Samson TROVIS 5400 Series Service manual

Series 5400
District heating controller
TROVIS 5430
Edition July 1997
Firmwarerelease1.12
Mounting and operating instructions
EB 5430 EN
Figure1⋅TROVIS5430

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notesfortheuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Technicaldata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Resistancevaluesofsensors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Installingthecontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installingthesensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Electricalconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Generalnotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Connecting the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Connectingthe sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Connecting the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Connectingthe pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Terminalconnection diagrams . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Descriptionof controller functions . . . . . . . . . . . . . . . . . . . . . 11
4.1 Optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Flashadaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Reduced operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Summertimeoperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Delayedoutdoortemperature adaptation . . . . . . . . . . . . . . . . . . 13
4.6 Automaticclockreset,summertime/wintertime . . . . . . . . . . . . . . . . 13
4.7 Public holidays and vacations . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8 Thermaldisinfection of drinking water storage tank . . . . . . . . . . . . . . 14
4.9 Returnflow temperaturelimiting . . . . . . . . . . . . . . . . . . . . . . . . 14
4.10 Buildupofcharging temperature via the return flow sensor with . . . . . . . . 15
theheatingloop switchedoff
4.11 Limiting of controldeviationfortheOPENsignal . . . . . . . . . . . . . . . 15
4.12 Forcedcharging of the drinking water storage tank . . . . . . . . . . . . . . . 15
4.13 Room sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.14 Frostprotection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.15 Sensorfailure /operation errors . . . . . . . . . . . . . . . . . . . . . . . 16
4.16 Forcedactuationofpumps . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.17 Masterswitchoverforheating upofdrinking waterin
storagetank chargingsystem . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.18 Monitoringof aflowmaximum temperature forheatingupof drinkingwater . . . 17
5. System diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Systemcodenumber1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Systemcodenumber2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Systemcodenumber3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Systemcodenumber4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Operating mode selection . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 The operating levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7. Commissioning and adjusting the controller . . . . . . . . . . . . . . . . . 35
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.1 Systemcodenumberadjustment . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.2 Functionblockadjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Codenumbersetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1.3 Functionblock lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.4 Sensorcalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Parameter entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.1 Defaultvalue adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.2 Entry or modificationofuserdata - overview . . . . . . . . . . . . . . . . . 41
Heatingcharacteristicsandtemperatures . . . . . . . . . . . . . . . . . . 41
Heatingutilization periods . . . . . . . . . . . . . . . . . . . . . . . . . 44
Timedata,heating updrinkingwater . . . . . . . . . . . . . . . . . . . . 47
Timedata,circulationpump . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjustmentof currenttime, dateandyear . . . . . . . . . . . . . . . . . . 48
Publicholidays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Vacations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8. Datasheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The device may only be installed and put into operation by specialist per-
sonnel familiar with installation, commissioning and operation of this pro-
duct.It isassumedthat the device istransported andstoredcorrectly.
The controller is intended for use with high-voltage systems. For connection
andmaintenance therelevantsafety regulationsmustbe observed
!
3

1. General
The digital heating and district heating controller TROVIS 5430 is for weather-sensitive flow
temperature control of heating systems, i.e. by way of a heating characteristic the flow tempera-
ture of a heating loop is regulated in such a way that the desired room temperature is adjusted,
independent of the outside temperature. The return flow temperature can be limited depending
on the outside temperature. Furthermore, the controller is capable of regulating heating up of
drinkingwater.
The controller reads the respective temperature via a sensor and relays it to thecentral processor
via corresponding input units. This modulates a control signal for the closed control loop accor-
ding to the adjusted setpoint value. Depending on the configuration, the output unit converts this
signal into a three-step or two-step signal. In addition, the controller controls the heating circula-
tionpump, the heatexchangerchargingpumpas well asthestorageloading pump.
Validityof these mounting and operating instructions
asof firmware release 1.12
(currentfirmware release appearsfor 2 secs. whenpower isswitchedon)
Modifications to firmware release 1.01:
Supplementtosystem 4
1.1 Notes for the user
Theinstallation of the controller described in the followinganditselectricalconnections aretobe
carriedoutby authorized personnelonly.
The adjustments concerning the configuration described in chapter 7 also require a specialist
knowledge of heating systems and should only be carried out by a specialist. The function des-
criptionsandsystem configurations described inchapters4 and 5arealsointended for his use.
Commissioning of the controller is normally carried out by the specialist - all adjustment data
shouldbeenteredin thedatasheet inchapter8.
Temperature values and time programs are preset for the controller as default values and can be
alteredbythe user during commissioningor later on inchapter7.2(parameter entries).
4

1.2 Technical data
Inputs Accordingtoselected systemcodes,
2-phase circuit
Sensorinputs Maximumof 7 configurableinputs for sensors
(PTCorPt 1000)
(Heating/drinkingwaterloop)
2flowtemperature sensors
1room temperaturesensor
1outdoortemperaturesensor
1returnflow temperaturesensor
2storagetemperature sensors
Binaryinputs Storagethermostat
Additional inputs Room control device for adjusting room temperature
andselecting operatingmode,potentiometer
Outputs Accordingto selectedsystemcode number
Controlsignal Three-stepsignals:20to250 V~, 0.5 A~
On-offsignal:20 to 250 V~, 0.5 A~
NoDCvoltage circuits!
Binaryoutputs 4outputsforcontrolling pumps
Non-isolated: 230 V~, 2A~
Auxiliary power 230 V~ (+10 %/–15%),48to 62 Hz
Powersupply Approx.2VA
Temperaturerange 0to 50 °C (operation),–10to60 °C (storage)
Degreeof protection IP40 accordingtoIEC529
Classofprotection I accordingto VDE 0106
Degreeofcontamination 2 accordingto VDE 0110
Overvoltage category II accordingtoVDE0110
Humidity rating F accordingto VDE 40040
Noiseimmunity According to EN50082part 1
Noiseemission According to EN 50081part 1
Weight Approx. 0.6 kg
5

1.3 Resistance values of sensors
Resistance thermometer with PTC measuring element
Sensorresistanceelements(with controllerdisconnected)
Sensor for outdoor temperature type 5224, for flow and return flow temperature type 5264,
5265,forstoragetanktemperaturetype 5264
°C –20 –10 0 +10 +20 +25 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
Ω694 757 825 896 971 1010 1050 1132 1219 1309 1402 1500 1601 1706 1815 1925
Room control device type 5244 (remote control)
Switch at"Clock"position
Terminal1 and 2 °C +10 +15 +20 +25 +30
Ω679 699 720 741 762
Resistance thermometer with Pt 1000 measuring element
Sensor for outdoor temperature type 5227, for flow and return flow temperature type 5207-21,
5207-26, 5207-27, 5277 (thermowell required) and 5267 (contact sensor with 3 m cable), for
storagetanktemperaturetype5207-46, 5207-47 and 5207-48
Sensorforroomtemperaturetype5257
°C –35 –30 –25 –20 –15 –10 –5 0 5 10
Ohms 862.5 882.2 901.9 921.6 941.2 960.9 980.4 1000.0 1019.5 1039.0
°C 15 20 25 30 35 40 45 50 55 60
Ohms 1058.5 1077.9 1097.3 1116.7 1136.1 1155.4 1174.7 1194.0 1213.2 1232.4
°C 65 70 75 80 85 90 95 100 105 110
Ohms 1251.6 1270.7 1289.8 1308.9 1328.0 1347.0 1366.0 1385.0 1403.9 1422.9
°C 115 120 125 130 135 140 145 150
Ohms 1441.7 1460.6 1479.4 1498.2 1517.0 1535.8 1554.5 1573.1
6

2. Installation
2.1 Installing the controller
The controller consists of the controller housing with electronics and a housing rear panel with
terminalstrips.The housing rear panelcanbe ordered as a flatordeepversion.
To connect electrically, the front screws must be loosened and the controller housing must be se-
paratedfromthe rear panel.
In the case of a wall mounting, the housing rear panel must be mounted on a wall using three
screws.Hole spacing isgivenindiagram 2.
In the case of a panel mounting, the controller housing is inserted through the panel section and
the enclosed screw brackets inserted on the left and right housing sides (if necessary, turn out
screw completely before inserting). Then turn the screws in until the ends are firmly in contact
withthe rear sideofthepanel.
Thepanelsectionis138+1 mm widex92+0.8 mmhigh.
Figure2⋅Dimensiondiagramcontroller
16.5
63.5
Mounting bolts Screwedbracket
flat
Rearpaneldeep Rear panel flat
deep
7

2.2 Installing the sensors
2.2.1 Outdoor sensors
Mountoutdoor sensorsusingtwo screwsina suitablelocation onanoutside wall.Ensure thatthe
sensor is not mounted above any warm air exits (windows, ventilation slats etc.). In the case of a
detachedbuilding,ifpossible,mountthesensoronthe wall nexttothe preferred livingarea.
2.2.2 Flow/return flow sensor
Mount the sensor as a duct temperature sensor or as a contact sensor in an easily accessible lo-
cationin the vicinityoftheheat exchanger.
Duct temperature sensor: Insert the duct temperature sensor in an existing thermowell and push
inas farasit willgo.
Contact sensor: Remove insulation in the area of the flow line where the sensor is tobe mounted
and clean the pipe to the bare metal. Press the sensor firmly onto the pipe and fasten securely
usingthe accompanyingtensioner.
2.2.3 Room sensor
Mount the sensor in a suitable location on the wall, approx.150 cm high. Onno account should
aircirculationbe impeded bycupboards,curtains orsimilarobjects.
3. Electrical connections
3.1 General notes
When laying cables and connecting the controller, VDE regulations and local electric
company regulations must be observed. For this reason, the work must be carriedout
by a specialist.
Sensor and mains lines must be inseparate cables. If contactors are in the vicinity of the control-
ler or if inductive consumer circuits exist nearby, then these mustbe wired with noisesuppression
capacitorsto avoidinterference withthecontroller.
Radio interference suppression: The controller type 5430 with SAMSON actuators is interfe-
rence-suppressed according to EN 50081 part 1 and 50082 part 1 If other actuators are used,
or if other actuators with sources of radio interference are additionally used in a system, then the
operator/persons installing a non-standard system must, in compliance with legal duties con-
cerning radio interference suppression, ensure that the entire system complieswith the demands
inaccordancewiththeabove-listedstandards.
3.2 Connecting the controller
Electrical connections must be carried out in accordance with the system code number predefi-
ned in the configuration (see chapter 7) according to the terminal diagram, figures 3 to 6. For
the purpose of feeding cables, holes should be made at the locations marked on the housing
rearpaneland the enclosed cableglandsinserted.
3.3 Connecting the sensors
Connect cables with a minimum cross-section of 2 x 0.5 mm2at the terminal strip of the housing
rearpanel.
!
8

3.4 Connecting the actuator
Wire cables as humid area cables with a minimum cross-section of 1.5 mm2to the terminals of
the controller output. When commissioning, it is necessary to check the direction of rotation, i.e.
whetherconnections have been made correctlyby positioningtheoperatingswitch to + and-for
openingandclosingthe valve.
3.5 Connecting the pumps
Connect all cables with a minimum of 1.5 mm2to thecontroller terminals according to the corre-
spondingcircuitdiagram(system1,2,3 or 4).
3.6Terminal wiring diagrams
The terminal wiring diagrams listed in the following (figures 3, 4, 5 and 6) contain all possible
input and output connections for the respective system code number. If input or output connec-
tions are to remain unassigned, then this must be defined in the configuration, chapter 7.1 (level
CO1toCO SYS).
Legend:
FG Potentiometer (terminal3on room controldevice type 5244)
RF Roomsensor (terminal 1 onroom controldevice type 5244)
AF Outdoorsensor
RüF Returnflowsensor
VF Flowsensor
GNDF Sensor earth
UP Circulationpump
SLP Storageloadingpump
ZP Circulationpump
PE Groundingconductor
NRK andL RK powersupplyactuator
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE NRK
LRK
UP
GNDF
+
–
312
12 11
GNDF
Option
Type
5244
Figure3
Systemcode number1
9

Figure5
Systemcode number3
Figure6
Systemcode number4
Figure4
Systemcode number2
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE N
RK
L
RK
UP
+
–
312
SF 2
SF 1
SLPZP
GNDF
12 11
GNDF
Option
Type
5244
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE N
RK
L
RK
UP
GNDF
+
–
312
SF 2
SF 1
SLPZP
TLP
VF 2
GNDF
12 11
Option
Type
5244
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE NRK
LRK
UP
GNDF
+
–
312
SLPZP
TLP
VF 2
GNDF
12 11
Option
Type
5244
10