Samson TROVIS 5100 Service manual

Automation System TROVIS 5100
Control and Processing Unit
TROVIS 5171
Mounting and
Operating Instructions
EB 5171 EN
®
Electronics from SAMSON
Firmware version 1.1x
Edition November 2005

Disclaimer of liability
We are constantly developing our products and therefore, reserve the right to change the
product or the information contained in this document at any time without notice.
We do not assume any liability for the accuracy or completeness of these mounting and
operating instructions. Moreover, we do not guarantee that the buyer can use the product for
an intended purpose. SAMSON rejects any liability for claims by the buyer, especially
claims for compensation including lost profits or any other financial loss, except the damage
was caused intentionally or by gross negligence. If an essential term of the contract is
breached by negligence, SAMSON’s liability is limited to the foreseeable damage.
Safety instructions
4The device may only be assembled, started up or operated by trained and
experienced personnel familiar with the product. Proper shipping and
appropriate storage are assumed.
4The device has been designed for use in electrical power systems. For wiring
and maintenance, you are required to observe the relevant safety
regulations.
2EB 5171 EN
Disclaimer of liability

Contents
1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Operating keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Displaying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Setting the controller time . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Setting the times-of-use . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Activating and deactivating functions. . . . . . . . . . . . . . . . . . 13
2.3 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Entering the key number. . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Configuring the universal inputs . . . . . . . . . . . . . . . . . . . . 16
2.6 Resetting to default values . . . . . . . . . . . . . . . . . . . . . . . 18
3 Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 System-wide functions . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Automatic summer time/winter time changeover . . . . . . . . . . . . 20
5 Operational faults . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Error status register . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Fault alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.1 Sending SMS text message in case of a fault . . . . . . . . . . . . . . 22
5.2.2 Sending fax in case of a fault alarm . . . . . . . . . . . . . . . . . . 23
6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 RS-232-C system bus interface. . . . . . . . . . . . . . . . . . . . . 25
6.2 System bus interface with RS-232/RS-485 cable converters
(for four-wire bus). . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Description of communication parameters to be adjusted . . . . . . . . 27
6.4 Meter bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4.1 Activating the meter bus . . . . . . . . . . . . . . . . . . . . . . . . 29
7 LON communication . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Sending outdoor temperatures and the controller time. . . . . . . . . . 31
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1 Function block list . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Contents

10.2 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3 Sensor resistance tables . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.5 Customer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Frequently used abbreviations. . . . . . . . . . . . . . . . . . . . . 54
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Contents

1 Operation
The TROVIS 5171 Control and Processing Unit (Programmable Logic Controller = PLC) is
freely programmable. The controller is delivered without an executable program in the mem-
ory. The application must be developed separately for the desired purpose on the PC using
ISaGRAF®(programming as in DIN IEC 61131-1) and then transferred to the controller.
On start-up, after transferring the generated application, the current time and date must be
set in the controller (–> section 1.4).
1.1 Operating elements
1.1.1 Operating keys
The keys are located in the front panel of the PLC and protected by a Plexiglas door.
Changeover key
(press with pen or other pointed item)
Switch between levels (–> inside of back cover)
Reset key
(press with pen or other pointed item)
Reset freely accessible parameters and function blocks to their default values
(factory settings)
Cursor key(s)
– Navigate in levels (also in application developed with ISaGRAF®)
– Change values
Enter key
– Open levels (also in application developed with ISaGRAF®)
– Activate editing mode for parameters and function blocks
– Confirm entered settings
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Operation

1.2 Display
After switching on and during operation, the PLC is in the operating level. When the applica-
tion is active, either the name of the application or a customer-specific menu is displayed.
This menu can be customized to meet your specific needs in the ISaGRAF®application.
If no application has been loaded or activated,
STOP is displayed.
If an active connection between the PC and PLC exists, the icon is displayed.
In the info level, the current controller time and operating data are displayed. The binary in-
puts and outputs are represented by black squares below the row of numbers. Icons indicate
the operating status of the PLC.
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Operation
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
BO BI START STOP
Fig. 1 · Icons
Binary inputs/outputs
Application active
No application
loaded in PLC/
application stopped
Vacation periods
Public holidays
Time-controlled
operation
Status binary input
Status binary output
Fault alarm
Manual operation
Connection PC – PLC
The icons can also be displayed with the application created in ISaGRAF®.

1.3 Displaying data
The states of the inputs and outputs, the available memory as well as information on fault
alarms and communication can be retrieved in the info level.
The following levels provide information on the device status:
4FREI _ _ _ KB: Free memory; for programming with ISaGRAF®
Bar graph indicates the cycle time:
Block 1 = 1 ms, Block 2 = 2 ms, Block 3 = 4 ms,
Block 4 = 8 ms, ...
4INF1 AI: Measured value of connected analog inputs (AE1 to AE17);
depending on configuration of universal inputs in CO6
[mA, °C, V]
BI: Status of the binary inputs (ON/OFF)
AO: Output value of the two analog outputs [V]
BO: Status of the binary outputs (ON/OFF)
4INF2…6 Do not exist
4INF7 LON communication
(in devices with LON interface and CO7 -> FB00 = ON)
4INF8 FSR: Error status register
BRUCH: Sensor failure information
4INF9 Modbus/meter bus communication
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Select END .
Switch to info level.
Display shows: controller time
Select info level (–> Fig. 6 on page 53).
Open info level.
Select data point.
Exit info level:
Select
END .
Return to operating level.
Display shows: name of the application or customer-specific menu
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Operation

1.4 Setting the controller time
The current time and date need to be set immediately after start-up and after a power failure
lasting more than 24 hours.
The time is set in
PA5 parameter level.
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Open PA5 parameter level.
Display shows: controller time
Activate editing mode for controller time.
Change controller time.
Confirm changed time.
Display shows: date (day.month)
Activate editing mode for date.
Change date.
Confirm date.
Display shows: year
Activate editing mode for year.
Change year.
Confirm year.
Display shows:
Zeit 1
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Operation
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Select END .
Exit PA5 parameter level.
Select
END .
Exit configuration and parameter level.
Display shows: controller time
Select
END .
Switch to operating level.
Display shows: name of the application or customer-specific menu
Note!
If no key is pressed for two minutes, the PLC returns to operating level.
1.5 Setting the times-of-use
The controller provides 12 times-of-use that can be utilized separately.
Within a specified time-of-use (ZEIT 1 to ZEIT 12), two usage periods can be programmed
for each day of the week. If you do not require all usage periods, the start and stop times of
the idle periods must be set to identical times.
Note!
The behavior of the PLC during and outside the times-of-use is to be determined in the
ISaGRAF®application.
Parameters Default Parameter level/Range of values
Period, day Mo -- So PA5 / Mo -- So, Monday to Sunday
Start time-of-use 1 7:00h PA5 / 0:00h to 24:00h; in steps of 30 minutes
Stop time-of-use 1 12:00h PA5 / 0:00h to 24:00h; in steps of 30 minutes
Start time-of-use 2 12:00h PA5 / 0:00h to 24:00h; in steps of 30 minutes
Stop time-of-use 2 22:00h PA5 / 0:00h to 24:00h; in steps of 30 minutes
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Operation

Proceed as follows: 3s Switch to configuration and parameter level.
Display shows:
PA5
Open PA5 parameter level.
Display shows: controller time
Select desired times-of-use (ZEIT 1 to ZEIT 12), e.g.
ZEIT 1.
Display shows:
ZEIT _
Activate editing mode for selected time-of-use.
Display shows:
Mo -- So (Monday to Sunday)
Select period/day for time-of-use.
Activate editing mode for selected time-of-use.
Display shows:
START ; blinks.
Edit start time (steps of 30 minutes).
Confirm start time.
Display shows:
STOP
Edit stop time (steps of 30 minutes).
Confirm stop time.
Display shows:
START
The second time-of-use is set similarly to the first.
To set times-of-use for each day, repeat the instructions in the fields highlighted in gray.
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Operation
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
START
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
STOP

Note!
Do not use the Mo -- So menu to check the programmed times-of-use.
If this menu is opened after the times-of-use have been set, the usage times programmed for
each day of the week are reset to their default settings.
Select END .
Exit parameter level.
Select
END .
Exit configuration and parameter level.
Display shows: controller time
Select
END .
Switch to operating level.
Display shows: name of the application or customer-specific menu
Note!
If no key is pressed for two minutes, the PLC returns to the operating level.
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Operation

2 Start-up
2.1 Programming
Programming the PLC requires a PC with ISaGRAF®software.
The ISaGRAF®software enables you to program a control system that is tailored to the spe-
cific needs of your plant (ISaGRAF®development environment 1400-7621). Programming
must follow the structures and rules stipulated in DIN IEC 61131-3. The PLC may be pro-
grammed with the languages defined in the standard: Sequential Function Chart (SFC), In-
struction List (IL), Flow Chart (FC), Function Block Diagram (FBD), Ladder Diagram (LD), and
Structured Text (ST).
There are 128 KB of memory available in the PLC for the ISaGRAF®application.
The programmed application is complied to machine code in the PC environment. This code
is then transferred to the PLC over the front RJ-45 jack (connecting cable 1400-7308).
Programming languages:
Sequential Function Chart
(SFC): Used to describe operations of a sequential process with a simple graphic representation
Instruction List (IL): Low-level textual language for logic and arithmetic operations
Flow Chart (FC): High-level language used to visualize the data flow
Function Block Diagram
(FBD): Graphics-based language for building and combining complex functions (logical, arithmetic)
Ladder Diagram (LD): Simple graphics-based language for logical operations (boolean)
Structured Text (ST): High level language similar to PASCAL and C especially designed for
control applications
For operation and application of the ISaGRAF®environment, refer to the documentation in-
cluded in the software package. To enable simple and clear programming, ready-made
functions and function blocks are available from SAMSON.
Note! In ISaGRAF®, internal variables can be assigned (hexadecimal) network addresses.
The status or value of the internal variable is written to the associated holding register and
can be read over Modbus. The PLC holding registers 42001 to 46999 are reserved for this
purpose.
Important! The PLC application must be reloaded after a cold start.
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Start-up

2.2 Activating and deactivating functions
A function is activated over the associated function block. The numbers 0 to 24 in the top
row of the display represent the respective function block numbers. When a configuration
level is opened, the activated function blocks are indicated by a black square on the
right-hand side below the function block number. For more details on function blocks, refer
to section 10.1.
The functions are grouped by topics:
4CO1…4 Do not exist
4CO5 Higher level functions
4CO6 Configuration of universal inputs
4CO7 LON communication
(in devices with LON interface and CO7 -> FB00 = ON)
4CO8 Fault initialization
4CO9 Modbus/meter bus communication
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Select configuration level (–> Fig. 6 on page 53).
Open configuration level.
Select function block.
Activate editing mode for selected function block.
Function block number blinks.
When the display shows
0 0 0 0 , the valid key number must be entered, see sec-
tion 2.4.
Activate function block (FB = ON).
An activated function block is indicated by a black square on the right-hand side be-
low the function block number.
Or:
Deactivate function block (FB = OFF).
Confirm changed settings.
If the function block is not closed, further function blocks can be edited.
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Start-up

Proceed as follows:
Change settings and confirm changes.
If applicable, the following function block parameter is displayed.
Once all parameters have been confirmed, the opened function block is closed.
To set further function blocks, repeat the instructions in the fields highlighted in gray.
Select
END.
Exit configuration level.
Select
END .
Exit configuration and parameter level.
Display shows: controller time
Select
END .
Switch to operating level.
Display shows: name of the application or customer-specific menu
Note!
If no key is pressed for two minutes, the PLC returns to the operating level.
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Start-up

2.3 Changing parameters
Depending on the activated functions, not all parameters listed in the Appendix (–> sec-
tion 10.2) might be available.
The parameters are grouped by topics:
4PA1…4 Do not exist
4PA5 Controller time, times-of-use
4PA6 Does not exist
4PA7 LON communication
(in devices with LON interface and CO7 -> FB00 = ON)
4PA8 Does not exist
4PA9 Modbus/meter bus communication
Proceed as follows:
3s Switch to configuration and parameter level. Display shows:
PA5
Select parameter level (–> Fig. 6 on page 53).
Open parameter level.
Select parameter.
Activate editing mode for selected parameter.
Change parameter.
Confirm parameter.
To set further parameters, repeat the instructions in the fields highlighted in gray.
Select
END .
Exit parameter level.
Select
END .
Exit configuration and parameter level.
Display shows: controller time
Select
END .
Switch to operating level.
Display shows: name of the application or customer-specific menu
Note!
If no key is pressed for two minutes, the PLC returns to operating level.
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Start-up

2.4 Entering the key number
Some functions are protected against unintentional and unauthorized access by a key num-
ber. The key number, which is required to activate and deactivate protected functions, can
be found on page 49. To avoid unauthorized use, remove the page or make the key number
unreadable.
Proceed as follows:
On the display,
0 0 0 0 blinks.
Enter key number.
Confirm key number.
When the correct number has been entered, the function block you wish to change
blinks on the display.
When an invalid key number is entered, the PLC switches to the next configuration
level.
The key number remains active for approximately 5 minutes.
2.5 Configuring the universal inputs
Note!
Connect a 50
Ω
resistor in parallel on using the 0(4) to 20 mA input.
When the inputs (0 to 10 V or 0(4) to 20 mA) are active, use terminal 13 for GND instead
of terminal 10.
17 universal inputs are available. The inputs can be configured to serve as a binary, analog
(0 to 10 V, 0(4) to 20 mA) or sensor input. The hardware must be configured accordingly
(sensor initialization).
The sensor resistance values can be found on page 44.
The following applies:
4CO6 -> Fb00 = ON: Pt 100 and Pt 1000 mixed (default)
4CO6 -> Fb00 = OFF: Pt 100 and PTC mixed
Each universal input can also be configured separately.
The following function block parameters are available: Pt 100/500/1000/2000,
Ni 200/1000/2000, PTC, NTC, OHM (1-2 kΩ ), BE, 0(4) to 20 mA, and 0 to 10 V (model
no. 5171-0003 and higher).
The function blocks FB01 to FB17 correspond to the binary inputs BE1 to BE17 in the wiring
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Start-up

diagram (–> page 37). The function block for the selected sensor is activated and the func-
tion block parameter associated with the type of input signal is selected.
If the temperature values displayed by the PLC deviate from the actual temperatures, the
measured values of the connected sensors can be changed or reset.
When calibrating a sensor, the currently displayed sensor value must be changed such that it
corresponds to the temperature value (reference value) measured directly at the point of
measurement.
Sensor calibration must be activated in CO6 using FB23.
An improper calibration can be deleted by setting FB23 = OFF.
Note!
The tolerance by which a sensor value can be corrected is ±12 °C.
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Select CO6 configuration level.
Open CO6 configuration level.
Select function block FB23.
Open function block FB23.
Select sensor input you wish to calibrate.
Display measured value. Measured value blinks.
Correct measured value.
Use the actual temperature from a thermometer installed directly at the point of mea-
surement as reference value.
Confirm corrected measured value.
Further sensors are calibrated similarly.
Select
END .
Exit configuration level.
Select
END .
Exit configuration and parameter level. Display shows: controller time
Select
END .
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Start-up

Switch to operating level.
Display shows: name of the application or customer-specific menu
2.6 Resetting to default values
All parameters and function blocks that were set without previously entering the key number
can be reset to their default values (factory settings) from configuration and parameter level.
Important!
Certain functions may no longer by available depending on the ISaGRAF®application once
the parameters and function blocks were reset to their default values.
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Load default settings.
Parameters are reset to their default values.
Note!
Function blocks that are protected by the key number will only be reset if the key number is
still active.
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Start-up

3 Manual operation
All outputs are configured in manual operating mode (see wiring diagram in section 9).
Proceed as follows:
3s Switch to configuration and parameter level.
Display shows:
PA5
Select END .
Switch to info level.
Display shows: controller time
Select
Hand .
Open manual level.
Select output:
A01 = analog output 1 (0 to 10 V)
A02 = analog output 2 (0 to 10 V)
B01 = binary output 1
B02 = binary output 2
Activate editing mode for selected output.
Display blinks.
Activate output, increase value.
Or:
Deactivate output, reduce value.
Confirm changes.
The changed values remain valid as long as manual operating mode is active.
Select
END .
Exit manual level.
Select
END .
Switch to operating level.
Display shows: name of the application or customer-specific menu
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Manual operation

4 System-wide functions
4.1 Automatic summer time/winter time changeover
The time is automatically adapted on the last Sunday in March at 2.00h and on the last
Sunday in October at 3.00h.
Function WE Configuration
Summer time/winter time changeover ON CO5 -> F05 = ON
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System-wide functions