Samson TROVIS 5432 Service manual

Automation System TROVIS 5400
Heating and District Heating Controller
TROVIS 5432
Mounting and
operating instructions
EB 5432-1 EN
Firmware Version 1.00
Edition September 2001
®
Electronics from SAMSON
Fig. 1 ⋅Type 5432

Contents Page
1. Notes for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Control levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Setting options on the display level . . . . . . . . . . . . . . . . . . . . . 9
4.1 Short-term change in room temperature . . . . . . . . . . . . . . . . . . . . 9
4.2 Party mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Holiday mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Setting options on the user level . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Setting the current time and date . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Setting the times-of-use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.1 Reading the set times-of-use . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Setting the reference value for room temperature or the flow temperature
set point for rated and reduced operation . . . . . . . . . . . . . . . . . . . 17
5.4 Viewing the outdoor temperature . . . . . . . . . . . . . . . . . . . . . . . 18
6. Configuration and parameterization . . . . . . . . . . . . . . . . . . . . . 19
6.1 Accessing the installation level . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Setting the function blocks and parameters . . . . . . . . . . . . . . . . . . 20
7. Description of the controller functions . . . . . . . . . . . . . . . . . . . . 22
7.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.1 Weather-compensated control . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.1.1 Heating characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.2 Fixed set point control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.2 Delayed outdoor temperature adaptation . . . . . . . . . . . . . . . . . . . 25
7.3 Control signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.1 Three-step control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.2 On/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Limitation of the flow temperature . . . . . . . . . . . . . . . . . . . . . . . 26
7.5 Limitation of the return flow temperature . . . . . . . . . . . . . . . . . . . 27
7.6 Drinking water priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.7 Subfloor drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.8 Heating deactivation during the time-of-use . . . . . . . . . . . . . . . . . . 28
7.9 Heating deactivation during the time of non-use . . . . . . . . . . . . . . . . 28
7.10 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Contents
2EB 5432-1 EN

7.11 Pump seizure protection . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.12 Defective sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.13 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8. Installation and electrical connections . . . . . . . . . . . . . . . . . . . 31
8.1 Installing the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2.1 Installation recommendations . . . . . . . . . . . . . . . . . . . . . . . . 32
8.3 Connecting the controller . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.4 Connecting the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.4.1 Pt 1000 sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.5 Connecting the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.6 Connecting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Quick guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inhaltsverzeichnis
EB 5432-1 EN 3

Assembly, start-up and operation of the device may only be performed by
trained and experienced personnel familiar with this product.
According to these mounting and operating instructions, trained personnel is
referred to persons who are able to judge the work they are assigned to and
recognize possible dangers due to their specialized training, their know-
ledge and experience as well as their knowledge of the relevant standards.
The controller is designed for use in power installations. For connection
and maintenance you are required to observe the relevant safety regula-
tions.
Proper shipping and appropriate storage are assumed.
Safety instructions
4EB 5432-1 EN

1. Notes for the user
The controller is ready for operation with its factory (default) settings for temperatures and
time schedules.
On start-up, after switching on the power supply, you must enter the current time and date.
Refer to chapter 3 for further information about how to proceed.
Times-of-use and room set points that can be easily changed by the end user are described
in chapter 5. In addition to this, the end user can make short-term changes to the reference
value or set point (chapter 4).
However, configuring the controller as well as setting the control parameters as described in
chapter 6 require specialized knowledge of heating systems and should only be performed
by an expert. This also applies for the description of the controller functions listed in chap-
ter 7.
PC-supported configuration
The TROVIS-VIEW Configuration and Operator Interface software allows you to create all
the configuration data on a PC/laptop and download them onto the controller via its in-
frared interface using an infrared adapter.
Refer to the operating instructions EB 5432-2 EN about how to configure the controller using
TROVIS-VIEW software.
Validity of these mounting and operating instructions:
Firmware version 1.00 and higher
(Current Firmware version appears in the display for 2 s when the power supply is switched
on)
EB 5432-1 EN 5
Notes for the user

2. Operation
Just one control knob is needed to operate the controller.
Turning the knob lets you change the current reference value or set point or lets you select
parameters and temperatures.
Pressing the knob for three seconds lets you switch over from one control level to the next.
Pressing the knob briefly lets you activate a parameter to change it or lets you acknow-
ledge a changed parameter.
2.1 Control levels
There are three levels to operate the controller.
Certain parameters with their assigned symbols appear in the display depending on the
level chosen.
The levels important for the end user are the display level and the user level.
The installation level designed for the expert is described in more detail in chapter 6.
Display level
Depending on the operating mode set in the installation level:
Lets you view the reference value for room temperature when the weather-compensated
control is active.
Lets you view the set point and the actual value of the flow temperature when the fixed set
point control is active.
Lets you change the currently valid reference value or set point. This change then applies
until the time-of-use or time of non-use ends.
User level
Lets you view the time, time-of-use periods and the reference values or set points.
Lets you view the outdoor temperature when a sensor is connected.
Lets you set the time (and date).
Lets you set the time-of-use periods for rated operation.
Lets you set the required reference values for room temperature for rated and reduced
operation during weather-compensated control or lets you set the set points for the flow
temperature during fixed set point control for rated and reduced operation.
Installation level
Lets you configure and parameterize the controller.
Lets you view the actual values measured by the connected sensors.
6EB 5432-1 EN
Operation

Counterclockwise Press Clockwise
Fig. 2 ⋅Control levels and symbols in the display
Week day Mon to Sun
Times-of-use periods
Malfunction
Manual operation or
Subfloor drying active
Automatic operation
Time-controlled operation with switchover
between rated and reduced operation
Reference value
for room temperature
Drinking water priority
Outdoor sensor
Reduced operation (timesofnon-use)
set-backoperatione.gatnight
Rated operation (times-of-use)
Continuousoperationwithoutset-back
3 s
*
*
*
3 s
*
3 s
*
*
*
End
End
End
End
Display level
Reference value for
room temperature or
set point and
actual value for
flow temperature
Short-term change
to reference value
or set point
User level
Time
Times-of-use
Reference values and
set points
Installation level
Function blocks
Parameters
Temperature values
See quick guide at the back of this booklet !
*
Control knob Note: The controller automatically switches over to the display
level if the control knob is not operated for 5 minutes
EB 5432-1 EN 7
Operation

3. Start-up
The controller is ready for use with its factory (default) settings after it has been installed and
the power supply has been connected.
To start up, switch on the power supply.
Setting the current time and date
When the controller is started up for the first time or the
controller is disconnected from the power supply for more
than 72 hours, the default setting with blinking time ap-
pears in the display.
Now set the time and date.
Turn the control knob until you reach the correct time and
press the knob to acknowledge the time.
The year 2001 appears in the display as the default setting.
Turn the control knob if you want to change the year and
press the knob to acknowledge the year.
The date (day and month) appear in the display as the de-
fault setting.
Turn the control knob to set the date and press the knob to
acknowledge the date.
You have now completed entering the time and date. The
controller switches automatically to the display level.
The reference value for room temperature or set point and
actual value for the flow temperature appear in the display.
For further information about setting other parameters,
please refer to the following chapters.
8EB 5432-1 EN
Start-up

4. Setting options on the display level
The display level provides the following setting options that are only effective for a certain time:
If the current room temperature is too warm or too cold, you can override the controller
setting.
If you would like to prevent the controller from switching over to the reduced mode (for
example, due to a party or public holiday) and continue heating, you can set the control-
ler to Party mode.
If you would like to switch off the heating for longer periods of time (for example, vaca-
tion), you can set the controller to Holiday mode.
4.1 Short-term change in room temperature
If you change the preset reference value for room temperature or set point for flow temperature,
this change remains effective until the next time-of-use or time of non-use comes into effect.
When the weather-compensated control is activated, the reference value for room tempera-
ture appears in the display or when the fixed set point con-
trol is activated, the set point for flow temperature appears
on the left-hand side of the display.
Turn the control knob clockwise or counterclockwise one
position,
after a brief interval, the clock and sun symbols start to
blink.
You can now set the reference value for room temperature
or the set point for flow temperature to the required value.
Press the knob to acknowledge the setting.
Alternatively, you can wait three seconds until the display
stops blinking. The new value is stored.
4.2 Party mode
If you would like to continue heating in rated operation, yet
this deviates from the time schedule, you can achieve this
as follows:
Turn the control knob clockwise until PArtY appears in the
display.
Press the knob to acknowledge the setting.
EB 5432-1 EN 9
Setting options on the display level

Alternatively, you can wait three seconds until the display stops blinking. The party mode is
activated.
The party mode remains effective until a different reference value or set point is entered.
Even after a power failure, the party mode remains effective.
If you want to end the party mode, turn the control knob counterclockwise one position. Wait
briefly and then turn the knob one position further, then the set reference value or set point
reappears in the display.
4.3 Holiday mode
If you switch off the heating, but would like the frost protection to remain active, proceed as
follows:
Turn the control knob counterclockwise until HolidAY
appears in the display.
Press the knob to acknowledge the setting.
Alternatively, you can wait three seconds until the display
stops blinking. The holiday mode is activated.
The frost protection function comes into effect when the outdoor temperature falls below 3 °C
when the weather-compensated control is activated or the flow temperature falls below 5 °C
when the fixed set point control is activated. The circulation pump is activated and the flow
temperature is controlled to 20 °C. During fixed set point control, the circulation pump runs
continuously.
Note: The frost protection function is not active when the controller is set to manual
operation.
The holiday mode setting remains effective until a different reference value or set point is en-
tered. Even after a power failure, the holiday mode remains effective.
If you want to end the holiday mode, turn the control knob clockwise one position. Wait
briefly and then turn the knob one position further, then the set reference value or set point
reappears in the display.
10 EB 5432-1 EN
Setting options on the display level

5. Setting options on the user level
The controller is set to the display level.
The controller is set to the operating mode
"Weather-compensated control" as default.
The room reference value appears in the display.
If the operating mode has been changed to "Fixed set point
control", the set point appears on the left-hand side and the
actual value of the flow temperature on the right-hand side
of the display.
Switching over to the user level
If you want to enter different times-of-use, reference value and set points that deviate from
the default settings, you must first press the control knob for three seconds to access the user
level.
At first, the time appears in the display on the user level. Turn the control knob to continue to
the setting options described in following.
EB 5432-1 EN 11
Setting options on the user level

5.1 Setting the current time and date
A time appears in the display or, if the controller has not been in operation for the past 72
hours, the default setting 10:00 appears in the display.
You only need to change the time and date, if they are different from the time and date en-
tered during start-up.
Press the control knob. The clock symbol starts to blink.
Turn the control knob to until you reach the correct time
and press the knob to acknowledge the time.
The year 2001 appears in the display as the default setting.
Turn the control knob if you want to change the year and
press the knob to acknowledge the year.
The date (day and month) appear in the display as the de-
fault setting.
Turn the control knob to set the date and press the knob to
acknowledge the date.
You have now completed entering the time and date. The
time, date and the clock symbol reappear in the display.
If you want to remain on the user level, you can now enter
the times-of-use (chapter 5.2) by turning the control knob
one position further.
If you do not want to continue, turn the control knob until
End appears in the display. Then press the knob to access
the display level.
Alternatively, if you wait five minutes, the controller auto-
matically returns to the display level.
12 EB 5432-1 EN
Setting options on the user level

5.2 Setting the times-of-use
You can enter three time periods for the time-controlled operation for every day of the week,
during which the heating system runs in rated operation.
The default setting is a daily rated operation with just one period of time-of-use from 7:00 to
22:00 hrs.
During this time period, the heating system runs dependent on the predetermined operating
mode: weather-compensated according to the set heating characteristic or over a fixed flow
set point.
The heating system is switched over to reduced operation when the time-of-use period ends.
This saves energy in the times of non-use, e.g. at night time.
The heating system runs with a lower reference value during reduced operation.
You can set the reference value for room temperature directly after setting the times-of-use
(chapter 5.3).
The heating system switches back to rated operation again when the reduced operation ends.
You can enter the three time-of-use periods (1, 2 and 3) weekly (1 to 7) with the same time
schedule daily or on a day-to-day basis (1, 2, 3 etc.).
Note:
If you want to enter time-of-use periods that are different on just one day or on a few days of
the week, first select the week entry with the same time schedule daily. Then turn the control
knob until the day, which should have different times-of-use, appears in a box at the top of
the display. Enter the new schedule. When you enter a new schedule, you write over the
weekly entered times-of-use on the selected day.
Caution:
If you select the week entry to enter schedule, you write over all time-of-use periods that have
already been entered.
Note: An optimize function is included in the controller. This function makes sure that the con-
troller automatically switches the heating circuit to the reference value or set point that ap-
plies to the time-of-use at least 59 minutes before it starts dependent on the outdoor tempera-
ture. The sun symbol blinks in the display when this function becomes effective.
If you are not on the user level, press the control knob for
three seconds.
First of all, the time appears in the display.
EB 5432-1 EN 13
Setting options on the user level

Entering a weekly schedule
Turn the control knob clockwise one position. The current
time-of-use appears in the display.
Press the control knob. The time period symbol starts to
blink.
Turn the control knob until the numbers for all days 1 to 7
in boxes appear at the top of the display and the first time
period 1 appears.
Press the control knob. The time when the first time period
starts appears in the display, the clock and sun symbols
start to blink.
Turn the control knob to set the time when you want the first
time period to start (30 min increments) and press the knob
to acknowledge the setting.
The time when the first time period stops appears in the dis-
play.
Turn the control knob to set the time when you want the first
time period to end and press the knob to acknowledge the
time.
The start and stop of the time period you have just entered
appears in the display. This time period applies to all days
of the week.
Turn the control knob clockwise one position to access the
second time period 2.
Press the control knob to the time when you want the sec-
ond time period to start and end as already described
above.
Note: The second time period has to be outside of time pe-
riod 1. If you set the start and stop of a time period to have
the same time, the time period is not activated.
You only need to set other times if you require time periods
2 and 3.
Proceed in the same manner for the third time period 3.
The third time period has to be outside of time periods
1 and 2.
14 EB 5432-1 EN
Setting options on the user level

After you have entered the last time-of-use period, the time
period symbol still blinks.
Turn the control knob clockwise one position further. End
appears in the display.
Press the control knob to acknowledge the settings.
The stop and start times for the time-of-use period 1 of the
current day (today) appear in the display.
If you do not want to continue:
Turn the control knob until End appears in the display.
Press the control knob. The controller switches to the display
level.
If you want to change the time schedule for individual
days:
Turn the control knob until the box for the required day ap-
pears at the top of the display.
Press the control knob and set the time-of-use periods for
this day in the same manner as already described for the
week entry.
Entering schedule on day-to-day basis
If you are no longer on the user level, press the control
knob for three seconds.
At first, the time appears in the display.
Turn the control knob clockwise one position. The currently
valid time-of-use appears in the display.
Press the control knob. The time period symbol starts to
blink.
Turn the control knob until the box for the required day ap-
pears at the top of the display.
The start and stop times for the first time-of-use period ap-
pear in the display.
Press the control knob and set the time-of-use periods for
this day in the same manner as already described for the
week entry.
EB 5432-1 EN 15
Setting options on the user level

After entering the last time-of-use period, the time period
symbol still blinks in the display,
turn the control knob to access the next day and set like-
wise the required time-of-use periods.
Repeat the setting procedure for all of the following days.
After entering the last time-of-use period, the time period
symbol still blinks in the display,
turn the control knob clockwise or counterclockwise until
End appears in the display.
Press the control knob to acknowledge the settings.
The start and stop times for the currently valid time-of-use
period appear in the display.
Turn the control knob until End appears in the display.
Press the control knob,
the controller switches over to the display level.
5.2.1 Reading the set times-of-use
If you want to check the set times-of-use, you can view each
individual day.
If you are not on the user level, press the control knob for
three seconds.
First of all, the time appears in the display.
Turn the control knob clockwise one position. The currently
activated time-of-use appears in the display.
Press the control knob. The time period symbol starts to blink.
Now you can read all the time-of-use periods for each day
of the week by turning the control knob.
If you want to exit this menu:
Turn the control knob until End appears in the display.
Press the control knob, the currently active time-of-use ap-
pears in the display.
Turn the control knob until End reappears in the display.
Press the control knob,
the controller switches over to the display level.
16 EB 5432-1 EN
Setting options on the user level

5.3 Setting the reference value for room temperature or the flow
temperature set point for rated and reduced operation
If you are not on the user level, press the control knob for
three seconds.
At first, the time appears in the display.
Turn the control knob clockwise two positions.
In the operating mode "Weather-compensated control",
the reference value for room temperature for rated oper-
ation (time-of-use) appears in the display.
The default value is 20.0.
In the operating mode "Fixed set point control", the flow
temperature set point for rated operation (time-of-use) ap-
pears in the display.
The default value is 65.0 °C.
If you want to change the currently displayed value:
Press the control knob. The symbols at the bottom of the dis-
play start to blink.
Turn the control knob to set the required value and press the
knob to acknowledge the set value.
Turn the control knob one position further to access the ref-
erence value for room temperature or flow temperature set
point for reduced operation (time of non-use).
In the operating mode "Weather-compensated control",
the reference value for room temperature for reduced
operation (time of non-use) appears in the display.
The default value is 17.0.
EB 5432-1 EN 17
Setting options on the user level

In the operating mode"Fixed set point control", the flow
temperature set point for reduced operation (time of non-
use) appears in the display.
The default value is 50.0 °C.
If you want to change the currently displayed value:
Press the control knob. The symbols at the bottom of the dis-
play start to blink.
Turn the control knob to set the required value and press
the knob to acknowledge the set value.
If you turn the control knob one position further, you can
view the current outdoor temperature (see the next chapter).
5.4 Viewing the outdoor temperature
When an outdoor temperature sensor has been connected,
the outdoor temperature is displayed on the user level after
the reference value for room temperature or flow tempera-
ture set points.
18 EB 5432-1 EN
Setting options on the user level

6. Configuration and parameterization
The controller configuration und parameterization are entered on the installation level.
After accessing the installation level, the function blocks F1 to F6 appear first of all, followed
by the parameters P1 to P15 and finally the measured temperatures t1 to t4.
You can select function blocks, parameters and measured temperatures you require by turn-
ing the control knob.
Set the function blocks to 1= ON or 0= OFF depending on the function required. Set the
parameters to any value within a predetermined value range.
The function blocks and parameters are listed together with their meaning and default setting
in the table on page 20 and 21.
6.1 Accessing the installation level
Press the control knob for three seconds to change over
from the display level to the user level.
At first, the time appears in the display.
Turn the control knob clockwise or counterclockwise until
End appears in the display.
Press the knob again for 3 seconds,
the installation level is opened when the first function block
F1 appears in the display.
Now you can continue to all other function blocks, to the
parameters and the temperatures by turning the control
knob.
To make any changes, press the control knob when you
reach the function block or parameter you want to change.
Turn the knob to set and press it to acknowledge the new
setting.
EB 5432-1 EN 19
Configuration and parameterization

6.2 Setting the function blocks and parameters
Note: When you set certain function blocks, the associated parameter needs to be set, too.
The function blocks (F) and parameters (P) are listed in sequence. Further details about the
functions are described in chapter 7.
FPFunction SFS
Comment / range
F= Function block P= Parameter S = Setting FS = Factory (default) settings
F 1 Operating mode 1
0
1 Weather-compensated control
Fixed set point control (Chap. 7.1)
P1 Gradient Heat. characteristic 1.6 0.2...3.2
P2 Level Heating characteristic 0.0 -30.0...30.0 °C
F 2 Manual operation 1
00
Active
Notactive (Chap. 7.10)
F 3 Delayed outdoor
temperature adaptation
1
00
Active with outdoor sensor AS
(Chap. 7.2)
P7 5 1....6 °C/hr
F 4 Control signal 3-step 1 1Three-step control (Chap. 7.3.1)
P10 Kp Gain 2.0 0.1...50.0
P11 Tn Reset time 120 0...999 s
P12 Ty Valve transit time 45 10...240 s
Control signal on/off 0 On/off control (Chap. 7.3.2)
P13 Differential gap 52...10 °C
P14 Minimum activation time 120 0...600 s
P15 Minimum deactivation time 120 0...600 s
F 5 Automatic clock reset
summer time/winter time
1
0
1Active
Not active
F 6 Subfloor drying 1 Active (Chap. 7.7)
0 0 Not active
20 EB 5432-1 EN
Configuration and parameterization