Gossen MetraWatt U1601 User manual

U1601, U1602, U1603
Summators – Energy Control System ECS 3-348-869-03
15/1.21
Operating Instructions

2Gossen Metrawatt GmbH
Device Overview
Contents Page
1 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Instrument Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Instrument Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Channels / Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Inputs E1 ... E12 and E1 ... E6 respectively (analog / binary) . . . . . . . . . . . . . 8
3.4 Analog Outputs A1 and A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 S0 Outputs S1 through S4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 RS232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9 ECS LAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 LAN LED (LANL/LANR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.11 LON Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 LON LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Measurement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Overview of Available Measurement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Synchronizing-Interval Data Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Characteristics U1601 U1602 U1603
64 channels ✔✔✔
Analog inputs / S0 I1 ... I12 — I1 ... I6
Binary outputs S1 ... S4 — S1 ... S4
Analog outputs O1, O2, — O1, O2,
Relay outputs
Relay 1, relay 2, status Status Relay 1, relay 2, status
RS 232 COM1 / COM2 ✔ (in a single plug) ✔✔
LANL / LANR ✔✔ ✔
LON ✔✔ ✔
24 V auxiliary power ✔✔ ✔
Control panel ✔——
LON LED
page 13
LAN LED
page 13 ESC Key
Menu Key
Enter Key
Status LED
page 9
RS 232
Interface
page 9

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5 Operation (menu displays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Menu: Overview (main menu display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Menu 1: Display Total Energy, Power and Costs . . . . . . . . . . . . . . . . . . . . . 19
5.3 Menu 2: Display Interval Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Menu 3: Display Maximum Values for Interval Energy . . . . . . . . . . . . . . . . . . 21
5.5 Menu 4: Display Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 In-Service Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.7 Menu: Display Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.8 Menu 5: Display Status Menu (time, relays, errors, interfaces). . . . . . . . . . . . 26
6 Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Setup Parameters Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Setup Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Station Parameters (IDs, intervals, tariffs, outputs, ... ) . . . . . . . . . . . . . . . . . 30
6.4 (Channel) Parameters (mode, name, units, displays, ... ) . . . . . . . . . . . . . . . . 33
6.5 RS232 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.6 LON Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.7 ECS LAN Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.8 SETUP Sub-Menus (edit, erase, outputs, bootstrap loader, password). . . . . 40
6.9 Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.10 Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.11 Basic Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1 Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2 Input and Output Configuration (DIP switches) . . . . . . . . . . . . . . . . . . . . . . . 50
7.3 Interface Pin Assignments, Connector Cable . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Parameters Configuration and Data Visualization at a PC . . . . . . . . . . . . . . . 55
10 Characteristic Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11 LON Bus System Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.2 Cable Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.3 Bus Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
12 Connecting LON Bus Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.1 Network Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.3 Device Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
12.4 Reinstalling a LON Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
12.5 Configuration at a PC with ECSwin Software . . . . . . . . . . . . . . . . . . . . . . . . 71
12.6 Replacing a LON Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.7 Additional LON Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
12.8 Channel Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13 Functions Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15 Maintenance, Repair, Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4Gossen Metrawatt GmbH
1 Applications
The Energy Control System (ECS) allows for unambiguous cost center accounting.
Electrical as well as non-electrical energy and its consumption can be recorded,
optimized and billed to individual cost centers.
The U1601, U1602 and U1603 summators are at the heart of the Energy Control
System (ECS) and enable the recording and billing of both analog and digital quantities.
ECS operating software revision level: V2.57
The current operating instructions covering the latest firmware update are available for download
on the internet at www.gossenmetrawatt.com.
LONis a registered trade mark of the Echelon Corporation.
2 System Description
•Analog signals from orifice plates, measuring transducers or other measuring
instruments are acquired, analyzed and stored together with meter pulses from energy
meters, flow meters and heat meters at the intelligent U1601 summator.
• Each summator can be connected to up to 12 energy meters with pulse output. Data
collected at the meter inputs are integrated and stored according to various criteria to
a semiconductor memory with battery back-up.
•64 channels are available for the generation of sums and/or differences based upon
meter values. Values from other summators which are connected to the ECS LAN can
be used to generate virtual channels as well. All of the stored measurement values
can be displayed at the summator.
• Stored values can be read out from the U1601 summator with a PC, or can be remote
queried with the help of a modem. A radio-controlled clock for correct time
synchronization or a printer for the generation of reports can be connected to the
second RS232 interface.
• Several summators can be linked to one another via the ECS LAN, a multi-master
compatible RS485 field bus, for applications which required the use of more than 12
inputs (analog/binary). The linking of up to 255 summators from 16xx series
instruments via the ECS LAN allows for the establishment of a powerful energy control
system, which is controlled and monitored with a PC.
• All of the instruments connected to the bus can be queried and programmed from any
desired summator thanks to the multi-master system structure. A limit value violation at
summator M can thus trigger a signal at summator N. Each bus user has access to all
data and functions throughout the entire system.
•LON is a new type of intelligent bus concept with allows controllers, sensors and
actuators to communicate with one another. In addition, up to 63 nodes can be
connected to a U1601 summator via the integrated LON network.
• Two freely programmable relays allow for the generation of messages or the triggering
of specific actions if certain criteria have been fulfilled.
• User generated programs can be installed to the summators through the use of the
system-specific programming language,Energy Control Language (ECL). The
summators can thus be adapted to customer-specific calculations, analyses,
monitoring and optimization independent of the energy control system.
•ECSwin PC software for configuring parameters at the summators, and for reading in
energy consumption data and displaying them in tabular and graphic form.

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3 Instrument Description
3.1 Instrument Overview
3.2 Channels / Calculations
64 software channels are available. The input type for each channel can be selected for
the basic configuration with the CMODE channel parameter (0 ... 4).
Cyclical Generation of Channel Registers
Due to the fact that many various energy data registers are made available to each
channel (33 registers without maximum values: Etot, EtotT1, EtotT2, Pmom, 10+1 times
Eday, 12+1 times Emon, 4+1 times Eyear), only the most important summations are
performed continuously, and less important summations are performed in accordance
with a rotating schedule. For example, Etot is calculated continuously, whereby Emon-
12 is determined less frequently (approximately every 30 to 90 seconds). Power values,
except for Pmom, are continuously calculated based upon energy values, and thus
need not be summated.
PC/Modem
Printer/Clock
Inputs
E1 ... E12
analog / S0
Binary Outputs
S1 ... S4
S0 Standard
Aux. Power, Uv
for external meter
2
Relay Outputs
2
Analog Outputs
A1, A2 (= K13,14)
Status Relay
LON MeterLAN L LAN R
412
Relay 1, Relay 2
to Summator Port Input
LCD
Display
LEDs
Com-Server
64 Channels
OFF
En
LON
Channel Kn
Meter
S0
Analog Value
OFF
Energy
LON Calculation Energy
Calculation
Desired
Channel Power
2
0
3
4
1
Channels

6Gossen Metrawatt GmbH
Channel Names
A name can be assigned to each channel with a length of up to 8 characters. These
names allow for improved channel identification during data processing, as well as for
graphic representations. System-wide access to a given channel is also enabled through
the use of such names.
A system-wide search for a channel with the name “Motor5” is performed from
summator A, and total energy from this channel is graphically displayed (see also ECL
command: FINDER).
Channel Numbers
If inputs (E1 ... E12) are to be assigned to the channels, each input can only be assigned
to the channel which bears the same number, i.e.:
Virtual Channels
• Any unused channel can be utilized as a virtual channel for the generation of any
desired sums or differences which result from physical inputs or other virtual
channels. It makes no difference which summators within the ECS LAN the channels
have been assigned to!
• Unused physical channels can also be utilized as virtual channels, in which case even
the maximum value registers for the corresponding physical channel are made
available.
• The synchronizing-interval data logger can record data from virtual channels.
Differential Linking (ECL commands dVSUM and dVIRT)
As soon as they have been defined, incoming energy quantities (~ meter pulses) from
the source channels are continuously summed and the summed energy quantities are
fed to the virtual channel, “as if they had actually just been measured”. The virtual
channel is decoupled from the source channels and data can be manipulated as
desired.
Areas of application: logical coupling of input signals (as if the corresponding input
signals had been switched together to a single channel).
Example 1:
Channel 26 at summator D generates a cost center based upon channels 1 ... 5+8 from
summator B weighted with a factor of 0.7, and channel 4 from summator C weighted
with a factor of 0.3
Example 2:
Channel 10 is the difference between 1 ... 8 and total-sum channel 9
(sum of 1 ... 8 minus channel 9):
Inputs E / Outputs A Channels
E1 1
... ...
E12 12
A1 13
A2 14
...
64
<A> Etot Motor5
H1=’B:dVSUM 1..5+8 0.7, C:dVSUM 4 0.3, D:dVIRT 26=’

Gossen Metrawatt GmbH 7
Channel Parameters (chapter 6.4, page 33)
Numbers Range
In order to ensure greatest possible accuracy, all internal calculation operations are
performed with 64 bit floating decimal point numbers. This means that 15 (!) significant
decimal places are possible.
Switching the Channel Display On and Off
The On/Off function only determines whether or not a channel is visible while browsing
through channel data at the display, or during read-out with '*' (ECL command:
ONOFF). The function of the channel remains otherwise entirely unaffected.
Channel Start/Stop
The Start/Stop function is used to determine whether or not meter pulses are to be
accepted at a given input (ECL command: STARTSTOP).
• A virtual channel which has been generated by means of “differential linking” can be
influenced with the Start/Stop function in an analog fashion.
• Since the binary input status of a channel is not influenced, this function can be used,
for example, to avoid taking undesired binary data into consideration.
Energy Metering
Meter pulses filtered out in this fashion are integrated, per channel, into a temporary
meter. The meter values are converted into their corresponding energy values every 1 to
2 seconds, and are added to total energy registers. Pulses are converted to energy
values by means of the following formula:
Energy Calculation
where:
Power Calculation
Instantaneous power, PMOM, is determined based upon the interval between the
incoming pulses. All other power values are calculated from the corresponding energy
value, taking the corresponding time interval into consideration.
The calculation of power assumes the assignment of an energy unit of measure per hour
(kWh). The power factor must be adapted accordingly for other units of measure (e.g.
liters per minute) (ECL command: PFACTOR). The default value is 3600, and it would be
60 for the “liters per minute” example.
Formula for the calculation of power based upon energy E and duration dt:
P = E * Pfactor / dt
Only sensors which have been connected via the LON network are capable of
transmitting already calculated power and energy values to the summators.
H2=’dVSUM 1..8, dVSUM 9 -1, dVIRT 10=’
Energy kWh Pulses Imp
MeterCons t Imp
kWh
---------
tan
-------------------------------------------------- Uratio Iratio
 KFactor=
Iratio
Iprimary
Isecondary
-----------------------=
Uratio
Uprimary
Usecondary
------------------------=

8Gossen Metrawatt GmbH
3.3 Inputs E1 ... E12 and E1 ... E6 respectively (analog / binary)
Analog Inputs
For summator U1601 12 optically isolated analog inputs are available, E1 ... E12, for
summator U1603 6 optically isolated analog inputs are available, E1 ... E6. These can
be configured as voltage, current or binary inputs. See page 50 and page 33 for DIP
switch settings and appropriate software settings.
One metering channel, 1 ... 12, can be assigned to each of the inputs, E1 ... E12,
one metering channel, 1 ... 6, can be assigned to each of the inputs, E1 ... E6.
The applied analog input value may correspond to a measured power quantity.
The input ranges (20 mA, 5 mA, 10 V, S0) must be pre-selected with the DIP switches,
as well as the I/O RANGE parameter. Energy is matched to the various ranges, and
calculated and recorded as a channel quantity with the configurable ANAFAKTOR and
ANAOFFSET parameters.
Binary Meter Inputs
The 12 analog inputs, E1 ... E12, of
summator U1601, and the 6 analog inputs,
E1 ... E6, of summator U1603 respectively,
can also be used as binary inputs (in
accordance with the S0 standard).
Configuration is accomplished by means of
DIP switches and software (see page 50 and page 33).
A binary input recognizes two different levels, high level “1” and low level “0” (max. low
level adjustable with ECL command: LEVEL). Thus switching back and forth between
tariffs T1 and T2 can be performed with input 12. The synchronization pulse from the
electric utility can also be connected, for example, to input 11. Status can be queried via
software with the ECL command INPUT.
Debouncing Time and Trigger Edge
Debouncing time and the trigger edge can be configured individually for each of the
maximal 12 channels. Sampling time for all maximal 12 channels amounts to 5 ms.
• Debouncing time is adjustable from 10 ms to 2.55 s in 10 ms steps, ECL command:
PULSE
• High level trigger flank (1): Triggering occurs for change from low level to high level,
ECL command: EDGE
• Low level trigger edge (0): Triggering occurs for change from high level to low level.
If an input is used as a binary input, the selected debouncing time applies to this
operating mode as well. For example, if debouncing time has been set to 1 s, only those
signals are processed which remain stable at either high or low level for at least 1
second. Only debounced signals appear at the input status display at the control panel
as well.
3.4 Analog Outputs A1 and A2
Two configurable analog outputs can be driven with the ECL command ANA. The
output quantity (20 mA or 10 V range) must be selected with the DIP switches and the I/
O RANGE parameter (see page 50 and page 37).
Input channels can be recorded, scaled and read out continuously as transduced
quantities with the help of a background program (see also ECL command: ANA 13,
ANA14).
AD
EN

Gossen Metrawatt GmbH 9
3.5 S0 Outputs S1 through S4
Just like the relay outputs, four freely programmable S0 outputs allow for the forwarding
of messages when certain conditions have been fulfilled. Selectable voltage is limited to
50 V. Additionally, these outputs can be used as floating pulse outputs for the
transmission of meter readings to remote locations with the help of ECL background
programs (see ECL command: S0REL 1 ... 4).
3.6 Relay Outputs
Two freely programmable relays (changeover contacts) allow for the generation of a
message or the triggering of an action, if certain criteria have been fulfilled. For example,
a relay output can be activated if the mean power value within the synchronization
interval exceeds a certain value. The current relay status is displayed at the LCD under
summator status. A ?
indicates that the contact is closed and active. Please observe the
characteristic values in the appendix.
Relay Names
A channel name can be assigned to each of the relays and may have a length of up to 8
characters. This name allows for improved relay identification during data processing, as
well as for graphic representations. System-wide access to a given relay is also enabled
through the use of such names:
A system wide search for a relay with the name “Horn” is performed from summator A,
and this relay is activated (see also ECL command: FINDER).
3.7 Self Test
As long as the electronics are functional and no system error has been detected, the
status LED and the status relay are on. If the instrument electronics malfunction, the
relay is released and the LED goes out. A horn which can be driven with the status
relay’s break contact can be used to indicate a malfunction.
The current relay status is displayed in the status window (see chapter 5.8, page 26).
Functional testing can be expanded by means of appropriate programming (ECL
command: STATCHECK, see detailed information in online help: ? STATCHECK). For
example, the output can be deactivated (error condition) as soon as the 24 V power
supply drops to below 16 V, or if the condition of the lithium battery no longer allows for
reliable data storage.
3.8 RS232 Interface
Communications with a host computer (PC), a terminal, a modem or a printer is made
possible via the RS232 serial interface.
Access to All Measurement Data
A PC which has been connected to the RS232 interface has full access to all stored
system measurement values. ECSwin parameters configuring software, which runs on
the PC, manages all ECS data and allows for tabular data analysis.
Port Configuration
The RS232 port is configured in the DTE format (data terminal equipment), and signals
are conducted by a 9-pin D-SUB plug. The DTE configuration is compatible with
standard PC and terminal configurations. Wiring of the connector cable is described in
chapter 7.3, page 50.
<A> REL Horn=1

10 Gossen Metrawatt GmbH
3.9 ECS LAN
Several summators can be linked to one another via a multi-master compatible RS485
field bus (ECS LAN) for applications which require the use of more than 64 channels.
The connection can be established by means of a 2-wire cable using either bus or a line
topology. The maximum length per segment is1200 meters. Distances of several
kilometers between 2 summators can be accommodated with fiber optic transmission
and
4-wire technology.
A maximum of 255 summators can be connected to the ECS LAN. This means that a
maximum distance of approximately 300 km can be covered without additional
boosters.
Multi-Master System Architecture
The most significant advantage of the multi-master system architecture is the fact that
each of the bus users has full access to all of the data and functions encompassed by
the overall system. It is thus unnecessary to assign the designation of bus master a
single summator.
General Notes Concerning the ECS LAN
•Theconnector technology for the individual LAN segments can be freely selected and
combined.
• The longest cable length is determined by the transmission speed in accordance with
RS485. The ECS LAN normally runs at 62.5 KBaud, which corresponds to a
maximum cable length of 1.2 km, (see also chapter 6.7, page 39).
• The transmission cable must be terminated at both ends (and only at the ends) with
matching resistors. The matching resistors are integrated and can be switched on or off
at the control panel. Correct functioning of the 2-wire connection can only be secured
through the use of these integrated matching resistors. No external resistors may be
used!
•Theloop resistance of the transmission cable may not exceed 100 Ohms in 2-wire
operation.
•Upto16 summators can be connected to a single bus segment. If the matching
resistors have been correctly installed (see above), if spur line lengths have been
minimized and if the overall loop resistance of the transmission cable is less than 100
Ohms, up to 32 summators can be operated within a single segment.
•User statistics can be queried via the control panel (instrument status).