Gossen MetraWatt SMARTCONTROL ECS Installation Instructions Manual

Installation Instructions

SMARTCONTROL | ECS 3-349-422-03

Energy Management-System 5/5.19

Installation Instructions

GMC-I Messtechnik GmbH

Südwestpark 15

90449 Nürnberg, Germany

Phone: [phone]

Fax: [phone]

e-mail: [e-mail]

Internet: www.gossenmetrawatt.com

Our instruction manuals are prepared with care, examined and continuously updated. No liability can be assumed for faulty
information. Errors and omissions are excepted. GMC-I Messtechnik GmbH reserves the right to implement technical
improvements to the function and/or the design of software and hardware products, and to revise instruction manuals at
any time without notice.
The information provided in this brochure includes general descriptions and performance features only, which do not always
apply to the application in actual practice, or which may change as the result of further development of the products. The
desired performance features are only binding if they have been explicitly agreed upon contractually. We make explicit
reference to the fact that hardware and software designations are, as a rule, protected by the brand name, trade mark and
patent rights of the respective manufacturers.

Subject to change without notice • PDF version included on the accompanying data storage medium

3 GMC-I Messtechnik GmbH

Table of Contents

Table of Contents ........................................................................................................................................... 3

1. Product Description ............................................................................................................................... 5

2. Document Information .......................................................................................................................... 6

2.1. Notes ............................................................................................................................................... 6

2.2. Identification of Important Text ..................................................................................................... 6

2.3. Explanation of Symbols and Typographical Conventions ............................................................... 6

3. General Safety Precautions ................................................................................................................... 7

4. Technical Data........................................................................................................................................ 8

5. Installation ........................................................................................................................................... 10

5.1. Before Installing ............................................................................................................................ 10

5.1.1. Scope of Delivery for SMARTCONTROL Standard.................................................................. 10

5.1.2. Scope of Delivery for SMARTCONTROL IP-65 ........................................................................ 10

5.2. Operating conditions ..................................................................................................................... 10

5.3. Wall Mounting .............................................................................................................................. 11

5.3.1. Wall Mounting the SMARTCONTROL Standard ..................................................................... 11

5.3.2. Wall Mounting the IP 65 SMARTCONTROL ........................................................................... 12

5.4. Power Supply Cable for the SMARTCONTROL IP 65 ..................................................................... 12

5.5. SMARTCONTROL IP 65 Power Supply ........................................................................................... 13

5.6. Low-Current Leads ........................................................................................................................ 13

5.6.1. SMARTCONTROL IP 65 ........................................................................................................... 13

5.6.2. SMARTCONTROL Standard .................................................................................................... 13

5.6.3. All Types of SMARTCONTROL After Mounting ...................................................................... 14

6. Connections Overview, Revisions 2.xx ................................................................................................ 15

6a. Connections Overview, Revision V3 ...................................................................................................... 16

Connections Overview, Revision V3 ............................................................................................................ 17

7. Inputs/Outputs .................................................................................................................................... 18

7.1. Note Regarding All Measuring Channels ...................................................................................... 18

7.2. Analog Inputs (current/voltage) ................................................................................................... 18

7.2.1. Selecting Relay Outputs / Analog Inputs ............................................................................... 18

7.2.2. Setting Analog Inputs to Current/Voltage Measurement ..................................................... 18

7.3. Temperature Inputs ...................................................................................................................... 19

7.4. Digital Inputs (pulse / status / tariff / time synchronization) ....................................................... 19

7.4.1. Setting the Operating Mode (passive/active) of the Digital Input ........................................ 19

7.4.2. Configuring the Digital Inputs ................................................................................................ 20

7.5. Broken Cable Detection (Namur) .................................................................................................. 21

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7.5.1. Mode of Operation ................................................................................................................ 21

7.5.2. Connection Example .............................................................................................................. 21

7.5.3. Connection Example 2 for Devices with Namur Output ....................................................... 22

8. Communication.................................................................................................................................... 23

8.1. Protocols ....................................................................................................................................... 23

8.1.1. RS 232 / M-Bus ...................................................................................................................... 23

8.1.2. M-Bus Routing Function ........................................................................................................ 23

8.1.3. RS 485 / Modbus RTU / Modbus TCP .................................................................................... 23

8.1.4. ASCII Fieldbus Modules ......................................................................................................... 24

8.1.5. TCP/IP ..................................................................................................................................... 25

8.1.6. Additional Protocols .............................................................................................................. 25

8.2. Communication Modules .............................................................................................................. 26

8.2.1. Applicable to All Modules ...................................................................................................... 26

8.2.2. Module Installation ................................................................................................................ 27

8.2.3. Analog-Modem Module......................................................................................................... 27

8.2.4. ISDN Module .......................................................................................................................... 28

8.2.5. Bluetooth Module .................................................................................................................. 28

8.2.6. GSM/GPRS Module ................................................................................................................ 29

9. Initial Start-Up / Configuration ............................................................................................................ 31

9.1. Firmware Options ......................................................................................................................... 31

9.2. Initial Start-Up ............................................................................................................................... 32

9.2.1. DIAG / COM LEDs ................................................................................................................... 32

9.2.2. Status Display / Error Diagnosis – DIAG LED .......................................................................... 33

9.3. Shutting Down and Restarting SMARTCONTROL .......................................................................... 33

9.4. Configuration ................................................................................................................................ 33

9.4.1. Configuration via the Ethernet Port ...................................................................................... 34

9.4.2. Configuration via Analog Modem or ISDN ............................................................................ 34

9.4.3. Deleting the Password ........................................................................................................... 34

10. Options ............................................................................................................................................. 35

10.1. Relay Outputs ............................................................................................................................ 35

10.2. I/O Modules ............................................................................................................................... 35

10.3. Compact Flash Card (support discontinued and replaced by microSD card) ........................... 35

10.4. Backing Up Configuration and Program to a Compact Flash Card ............................................ 36

10.5. TCP/IP Serial Modem Port ......................................................................................................... 37

Appendix A, Connection Log ......................................................................................................................... A

Index ............................................................................................................................................................. C

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1. Product Description

SMARTCONTROL: Diverse Data Collector and Data Messenger

The SMARTCONTROL renders energy consumption measurable without delay in a detailed fashion, and thus
controllable. This, in turn, is the basic prerequisite for a great variety of measures for the reduction of energy
consumption and costs, for example with regard to:

 Optimized utilization
 Contracting
 Component modernization
 Conversion

The SMARTCONTROL is an inexpensive, user-friendly, easy to integrate data logging system.

This is the prerequisite for quickly establishing efficient, sustainable, widespread energy management for
industrial systems, buildings and properties.

Amongst other data, the SMARTCONTROL is capable of recording the following:

 Meter readings (electrical power, heat, water, gas etc.)
 Temperatures (inside, outside, inlet, return etc.)
 Statuses (burner and pump on-times etc.)
 Analog signals from external signal converters and measuring transducers (pressure, humidity etc.)
 M-Bus protocol (up to 450 meters), Modbus RTU / TCP, SBus, CLBus and LON

One of the system’s important advantages is its ability to access all relevant data at any time – quickly and
conveniently.

We’re at your disposal and can provide you with solutions if you want to make actual energy consumption more
transparent in the future, and optimize it as well.

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2. Document Information

2.1. Notes

Please keep these instructions in a safe place and make them accessible to new users, or hand them over to the
new owner in the event of a change of ownership.

These instructions must always be available, must be adhered to during installation, operation and maintenance,
and must be provided to the installation technician for his or her perusal.

2.2. Identification of Important Text

The following identifiers are used in order to place emphasis on special texts within this document:

Tip:

Useful information and tips can be found here, which make your work easier.

Note:

Notes warn of possible damage to the product
or identify especially important settings.

Warning:

Warning regarding personal injury of massive property damage

2.3. Explanation of Symbols and Typographical Conventions

The following symbols are used as well:



Bullets

►

Action required by you

a)
b)
c)

Execute several steps in the specified order

Boldface

Terms and important passages are highlighted in boldface.

Cross
Reference

This formatting identifies a cross-reference to another place within the document. With
documentation in electronic form, you can click this text in order to jump to the corresponding
place in the document.

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3. General Safety Precautions

Warning:

The SMARTCONTROL may only be installed by trained, authorized personnel. In particular, all
VDE and EVU regulations, as well as other connection regulations and stipulations, must be
complied with.

Electrostatic charging must be avoided. For this reason, avoid touching the PCB and provide for

electrostatic discharging or personnel and tools before beginning work.

Do not install during a thunderstorm.
Make sure that all sources of electrical power have been disconnected before conducting work

on the system’s electrical section.

Note:

The SMARTCONTROL is not approved for use as a life support device in safety relevant systems or

other vitally important equipment.
Examples: fire alarms, reactor monitoring, medical devices, aircraft
It is the responsibility of the user to install suitable safety and protective devices in all areas of

application.

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4. Technical Data

Basic Data

Mains power

SMARTCONTROL Standard: Power pack, 230 V AC to 24 V DC
IP65 variant: Integrated power pack, 100 to 240 V AC, 50 to 60 Hz, to 24 V DC

Power consumption

< 2.5 W (Actual power consumption depends upon power pack efficiency, as well as any other
connected sensors and devices.)

Control keys

Two function keys: F1 and reset in the housing

Operating conditions

5 to 50 °C, no condensation

Housing

SMARTCONTROL-Standard: Steel sheet metal, 226 x 210 x 70 mm (W x H x D) (special housing avail.)
IP65 variant: Steel sheet metal 380 x 380 x 210 mm (W x H x D)

Weight

SMARTCONTROL Standard: Approx. 1.5 kg
IP65 variant: Approx. 10 kg

Protection (IP 65 variant)

IP65 if installed correctly (applies to the non-lockable version only)

Analog Inputs

Up to 8 analog inputs

0 to 10 V voltage measurement or 0 to 20 mA current measurement, switchable (JP1 jumper series)

Internal resistor

Voltage measurement: 200 kOhm
Current measurement: 249 Ohm

Accuracy

Electrical Isolation

Common ground, no electrical isolation

Frequency

Max. recording rate: 1 per sec.

Suppressor diodes for voltage peaks

Yes

Relay Outputs

Up to 2 relay outputs

Up to 2 analog inputs can be reconfigured as relay outputs (jumper series JP6).

Relay type

1 each NO, 1 A, 40 V DC, PhotoMOS, no inductive loads

Temperature Inputs

Up to 8 temperature inputs per sensor type

Pt 1000 platinum temperature sensors with 2-wire connection

Measuring range

–50 to +170 °C

Accuracy

Better than ± 0.5 °C (depending on DIN class)

Suppressor diodes for voltage peaks

Yes

Frequency

Max. recording rate: 1 per sec.

Resolution

Better than 0.05 K

Digital Inputs

Up to 8 digital inputs

Either passive (e.g. reed contacts) or active pulse sources can be connected. Configurable via the (JP2
jumper series).

Passive reed contact load capacity

15 mA / typical input voltage: 12 or 24 V DC

Active signals

Min. 12 mA, max. 24 V, min. 12 V

Electrical isolation

Active operating mode: electrically isolated
Passive operating mode: not electrically isolated

Edge slope

Any

Filter (debouncing)

Digital (5 ms)

Pulse sequence

Min. 10 / 10 ms (0/1)

Frequency

Max. 50 Hz

Maximum recording rate

1 per second

Maximum cable length

200 m

Pulse inputs / status inputs

8, for example meters with pulse output or door contact as status input

Inputs which can be setup as tariff inputs

3 (IS1, IS3 and IS5), the respective upstream inputs (IS0, IS2, IS4) are counted.

Input can be used as a synchronizing input

1 (IS7), the clock is synchronized to the next quarter hour

Optical pulse display

LED on the PCB

typical ± 0.05 V

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Interfaces

RS 232 serial interface (MBUS/PRG)

Preferred protocol: M-Bus or uploading of firmware updates by means of field utility.
An M-Bus level converter with RS 232 interface is required in order to read out M-Bus compatible
devices in accordance with EN1434-3. Up to 250 devices can be addressed, baud rate can be set to
300, 2400 or 9600 baud, primary or secondary readout (selection).
Prerequisite: M-Bus protocol per EN1434-3, unlimited read-out interval (e.g. every 15 minutes),
devices preprogrammed at the factory with unique addresses.

RS 232 serial interface (FIELD 1)

Actuation of various fieldbus devices which are not equipped with an RS 485 interface.
FIELD 1 and the RS 485 interface are parallel wired.

RS 232 serial interface (FIELD 2)

Connector pin assignments upon request

Ethernet interface

Layout / parameters configuration of the SMARTCONTROL directly via TCP/IP at 10/100 MBit/s.
TCP/IP address via DHCP server or static. Interface for Modbus/TCP protocol (FW).
A public IP address is required for readout via the Internet, and port 2083 must be open or routed to
the SMARTCONTROL (firewall). Internet access must be set up with a flat rate (permanent
connection). Required hardware includes a DSL modem and a router. In the case of a non-static
public IP address, the router must support DynamicDNS service. Use of a VPN channel (virtual private
network) must be made available via separate hardware.

RS 485 interface

Fieldbus interface, distances of up to 1.2 km, connection of devices compatible with the ModBus or
ASCII protocol. Bus termination: internal, 220 Ohm, can be connected with jumper. Up to 32 devices.

Two RS 485/1 RS 485/2 interfaces
(SMARTCONTROL V3 only)

Fieldbus interface, distances of up to 1.2 km, connection of devices compatible with the ModBus or
ASCII protocol. Bus termination: internal, 110 Ohm, can be connected with jumper. Up to 250 devices.
FIELD 1 and the RS 485/1 interface are parallel wired.
FIELD 2 and the RS 485/2 interface are parallel wired.

Optional M-Bus Level Converter
(SMARTCONTROL V3 only)

M-Bus level converter, 80 socket module, article
no. Z301Y

1 slot for an M-Bus level converter module, up to standard loads

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5. Installation

5.1. Before Installing

Note:

Please check to make sure that the SMARTCONTROL and all included accessories are complete and
undamaged. The freight forwarder must be notified without delay in the event of transport
damage. The device may not be placed into operation in the event of damage.

5.1.1. Scope of Delivery for SMARTCONTROL Standard

The following is included in scope of delivery:

 SMARTCONTROL
 Installation instructions
 Installation report
 CD with SMARTCONTROL Manager software and documentation
 RJ-45 crossover patch cable for connecting the SMARTCONTROL to a PC

The PC can also be connected by means of an additional module via analog modem, ISDN, GSM or Bluetooth. See
also section 8.2. , “Communication Modules”.

5.1.2. Scope of Delivery for SMARTCONTROL IP-65

The SMARTCONTROL is delivered in a control cabinet which fulfills IP 65 requirements (optionally lockable, lock
meets IP 34). The SMARTCONTROL consists of a single PCB system, a power pack, a circuit breaker and various
attachable components. In addition to this, optional devices (e.g. M-Bus, fieldbus) can be secured to the
integrated mounting rail or inserted into available slots on the PCB (e.g. socket modules or memory expansions).
Heavy duty cable glands (1 ea. M25, 4 ea. M16) are provided at the bottom for cable entry. The control cabinet is
available in other sizes upon request.

5.2. Operating conditions

Tip:

Carefully select the location at which the SMARTCONTROL will be installed. Don’t forget that a

230 V AC mains connection is required for operation of the SMARTCONTROL and, if applicable, that
communication facilities must be provided for remote read-out.

Recommended installation height: at least 50 cm, and not more than 150 cm from the floor to the
bottom edge of the cabinet or housing. The wall to which the device is mounted must be flat, dry and
sturdy.

Furthermore, the location of sensors, transducers and other devices which will be connected to the
SMARTCONTROL must also be taken into consideration in order to minimize wiring expenses.

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Note:

Close proximity to water, sources of heat, direct sunlight, radiators, devices which generate
electromagnetic fields, transmitters, high frequency sources, radiation emitting devices and
locations which are exposed to excessive vibration or shock must be avoided.

Ambient temperature should lie within a range of +5 and +50°C, and no condensation is allowed.
If these requirements are not fulfilled by the ambient conditions, please install fully encapsulated
devices only.

Note:

When recording energy data, make sure that the SMARTCONTROL is protected against
manipulation and destruction.

The devices are not intended for use in explosion-proof zones.

Observe additional information included section 3. , “General Safety Precautions” and section 4. , “Technical
Data”.

5.3. Wall Mounting

Warning:

Before drilling holes, make sure that there are no cables, pipes or other lines which have been
laid inside the wall in close proximity to the intended installation position.

5.3.1. Wall Mounting the SMARTCONTROL Standard

The housing has the following dimensions: approx. 226 x 210 x 70 mm (W x H x D).

The 3 holes in the housing are used to mount the SMARTCONTROL. Remove the 2 housing screws at the bottom
and open the housing cover in order to expose the mounting holes.

The top mounting hole is laid out as a slot, and the thickness of the housing wall is approximately 1 mm. The
SMARTCONTROL Standard is shipped with 4 installed housing screws. Only the two screws at the bottom need to
be loosened for mounting, because the opening in the housing top is only intended for the fiber-optic cable. The
top screws may not be loosened for this reason.

22.6 cm

16 cm

21 cm

The box must be securely
mounted with 3 suitable
screws and anchors, depending
upon substrate and material.

Housing Rear Panel

11.3 cm

11.3 cm

16 cm

Box mounting tab diameter:

approx. 5 mm

3.3 cm

3.3 cm

2.6 cm

Top Housing Screw

Top Housing Screw

Bottom
Housing
Screw

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The housing top can be tipped up after removing the two bottom screws with the included tool (stiff wire,
approx. 25 cm long) in order to work on the installed SMARTCONTROL.

Remove the bottom two screws and tip up the housing top to this end. Now insert one end of the tool into the
threaded drill hole for the bottom housing screw in the SMARTCONTROL base plate at either side of the
SMARTCONTROL – from the outside.

Insert the other end of the tool into the drill hole for the bottom screw in the housing top after it has been tipped
up.

5.3.2. Wall Mounting the IP 65 SMARTCONTROL

The standard version of the IP 65 housing has the following dimensions: approx. 380 x 380 x 210 mm (W x H x D).

The 4 holes in the housing are used to mount the SMARTCONTROL. Remove the right-hand cable duct cover in
order to expose all four mounting holes.

In the case of special orders, please check the dimensions of the IP 65 housing.

5.4. Power Supply Cable for the SMARTCONTROL IP 65

Warning:

Cables must be voltage-free.

Note:

The cables must be led in from the top and are secured by
means of heavy duty cable glands.

It must be assured that the cables are long enough to reach
the connector terminals.

38 cm

34 cm

34 cm

38 cm

The box must be securely
mounted with 4 suitable
screws and anchors,
depending upon substrate and
material.

Box Mounting Hole
Diameter:
Approx. 8.2 mm

2 cm

2 cm

Housing
Rear Panel

2 cm

2 cm

Terminal

Block

Heavy-Duty Cable Gland

Cable Duct

Ground Bus Bar

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SMARTCONTROL

5.5. SMARTCONTROL IP 65 Power Supply

The power supply cable may have no more than 3 conductors with a maximum cross-section of 4 square mm
each, and must be led in through the heavy duty cable gland at the bottom of the housing. This cable must be
connected to the 230 V AC terminal block (see below): N, PE and L1.

PE N F1

L1

Green­yellow

Blue

Brown­black

230 V AC supply power is fed via a circuit breaker (B6A) to the power pack (F1).

The SMARTCONTROL can be supplied with 12/24 V DC. The power pack is supplied with a standard output of
24 V DC, or with 12 V DC as an option. It’s also possible to install both power packs. If applicable, 24 V DC is
required for additional components such as an M-Bus level converter, and 12 V DC is required for certain sensors.

The SMARTCONTROL PCB is supplied with electrical power via the connector terminal [see “Connections

Overview,” in section 6. as of item 20].

5.6. Low-Current Leads

5.6.1. SMARTCONTROL IP 65

The leads are fed through the heavy duty cable glands at the bottom of the housing.

Note:

Tighten the threaded cable glands to the specified tightening torque. The housing must be water­proof. If necessary, the included connectors must be replaced with more suitable ones, and
unused connectors must be replaced with blanking plugs. It must be assured that only
standardized materials which are suitable for the IP 65 standard and which seal the openings
appropriately are utilized.

The shields of all shielded cables must be connected to a ground bus bar by means of shield terminals assuring
large surface-area connection. Identify all cables which are fed into the housing with the respective cable number
in accordance with the wiring diagram in a readily legible fashion using cable ties. Secure the cables firmly, with
cable ties if necessary.

5.6.2. SMARTCONTROL Standard

Warning:

Cables must be voltage-free.

Note:

The cables must be led in from the bottom and secured by
means of heavy duty cable glands.

It must be assured that the cables are long enough to reach the
connector terminals.

Ground Bus Bar