20 mA / 10 V

20 mA

10 V

out 1

A1

A2

GMC-I Messtechnik GmbH R2500–10

Operation

Setting Values with the Up and Down Scroll Keys

– At the operating level, the setpoint can be adjusted within a range extending from the minimum to the maximum setpoint.
– Configuration and parameter settings can be changed if password protection has not been activated, or if the correct password has been entered.
– In order to avoid erroneous settings, changes must be acknowledged within 5 seconds with the key.
– The change can be discarded by pressing the key.

Actual value

Setpoint / heating current /

Switching output for heating active
Switching output for cooling active

Alarm 1 active

Select: Off/manual  automatic operation

Setpoint 2 active

Manual operation

Reduce value / increase value

Switch displays, levels and values
(see operating flow chart)

Figure 3: Controls

Alarm 2 active
Infrared interface (see page 50)

manipulating factor (operating level)

GMC-I Messtechnik GmbH R2500–11

Disabling Modifications

The default setting (PSEt = dEF) allows for modification of all parameters and configurations. The following settings can be used in order to disable the
entry of changes:

Disabling Setpoint Changes

The setpoint can only be adjusted between its minimum and maximum values. The SPL and SPH parameters must be set accordingly.

Disabling Changes to Parameters and Configurations

After password protection for device operation has been activated (PAS S not equal to diS), changes can only be made after the correct password has
been entered. However, changes are always possible via infrared or bus interface!

Disabling Self-Tuning

Starting self-tuning by pressing the corresponding keys can be separately disabled with the configuration tunE = diS.
However, self-tuning can always be started via infrared or bus interface!

Performance After Activating Auxiliary Voltage

Actual Value

Setpoint or oFF

U/M

Firmware Version

LED Segment Test

Approx. 1.5 s Approx. 1.5 s

Approx. 1.5 s

Designations

GMC-I Messtechnik GmbH R2500–12

Operating Flow Chart

Actual

Ht. Current Man. Factor

Automatic Operation

Actual

Setpoint

Actual Actual

Param. Value

Param. Value

Operating Level

Press key briefly. Press and hold key until display switches.

(

page 27)

(

page 14)

With heat current
monitoring only

Setpoint can only be
set here

Configuration

Configuration

ConfigureParameter Level

*

*

*)

If password protection for device operation is activated (configuration:

PASS

=

EnA

),
the correct password must be entered in order to change values.
Otherwise

-no-

appears at the display if an attempt is made to change a value.

Actual

With program
controller only

Program

Program

Program Controller

*

Press and hold both keys until display switches.

GMC-I Messtechnik GmbH R2500–13

Automatic Operation / Off

Manual / Automatic Selection

Actual

Off

– No alarm function
– No indication of errors

Operating Level

The controller can be deactivated by pressing and holding the key, if it
is configured to on/off.

Man. Factor

Actual

Manual Operation

Operating Level

– Alarm function and error indication identical to automatic operating mode.
– The actuator outputs are controlled with the scroll keys and not by the controller function.
– Switching between manual and automatic modes is bumpless in both directions.
– PDPI controller:

The manipulating factor is displayed as a percentage. Value
changes are forwarded immediately to the control outputs.

– Step-action

controller:

The switching outputs can be adjusted directly with “more” or
“less” by pressing the up and down scroll keys.

I

f the key is configured to

manual / automatic

GMC-I Messtechnik GmbH R2500–14

Configuration

press and hold simultaneously

Configuration Display Selection Standard Comment

Sensor type

SEnS

tYP.j

Types J

tYP.L

L

tYP.K

K

tYP.b

B

tYP.S

S

tYP.r

R

tYP.n

N

tYP.E

E

tYP.t

T

tYP.v

U

tYP.C

C

tYP.-

–

Pt 1

Pt100

ni 1

Ni100

ni12

Ni120

rES

–

0HM

Resistor in



Lin

Voltage in mV

Type J

Not with standard signal

U/M SEnS 1° C, 1° F, 0.1° C, 0.1° F 1°C
Input quantity SEnS 0 - 20 / 4 - 20 dead / live zero 0 - 20

With standard signal only

Controller type COut

MEAS Measure only
P0W Actuator
0n0F Limit transducer
PdP1

2/3 step, step-action, split range

ProP Proportional actuator

PdPI See page 19

+

GMC-I Messtechnik GmbH R2500–15

Derivative action tu 11 dis / ena

–/ Extra derivative action for cooling

diS

only with 3-step controllers

Binary input 1n 1

phlt Pause program controller
prun

Start/stop program controller

oFF No function
SP 2 Setpoint 2 active
LooP Controller on
HAnd Manual operation
tunE Start self-tuning
Quit Clear limit value error
FEF0 Feed-forward control
StvP Start-up active
booS Start boosting
LoGG Data logger recording
Dark Display darkl
set2 Parameter set conversion
baCk Backup function

SP 2

The function of the binary
input has precedence over
operation and
configuration.

Binary input 1n

stat Binary input
dyn dynamic, switching by key

StAt

Configuration Display Selection Standard Comment

GMC-I Messtechnik GmbH R2500–16

out1 switching output 0ut1

tr2 Controller 2
tr1 Controller 1
phlt Program pause
prun Program running
oFF No function
HEAt Heater, more heat

with step-action controller

CooL Cooling, more cooling

with step-action controller

H20 Water cooling
Hclo

Less heat w. step-action controller

Cclo

Less cooling w. step-action controller

Hotr Hot-runner heat
1ndu Induction heating

al1l 1st lower limit value

HEAt

See page 21

out2 switching output 0ut 2 Same as out1 switching output oFF

Switching output selection 0ut

nor

As configured

xCh Outputs out1 and out2

exchanged with A1 and A2

nor See page 21

Continuous Output Cont

oFF No function
HEAt Heater,
CooL Cooling,
Proc Current controlled variable
SP Current setpoint

oFF

See pages 21 and 22,
only if a continuous
output is present
(designation A5)

Continuous output

Cont

0 - 20 / 4 - 20 Dead / live zero

20-0 / 20-4 dead / live zero invers

0 - 20

Alarm 1 A 1 noc / ncc

Operating current / idle current

noc

See page 39

Alarm 2 A 2 noc / ncc

Operating current / idle current

noc

Configuration Display Selection Standard Comment