Gossen MetraWatt R2500 Operating Instructions Manual Download Page 1

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3-349-374-03

19/6.18

R2500

Compact Controllers and Temperature Limiters

Operating Instructions

Summary of Contents for R2500

Page 1: ...3 349 374 03 19 6 18 R2500 Compact Controllers and Temperature Limiters Operating Instructions ...

Page 2: ......

Page 3: ...0 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...

Page 4: ...te 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 temperat...

Page 5: ...net at www gossenmetrawatt com by entering the search term WEEE We identify our electrical and electronic devices in accor dance 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 S...

Page 6: ... 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 ...

Page 7: ...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 ...

Page 8: ... 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 protec...

Page 9: ... be connected to terminal 13 Binary Input Transistor Output Cont Output Auxiliary Voltage A1 A2 A5 A5 C1 C2 1 1 11 2 2 12 3 out1 3 13 4 out2 out2 4 14 5 5 15 6 6 16 7 7 17 8 A 8 18 9 B 9 19 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 ...

Page 10: ...een 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 le...

Page 11: ...onfigurations After password protection for device operation has been activated PASS 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 al...

Page 12: ...h heat current monitoring only Setpoint can only be set here Configuration Configuration Configure Parameter 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 Contro...

Page 13: ...r 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 ...

Page 14: ...N tYP E E tYP t T tYP v U tYP C C tYP Pt1 Pt100 ni1 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...

Page 15: ...oP 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 ...

Page 16: ... page 21 out2 switching output 0ut2 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 C...

Page 17: ... nSUP Alarm 2 AL 2 nSto Stor Alarm memory off on nSto Limiter L1M no yes no See page 39 Heating circuit monitoring LbA no yes no See page 41 Adaptive measured value correction AMC no yes no See page 24 Actuator output for contactor rELA no yes no See page 22 PI performance p1 no yes no See page 20 Manual key function HKEY oFF HAnd oFF See page 13 Start self tuning tune EnA diS Enable disable EnA S...

Page 18: ...S Password for operation 1 PASS EnA diS Enable disable 1 499 access with CompactConfig 500 999 read access only with CompactConfig diS See pages 11 and 12 Device settings parameter set pset Act Retain active configuration dEF Load default settings GEt1 Load user configuration 1 GEt2 GEt3 GEt4 Load user configuration 4 Put1 Save active configuration as user configuration 1 Put2 Put3 Put4 Save activ...

Page 19: ...cle Actuating cycle time is used as a time constant for an additional input filter PDPI controller and PDPI step action controller Cout PdPI The PDPI control algorithm assure short settling time without overshooting The actuating cycle is at least as long as the selected value The dead band inhibits switching back and forth between heating and cooling if no lasting deviation occurs Selection of th...

Page 20: ...o configuration PI Performance The differential component of the PDPI controller type can be attenuated to such an extent by activating PI performance configuration PI YES that practically no more derivative action occurs As opposed to a pure PI controller response to setpoint changes can be configured without overshooting This setting is advisable for control systems which include true delay time...

Page 21: ...neously for the respective controller Both switching outputs can be assigned to the same controller output for separate control of several actuators with a single controller output If a continuous and a discontinuous output are both configured for heating or cooling at the same time the channel performs like a continuous action controller and the discontinuous output is inactive If inadvertently o...

Page 22: ...count for the disproportionately powerful cooling effect which prevails when water is evaporated the cooling control variable can be read out in a modified fashion by configuring the switching output for water cooling Outx H2O Configuration of the Controller with Continuous Output Switching back and forth between current output and voltage output is automatic based upon load impedance Continuous o...

Page 23: ...value may fluctuate between its extreme values resulting in unsatisfactory control results If the period is constant this oscillation can be filtered out by setting the period in the oscillation suppression tSUP parameter This is accomplished by means of narrow band filtering in order to remove the signal component with the selected period which is then disregarded for measuring signal control The...

Page 24: ...ean value is forwarded to the controller Adaptation of correction to the disturbance is matched to prevailing control dynamics and requires no further parameters Prerequisites for improved control The oscillation amplitude of the disturbance must be constant or may only change slowly The oscillation period must be less that half of the system s delay time parameter tu Due to the fact that correcti...

Page 25: ... start up setpoint after auxiliary voltage is turned on reset or after the off state has been ended or if the actual value drops to more than 40 C less than the start up setpoint after a start up procedure has been completed or during dwell time Start up continues until the actual value exceeds the start up value minus 2 C The control variable is limited to the start up manipulating factor Dwell t...

Page 26: ... to the boost time parameter The increase effects the setpoint or setpoint 2 only and has no influence on the start up setpoint or the ramp function The setpoint value and not the increase is indicated with a b in the left digit Feed Forward Control When configured as a discontinuous or continuous action controller not as a step action controller control quality can be significantly improved by me...

Page 27: ...p for falling setpoints spdn oFF 1 MRS 2 per min oFF Heating current setpoint see balancing amps Auto oFF 0 1 A H oFF Not with step action controller or bus interface Proportional band heating pb 1 0 MRS 2 50 Proportional band cooling pb11 0 MRS 2 50 Only with 3 step controllers Dead band H C dbnd 0 MRS 2 0 Not with 2 step controllers Path delay time tu 0 900 s 50 s Cooling path delay time tu11 0 ...

Page 28: ...ge limit standard signal rn h r n L 9999 100 Lower range limit standard signal rn l 1999 r n H 0 Manip factor for actuation mode y st 100 100 0 Manip factor for feed forward control y ff 100 100 0 See page 26 Sensor error manipulating factor y se 100 100 0 See page 43 Actuation setpoint spsv SP L SP H 0 For hot runner controllers only see pages 25 and 26 Start up manipulating factor y sv 100 100 1...

Page 29: ...ent as well Sequence StoP The program has been completed or stopped or hasn t yet been started after a reset The controller and the actuator outputs are inactive relative limit value errors are suppressed The momentary setpoint is set to the actual value The program is started over again after it has been stopped run X The program has been started possibly automatically after a reset X stands for ...

Page 30: ...ause a constant setpoint is required for usable optimization results Select ProG diS to this end Display The displays are supplemented as follows at the operating level The momentary setpoint appears at the setpoint display when a program is running and only dashes appear after the program has been ended because there is no longer an active setpoint The setpoint cannot be changed A status display ...

Page 31: ...l Setpoint is reached wait no yes no Valid for all 8 programs Type of segments segs ramp step Ramps increments rAMP Valid for all 8 programs Unit of time for segments tIME M S H M Seconds minutes M S Valid for all 8 programs Duration of segment 1 MS1 0 00 99 59 0 00 Target setpoint segment 1 SP1 SPL SPH 0 C Control tracks segment 1 tr1 21 Specified numbers designate active control tracks Duration ...

Page 32: ...99 59 End Target setpoint segment 12 SP12 SPL SPH 0 C Control tracks segment 12 tr12 21 Segment 1 2 3 4 5 6 7 Duration MS 1 7 HM 1 7 0 40 0 30 0 20 0 50 0 00 0 50 End Setpoint SP 1 6 100 100 180 180 120 120 Tracks tr 1 6 1 1 2 2 2 Configuration Display Selection Standard Comment setpoint Actual value Control track 1 Control track 2 ...

Page 33: ...nal recorder channel or a stopwatch Configure limit transducer Cout OnOF Set read out cycle time to the minimum value tc 0 1 If possible deactivate manipulating factor limiting Y H 100 Reduce or increase the setpoint so that overshooting and undershooting do not cause any impermissible values Performing the Start Up Test dbnd MRS Setting for 3 step and split range controllers switching output for ...

Page 34: ...s overshooting x If manipulating factor limiting was active the proportional band must be corrected Y H positive Pb I multiply by 100 Y H Y H negative Pb II multiply by 100 Y H Parameter Value tu 1 5 t t tY 4 tc tu 12 tY 100 Pb I xss 2 xss x 2 Pb II Pb I TI TII Pb I TI TII Parameter 2 step controller 3 step controller Cont action controller Split range controller Step action controller P t x xss T...

Page 35: ... 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 if applicable start the recorder Record several oscillations until they become uniform in size Measure oscillation amplitude xss Record on time TI and off time TII for the oscillations at the switching output for h...

Page 36: ...TII 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 type Cout Adjust the setpoint to the required value For 3 step split range and step action controllers the dead band can be increased ...

Page 37: ...shipment from the factory default setting Starting the self tuning function can be disabled in the configuration Self tuning is used to optimize controller dynamics i e the Pb I Pb II tu and tc parameters are set Preparation Complete configuration must be performed before self tuning is started The setpoint value is adjusted to the value which is required after self tuning Deactivate the program c...

Page 38: ...viates from it the GAin parameter is set to a value other than 100 temperature to be displayed in C 100 GAin measured temperature in C 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 outpu...

Page 39: ...ontroller types The limiter responds to the second limit value which must be set and configured accordingly The controller is deactivated as soon as a second limit value is violated The controller becomes active again when there are no more limit value errors If the controller is to remain continuously deactivated after limit value monitoring has been triggered the alarm memory must be activated c...

Page 40: ...triggered until heating current is high enough when the switching output for heating is active and when current drops to zero when the switching output for heating is inactive Monitoring is only active if discontinuous heating has been selected in the configuration and not in the case of continuous and step action controllers Threshold The default monitoring threshold is 20 AMPS current setpoint H...

Page 41: ... monitoring must be activated before self tuning is started In the event of manual optimization or subsequent adaptation of control parameters the lower limit for the tu parameter must be observed 2 Pb I Minimum tu t t maximum temperature rise during start up Error message LE appears after approximately 2 times tu if heat remains on at 100 and measured temperature rise is too small Monitoring is n...

Page 42: ... the infrared interface See the interface description for detailed information Data Logger The data logger has enough capacity for 3600 sampled value pairs including actual values and manipulated variables The logger sampling cycle can be configured within a range of 0 1 to 300 0 seconds This results in recording times of 0 1 to 300 hours 6 minutes to 12 days Recording must be started over again e...

Page 43: ... limit 1 Heatingcurrent display current error Current transformer has reversed polarity is unsuitable or defective Same as heating current monitoring alarm continues to control temperature 2 no tune Self tuning cannot be started controller sort actuator or limit transducer No response to error error display remains until acknowledged see below tune error 2 Disturbance in self tuning sequence in st...

Page 44: ...gital component monitoring Control outputs inactive 6 analog error Hardware error detected by analog component monitoring Control outputs inactive 6 Display Error Message Source Response Remedy 1 Eliminate sensor error 2 Inspect current transformer 3 Avoid disturbances which impair the self tuning sequence e g sensor errors 4 Close the control loop Check the sensor the actuators and the heater for...

Page 45: ...ages can be assigned to outputs A1 and A2 in a targeted fashion with the error masks The values must be added and entered hexadecimally to this end Configuration is more user friendly with the Compact Config PC tool Device error mask A1M2 and A2M2 Value Meaning Display default 0002 Heating current overrange CE A1 0004 Cold junction error CJE A1 0010 Heating current not off Blinks A1 0020 Heating c...

Page 46: ...8 Broken sensor SE H A1 0010 Reversed polarity SE L A1 0020 1st Lower limit value fallen short of Blinks A1 0040 2nd lower limit value fallen short of A2 0080 1st upper limit value exceeded Blinks A1 0100 2nd upper limit value exceeded A2 0200 Parameter impermissible for entry via interface 0800 Heating circuit error LE A1 1000 Self tuning start up error no t 2000 Self tuning error or abort tE X A...

Page 47: ...A1 Transistor A1 Out1 CooL Out2 oFF A1 Relay A2 Out1 CooL Out2 oFF A2 A4 Transistor Transistor A1 Out1 HEAt Out2 CooL A2 A4 Relay Transistor A2 Out1 HEAt Out2 CooL A2 A4 Transistor Relay A2 Out1 CooL Out2 HEAt Rewiring 3 to 4 and 17 to 15 A2 A4 Relay Relay A2 Out1 HEAt Out2 CooL Out XCh Rewiring 15 to 20 16 to 19 17 to 18 19 to 16 20 to 15 A3 Continuous A5 Out1 oFF Cont HEAt A3 Continuous A5 Out1 ...

Page 48: ...plug connectors can be pulled out after loosening the lacquered screws In the case of 230 V AC auxiliary power R2400 feature C1 the conductor connected to terminal 13 is moved to terminal 12 If the actuating signal for cooling is read out via the relay the corre sponding connection must be changed see table on page 47 If both actuating signals are read out via relay the relay connections must be c...

Page 49: ... Typically 1 5 W 24 V DC 20 to 30 V DC Relay output Floating NO contact common phase for switching outputs A1 and A2 Switching capacity 250 V AC DC 2 A 500 VA 50 W Service life 5 105 switching cycles at nominal load Interference suppression Utilize external RC element 100 47 nF at contactor Electrical Safety Safety class II panel mount device per DIN EN 61010 1 section 6 5 4 Fouling factor 2 per D...

Page 50: ...ontrol process Read out and storage of values from the data logger and from alarm history Administration of 4 parameter sets Programming of the program section 8 programs with 12 segments each The Z250I IR adapter is required in order to use the configuration tool Further information regarding accessories and the latest version of the software which can be downloaded free of charge are available o...

Page 51: ...GMC I Messtechnik GmbH R2500 51 ...

Page 52: ...Südwestpark 15 90449 Nürnberg Germany Phone 49 911 8602 111 Fax 49 911 8602 777 E Mail info gossenmetrawatt com www gossenmetrawatt com Edited in Germany Subject to change without notice PDF version available on the Internet ...

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