Gossen MetraWatt R2900 Operating Instructions Manual

Operating Instructions

R2900

Compact Controller, 96 x 96 mm

3-349-203-15

3/3.03

Contents Page Page

Safety Features and Precautions . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Repair and Replacement Parts Service . . . . . . . . . . . . 4

Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Device Identification . . . . . . . . . . . . . . . . . . . . . . . . . 5

Data Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mechanical Installation / Preparation . . . . . . . . . . . . . 6

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

Performance After Activating Auxiliary Voltage . . . . . 10

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operating Flowchart,

“Discontinuous-Action Controller” . . . . . . . . . . . . . . 12

Operating Flowchart, “Discontinuous-Action Controller”

with Differential Control . . . . . . . . . . . . . . . . . . . . . . 13

Operating Flowchart,
“Continuous-Action and Step-Action Controllers” . . . 14
Operating Flowchart, “Cont.-Action and

Step-Action Controller” with Diff. Control . . . . . . . . . 15

Off / Manual Operation . . . . . . . . . . . . . . . . . . . . . . 16

Manual Operation with Binary Input . . . . . . . . . . . . . 17

PWR Out Offset with Binary Input . . . . . . . . . . . . . . . 17

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Saving and Loading Device Settings: . . . . . . . . . . . . 21

Differential Controller . . . . . . . . . . . . . . . . . . . . . . . . 21

Slave Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Controller Sorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Configuration of the Controller with Continuous Output

(desig. A7 and A8) . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parameters Configuration . . . . . . . . . . . . . . . . . . . . 24

Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Self-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Manual Self-Tuning . . . . . . . . . . . . . . . . . . . . . . . . .28

Setpoint Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Heating Current Monitoring . . . . . . . . . . . . . . . . . . .32

Heating Circuit Monitoring . . . . . . . . . . . . . . . . . . . .32

Limit Value Monitoring . . . . . . . . . . . . . . . . . . . . . . .33

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . .36

Meanings of symbols on the instrument:

Indicates EC conformity

Continuous doubled or
reinforced insulation

Warning concerning a source of danger
Attention: observe documentation!

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

2 GOSSEN METRAWATT GMBH

Safety Features and Precautions

The R2900 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, safety of the user and of the device is assured.

Read the operating instructions completely and carefully before using the device, and follow all instructions included
therein. The operating instructions should be made available to all users.

Observe the following safety precautions:

– The device may only be connected to electrical systems which comply with the specified nominal range of

use (see circuit diagram and serial plate), and which are 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 visible damage is apparent
– If it no longer functions flawlessly
– After lengthy periods of storage under unfavorable conditions (e.g. humidity, dust, temperature)
In such cases the device must be removed from service and secured against any possible inadvertent use.

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

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

GOSSEN METRAWATT GMBH 3

Repair and Replacement Parts Service

When you need service, please contact:

GOSSEN METRAWATT GMBH
Service-Center
Thomas-Mann-Strasse 20
90471 Nürnberg • Germany
Phone [phone]/256
Fax [phone]
E-Mail [e-mail]

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

Product Support

When you need support, please contact:

GOSSEN METRAWATT GMBH
Product Support Hotline
Phone [phone]
Fax [phone]
E-Mail [e-mail]

4 GOSSEN METRAWATT GMBH

Device Identification

Electronic controller with self-tuning and 2nd setpoint, front panel dimensions: 96 x 96 mm
Controller Types

2 / 3-step controller with heating current monitoring / step-action controller 2 transistor outputs
2 / 3-step controller with heating current monitoring 1

2 / 3-step controller with heating current monitoring 1

2 / 3-step controller with heating current monitoring / step-action controller 2 relay outputs
Step-action controller with repeater / 3-step controller 2 transistor outputs
Step-action controller with repeater / 3-step controller 2 relay outputs
Cont.-action contr. / step-action contr. / 3-step contr. w. heat current monit. 1 continuous output and 2 transistor outputs
Cont.-action contr. / step-action contr. / 3-step contr. w. heat current monit. 1 continuous output and 2 relay outputs

Measuring Ranges

Input Thermocouple, configurable Type J, L –18 ... 850 °C / 0 ... 1562 °F

Type K –18 ... 1200 °C / 0 ... 2192 °F
Type S, R –18 ... 1770 °C / 0 ... 3218 °F
Type B 0 ... 1820 °C / 32 ... 3308 °F (especially 600 °C)
Type N –18 ... 1300 °C / 0 ... 2372 °F

Resistance thermometer Pt 100 – 100 ... 500 °C / –148 ... 932 °F
Input Standard signal, configurable 0 / 2
Both measurement inputs can be mutually

st

measurement input same as B1, 2nd same as B2, can be configured for slave controller B4

1

configured as per B1 for differential controller.B3

... 10 V or 0 / 4 ... 20 mA B2

Auxiliary Voltage AC 110 ... 230 V C1
Limit Contacts None

Two 2 relay outputsD0D1

Data Interface None

RS 485 or RS 232 (internally selectable)

Configuration Default settings

Configure per customer requirements

Operating German / English
Instructions French / Italian

None

st

switching point: transistor output

nd

2

switching point: relay output

st

switching point: relay output

nd

2

switching point: transistor output

R2900

A1
A2

A3

A4
A5
A6
A7
A8

B1

F0
F1
K0
K9
L0
L1
L2

GOSSEN METRAWATT GMBH 5

Data Interface

Refer to operating instructions 3-349-204-15 for detailed information regarding the data interface.

Mechanical Installation / Preparation

The R2900 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

96

5

96

50

Variants

A1 ... A6, D0, F0

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 left and right-hand sides with the two included
screw clamps. Typical tightening torque amounts to 10 Ncm, and
a value of 20 Ncm should not be exceeded.

+0,8

92

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.

+0.8

92

Panel Cutout

Figure 1, Housing Dimensions and Panel Cutout

6 GOSSEN METRAWATT GMBH

Variant A7, A8 or D1, or

570

F1

1

2

Securing the two screw clamps at the
right and left-hand sides of the housing:

– Push in direction 1 all the way up to the limit stop
– Push in direction 2 all the way up to the limit stop

Figure 2, Securing the Housing

GOSSEN METRAWATT GMBH 7

Electrical Connection

Binary In-

put

Transistor Output for Controlling SSRs 110 - 230

A1, A2,
A5, A7

A3, A4,
A6, A8

– + I – + II

1 234 56 789

I

II

Switching Output Heating Current Transf.

11 12 13 14 15 16 17 18 19

A1, A3,
A5, A7

A2, A4,
A6, A8

Auxiliary

Voltage

V∼

NL

A1, A2, A3,

A4, A7, A8

B1, B3, B4 B3

A5, A6

Repeater

10 V

10 V

B2 B4

20 mA

20 mA

Sensor 1 Sensor 2

21 22 23 24

A1 A2

D1

A7, A8

25 26 27 28 29

– +CB A

10V / 20 mA GND TxD RxD

F1

Alarms Continuous Output RS 232 / RS 485

8 GOSSEN METRAWATT GMBH

EN 55022 requires the following warning as regards electromagnetic compatibility:

Warning

This is a class A device. It may cause radio interference in residential surroundings. If this is the

case, the operator may be required to implement appropriate corrective measures.

Connectors: Screw terminals for wire with a cross section of 1.5 square mm or

two-core wire-end ferrules with a cross-section of 2 x 0.75 square mm

Tighten screws with a manual screwdriver only! Tightening torque for all screw termi­nals: max. 0.6 Nm

Figure 3, Connector Terminal Positions

GOSSEN METRAWATT GMBH 9

Performance After Activating Auxiliary Voltage

LED Segment Test

U/M Software Version

B Designation

A Designation

Current
Configuration

CnF2

approx. 2 s

D Designation

approx. 1.5 s

Current Configuration

CnF1

Actual Value

approx. 1.5 s

Setpoint or oFF

10 GOSSEN METRAWATT GMBH

Operation

Actual value or
parameter value

Setpoint / heating current /

manipulating factor / 2nd actual

value or parameter designation

I

II

A1
A2

W2

Switching output I
active

Switching output II
active

Alarm(s) active

Setpoint 2 active

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

Off / manual operation

R2900GOSSEN METRAWATT

Up and down scrolling keys for value selection

Select: off / manual ↔

Figure 4, Controls

Value Selection

The selected value can be changed using the up and down scrolling keys.
The selected value is saved to memory and becomes active after 2.5 seconds, or after pressing the key.
The display goes dark briefly to indicate activation of the selected value.

GOSSEN METRAWATT GMBH 11

automatic operation

Operating Flowchart, “Discontinuous-Action Controller”

Off

Actual

I

II

A1
A2

W2

PARAMETER LEVEL

Param. Value

Param. Value

(page 24)

I
II

A1
A2

W2

I
II

A1
A2

W2

Automatic Operation

Actual

Setpoint

I
II

A1
A2

W2

Setpoint can only be
selected here for

fixed setpoint controllers.

Actual

I Heat

Only appears when heating current
monitoring is activated.

CONFIGURATION

(page 18)

Press key briefly.
Press and hold key until

the display is switched.
Press and hold both keys until

the display is switched.

OPERATING LEVEL

I
II

A1
A2

W2

I

II

A1
A2

W2

Actual

M. Factor

I
II

A1
A2

W2

I
II

A1
A2

W2

Extended oper­ating level when
configured as
differential con­troller see page
13

12 GOSSEN METRAWATT GMBH

Operating Flowchart, “Discontinuous-Action Controller” with Differential Control

Off

Actual Diff.

I

II

A1
A2

W2

PARAMETER LEVEL

Param. Value

Parameter Value

Actual Diff.

Diff. Set-

(page 24)

I
II

A1
A2

W2

I

II

A1
A2

W2

Automatic Operation

I
II

A1
A2

W2

Differential setpoint can
only be selected here.

Act. Val. 1

Act. Val. 2

CONFIGURATION

Press key briefly.
Press and hold key until

the display is switched.
Press and hold both keys until

the display is switched.

OPERATING LEVEL

I
II

A1
A2

W2

Only appears when heating
current monitoring is activated.

Actual Diff.

I Heat

(page 18)

I

II

A1
A2

W2

I
II

A1
A2

W2

I

II

A1
A2

W2

Actual Diff.

M. Factor

I
II

A1
A2

W2

GOSSEN METRAWATT GMBH 13

Operating Flowchart, “Continuous-Action and Step-Action Controllers”

Manual Operation

Act. Val.

M. Factor

PARAMETER LEVEL

Param. Value

Param. Value

I
II

A1
A2

W2

(page 24)

I
II

A1
A2

W2

I

II

A1
A2

W2

Automatic Operation

Act. Val.

Setpoint

I

II

A1
A2

W2

Setpoint can only be selected here
for fixed setpoint controllers.

CONFIGURATION

Press key briefly.
Press and hold key until

the display is switched.
Press and hold both keys until

the display is switched.

(page 18)

II

A1
A2

W2

OPERATING LEVEL

Act. Val.

M. Factor

I

I
II

A1
A2

W2

Extended operating level when
configured as differential con­troller, see page 15

Only for step-action
controllers with

designation A5, A6

I

II

A1
A2

W2

14 GOSSEN METRAWATT GMBH

Operating Flowchart, “Cont.-Action and Step-Action Controller” with Diff. Control

Manual Operation

Actual Diff.

I
II

A1
A2

W2

PARAMETER LEVEL

Param. Value

Param.Value

(page 24)

I
II

A1
A2

W2

I

II

A1
A2

W2

Automatic Operation

Actual Diff.

Diff. Set-

I
II

A1
A2

W2

Differential setpoint can only
be selected here.

Act. Val. 1

Act. Val. 2

CONFIGURATION

(page 18)

Press key briefly.
Press and hold key until

the display is switched.
Press and hold both keys until

the display is switched.

OPERATING LEVEL

I
II

A1
A2

W2

Only for step-action controllers
with designation A5, A6

Actual Diff.

M. Factor

I

II

A1
A2

W2

I
II

A1
A2

W2

I
II

A1
A2

W2

GOSSEN METRAWATT GMBH 15

Off / Manual Operation

OPERATING LEVEL, DISCONTINUOUS-ACTION CONTROLLER

–No alarm function
– No indication of errors

– Alarm function and error indication identical to automatic operat-

ing mode.

– The actuator outputs are controlled with the and keys

and not by the controller function.

– Switching between manual and automatic modes is bumpless in

both directions.

– Continuous-action controller:

Manipulating factor is displayed in %. Values are
changed with the and keys, and are
forwarded immediately to the control outputs.

– Step-action controller:

Switching output I (more) or II (less) is triggered
directly by pressing the or key. If posi­tion acknowledgement is utilized (designations
A5 and A6), the measured position is displayed
as a percentage, and bars are displayed for all
other designations.

Off

Act. Val.

I
II

A1
A2

W2

– The actuator outputs are inactive

as long as the keys are not acti­vated.

–When the or key is

activated, switching output I
(“heat”) or II (“cool”) is triggered
directly.

OPERATING LEVEL, CONTINUOUS-ACTION

STEP-ACTION CONTROLLERS

Manual Operation

Act. Val.

M. Factor

I

II

A1
A2

W2

16 GOSSEN METRAWATT GMBH

Manual Operation with Binary Input

Switching to manual operation is possible via the binary input (terminals 5 and 6).
This is distinguished from off / manual operation with the key as follows:

– Bumpless switching to manual operation with all controller sorts
– The last manipulating factor is “frozen” for step-action controllers as well.
– The last switching status is retained for limit transducers.
– Operation and display are identical to automatic operation, except that the LED lights up and the

manipulating factor can be changed in the manipulating factor display with the and keys.

– When configured as a step-action or a continuous-action controller (controller sort set to 2 through 5), the

Y St parameter must be set to 0.

– The “alarm 2” configuration digit must be set to a value of 8 ... F to this end (see also CnF2 on page 20).

PWR Out Offset with Binary Input

When configured as a step-action or a continuous-action controller (controller sort set to 2 through 5), control
quality can be significantly improved by means of PWR out offset where abrupt load fluctuations prevail.

– When the contact at the binary input is closed, the controller’s manipulating factor is increased by an

amount equaling Y St.

– It is reduced by the same value when the contact is opened.
– No function during self-tuning
–Where Y St = 0, the binary input activates manual operation (see above).
– The “alarm 2” configuration digit must be set to a value of 8 ... F to this end (see also CnF2 on page 20).

Example:
If a machine requires an average of 70% heating power during production operation, but only 10% during idle

time, the difference of Y ST is set to 60%, and the binary input is only activated during production.

GOSSEN METRAWATT GMBH 17

Configuration

(continued on page 20)

Controller Sort Alarm 1

Code Code

Limit transducer
Actuator Absolute
2-step controller, heat *) Relative
2-step controller, cooling *) Absolute
3-step controller *) Relative
3-step controller, water cooling Absolute
Step-action controller Relative

*) Settings for continuous-action controller: see page 23

I

II

A1
A2

W2

I

II

A1
A2

W2

Relative

Absolute
Relative
Absolute
Relative
Absolute
Relative
Absolute
Relative
Absolute

Actuation

Suppression

Inactive

Active

Inactive

Active

Inactive

Active

Inactive

Active

Contact

NO contact

NC contact

NO contact

NC contact

Heating Cir­cuit Monitor-

ing

Inactive

Active

Gray highlighting: default setting K0

18 GOSSEN METRAWATT GMBH

1)

Sensor / Continuous Output2) Unit of Measure Sensor type

1)

Code U/M

°C

°C

°C

°C

°C

°C

Output Range 2)Output Quantity 2)Code Type Design Condition

°F

°F

°F

°F

°F

°F

0 ... 20 mA

0 ... 10 V

4 ... 20 mA

2 ... 10 V

0 ... 20 mA

0 ... 10 V

4 ... 20 mA

2 ... 10 V

0 ... 20 mA

0 ... 10 V

4 ... 20 mA

2 ... 10 V

Actual value
(step-action

controller)

Manipulating

factor

(cont.-action

controller)

Select output

quantity

with Cont

(see also page

23)

(no function)

Saving and loading device settings:

see page 21

1) Switching to and from °C and °F is only effective for designations B1, B3 and B4.

2) Only effective for designations A7 and A8

I

II

A1
A2

W2

I

II

A1
A2

W2

J

L

K

B

S

R

N

1 ° Display

0,1 ° Display

0 ... 20 mA / 0 ... 10 V

4 ... 20 mA / 2 ... 10 V

Thermo-

couple

Pt 100

Std.

signal

For measurement

input 1 with

designation B1, B4

For both

measurement inputs

with designation B3

For measurement

input 1 with

designation B2

GOSSEN METRAWATT GMBH 19

Configuration

Function, Measurement Input 2 Standard Sig-

(continued)

nal 2

Code B3 B4 B4 Code

Fixed setpoint contr. (int. setpoint)

Differential Fixed setpoint Absolute

–

– Absolute

–

– Absolute

–

– Absolute

Slave controller

Fixed setpoint

controller

Slave controller

0 ... 20 mA

0 ... 10 V

4 ... 20 mA

2 ... 10 V

Relative

Relative

Relative

Relative

Relative
Absolute
Relative
Absolute
Relative
Absolute
Relative
Absolute

Actuation sup­pression

Inactive

Active

Inactive

Active

Inactive

Active

Inactive

Active

Alarm 2

Contact Binary input

NO contact

Setpoint 2
delete!!!

NC contact

NO contact

Manual /
automatic or
PWR out off-

NC contact

set

I
II

A1
A2

W2

I
II

A1
A2

W2

Gray highlighting: default setting K0

20 GOSSEN METRAWATT GMBH

Saving and Loading Device Settings:

Code Function Comment

Current settings

User-defined default settings
If settings have not already been saved with d in the past,
the factory default settings or a configuration per customer
specifications (K9) is loaded.

1)

Factory default settings

The configuration digits and all parameter s except for the interface address Addr

1)

are saved as user-defined default settings.

1)

are loaded.

1)

are loaded.

A configuration per customer specifications (K9) is stored
here, and is overwritten in the process.
All entries, including self-tuning and calibration results, are
overwritten in the process.

Differential Controller

– Actual value difference, i.e. 1

Parameters: see page 24

st

actual value – 2nd actual value, is regulated to the selected differential set-

point.
– The differential setpoint can be set within a range of ± one half of the measuring range.
– Limit value monitoring is relative to actual value difference, and not the two actual values.
– If an attempt is made at the operating level to change the differential setpoint (display mode: 1

Slave Controller

– The external setpoint which is applied to the 2

value / 2

nd

actual value), no appears briefly at the bottom display.

Parameters: see page 24

nd

measurement input replaces the internal setpoint.

st

actual

– The setpoint ramp function (see page 31) is retained.
– After switching to setpoint 2 via the binary input, the controller becomes a fixed setpoint controller using set-

point 2 (SP 2).
– Upper and lower limits for the external setpoint are scaled with the rn L and rn H parameters

nd

(2

measurement input, standard signal for designation B4).

–The SP L and SP H parameters limit the external setpoint for control and display purposes.
– If an attempt is made at the operating level to change the setpoint (display mode: actual value / setpoint),

no appears briefly at the bottom display.

GOSSEN METRAWATT GMBH 21

Controller Sorts

Code Controller Sort Comment

Limit transducer

Actuator

2-step controller, “heat” A harmonic-free PDPI control algorithm regulates switching output I in order to increase /
2-step controller, “cooling”

3-step controller

3-step controller, water
cooling

Step-action controller

Switching output I is active where actual value < current setpoint, and switching output II is
active where actual value > current setpoint + dbnd. Switching hysteresis is equal to HYST.
Switching status changes are possible once per tc.
Read-out of a constant actuating signal to switching output I where YST > 0, or switching
output II where YST< 0. The actuating cycle is equal to at least tc. No alarm functions.

decrease the actual value. The actuating cycle is equal to at least tc.

A harmonic-free PDPI control algorithm regulates switching output I in order to increase the
actual value, or switching output II in order to decrease the actual value. The actuating cycle
is equal to at least tc.
The dead band dbnd suppresses switching back and forth between “heating” and “cooling”
if no lasting deviation occurs.
The manipulating factor at switching output II is adapted to the non-linear performance char­acteristics of a water cooler. The actuating cycle is equal to tc.
A harmonic-free PDPI control algorithm regulates switching output I or II in order to increase
or decrease the actual value. The duration of the actuating impulse is equal to tc. The dead
band dbnd is symmetric to the setpoint.

Parameters: see page 24

22 GOSSEN METRAWATT GMBH

Configuration of the Controller with Continuous Output (desig. A7 and A8)

• Continuous output = actual value (“sensor U/M / continuous output” configuration digit = 0, 1, 2, 3)

– The controller sorts demonstrate the same performance characteristics as with designations A1 to A4.

– Read-out of the actual value (actual value difference for differential controllers) is scaled with the rn L

and rn H parameters.

• Continuous output = manipulating factor (“sensor U/M / continuous output” configuration digit = 4, 5, 6, 7)

– Switching output I is inactive.

– The various continuous controller sorts result from the “controller sort” configuration digit:

Code Controller Sort Comment

Limit transducer

Actuator Read-out of a manipulating factor which can be adjusted with parameter Y St.
Continuous controller with falling char­acteristic curve
Continuous controller with rising char­acteristic curve

Split range controller

, No practically relevant function

• Continuous output = “select with Cont” (“sensor U/M / continuous output” configuration digit = 8, 9, A, b)

Cont Cont. Output Comment

The read-out is scaled with the rn L and rn H parameters (the current differential setpoint for differ-

Current setpoint

“Cooling”
manip. factor

ential controllers).
The controller sorts demonstrate the same performance characteristics as with designations A1 to A4.
Negative manipulating factors are read out continuously, and switching output II remains inactive.
Controller sort = 4: split range controller with inverted output performance

Read-out of a manipulating factor which can be adjusted with the Y H parameter
where actual value < setpoint

A harmonic-free PDPI control algorithm regulates the continuous output every

0.5 seconds. An output filter assures smoothest possible actuating signal char­acteristics. tc is used to set the time constant for an additional actual value filter.

Continuous controller with falling characteristic curve for positive manipulating
factors (increase actual value). Negative manipulating factors are read out via
switching output II (decrease actual value).
The actuating cycle for switching output II has a duration of at least tc. The dead
band dbnd suppresses rapid switching back and forth between the continuous
output and switching output II if no lasting deviation occurs.

GOSSEN METRAWATT GMBH 23

Parameters Configuration

X1 = lower range limit, X2 = upper range limit,

Parameter Display Range Default Comment

Upper limit value for relay A1

Lower limit value for relay A1

Upper limit value for relay A2

oFF, 1 ... MR
oFF, X1 ... X2

oFF
oFF

Lower limit value for relay A2

Setpoint 2 SP L ... SP H X1

Ramp for rising setpoints oFF, 1 ... MR per min. oFF

Ramp for falling setpoints oFF, 1 ... MR per min. oFF

Heating current setpoint
(see Balancing)

Auto, oFF, 0.1 ... A H oFF

Proportional band heating 0.1 ... 999.9% 10.0

Proportional band cooling 0.1 ... 999.9% 10.0 Only with 3-step controllers

Dead band 0 ... MR 0 Not with 2-step controllers

Path delay time 0 ... 9999 s 100

Read-out cycle time 0.5 ... 600.0 s 10.0

Motor run-time

Switching hysteresis

5 ... 5000 s 60

0 ... 1.5% MR 0.5%MR

Maximum setpoint SP L ... X2 X2

Minimum setpoint X1 ... SP H X1

Maximum manipulating factor –100 ... 100 % 100

Actual value correction
(see Balancing)

Decimal point position 9999, 999

(Auto), –MR/4 ... +MR / 4 0

•9, 99•99, 9•999 9999 Only with designation B2

Upper range limit, standard signal rn L ... 9999 100

Lower range limit, standard signal –1500 ... rnH 0

MR = X2 – X1

Relative (= default config.)
Absolute

Not with step-action control-

1)

lers

4)

Only with step-action control-

5)

lers
For limit value monitoring and
limit transducers

Only with designations B1,
B3 and B4

Only with designations
B2, B4, A7 and A8

2)

3)

24 GOSSEN METRAWATT GMBH

Parameter Display Range Default Comment

Upper range limit, heating current
(see Balancing)

Calibration, position acknowledge­ment

Manipulating factor for actuator
mode, or for PWR out offset

1.0 ... 99.9 A 42.7

See Balancing

–100 ... 100% 0

Not with step-action control-

1)

lers
Only with step-action control-

lers with position acknowl-

6)

edgement

Sensor error manipulating factor –100 ... 100% 0

Continuous signal

Interface address 0 ... 250 250 Only with designation F1

1)

Only where:“controller sort” conf iguration digit ≠ 6 and designation ≠ A5, A6

2)

Only where:“controller sort” configu ration digit = 4 or 5

3)

Only where:“controller sort” configuration digit = 0, 4, 5 or 6

4)

Additional actual value filter for continuous-action controllers (controller sort = 2 or 3), tc = time constant

5)

Only where:“controller sort” configuration digit = 6

6)

Only where:“controller sort” configuration digit = 6 and designation = A5, A6

See page 23 0

Only for designations A7 and
A8

Parameters Pb 1 through Addr are disabled for the operator during self-tuning.

GOSSEN METRAWATT GMBH 25

Balancing

Thermocouple Correction (parameter: CAL)

The correction value is selected in °C or °F. The displayed correction value is added to the measured temper-
ature.

Cable Compensation for Pt 100 with 2-Wire Connection (parameter: CAL)

The correction value can be determined automatically in the “Off / manual operation” mode:
– Short circuit the sensor at the measuring point.

–Set the CAL value to Auto.
Measured cable resistance is converted to temperature change and is entered as the CAL value.
Balancing can also be performed manually if the sensor temperature is known:

CAL = known sensor temperature – displayed temperature value

Scaling for Heating Current Monitoring (parameter: A H)

The default setting for the GTZ 4121 is 42.7 A. If the GTZ 4121 current transformer is not used for acquiring
heating current, the current value must be selected at which the utilized transformer generates an output volt­age of 10 V DC.

Calibrating the Position Acknowledgement Display (parameter: Y100, Y0)

Calibration is performed in the manual operating mode at the parameter level with the device configured as a
step-action controller (“controller sort” configuration digit = 6):

1. Select parameter Y 100. The stored value appears at first: a standardized value between 0 and 255.

The scroll up key controls switching output I directly (more), and the currently measured actuator

position appears at the display. The scroll up key must be pressed and held until the displayed value

no longer fluctuates. The displayed value is saved to memory.

2. Select parameter Y0.

Same procedure as for parameter Y100. In this case, the scroll down key must be pressed and

held. It controls switching output II directly (less).
Y100 must be greater than Y0!
The Y100 and Y0 parameters are displayed only in the automatic operating mode.

26 GOSSEN METRAWATT GMBH

Self-Tuning

Self-tuning is used to achieve optimized controller dynamics, i.e. parameters
Pb 1, Pb 11, tu and tc are determined.
Read-out cycle time tc is not changed during self-tuning.

We recommend for tc a value of tu/12 to guarantee satisfactory controller

Start

Slow Blinking

Abort

Current

Current

Current

or

– The controller is switched to the automatic operating mode after self-tuning has been successfully com-

pleted.
– In the case of 3-step controllers (controller sorts 4 and 5), cooling is activated if the upper limit value is

exceeded in order to prevent overheating. Self-tuning then performs an oscillation test around the set-

point.

Sequence

– The setpoint which is active when tuning is started remains valid and can no longer be changed (slave

controllers: changing external setpoints are only displayed).
– Activation or deactivation of setpoint 2 does not
– Selected setpoint ramps are not taken into consideration.
– If started at the operating point (actual value approximates the setpoint value), overshooting cannot be

avoided.

Abort

– Self-tuning can be aborted at any time with the keys (→ automatic operating mode), or by

switching to manual / off with the key.
– If an error occurs during self-tuning, the controller no longer reads out an actuating signal. Self-tuning

must be aborted in this case.

Additional information regarding error messages upon request.

I
II

dynamics. When controlling contactors, tc should be adequately increased.

A1
A2

Preparation

W2

– Complete configuration must be performed before
– The setpoint value is adjusted to the value which is required after

I
II

A1
A2

W2

self-tuning.

Start

– Briefly press the keys simultaneously at the operating level (auto-

self-tuning is started.

matic or manual / off operating mode) in order to trigger self-tuning. Self­tuning cannot be started in the “actuator” or “limit transducer” mode.

– tun1...tun8 blinks at the display at all operating levels during self-tuning.

become effective.

GOSSEN METRAWATT GMBH 27

Manual Self-Tuning

Preparation

– Complete configuration (page 18) and parameter settings (page 24) must first be entered for use of the con-

troller.
– The actuators should be deactivated with the off / manual operation function (page 16).
–A recorder must be connected to the sensor and adjusted appropriately to prevailing circuit dynamics and

the setpoint.

In the case of differential controllers, the actual value difference must be recorded.
– For 3-step or split range controllers, on and off-time must be recorded for switching output I or the contin-

uous output (e.g. with an additional recorder channel or a stopwatch).
– Configure as limit transducer (controller sort = 0).
– Set read-out cycle time to the minimum value: tc = 0.5.
– If possible, deactivate manipulating factor limiting. YH = 100.
– Reduce (or increase) the setpoint so that overshooting and undershooting do not cause any impermissible

values.

Performing the Actuation Test

– dbnd = MR Setting for 3-step and split range controllers (switching output II may not be triggered)

dbnd = 0 Setting for step-action controllers (switching output II must be triggered)

– Start the recorder.
– Activate the actuators with automatic operation.
– Record two overshoots and two undershoots.

The actuation test is now complete for 2-step, continuous-action and step-action controllers.
Continue as follows for 3-step and split range controllers:

–Set dbnd to 0 in order to cause further overshooting with active switching output II. Record two over-

shoots and two undershoots.
–Record on-time T

and off-time TII at switching output I or the continuous output for the last oscillation.

I

Parameters Pb 1, Pb 11, tu and tc are determined by means of manual
self-tuning in order to maintain optimized controller dynamics. An actua­tion test or an oscillation test is performed to this end.

28 GOSSEN METRAWATT GMBH

∆

t

∆

x

P

x

ss

dbnd = 0dbnd = MR

(3-step and split range controllers only)

T

I

T

II

Evaluating the Actuation Test

– Apply a tangent to the curve at the intersection of the actual value and the setpoint, or at the cut-off point

of the output.
– Measure time ∆t.
– Measure oscillation amplitude x

, or overshooting for step-action controllers ∆x.

ss

Parameter Values

Parameter

2-step controller 3-step controller Continuous-action

tu 1.5
tc tu / 12
Pb 1 (x
Pb 11 – Pb 1

1) When controlling contactors, tc should be adequately increased.

/ MR) • 100 % (xss / MR) • 200 % (∆x / MR) • 50 %

ss

• (T

/ TII)–Pb 1• (TI / TII)–

I

controller

• ∆t ∆t – (tY / 4)

1)

Split range

controller

Step-action

controller

tY / 100

If manipulating factor limiting was active, the proportional band must be corrected:

YH positive: Pb 1 multiply by 100% / YH
YH negative: Pb 11 multiply by –100% / YH

GOSSEN METRAWATT GMBH 29

Performing the Oscillation Test

If an actuation test is not possible, for example if neighboring control loops influence the actual value too
greatly, if switching output II must be active in order to maintain the actual value (cooling operating point), or if
optimization is required directly to the setpoint for any given reason, control parameters can be determined by
means of sustained oscillation. However, calculated values for tu may be very inaccurate in this case under
certain circumstances.
– Preparation as described above. The test can be performed without a recorder if the actual value is

observed at the display, and if times are measured with a stopwatch.
– dbnd = 0 Setting for 3-step, split range and step-action controllers
– Activate the actuators with automatic operation, and start the recorder if applicable. Record several oscilla-

tions until they become uniform in size.
–Measure oscillation amplitude x
–Record on-time T

and off-time TII at switching output I or the continuous output for the oscillations.

I

.

ss

x

ss

T

T

I

II

Evaluating the Oscillation Test

Parameter Values

Parameter

1)

tu

2-step controller 3-step controller

tc tu / 12
Pb 1 x

• 100 %

ss

MR

Pb 11 – Pb 1

1) If either TI or TII is significantly greater than the other, value tu is too large.

2) When controlling contactors, tc should be adequatel y increased.

xss • TII • 100 %

MR (T

+ TII)

I

• (T

/ TII)–Pb 1 • (TI / TII)–

I

Continuous-action

controller

0.3 • (TI + TII)0,2 • (TI + TII – 2tY)

2)

• 200 %

x

ss

MR

Split range

controller

xss • TII • 200 %

MR (T

+ TII)

I

Step-action

controller

tY / 100

• 50 %

x

ss

MR

Correction with manipulating factor limiting YH positive: Pb 1 multiply by 100% / YH

YH negative: Pb 11 multiply by –100% / YH

30 GOSSEN METRAWATT GMBH

Correction for step-action controllers in the event that TI or TII is smaller than tY:

tY

Multiply Pb 1 by , if T

• tY tY • tY

• T

T

I

is smaller, or by , if TII is smaller.

I

I

TII • T

II

The value for tu is very inaccurate in this case. It should be optimized in the closed loop control mode.

Closed Loop Control Mode

The closed loop control mode is started after self-tuning has been completed:
– Configure the desired control algorithm with controller sort.

–Adjust the setpoint to the required value.
– The dead band can be increased from dbnd = 0 for 3-step, split range and step-action controllers if con-

trol of switching output I (or the continuous output) and II changes too rapidly, for example due to an

unsteady actual value.

Setpoint Ramps

Function Parameters SPuP and SPdn cause a gradual temperature change

Activation – When auxiliary power is switched on

Setpoint display The targeted setpoint is displayed (not the currently valid setpoint) with a blinking r at

Limit values Relative limit values make reference to the ramp, not the targeted setpoint. As a rule, no

(rising / falling) in degrees per minute.

– When the current setpoint is changed
– When setpoint 2 is activated
– After switching from manual to automatic operation

the left-hand digit.

alarm is triggered for this reason.

GOSSEN METRAWATT GMBH 31

Heating Current Monitoring

FunctionHeating current is acquired with an external transformer (e.g. GTZ 4121).

AMPS current
setpointHeater phase current is entered for this parameter. AMPS can be set to Auto for automatic adjustment

An alarm is triggered if the current setpoint is fallen short of by more than 20% with acti­vated heat (control output I active), or if current is not “off” when the heat is switched
off. The alarm is not triggered until heating current is high enough when output I is
active, or when current drops to zero when output I is inactive.
Monitoring is inactive if the controller is switched to oFF, as well as in the case of contin-
uous and step-action controllers.

with the heater switched on. The measured current value is saved to memory.

Heating Circuit Monitoring

Function– Can be set to active or inactive with the “alarm” configuration digit

(see Configuration).

– Without external transformer, without additional parameters
– Assumes correct optimization of tu and Pb 1 control parameters,

i.e. heating circuit monitoring must be activated before self-tuning is started.
In the event of manual optimization or subsequent adaptation of control parameters,
the lower limit value for the tu parameter must be observed:

minimum tu =

∆ϑ

⁄ Dt = maximum temperature rise during actuation

– Error message LE appears after approximately 2 times tu, if heat remains on at

100% and measured temperature rise is too small.

– Monitoring is not active:

where controller sort = limit transducer, actuator or step-action controller
during self-tuning
with standard signal input (designation B2)
where manipulating factor limiting YH < 20%

Pb 1 MR

•

50% ∆ϑ

⁄ Dt

32 GOSSEN METRAWATT GMBH

Limit Value Monitoring

Alarm Relay n,
NO Contact
Alarm Relay n, NC Contact

Hysteresis (HYSt)

ALnL ALnH

ALnL ALnH

Actual ValueSetpoint

n = 1, 2

Relative Limit Values
Absolute Limit Values

Actuation suppression: Alarm suppression remains inactive during actuation (configuration digit “alarms 1 and
2”) until temperature has exceeded the lower limit value for the first time. During cooling, suppression is active
until temperature has fallen below the upper limit value for the first time. Suppression is active when auxiliary
power is activated, if the current setpoint is changed or setpoint 2 is activated, or if switching takes place from
off to automatic operation.

Alarms

Blinking Display

(at operating level only)

Heating current Heating current monitoring LED A1 blinks Alarm output A1 and

Actual value Limit value monitoring 1 LED A1 blinks Alarm output A1 and

Actual value Limit value monitoring 2 LED A2 blinks Alarm output A2 and

1)

Only for designation D1

2)

In the case of designation D0 and config uration as a 2-step controller

The display is switched to the operating level 30 seconds after value selection has been completed during
configuration or parameter setting.

Error Message Source Display Response Comment

LED A1 are activated

LED A1 are activated

LED A2 are activated

1)

NO / NC contact selected
in configuration digits

1)

“alarms 1 and 2”
LED blinks at all levels

2)

GOSSEN METRAWATT GMBH 33

Error Messages

Responses in the event of an error:

1. Alarm output A1 is activated, output performance is determined by the “alarm 1” configuration digit

(see Configuration on page 18).

In the case of designation D0 and configuration as a 2-step controller, read-out takes place at switching

output II. The LED lights up when relay contact II is closed and/or transistor output II is active.

2. LED A1 blinks at all levels. The (blinking) error message only appears at the operating level: in the event of

faulty measured values at the display, at which the error-free measured value is otherwise displayed (SE H,

SE L, CE and YE) when other error messages appear in the upper display.

3. The display is switched to the operating level 30 seconds after value selection has been completed during

configuration or parameter setting.

4. Exceptions and additional information are included in the following table:

Display

sensor error
high

sensor error low

current error

y error

Error Message Source Response

Broken sensor or actual
value greater than up-

Ctr. Sort Manipulating Factor Read-Out

per range limit

2 or 3-step

Sensor polarity reversed
or actual value less than
lower range limit

Current transformer has
reversed polarity, is un­suitable or defective
Position ackn. incorrectly
calibrated, Y100 ≤ Y0

Step
On/off ctr.
Actuator No response to error

Same as heating current monitoring alarm
Continues to control temperature

No

response to error 3

YSE = –100/0/100% YSE ≠ –100/0/100%

–100/0/100%

If the controller has settled in:

last “plausible” manipulating

factor, if not: YSE

YSE

Remedy

1

2

Self-tuning cannot be

no tune

started (controller sort:
“actuator” or “limit

No response to error
Error message is not cleared until key is pressed

–

transducer”)

34 GOSSEN METRAWATT GMBH

Display

Error Message Source Response

Remedy

Disturbance in

tune error 2

self-tuning sequence in
steps 1 through 13 (step

Control outputs I and II inactive
Self-tuning must be aborted.

4

2 in this case)

Control outputs I and II inactive.
Error message is not cleared until key is pressed
and held.
Control outputs I and II inactive.
The parameter level is disabled.

Control outputs I and II inactive 7

5

6

loop error

parameter error

digital error

Measured temperature
rise is too small with
heat on at 100%
Parameter not within
permissible limits
Error detected by digital
component monitoring
Hardware error de-

analog error

tected by analog compo-

Control outputs I and II inactive 7

nent monitoring

Remedies

1. Eliminate sensor error.

2. Inspect current transformer.

3. Check for correct connection of the position acknowledgement potentiometer and re-calibrate.

4. Avoid disturbances which impair the self-tuning sequence, e.g. sensor errors.

5. Close the control loop: Check the sensor, the actuators and the heater for correct functioning.

Check sensor-heater assignments (wiring).

Correctly optimize control parameters tu and Pb 1.

6. Restore default configuration and default parameters, and then reconfigure, or load user-defined default

settings.

7. Arrange for repair at authorized service center.

GOSSEN METRAWATT GMBH 35

Technical Data

Annual mean relative humidity, no condensation 75%
Ambient temperature

Nominal range of use
Operating range
Storage range

Aux. Voltage Nominal Ranges of Use Power Consumption
Nominal Value Voltage Frequency

AC 110 V /
AC 230 V

Relay Output Floating, normally open contact
Switching capacity AC/DC 250 V, 2 A, 500 VA / 50 W
Service life > 2•105 switching cycles at nominal load
Interference suppression Utilize external RC element (100 Ω - 47 nF)

Transistor output suitable for commercially available semiconductor relays (SSR)
Switching Status Open-Circuit Voltage Output Current

Active (load ≤ 800 Ω) < DC 17 V 10 ... 15 mA
Inactive < DC 17 V < 0.02 mA
Overload limit Short-circuit, continuous interruption

Electrical Safety

Safety class II, panel-mount device, DIN EN 61010-1 section 6.50.4
Fouling factor 1, per DIN EN 61010-1 section 3.7.3.1 and IEC 664
Overvoltage category II, per DIN EN 61010 appendix J and IEC 664
Operating voltage 300 V per DIN EN 61010
EMC requirements IEC/EN 61326

For complete technical data refer to the following data sheet:
order no. 3-349-202-03

Printed in Germany • Subject to change without notice

AC 95 V ... 253 V 48 Hz ... 62 Hz

at contactor

0 °C ... + 50 °C
0 °C ... + 50 °C

–25 °C ... + 70 °C

Max. 10 VA
typically 6 W

GOSSEN METRAWATT GMBH
Thomas-Mann-Str. 16-20
90471 Nürnberg, Germany

Phone [phone]
Fax [phone]
E-mail [e-mail]
www.gmc-instruments.com