Samson Trovis 6400 Service manual

Automation System TROVIS 6400
Compact Controller TROVIS 6494
Edition June 1994 Mounting and operating instructions
EB 6494 E

Contents
1. Description
1.1 Version
1.2 Technical data
2. Installation
3. Electrical connections
4. Operation
4.1 Control panel, displays and operating elements
4.2 Operation of the three levels
4.2.1 Operating level
Modify setpoint W1
Display sensor line breakage
4.2.2 Parameterization level
Determine and modify the control parameters
Open the parameterization level
Proportional-action coefficient
P
(Kp)
Integral-action (reset) time
I
(Tn)
Derivative-action (rate) time
d
(Tv)
Derivative-action (rate) gain
dP
Output variable limits
Y__
and
Y
—
Working point
YP
Limit values
1A
and
2A
Differential gap
1H
and
2H
Duration of switching period and motor operating time
t1
Dead band (neutral zone)
td
Hysteresis
th
4.2.3 Configuration level
Determine and modify controller functions
Open the configuration level
Select input signal
In
Measuring range limits
In__
and
In
—
Decimal point
Ind
Select the current or voltage ranges of controlled variable x with
In0
Unit of temperature
Int
Digital filter
InF
Select the input circuitry of the D (derivative)-action component with
dI
Select setpoint
SP
Setpoint ramp
SPr
Inhibit (HOLD) modification of setpoint
SPH
Lock (HOLD) the MANUAL/AUTOMATIC key
YH
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Contents
Select controller output
Y
Operating direction
Yr
Select the current range of controller output Y with
Y0
Safety output (restart) value
YSt
Limit alarm condition for switching output Y1
Switching output Y1 as break or make contact
Y1C
Limit alarm condition for switching output
Y2
Switching output Y2 as break and make contact
Y2C
Adaption (self-tuning)
AdP
Enter code numbers
CPA
and
CCO
Code number for servicing
Figure, setpoint ramp
SPr
5. Switching outputs
Y1
and
Y2
5.1 Three-step controller with internal feedback (Y = 1)
5.2 Limit contacts
5.2.1 General definition
5.2.2 Assignment of the limit alarm conditions for switching outputs
Y1
and
Y2
5.2.3 Monitor output signal Y
5.2.4 Pulse-modulated on-off controller output at switching output
Y1
and/or
Y2
5.2.5 On-off pulse-modulated controller output with limit alarm
5.2.6 Two pulse-modulated on-off switching outputs
6. Start-up procedure
EEPROM version
6.1 Configure the different controller outputs
6.1.1 Continuous-action controller (
Y
=
0
)
6.1.2 Three-step controller with internal feedback (
Y
=
1
)
6.1.3 Controlled variable x as recorder input (
Y
=
2
)
6.2 Optimize the control parameters
6.3 Adaption (self-tuning)
6.4 Checklist
Figure depicting front view, see folding page on back cover
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1. Description
TROVIS 6494 is a digital controller integrating many sophisticated functions into a single com-
pact module used to automate plants used in industrial applications and process engineering.
Its well-thought functional design, which takes user needs into mind, allows diverse control cir-
cuit arrangements to be configured. TROVIS 6494 can be effectively used in a wide-range of
applications as a either a continuous-action controller, on-off (two-step) controller or three-step
controller with the option of P (proportional), PI (proportional-plus-integral), PD (proportional-
plus-derivative) or PID (proportional-plus-integral-plus-derivative) action.
Self-tuning, a standard option, uses the built-in intelligence capabilities to automatically deter-
mine and set the appropriate control parameters.
Operation of this advanced controller is designed according to the concept of user friendliness
and uses the following three-level operating structure: 1) operating level (standard operation),
2) parameterization level and 3) configuration level.
The first level, the operating level, contains visual displays for standard control operation and
can be accessed at any time, whereas the parameter and configuration levels are protected by
user-definable code numbers. Functions in the second level, the parameterization level, include
modification of control parameters and optimum adaption to the controlled system. Selection of
controller functions is facilitated in the third level, the configuration level.
Controller input options include the following: Pt 100 resistance thermometers, Ni 100 resist-
ance thermometers and standardized current/voltage signals.
The controller’s command variable, to be called the setpoint (SP) in the remainder of this text for
reasons of conformity, can be selected between setpoint W1 and setpoint W2 via a key, or by
means of a binary signal.
Bumpless transfer in the respective operating mode (MANUAL or AUTOMATIC) is facilitated by
means of the MANUAL/AUTOMATIC key.
1.1 Version
This compact controller is delivered in panel-mount design according to DIN 43 700 (dimen-
sions of front frame: 48 mm x 96 mm) as the following versions:
Universal input options:
Ni 100 or Pt 100 resistance thermometer in three-wire circuit, standardized mA/V signals
Standard controller output:
Continuous/on-off/three-step/limit contact
Power supply:
100 to 253 V AC (TROVIS 6494-0111)
20 to 30 V AC (TROVIS 6494-0121)
Connection:
Crimp contacts or optional screw terminals
This manual applies to controllers implementing firmware version 1.00 or later
WARNING
Assembly, commissioning and operation of this controller may only be performed
by experienced personnel.
4

Fig. 1 ⋅Functional structure of controller
W2
ext. BE
SP
4
1,2
2,3
01,2,3
X
+
_
In
In0 InF
Y0
Y
Y
Y0,2
1
0
1,2
0,2
YSt
YH
-
-
YHd
SPr
dP
d
P
P
I+
dI
P
I
YPID
P
Yr
W1
SPh
D
Output analog
0(4) to 20 mA
Y or X
Three-step
on-off
-Switching
-Clocked
for
Y
=
1
————————
Limit contacts
for
Y
=
0,2
MANUAL/
AUTOMATIC
key
Safety output
(restart) value
Operating direction
Setpoint key W1/W2
Inhibition (HOLD) of setpoint modification
On
Setpoint ramp
Digital filter
5

1.2 Technical data
Input options Controlled variable x
d.c. current signal 4(0) to 20 mA Ri = 50 Ω
d.c. voltage signal 2(0) to 10 V Ri > 100 kΩ
Resistance thermometer Pt 100 (three-wire circuit)
Measuring ranges –100.0 to 400.0 °C
–30.0 to 150.0 °C
Resistance thermometer Ni 100 (three-wire circuit)
Measuring ranges –60.0 to 180.0 °C
–20.0 to 90.0 °C
External changeover of the setpoint
Binary input for selection of setpoint W1 – W2 with 24 V d.c.
Signal 0 V →W1; 24 V →W2 (select using
SP
) or
external restart of the setpoint ramp
Controller outputs Standardized output signals
Standardized current signal 4(0) to 20 mA, load RB < 650 Ω
Switching outputs
Y1
and
Y2
a.c. voltage contacts 24 to 250 V a.c./0.5 A
CAUTION:
Never apply d.c. voltage
Power supply 100 to 253 V a.c.
48 to 62 Hz, 7 VA or optionally 20 to 30 V AC/DC 7 VA
Permissible temperature Ambient 0 to 50 °C Shipping and storage 0 to 70 °C
Measuring accuracy Linearity error Zero error Span error
mA, V, Pt 100, Ni 100 0.2 % 0.2 % 0.2 %
Temperature effect Zero error Span error
Pt 100, Ni 100 0.3 % / 10 °K 0.3 % / 10 °K
mA, V 0.2 % / 10 °K 0.2 % / 10 °K
Utilization category
according to DIN 40 040 Humidity rating F
Degree of protection IP 54 (front side), IP 20 (encapsulation)
Power failure All control parameters and configuration blocks are stored in a
non-volatile EEPROM protected against power down (i.e. no-
battery design)
Weight 0.3 kg
6

2. Installation
TROVIS 6494 is smartly engineered as a panel-mount unit, the front dimensions of which com-
pactly measure 48 x 96 mm2. A panel cut-out of 45+0.6 x 92+0.8 mm2is to be fabricated for as-
sembly of the plastic enclosure. After sliding the controller in the panel cut-out, the supplied
clamps depicted in Fig. 3 are to be locked in place at the top and bottom in the accommodating
pins of the enclosure. A screw driver can consequently be used to turn the threaded rods, clamp-
ing the controller’s front frame against the panel.
Fig. 2 ⋅Dimensions in mm (inch)
Fig. 3 ⋅Assembly
48 (1.89)
96 (3.78)
123 (4.84)
111 (4.37)
89.5 (3.52)
Front Front
Pivot 2)
Lock in
place
3)
Screw tight
1)
Inserting on pivot
and turning
7

3. Electrical connections
The easy-to-install compact controller is equipped with plug-type connectors (snap-in contacts)
for lead sizes 0.3 to 0.8 mm2and an insulating diameter of 1.3 to 2.4 mm2or screw terminals
for lines 0.5 to 1.5 mm2. When connecting the electric leads, note the pertinent VDE 0100 regu-
lations and the currently valid regulations mandated by the country where the controller is in-
tended for use.
Wiring information
The signal and sensor leads are to be isolated from those of the controller and power supply.
To avoid measuring errors when radio interference is present, use shielded lines for signals and
sensors.
The power supply lines of each controller are to be led separately to the corresponding distribut-
ing bus bar.
Suppress contactor circuits located in the vicinity against interference using an RC element.
Fig. 4 ⋅Terminal assignment
1C
L N
5F7H5F7H
+_
Y1 Y2
LN
+_
5EDC4C 3
+
-
+
-
2B
+-
mA V
A
B
C
D
E
G
H
1
2
3
4
5
7
8
X1 X2
H7F5C1
X1 X2
mA
A1
+-
51E423C/D A/B
A
B
C
E
F
G
H
1
2
3
5
6
7
8
Snap-in Contacts
Screw terminals
Code
Back
Back
Power supply
100 to 253 V a.c.
or 24 V a.c./d.c. 2 x limit contacts (TRIAC) Three-step switching output
for a current >0.5 A requires
contactors or relays
Note:
Y1 or Y2 can only be operated with
a.c. voltage. Note correct phase
connection of power supply.
Pt 100/Ni 100 4(0) to 20 mA 2(0) to 10 V
Terminals X2
Controller input (controlled variable x)
Binary input BE
0/24 V Controller output (output signal y)
(continuous) 4(0) to 20 mA
Note:
When using a three-step switching output or limit contacts,
the continuous controller output is available as analog output
for controlled variable x.
Terminals X1
8

Fig. 5 ⋅Diagram of connections
WARNING
Always disconnect the power supply lines prior to plugging/removing the plug
connectors.
If this is ignored, the glass fuse Type T63 mA/250 V (order no. 8834-0298) con-
tained on the power board in the device may be required to be exchanged.
5
E
D
4
C
3
C
+
+
I
U
V
mA
PE PE PE
HE
HE
+ - + -
Pt 100
Ni 100
_
_
LN
1C
BE
2B
1
A
F
5
7
H
+
Y
Y1
Y2
_
t
A
PE
PELN
+
_
24 V DC
+ _
+ _
x-Recorder
4(0) to 20 mA
Y1 and Y2 can defined by the user for use
as limit values or motor drive
9

4. Operation
4.1 Control panel, displays and operating elements
1 Controlled variable display (top display)
Controlled variable x, sometimes referred to as the Process Variable PV, is displayed in the
operating level. The value of the selected entry option is can be viewed in the parameteriza-
tion and configuration level.
2 Setpoint (SP) display
The current setpoint is displayed in the operating level. The display mode can be modified
in the following sequence by actuating the operating key (7): setpoint W1, control deviation
(error) XD, output variable Y, setpoint W2.
Configuration blocks and parameters values are presented in both the configuration and
parameterization levels, resp.
3 Control deviation
Whenever xd is greater than 0.9 % or less than –0.9 %, the red LED (light-emitting diode) il-
luminates.
4 Display of switching outputs Y1 and Y2
Two red LEDs display indicate the circuit state of the three-step/on-off controller output, or
the limit alarms.
Fig. 6 ⋅Front view
W1
XD
XD
Y
W2
Y1
Y2
°C
W2
11
1
2
7
5
6
9
8
4
3
10
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