R6000

8-Channel Controller 3-349-157-03

12/8.14

New
• freely configurable control channels
• Software tool for complete configuration and parameter setting
• Sampling cycle – 10 ms per channel
• PDPI control without overshooting 20 mA
• Control parameters adaptation can be started at any time for each channel Measuring Input
• Functions: limit transducer / 2 and 3-step, continuous and step-action controller
• Ratio, cascade, differential and switch control
• Hot runner control with actuating circuit and booster circuit
• Assignment to groups for control zones for synchronous heating
• Algorithms for water cooling
• 16 binary inputs/outputs with short-circuit detection – can be freely assigned to
controller states, functions and channels
• 4 additional continuous outputs or 4 additional binary I/Os as option
• Fieldbus options: Profibus-DP, CAN-Bus, Modbus (RS 485)
• Handling modules for SIMATIC Manager
• Power limitation
• Data logger for all actual values and setpoints
• Alarm history with time stamp
• Several measuring inputs are taken into account to determine the controlled variable
• In the SIMATIC project, not assigned I/Os are freely available to the CPU

Features Filter and Functions with Distorted Controlled Variable

Designation / Function Limitation
• 8 sensor inputs – can be switched individually with software to Parameter
thermocouple, Pt100 or 50 mV linear
Peak filter Individual erroneous measurements caused by, ---
• Thermocouple inputs immune to interference due to leakage for example, electrostatic discharge to the sen-
current (up to 230 V) sor, are suppressed.
• Removable cold junction Smoothing filter In accordance with controlled system dynamics, ---
• Suitable for zones with temperature rises of approximately several measured values are combined for control
purposes to avoid an unsteady controlled variable.
100 K/s to less than 100 K/h
Actual value correction, Linear correction of measured values, if, ---
• Direct connection of melt pressure transducers actual value factor amongst other factors, measured temperature
• Monitoring for sensor breakage, polarity reversal and short-circuiting deviates from the temperature to be measured /
to be displayed due to a temperature gradient.
• Regulated value is active in the event of sensor breakage
Adaptive measured Suppression of constant periodic, or slowly Not active if
• Actual value correction for periodic measured-value fluctuation value correction changing oscillation. period is
• Deactivate zones as desired with internal or external signal > ½ Tu*
• Setpoint ramps (up-down), 2nd setpoint, setpoint limiting Oscillation disabling Suppression of oscillation with a constant ---
(oscillation period: 0.3 period, if the period is longer than ½ Tu.
• Feed-forward control for the avoidance of overshooting and to 20 s)
undershooting during load changes
Feed-forward control Suppression of controlled variable swells and Load fluctua-
• Heating circuit monitoring without additional transformer dips in the event of load fluctuations, e.g. tion interval
• Heating current monitoring with single-phase/three-phase caused by operation/standstill of a machine/ much greater
external current transformers, and an optional voltage trans- system than Tu*
former for compensation of voltage fluctuation Response in event of If operation must be continued with a defective ---
sensor failure, sensor sensor, the controller reads out a plausible
• Remote diagnosis supported with numerous monitoring functions error manipulating manipulated variable in order to maintain the
• 2nd set of parameters factor working level.
• Short-circuit detection at the binary outputs * Tu = delay time
• Integrated self-restoring overload protection for binary outputs Detailed information is included in the operating instructions.

• 24 V DC auxiliary power supply

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R6000
8-Channel Controller

Applications Applicable Regulations and Standards

The R6000 compact 8-channel temperature controller offers con- IEC 61010-1 / EN 61010-1 / Safety requirements for electrical equipment for
centrated control technology know-how in a rail mount housing. VDE 0411, part 1 measurement, control and laboratory use
The autonomous controller can be very quickly configured and IEC 60529 / EN 60529 Protection provided by enclosures for electrical
adapted to control systems by means of self-tuning. Outstanding DIN VDE 0470, part 1 equipment (IP code)
control performance is achieved by means of DIN EN 60204-1 /
GOSSEN METRAWATT’s own dead-beat PDPI algorithm, which Machine safety
VDE 0113, part 1
even assures outstanding results for critical applications. Com- IEC 61326/ Electromagnetic compatibility (EMC)
munications are possible via a number of standardized fieldbus EN 61326
interfaces, or by means of the integrated service interface. IEC 60584 / EN 60584 Thermocouples
Advantages for your quality management system include the (DIN 43710)
integrated data logger for all actual values and setpoints, an alarm IEC 60751 / DIN EN 60751 Industrial platinum resistance thermometers and
history for error status entries with time stamp, and alarm value platinum resistance elements, Pt100 sensors
reports. DIN EN 50022 Mounting rails, top-hat rail with 35 mm width for snap
The controller’s range of applications includes multi-channel mounting devices
temperature control for plastics processing machines (injection
molding, extrusion, blow molding and hot runner technology),
semiconductor manufacturing processes, industrial and
laboratory ovens, textile machinery, climatic test cabinets,
environmental simulation chambers, pharmaceuticals, food and Characteristic Values
beverage vending machines, packaging and printing machinery,
temperature stabilizers and similar thermal processes.
The specially developed control algorithm (compensation for non-
linear water evaporation characteristics) allows for water-cooled Inputs / Outputs
extruder zone applications.
Sampling Rates 10 ms per channel

Terminal Assignment Thermocouple Measurement Input / Linear 50 mV

Thermocouples per IEC 60584 / EN 60584 / DIN 43710
type J, L, K, R, S, B and N, C
Auxiliary voltage Measuring Range linear 0 ... 50 mV
Binary inputs / outputs (I / O)
Nominal Input
Range for Type J, L 0 ... 900 °C
K –100 ... 1300 °C
R, S 0 ... 1750 °C
B 0 ... 1800 °C
N 0 ... 1300 °C
C 0 ... 2300 °C
Service Accuracy / Error < 0.7% of measuring range span
interface
for types J, L, K, N
< 2.0 % of measuring range span for
Profibus-DP types R, S, for type B from 600 °C and
greater
alternative

(Version F2)
Connection Resolution 0.1 K
CAN / RS-485
(Version F1/F3/F4/F7/F8) Cont. AC Overload 50 / 60 Hz / 50 V AC, sinusoidal
Bus connection resistance DC 1 V DC
on / off
Input Impedance > 50 k
Reference junction connection Error Messages for sensor breakage or polarity reversal, or
temperature outside of measuring range
Optional additional outputs

Version A0 Reference Junction Measurement Input

not assigned
Nominal Input Range 0 ... 70 °C
Version A1
Sensor Accuracy 2K
Heating circuit monitoring Reference Junction two-step

Binary inputs/outputs (I/O)

Version A2

Binary inputs/outputs refer to

minus (–) of auxiliary voltage
Contiuous outputs (AO)

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 R6000
8-Channel Controller
Pt100 Resistance Thermometer Measurement Input, Continuous Outputs
2 or 3-Wire Connection Output Function Actuator Output for Proportional Actuator
Pt100 per IEC 60751 / DIN EN 60751 Output Quantity 0 (2) ...10 V at > 1 k load,
Measuring Range 18 ... 320  0 (4) ... 20 mA at < 300  load
Nominal Input Range –200 ...850 °C Resolution 0.1% of upper range value
Sensor Current < 0.2 mA Accuracy < 3% of upper range value
Offset Compensation possible by means of parameter entry
Accuracy / Error < 0.5 % of measuring range
Resolution 0.1 K Status Displays
Cont. AC Overload 50 / 60 Hz / 50 V AC, sinusoidal Power on green
DC 1 V DC Run green
Input Impedance 13 k Bus communication 3 mm dia. LEDs
Cable Resistance active yellow on metal housing
(both directions) 2-wire connection: 0 ... 30 , adjustable Error red
3-wire connection: 0 ... 30 , compensated
Binary Inputs / Outputs
Error Messages for sensor breakage or short-circuit, or Active yellow SMD LEDs at clamp-
temperature outside of measuring range type terminal blocks
Sensor Input Configuration
Sensor type is selected separately for each input via the interface.
Switching between thermocouple and Pt100 is accomplished with the
Control Performance
DIP switch at the left-hand side of the housing. Setpoints
Setpoint limiting Adjustable upper and lower setting limits
Heating Current Monitoring Input
Proxy setpoint Activated via binary input or bus, adjustable value
Measuring Range 1 A AC (direct connection of a
Setpoint increase Activated via binary input or bus,
commercially available measuring transducer) (boost) value and maximum duration can be configured
Resolution < 0.1% of upper range value Ramp function Specification of a gradual temperature change in degrees per minute
Accuracy typically < 5% of upper range value (separate for rise and Activated by means of:
Reproducibility < 1% of measurement value + 0.5% of upper fall) – Turn on auxiliary voltage
range value – Change current setpoint value
– Activate proxy setpoint
Heating Voltage Monitoring Input – Switch from manual to automatic operation
Measuring Range 10 ... 50 A AC (direct connection of a
Configurable Control Modes
commercially available measuring transducer)
Resolution < 0.1% of upper range value Not in use No error monitoring
Accuracy typically < 5% of upper range value Measuring
With limit value monitoring
Reproducibility < 1% of measurement value + 0.5% of upper Actuator
range value Limit transducer Two / three position controller without time response
PDPI controller Heating Cooling
Binary Inputs / Outputs Can be combined as desired
Output Function Active switching outputs, Switching Switching
supplied directly from auxiliary voltage Hot-runner Water cooling
Function Switching output (heating/cooling, or more/less Continuous Continuous
for step-action controllers)
Alarm output Step Step
Read-Out Cycle Adjustable within a range of 0.1 ... 300 s No heating No cooling
Nominal Range Proportional actuator Two / three position controller without time response
of Use H signal: U  auxiliary voltage, – 0.5 V In addition to fixed value control, the PDPI controller also includes
I 500 mA differential, cascade and switching controller functions.
Total current 3 A per device
L signal: < 0.1 mA Control Channel Combinations
e.g. for driving up to 3 commercially available
Differential controller The temperature difference is corrected.
semiconductor relays (SSR) in series
Cascade controller The setpoint from one or more control channels is manipulated dynamically.
Input Function Read back output status, external control of
PLC etc. Switching controller Depending upon operating state, a control loop with only one actuator
can be controlled at two different (temperature) measuring points.
Nominal Range
of Use H signal: > 14 V Ratio controller 2 controlled variables are controlled at a ratio that is fixed by a setpoint
value. To this end, the master variable is determined from the product of the
8 ... 16 mA at 24 V setpoint value divided by a thousandth and the actual value of the partner
L signal: < 7 V / < 0.2 mA channel. An activated setpoint ramp influences the master variable. The
Overrange Limit controller type of the partner channel can be selected independently, e.g.
H, L Signal Continuous short-circuit, interruption fixed-value control.

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R6000
8-Channel Controller
Self-Optimization Monitoring Functions
Can be activated from any operating state.
Control parameters can be changed. Limit Value Monitoring
Two upper and two lower limit values can be configured per
channel.
2 point optimization Alarm memory and actuation suppression can be set up.
3 point optimization

Hysteresis
Setpoint

Actual
Upper Value
Lower Limit Value
Limit Value

Lower Limit Value Upper Limit Value

Fig. 2 Schematic Representation of Relative Limit Value Monitoring

Optimization Optimization Heating Current Monitoring

of heating of cooling
Heating Current Monitoring Permanently installed
Start optimization
Heating Current Acquisition With external, commercially available
Fig. 1 Control Performance with Self-Optimization current transformer
measurement of the total current of all 8 channels
measurement of the total current of up to 24
channels possible with a transformer
Alarms Nominal value transfer To be initiated automatically via the bus
Compensation of
All errors and alarms for all channels, I/Os and functions can be current fluctuation By measuring heating voltage
accessed separately via the bus or the service interface.
Error messages for
Selected errors and alarms can be read out to binary outputs.
– Antivalence Actuator signal OFF + heating current ON
Selection and assignment to a specific output can be configured
Actuator signal ON + heating current OFF
as desired.
– Actual current value less than Dip below nominal heating current value by
nominal value more than 5% + 0.1 A with actuator signal ON
Channel-Specific Alarms
• Broken sensor, reversed polarity Heating Circuit Monitoring
• Two upper and two lower limit values, relative and absolute Without external transformer, without additional parameters
• Heating current / heating circuit errors Configurable Heating circuit monitoring active / inactive
• Adaptation errors Error messages for 100% heat without rising temperature, i.e.
short-circuited thermocouple,
Device-Specific Alarms interrupted heating,
• Hardware errors no sensor in heating circuit
• Overloading of the measurement inputs
• Reference junction errors
• I/O errors
• Mapping errors
• Parameter errors

Alarm History
The alarm history includes 100 error status entries with the
respective time stamps. Recording is started over each time the
device is reset, and data are lost if auxiliary power fails.
After memory has been filled to capacity with 100 entries, the
oldest entry is deleted each time a new one is recorded.
Data can be accessed via the RS 232 service interface and via
bus (CAN-Bus, Profibus-DP, RS485-Modbus).

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 R6000
8-Channel Controller

Hot Runner Control Functions Power Limitation

Actuating Circuit With this function it is possible to prevent peaks in the power
consumption of the heaters and/or to limit the total current
Actuation with a reduced manipulating factor and dwelling at a consumption.
specific actuation setpoint serves to dry out hygroscopic heating
The positioning output of the heaters of all 4/8 channels is
elements.
synchronized and the heaters are activated in a staggered pattern
to ensure that only a minimum number of heaters are active at the
Group Actual Value Control – Synchronous Heat-Up
same time.
Synchronous heat-up prevents thermal stress by minimizing
actual value differences. Settings
If self-optimization has been started, it takes actual value 0% function inactive, power peaks possible in regular operating mode
management into consideration, as well as the actuating circuit. 100% Avoidance of power peaks, actuation at full throttle;
Synchronous heat-up is also possible via several control modules. Advantage: This function is also active when power limita-
tion has been set to 100% so that all 4/8 channels pro-
Boosting – Temporarily Increased Setpoint duce full heat during actuation. However, current loading
Temporarily increasing the setpoint frees clogged mould nozzles is more evenly spread at the operating point, thus avoiding
of “frozen” material remnants. power peaks.
X% Current limitation, a maximum number of 1 to 7 heaters of
a total of 8 is simultaneously activated, i.e. avoidance of
power peaks during regular operation; power is limited
during actuation.

Data Interfaces
Zone 1 (slow) Type Service Fieldbus Interface
Zone 2 (fast) Interface
Interface RS 232 Profibus DP CAN / RS 485
CANOpen
Maximum number 1 32 100 32
Dwell time: 2 min. Optimization Boost duration: 2 min. of devices
is performed Range of addresses – 0 ... 126 0 ... 127 0 ... 254
Start self-optimization, Binary input for boosting is active
group actual value control, Transmission speed 9.6 or 19.2 9.6 kBaud ... 10 kBaud ... 9.6 or 19.2
actuating circuit: 30% without kBaud 12 MBaud 1 MBaud kBaud
sensible control parameters
Protocol per EN 60870 EN 50170 IEC 1131 EN 60870
CANOpen Modbus/
HB-Therm/
DIN 19244
Connection 9-pin D sub 9-pin D sub 4-pole screw terminal
Mapping for Checking Sensor and Heater Assignments
Bus Address Selection
This function is used to test for correct wiring of the heater and
the sensors. Assignments can be checked when the machine is The bus address is selected with the DIP switch at the front panel.
started up before initial heat-up. Testing is conducted in several
phases in order to determine whether or not the temperature Service Interface
changes at the individual channels coincide with the actuating A laptop or a notebook can be connected to the RS 232 interface
signals. If an error is detected, all actuating outputs remain for service purposes.
inactive until the error has been acknowledged.
Profibus DP Interface with Protocol per EN 50170
The R6000 is equipped with a Profibus DP interface for
Data Logger communication with a master computer or a PLC. Baud rates of
up to 12 Mbit per second are supported.
The data logger has enough capacity for 3600 sampled value Device Database File (DDBF)
pairs including actual values and manipulated variables for all 8
channels. The file required for configuring the Profibus DP (DDBF, multi-
channel Profibus DP) can be downloaded free of charge from the
Recording is started over each time the device is reset, and data GMC-I Messtechnik GmbH website
are lost if auxiliary power fails. (http://www.gossenmetrawatt.com).
After memory has been filled to capacity with 3600 entries, the
oldest values are deleted as new ones are recorded.
Data can be accessed via the RS 232 service interface and via
bus (CAN-Bus, Profibus-DP, RS485-Modbus).

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R6000
8-Channel Controller
CAN Bus Electrical Safety
The CANopen protocol is used for communication.
ESD File Standard IEC 61010-1 / EN 61010-1 / VDE 0411, part 1
The ESD file which is required for project engineering can be Safety class II
downloaded from the Internet at: http://www.gossenmetrawatt.com. Overvoltage category CAT II
Fouling factor 2
RS 232 / RS 485 Interface, Modbus Protocol Protection IEC 60529 / EN 60529 / VDE 0470, part 1
The Modbus protocol is used for communication with control Housing IP 20
terminals or a PLC. PCB IP 10
The RTU mode and conformity class 0 (read and write words) are Terminals IP 20
utilized by the R6000.
Attention: The instrument is not equipped with an integrated
circuit breaker.
Auxiliary Power
A completely separate safety power supply unit is to be used for Electromagnetic Compatibility
operating the controller.
Nominal Value 24 V DC Interference Emission IEC 61326/EN 61326
Nominal Range of Use 18 V ... 30 V DC
Power Consumption Max. 10 VA, typically 6 W (without load) Interference Immunity IEC 61326/EN 61326
Test type Standard Test Severity Criterion
ESD EN 61000-4-2 4 kV contact discharge B
Reference Conditions 8 kV atmospheric discharge B
E field EN 61000-4-3 10 V / m 80 ... 1000 MHz A
Reference Quantity Reference Condition Burst EN 61000-4-4 2 kV at all connector cables B
Auxiliary voltage 24 V DC  1 V Surge EN 61000-4-5 1 kV symmetrical A
Superimposed alternating sinusoidal, or sinusoidal half-waves: 0.1 V AC 2 kV asymmetrical A
voltage HF EN 61000-4-6 3V 0.15 ... 80 MHz, all terminals A
Allowable common-mode to electrically connected
voltage inputs: 0 V DC / AC
Ambient temperature 23 C 2 K
Reference junction temperature 23 C 2 K
Ambient Conditions
Warm-up time 3 minutes Annual mean relative humidity, no condensation 75%
Measuring inputs Thermocouple, low-resistance termination:  10  Ambient temperature
Pt100: 110 10  0 C ... + 50 C
– Nominal range of use
– Operating range 0 C ... + 50 C
– Storage range – 25 C ... + 70 C

Influencing Quantities and Influence Error

Influencing Quantity Nominal Range of Use Maximum Influence Error Mechanical Design
Ambient temperature
– Thermocouple / Pt100 0 C ... + 50 C 0.05% MRS 1) /K Housing Sheet metal / plastic per UL-V0
– Reference junction 0 C ... + 50 C 0.1 K / K Dimensions Including
Cable resistance Terminal Blocks H x W x D: max. 182 x 109 x 78 mm
R = 0 ... 200  0.1% MRS 1) / 10  Weight Approx. 0.6 kg including terminal blocks
– Thermocouple
R = 0 ... 30  approx. 3 K / 
– Pt100, 2-wire Connectors Terminal blocks
R = 0 ... 30  (adjustable)
– Pt100, 3-wire 2 K / 10  for wire cross-sections to 2.5 mm2 or
Warm-up influence 3 minutes 1 % double wire-end ferrules for 2 x 1.0 mm2
1)
Mounting Integrated
MRS = measuring range span
for top-hat rails per DIN EN 50022,
35 x 7.5 mm or 35 x 15 mm

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 R6000
8-Channel Controller

Dimensional Drawing

All dimensions in mm

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R6000
8-Channel Controller

Order Information Accessories

Description Article Number / Feature Description Article Number
8-channel controller with installation instructions R6000 Two-step reference junction Z306A
Inputs / Outputs Operating instructions German Z307A
16 binary inputs / outputs A0 English Z307B
20 binary inputs / outputs A1 French Z307C
16 binary inputs / outputs, 4 continuous outputs A2 Italian Z307D
Connectors Modem cable for connection of service interface GTZ3241000R0001
Screw terminal blocks D0
Bus Interface
CAN / CANOpen F1
Profibus DP F2 R6KONFIG Configuration Tool
RS-485 / Modbus protocol F3 The R6000 can be fully configured with this tool. All values are
RS 485 / EN 60870 protocol F4
uploaded and downloaded via the serial interface. Cyclically
occurring values such as actual values, control variables, heating
RS 485 / HB-Therm protocol F7 current and alarms can be visualized, recorded and documented
RS 485 / DIN 19244 protocol as R7000 F8 online.

Edited in Germany • Subject to change without notice • A pdf version is available on the internet

Phone +49 911 8602-111

GMC-I Messtechnik GmbH Fax +49 911 8602-777
Südwestpark 15 E-Mail info@gossenmetrawatt.com
90449 Nürnberg • Germany www.gossenmetrawatt.com