Samson TROVIS 5432 Service manual

Automation System 5400
Heating and District Heating Controller
TROVIS 5432
Mounting and
Operating Instructions
EB 5432 EN
Firmware version 2.1x
Edition July 2004
®
Electronics from SAMSON

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 op-
erating 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 ap-
propriate storage are assumed.
4The controller has been designed for use in electrical power systems. For
wiring and maintenance, you are required to observe the relevant safety
regulations.
2EB 5432 EN
Disclaimer of liability

Table of contents
1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Control knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Displaying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Setting the system time . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Setting the times-of-use . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Stand-by mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.1 Vacation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.2 Outdoor temperature dependent deactivation. . . . . . . . . . . . . . 12
1.8 Party mode
(constant rated operation) . . . . . . . . . . . . . . . . . 13
1.9 Correcting the set point . . . . . . . . . . . . . . . . . . . . . . . . 14
1.9.1 Correcting the set point temporarily . . . . . . . . . . . . . . . . . . 14
1.9.2 Correcting the set point permanently . . . . . . . . . . . . . . . . . . 14
2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Configuration and parameterization . . . . . . . . . . . . . . . . . . 15
3 Manual operation mode . . . . . . . . . . . . . . . . . . . . . . . 16
4 Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Functions of the heating circuit . . . . . . . . . . . . . . . . . . . . 23
5.1 Weather-compensated control . . . . . . . . . . . . . . . . . . . . . 23
5.2 Fixed set point control . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Drying of jointless floors . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Automatic deactivation of the heating . . . . . . . . . . . . . . . . . 26
5.5 Outdoor temperature dependent advance heating . . . . . . . . . . . 27
5.6 Delayed adaptation to the outdoor temperature . . . . . . . . . . . . 27
5.7 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.8 Flash adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.9 Room temperature-based control. . . . . . . . . . . . . . . . . . . . 29
6 Functions of the DHW circuit . . . . . . . . . . . . . . . . . . . . . 30
6.1 DHW priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 System-wide functions . . . . . . . . . . . . . . . . . . . . . . . . 32
7.1 Automatic summer time/winter time changeover . . . . . . . . . . . . 32
7.2 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3 Forced operation of the pumps. . . . . . . . . . . . . . . . . . . . . 32
7.4 Limiting the return flow temperature . . . . . . . . . . . . . . . . . . 33
EB 5432 EN 3
Contents

7.5 Three-step control . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6 On/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9 Infrared interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 39
12 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.1 Function block list . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.2 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.3 Resistance values with Pt 1000 sensor . . . . . . . . . . . . . . . . . 43
12.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.5 User data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4EB 5432 EN
Contents

1 Operation
The controller is ready for use with the temperatures and operating time schedules preset by
the manufacturer.
On start-up, the current time and date need to be set at the controller (–> section 1.5).
1.1 Control knob
Turn q:
Select parameters, displays and temperature displays
Press :
Confirm adjusted selection or settings
Press for three seconds 3s:
Switch from the operating level to the user level as well as from
the user level to the installation level
1.2 Operating modes
Automatic mode
Display: and in the time-of-use periods, and outside of the times-of-use periods
The controller works in rated operation within the programmed times-of-uses and in reduced
operation outside of the times-of-use, provided that the control operation is not deactivated
due to the outdoor temperature. The controller switches automatically between both operat-
ing modes.
Day mode (constant rated operation)
Display:
PArTY or
Regardless of the programmed times-of-use, the set points relevant for rated operation are
used constantly by the controller.
Stand-by mode (vacation mode)
Display:
HoLidAY or – – –
In stand-by mode, the heating is switched off regardless of the programmed times-of-use.
The frost protection mode is still active.
Night mode (reduced operation; can only be set over the room panel)
Display:
Regardless of the programmed times-of-use, the set points relevant for reduced operation are
used constantly by the controller.
EB 5432 EN 5
Operation
*

1.3 Display
The current set point appears on the display during operation.
Which set point is displayed depends on:
4The configured type of control
4The programmed times-of-use
Weather-compensated control, room set point mode (F1 - 1 and F9 - 1)
Day set point (time-of-use period)*
or night set point (outside of time-of-use period)
Weather-compensated control (F1 - 1 and F9 - 0), fixed set point control (F1 - 0 and F7 - 0)
Flow temperature (times-of-use period)*
or reduced flow temperature (outside of time-of-use period)
The set point (left) and the measured value (right) are
displayed in this example.
* Appears on the depicted display
Note!
The icon appears additionally on the display for a control functioning with the room
panel unit (F7- 1).
A temporarily active set point (corrected once) is indicated on the display by the icon
together with the icon (refer to section 1.9.1).
An active function for drying of jointless floors is indicated on the display by the icon
together with the icon (refer to section 5.3).
6EB 5432 EN
Operation

1.4 Displaying data
The times-of-use periods, measured values as well as set points or limit values can be re-
trieved and displayed in the user level (–> Fig. 10 on page 49). The controller configuration
determines which measured values as well as which set points or limit values appear on the
display.
Proceed as follows:
3s Switch to user level.
Display: Time
qSelect value.
The different data points appear on the display in sequence:
Display Meaning
,
Current time-of-use
Open data point
Times-of-use .
qDisplay daily times-of-use.
Confirm
Times-of-use by pressing the knob when End
appears on the display.
EB 5432 EN 7
Operation
Fig. 1 · Icons
1
2
3
4 5 6 7 8 9 10
1 Days of week
Mon (1) to Sun (7)
2 Times-of-use
periods
3 Malfunction
4 Manual mode
5 Automatic mode
6 Day operation
(rated operation)
7 Night operation
(reduced operation)
8 Outdoor sensor
9 Room sensor
10 Hot water demand

Display Meaning
* Day set point
or flow temperature set point (F1 - 0 and F7 - 0)
* Night set point
or reduced flow temperature set point (F1 - 0 and F7 - 0)
OT deactivating value in rated operation (F1 - 1 and F9 - 0)
OT deactivating value in reduced operation (F1 - 1 and F9 - 0)
t1
Measured value: Flow temperature
Flow temperature set point
t2 ,
t2 ,
Measured value: Outdoor temperature
Delayed outdoor temperature (F3 - 1)
Measured value: Storage tank temperature (F1 - 0 and F7 - 1)
Activating/deactivating value for DHW system
(DHW set point + on/off differential)
t3
Measured value: Return air temperature
Maximum return air temperature
t4
t4
,
Measured value: DHW temperature monitoring
Monitoring value
Measured value: Room temperature (F7 - 1)
Day set point or night set point
(influenced by a room panel, if applicable)
t5 , Measured value: Storage tank temperature (F7 - 0)
Activating/deactivating value for DHW system
(DHW set point + on/off differential)
qSelect
End on the display.
Switch to operating level.
* Note!
The icon appears additionally on the display for a control functioning with the room
panel unit (F7- 1).
8EB 5432 EN
Operation

1.5 Setting the system time
The current time and date need to be set immediately after start-up and after a power failure
lasting more than 72 hours has occurred. This is indicated by the time blinking on the dis-
play. The time is already in the edit mode and can be changed directly. The first two instruc-
tions steps are then omitted.
Proceed as follows:
3s Switch to user level.
Display: Time.
Open time data point.
blinks.
qChange time.
Confirm time setting.
Display: Year.
qChange year.
Confirm year.
Display: Date (day.month) as well as day of the week
( = Mon, = Tue, …, = Sun)
qChange date.
Confirm date.
Display: Time
qSelect
End on the display.
Switch to operating level.
Note! On initial start-up and after a power failure lasting more than 72 hours, the controller
switches automatically to the operating level after the date has been set and confirmed. The
last two steps are omitted.
Note! The controller automatically switches to the operating level if the control knob is left
untouched for five minutes.
EB 5432 EN 9
Operation

1.6 Setting the times-of-use
Three time-of-use periods can be set for each day of the week.
If not all the time-of-use periods are required, the start and stop times of the third time-of-use
period (for just two periods) must be set to identical times or, alternatively, the start and stop
times of the second time-of-use (for just one period). The controller then automatically sets the
start and stop times to the stop time of the previous time-of-use period.
The times-of-use are displayed in the user level (–> Fig. 10 on page 49).
Note!
You can set the times-of-use for each day or for an entire week. If you want to set the
times-of-use for certain days to be different than the rest of the week, we recommend you set
the times-of-use for the entire week first (display: ) and then al-
ter the times-of-use for each day which require different times-of-use.
The week setting of the times-of-use writes over any already programmed times-of-use.
Parameter WE Range of values
Time period/day 1–7 = daily,
= Monday, = Tuesday, …, = Sunday
Start time of first time-of-use 07:00 00:00 to 24:00 h; in steps of 30 minutes
Stop time of first time-of-use 22:00 00:00 to 24:00 h; in steps of 30 minutes
Start time of second time-of-use 22:00 00:00 to 24:00 h; in steps of 30 minutes
Stop time of second time-of-use 22:00 00:00 to 24:00 h; in steps of 30 minutes
Start time of third time-of-use 22:00 00:00 to 24:00 h; in steps of 30 minutes
Stop time of third time-of-use 22:00 00:00 to 24:00 h; in steps of 30 minutes
Note!
The controller includes an optimized activation function which makes sure the controller auto-
matically changes to the valid set point ( blinks), six hours at the earliest before the pro-
grammed time-of-use starts, to compensate for low outdoor temperatures.
10 EB 5432 EN
Operation

Proceed as follows: 3s Switch to the user level.
Display: Time
qSelect
Times-of-use .
Open data point
Times-of-use .
blinks.
qSelect time period/day and times-of-use:
= Monday, = Tuesday, …, = Sunday and
= daily
with = first time-of-use period,
= second time-of-use period,
= third time-of-use period.
Open time period/day.
Display: Start time of first time-of-use period
and blink.
qChange start time (in steps of 30 minutes).
Confirm start time.
Display: Stop time of first time-of-use period
and blink.
qChange stop time.
Confirm stop time.
Display: Set time-of-use period
blinks.
To set other times-of-use, repeat the instructions in the fields highlighted in gray.
qSelect
End on the display.
Exit
Times-of-use .
qSelect
End on the display.
Switch to operating level.
Note!
The controller automatically switches to the operating level if the control knob is left un-
touched for five minutes.
EB 5432 EN 11
Operation

1.7 Stand-by mode
1.7.1 Vacation mode
Function independent of controller setting.
The vacation mode function places the heating circuit into the stand-by mode: the heating is
deactivated, however, frost protection is guaranteed. The functions of an existing DHW cir-
cuit remain unchanged.
The vacation mode function is set in the operating level (set point display).
Proceed as follows:
qSelect menu
HoLidAY (turn knob to the left as far as it
will go).
The display blinks.
Confirm vacation mode. Alternatively:
Wait 3 minutes until the display stops blinking.
The vacation mode is activated.
Note!
The controller is in vacation mode when HoLidAY appears on the display.
The controller exits the vacation mode when the current set point is reset (–> section 1.9).
1.7.2 Outdoor temperature dependent deactivation
Controller setting F1 - 1 and F9 - 1
The outdoor temperature dependent deactivation function places the heating circuit into the
stand-by mode dependent on the outdoor temperature. The heating is deactivated when the
outdoor temperature exceeds the active limit value (plus 1 °C on/off differential), however,
frost protection is still guaranteed. – – – appears on the display as the flow temperature set
point while the outdoor temperature dependent deactivation function is active. The functions
of an existing DHW circuit remain unchanged.
The
OT deactivating value in rated operation within the times-of-use and OT deactivating
value in reduced operation
outside of the times-of-use apply and are set in the user level.
12 EB 5432 EN
Operation

Proceed as follows:
Vorgehen: 3s Switch to user level.
Display: Time.
qSelect
OT deactivating value in rated operation or
OT deactivating value in reduced operation .
Open data point.
qChange data point.
Confirm data point.
qSelect
End on the display.
Switch to operating level.
1.8 Party mode (constant rated operation)
Function independent of controller setting.
The party mode function sets the controller in rated operation mode: regardless of the pro-
grammed times-of-use, the
Set point day or Flow temperature set point are constantly used
by the controller.
The party mode function is set in the operating level (set point display).
Proceed as follows:
qSelect menu
PArtY (turn knob to the right as far as it
will go). The display blinks.
Confirm party mode. Alternatively:
Wait 3 minutes until the display stops blinking.
The party mode is activated.
Note!
The controller is in constant rated operation when PArtY appears on the display. The controller
exits the constant rated operation mode when the current set point is reset (–> section 1.9).
EB 5432 EN 13
Operation
OT deactivating value in
reduced operation
OT deactivating value in rated
operation

1.9 Correcting the set point
The current set point is displayed in the operating level. In rated operation, the Day set point
or the Flow temperature set point appears on the display (–> section 1.3). In reduced opera-
tion, the
Night set point or the Reduced flow temperature set point appears on the display.
1.9.1 Correcting the set point temporarily
The current set point which appears on the display can be changed for just as long as the
rated operation mode (programmed time-of-use period) is running or the reduced operation
mode (outside of the time-of-use period) is running.
This temporary correction of the set point is made in the operating level (set point display).
Proceed as follows:
qTurn the control knob one position.
The icon display blinks.
qChange the parameter.
Confirm the new parameter setting. Alternatively:
Wait until the display stops blinking.
The new parameter setting has been saved.
The temporarily active set point (corrected once) is indicated on the display by the
icon together with the icon.
1.9.2 Correcting the set point permanently
The permanent change of Day set point or Flow temperature set point in rated operation as
well as the
Night set point or Reduced flow temperature set point in reduced operation is
made in the user level.
Proceed as follows:
3s Switch to user level. Display: Time
qSelect menu
Set point (–> page 6).
Open the set point.
qChange the set point.
Confirm the set point.
qSelect
End on the display.
Switch to operating level.
14 EB 5432 EN
Operation

2 Start-up
2.1 Configuration and parameterization
The controller is configured and parameterized in the configuration and parameterization
level (–> Fig. 10 on page 49). After accessing the configuration and parameterization level
(CoPa level), the function blocks F1 to F9 appear at first, followed by the parameters P1 to
P18. The individual functions and parameters are listed in the Appendix (–> page 41).
The configuration and parameterization level is locked to prevent unintentional and unautho-
rized access. This level can only be opened when the key number is known. The key number
can be found on page 48. To avoid unauthorized use of the key number, remove the page
or make the key number unreadable.
Proceed as follows:
3s Switch to user level. Display: Time
qSelect
End on the display.
3s Switch to the configuration and parameterization level (CoPa level).
Display: 0,
nr blinks.
qSet key number.
Confirm key number. Display: F1
qSelect function block* or parameter.
Open selected data point.
qChange data point.
Confirm setting of the data point.
To set further function blocks and parameters, repeat the instructions in the fields highlighted
in gray.
qSelect
End on the display.
Return to operating level.
Display: Current set point
* Note!
A function block is activated when F_ 1 appears on the display; it is deactivated when F_ 0
appears on the display.
EB 5432 EN 15
Start-up

3 Manual operation mode
In manual operation mode, the circulation pump UP is always switched on. The output SLP is
usually switched off. Initially, no control signal is issued for the heating circuit.
Activate the manual operation mode in the configuration and parameterization level (CoPa
level) over function block F2.
Functions WE Configuration
Manual operation of an actuator 0 F2 - 1
Proceed as follows:
3s Switch to user level.
Display: Time
qSelect
End on the display.
3s Switch to the configuration and parameterization level (CoPa level).
Display: 0,
nr blinks.
qSet key number.
Confirm key number.
Display: F1
qSelect function block F2.
Open function block F2.
qActivate function block F2.
Display: F2 - 1.
Activate manual operation mode.
Display: and
StoP
qMove the actuator manually:
oPEn: OPEN (3-step signal); activate output (on/off signal)
StoP: Last position (3-step signal); deactivate output (on/off signal)
cLoSE: CLOSED (3-step signal)
Note!
The frost protection function is not active in manual operation mode.
16 EB 5432 EN
Manual operation mode

Exit manual operation mode:
qSelect cLoSE on the display.
3s Close manual operation mode and return to operating level.
Displaying measured values during manual operation mode
qSelect StoP on the display.
3s Switch to user level.
Display: Time
qSelect the measured values t1 to t5 in sequence.
qSelect
End on the display.
Switch to menu for moving actuator manually (oPEn, StoP or cLoSE).
Note!
The manual operation mode is maintained even after a power failure (display: StoP).
EB 5432 EN 17
Manual operation mode

4 Systems
The heating system can be designed either as a primary system, secondary system or a sin-
gle-stage boiler system.
The flow temperature can either be controlled weather-compensated, based on the room
temperature or a fixed set point. The hydraulic schematics of the heating system and the con-
troller configuration are the factors that determine how the flow temperature is controlled.
18 EB 5432 EN
Systems
BE
BA
AE
RK
S3 S1UPHK_3-step S4
BE
BA
AE
RK
S1UP S3HK_3-step S4 S2S2
S2 S2
BE
BA
AE
RK
S3S1UP HK_3-step S4
BE
BA
AE
RK
UPHK_on/off S4S1
Single-stage
boiler
Secondary system Boiler system
Primary system, indirect Primary system, direct

Weather-compensated control without room panel (= default setting)
Setting F1 - 1 (with outdoor temperature sensor S2)
F7 - 0 (without room panel)
Comments With or without S3 (depending on the circuit)
F4 - 0 for single-stage boiler system
Storage tank charging/DHW priority possible (–> Figs. 2 and 3)
Weather-compensated control with room panel
Setting F1 - 1 (with outdoor temperature sensor S2)
F7 - 1 (with room panel)
Comments With or without S3 (depending on the circuit)
F4 - 0 for single-stage boiler system
Storage tank charging/DHW priority not possible
Fixed set point control
Setting F1 - 0 (without outdoor temperature sensor S2)
F7 - 0 (without room panel)
Comments With or without S3 (depending on the circuit)
F4 - 0 for single-stage boiler system
Storage tank charging/DHW priority possible (–> Figs. 2 and 3)
Room temperature-based control
Setting F1 - 0 (without outdoor temperature sensor AS)
F7 - 1 (with room panel)
Comments With or without S3 (depending on the circuit)
F4 - 0 for single-stage boiler system
Storage tank charging/DHW priority possible (–> Fig. 4)
EB 5432 EN 19
Systems

Weather-compensated control Fixed set point control
Setting F1 - 1 and F7 - 0 F1 - 0 and F7 - 0
Comments With or without S3 (depending on the circuit)
Storage tank charging over storage tank sensor S5
(depending on the circuit)
Monitoring priority at S5
20 EB 5432 EN
Systems
BE
BA
AE
RK
WW
KW
S2TW_on/off
S3 S1
UP
S5
HK_3-step
Fig. 2 · Weather-compensated control or fixed set point control and on/off control for storage tank
system in the primary circuit