Samson Trovis 5475-2 Service manual

Automation System TROVIS 5400
Heating and District Heating Controller
TROVIS 5475-
Edition January 001
Firmware Version 1.10
Mounting and operating instructions
EB 5475- EN
Fig. 1 ⋅ TROVIS 5475-2
®
Electronics from SAMSON
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Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Te hni al data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Sensor resistan e values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Installing the ontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Conne ting the ontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Conne ting the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Terminal wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Description of the controller functions . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Optimize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Redu ed operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Summer time operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Automati lo k reset summer time/winter time . . . . . . . . . . . . . . . . . . 15
4.6 Publi holidays and va ations . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.7 Delayed outdoor temperature adaptation . . . . . . . . . . . . . . . . . . . . 15
4.8 Limitation of the return flow temperature . . . . . . . . . . . . . . . . . . . . . 16
4.9 Limitation of the system deviation for OPEN signal . . . . . . . . . . . . . . . . 17
4.10 For ed harging of the drinking water storage tank . . . . . . . . . . . . . . . . 17
4.11 Thermal disinfe tion of the drinking water storage tank . . . . . . . . . . . . . . 17
4.12 Frost prote tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.13 Defe tive sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14 For ed operation of the pumps . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.15 Limitation of flow rate or apa ity . . . . . . . . . . . . . . . . . . . . . . . . 19
5. System descriptions and diagrams . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 System ode number 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 System ode number 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
System ode number 2 .0 with hangeover valve . . . . . . . . . . . . . . . . . 21
System ode number 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 System ode number 3.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 System ode number 4.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System ode number 4 .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System ode number 4.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 System ode number 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 System ode number 6.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Operating ontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 Sele ting the operating modes . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.1 Remote ontrolling the heating system . . . . . . . . . . . . . . . . . . . . . 33
6.3 Control levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.1 Configuration level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.2 Parameter level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.3 Operating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Increasing/decreasing the room temperature . . . . . . . . . . . . . . . . . 37
7. Starting up and configuring the controller . . . . . . . . . . . . . . . . . . . 38
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.1 Setting the ode number . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.2 Setting the system ode number (Anl) . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 Setting the fun tion blo ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.4 Fun tion blo k list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.4 Sensor alibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.1 Resetting to default values . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.2 Entering and modifying user data . . . . . . . . . . . . . . . . . . . . . . . 48
Entering urrent time and date . . . . . . . . . . . . . . . . . . . . . . . . . 48
Entering parameters for heating circuit:
Heating hara teristi s and temperatures . . . . . . . . . . . . . . . . . . . 48
Time s hedule for heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Publi holidays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Va ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Entering parameters for drinking water circuit:
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Time s hedule for drinking water heating . . . . . . . . . . . . . . . . . . . . 56
Time s hedule for ir ulation pump . . . . . . . . . . . . . . . . . . . . . . 56
7.3 Personal ode numbers, lo king the mode swit h for manual operation and
enabling the write prote t fun tion for the onfiguration level . . . . . . . . . . 57
7.4 Configuring the orre tion swit h . . . . . . . . . . . . . . . . . . . . . . . 58
8. Data transfer using memory module . . . . . . . . . . . . . . . . . . . . . 59
9. Configured data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly, start-up and operation of the devi e may only be performed
by trained and experien ed personnel familiar with this produ t. Proper
shipping and appropriate storage are assumed.
The ontroller is designed for use in power installations. For onne tion
and maintenan e you are required to observe the relevant safety regula-
tions.
!
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1. General
The heating and distri t heating ontroller is designed for weather- ompensated flow tempera-
ture ontrol. This means it ontrols the flow temperature of a heating system based on a heating
hara teristi so that the room temperature is always maintained at the desired level regardless
of the outdoor temperature. When used as a distri t heating ontroller, the ontroller an limit
the return flow temperature variably a ording to the outdoor temperature.
A drinking water heating system may be operated from the primary heating ir uit, using a se -
ond ontrol loop, or from the se ondary heating ir uit.
A differential temperature ontrol featuring a meter tra king the operating hours of the solar
ir uit pump is in luded in three system onfigurations for the solar heating of drinking water
storage tanks.
The onne ted sensors allow the ontroller to measure the respe tive temperatures whi h are
transmitted to the entral signal pro essing system. Subsequently, this system issues a three-step
or on/off ontrol signal orresponding to the preset set points for ea h of the two ontrol loops.
In addition, the ontroller ontrols the heating ir ulation pump and the pumps for drinking
water heating. The signal from a heat meter that is proportional to the flow rate or apa ity an
be onne ted to a pulse or urrent input. This enables the limitation of a maximum and/or mini-
mum flow rate or apa ity.
These mounting and operating instructions are valid for:
Firmware version 1.0 upwards
(The firmware version installed appears for 2 se onds in the display when the ontroller is
swit hed on)
Whats new compared to the previous version?
The ir ulation pump ZP runs on a time s hedule in all systems.
1.1 Notes for the user
The installation of the ontroller and its ele tri al onne tion des ribed in the following and,
must be arried out by authorized personnel only.
The settings for onfigurations des ribed in hapter 7.1 also require spe ialized knowledge of
heating systems and should only be performed by an expert. This also applies for the des rip-
tion of the ontroller fun tions and system onfigurations des ribed in hapter 4 and 5.
The start-up of the ontroller is normally arried out by authorized personnel  all onfiguration
data should be entered into the onfigured data tables in hapter 9.
The ontroller is programmed with default temperature values and time s hedules that an be
hanged on start-up or by the user at a later date over the menu des ribed in hapter 7.2.2.
The settings for the end user and non-expert should be restri ted to hanging the heatings flow
temperature to in rease or de rease room temperatures ( hapter 6.3.3 on page 37) and
hanging the set times-of-use ( hapter 7.2.2 on page 51).
The current time and date are saved in memory for at least 4 hours when the controller is
left unconnected to the power supply. Other configuration data are stored in memory indefi-
nitely and cannot be lost.
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1.1 Technical data
Inputs
Sensor inputs Max. 7 PTC and Pt 100 or NTC and Pt 100, or Pt 1000 and Pt
100 sensors
2-wire ir uit
(heating ir uit/drinking water ir uit)
2 flow temperature sensors, alternatively 1 solar olle tor sensor
1 room temperature sensor
1 outdoor temperature sensor1)
1 return flow temperature sensor ( 2 in system ode no. 4)
2 storage tank temperature sensors
Binary inputs Storage tank thermostat
Additional inputs Current input 4(0)...20 mA for flow rate limitation or pulse
ounting input for limitation of apa ity or flow rate
Current input 4(0)...20 mA for outdoor temperature
Remote ontrol option for orre ting flow temperature and
sele ting the operating mode
Outputs
Control signal y Three-step signals: max. load 250 V AC, 2 A;
min. 10 mA, varistor suppression 300 V
On/off signal: max. load 250 V AC, 2 A;
min. 10 mA, varistor suppression 300 V
Binary outputs Max. 4 outputs for pump ontrol
Load: max. 250 V AC, 2 A min. 10 mA, varistor
suppression 300 V
Control parameters Kp = 0.1...50; Tn = 1...999 s; valve transit time Ty = 15...240 s
Operating voltage 230 V AC (+10 %/15 %), 48 to 62 Hz,
Power failure: All parameter and onfiguration data are saved
in an EEPROM.
Power onsumption Approx. 1.5 VA
Temperature range Operation: 0...40 Storage: 20 to 60 °C1)
Degree and lass of prote tion IP 40 a ording to IEC 529 and II a ording to VDE 0106
Degree of ontamination 2 a ording to VDE 0110
Overvoltage ategory II a ording to VDE 0110
Humidity rating F a ording to VDE 40040
Noise immunity Corresponding to EN 50082 Part 1
Noise emission Corresponding to EN 50081 Part 1
Weight approx. 0.5 kg
1) On using Pt100 or Pt100 resistan e thermometers, permissible temperature
range down to −65 °C, however, display only indi ates down to −40 °C
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CAUTION
Safety features su h as frost prote tion monitoring and ex ess temperature prote tion are not
a tive in the following ases:
•Defe tive heating ontroller and failure of its fun tions
•Sensors are faulty, not onne ted or have not been dea tivated
•No power supply to the ontroller
•Mode swit h set to manual operation
1. Sensor resistance values
Resistance thermometer with PTC measuring element
Sensors for outdoor temperature Type 5224, for flow and return flow temperature Types 5264
and 5265, for storage tank temperature Type 5264, sensor for room temperature with remote
ontrol Type 5244
°C 20 10 0 +10 +20 +25 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
Ohm 694 757 825 896 971 1010 1050 1132 1219 1309 1402 1500 1601 1706 1815 1925
Room temperature
sensor with remote
ontrol Type 5244
Swit h position " lo k", terminals 1 and 2 °C +10 +15 +20 +25 +30
Ohm 679 699 720 741 762
Resistance thermometer with Pt 100 measuring element
Sensors for outdoor temperature Type 5225, for flow and return flow temperature Types 5204
and 5205-47, for storage tank temperature Types 5205-46 and 5205-48, sensor for room tem-
perature Type 5255
°C -35 -30 - 5 - 0 -15 -10 -5 0 5 10
Ohm 86.25 88.22 90.19 92.16 94.12 96.09 98.04 100.00 101.95 103.90
°C15 0 530354045505560
Ohm 105.85 107.79 109.73 111.67 113.61 115.54 117.47 119.40 121.32 123.24
°C 65 70 75 80 85 90 95 100 105 110
Ohm 125.16 127.07 128.98 130.89 132.80 134.70 136.60 138.50 140.39 142.29
°C 115 1 0 1 5 130 135 140 145 150
Ohm 144.17 146.06 147.94 149.82 151.70 153.58 155.45 157.31
Resistance values with Pt1000 measuring element
Use the resistan e values in the table for the Pt100 and multiply the values by the fa tor of 10.
Sensor for outdoor temperature Type 5227, for flow and return flow temperature Types 5207-
21, 5207-27, 5277 (thermowells required) and Type 5267 (surfa e sensor),
for storage tank temperature Type 5207-46 and Type 5207-48,
sensor for room temperature Type 5257-1,
room temperature sensor with remote ontrol Type 5257-4.
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. Installation
.1 Installing the controller
The ontroller is made up of the ontroller asing whi h ontains the ele troni s omponents
and the rear asing se tion with the terminal blo ks. To onne t the ontroller, remove the s rews
on the front panel and separate the ontroller housing from the rear asing.
For wall mounting, use four s rews to mount the rear asing to a wall. The distan es between the
holes are shown in Fig. 2.
For top hat rail mounting, mount the ontroller onto the top hat rail using the spring-mounted
hook on the rear asing.
For panel mounting, push the ontroller asing through the panel ut-out (92 x 138 mm) and in-
sert the fastening lips (delivered with the ontroller) into the not hes at the top and bottom of
the asing. Then turn the threaded bolts in the dire tion of the ontrol panel so that the asing is
pressed with its front frame against the ontrol panel.
144 59
30 10
138
57 41
Ø 4.5
98
62
15
93
Fixing s rew on ontroller se tion
Fastening se tion on ontroller rear asing
Panel ut-out
92 x 138 mm
Fig. 2 ⋅ Dimensional diagram
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. Installing the sensors
. .1 Outdoor sensor
Use two s rews to mount the outdoor sensor to the outside wall at an appropriate pla e. Make
sure that the sensor is mounted away from dire t heat sour es (windows, vents et .). In ase of
single family dwellings, preferably mount the sensor on the wall at the side of the house where
the most frequently o upied rooms are situated.
. . Flow/return flow sensor
Mount the sensor as du t sensor or surfa e sensor in an easily a essible lo ation near the on-
trol valve:
Duct sensor: Insert the du t sensor into a thermowell as far as it will go.
Surface sensor: Remove insulation from the flow pipe where the sensor is to be mounted and
polish the pipe lean. Firmly press the sensor onto the pipe and se ure it to the pipe using the en-
losed tightening strap.
. .3 Room sensor
Mount the sensor on the wall approx. 150 m above the floor at an appropriate pla e. Make
sure that the air ir ulation is not obstru ted by upboards, urtains or similar items.
3. Electrical connections
3.1 General
CAUTION!
For wiring and connection of the controller, you are required to observe the VDE
regulations and the regulations of the local power supply company. For this reason,
this type of work must be carried out by a specialist.
•Use separate ables for 230 V supply line and the signal lines!
•Also use separate ables for the digital signal lines (bus lines) and the analog signal lines
(sensor lines).
•In systems with a high ele tromagneti noise level, we re ommend that shielded ables be
used for the analog signal lines.
Ground the shield at the inlet or outlet of the ontrol abinet, using the largest possible ross
se tion and via the shortest possible route.
The entral grounding point must be onne ted to the grounding ondu tor using a min.
10 mm2 able.
As a rule, the shield needs only be grounded on one side at the ontrol abinet inlet, ex ept
when an equipotential bonding exists that has mu h lower resistan e than the shield resist-
an e.
•To in rease the noise immunity, make sure that there is a minimum distan e of 10 m be-
tween the power ables and signal lines. We re ommend that this distan e between these
lines is also kept in the ontrol abinet!
•Indu tan es in the ontrol abinet, e.g. onta tor oils, must be equipped with suitable inter-
feren e suppressors (RC elements)!
Control abinet elements with a high field strength, e.g. transformers or frequen y onver-
ters, should be shielded by means of separators that have good hassis ground.
!
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Surge protection
The following measures must be taken if lines are installed outside of the building or over long
distan es:
•The shield of signal lines routed outside of buildings must have urrent arrying apa ity
and must be grounded on both sides.
•Surge diverters must be installed at the ontrol abinet inlet.
3. Connecting the controller
Conne t the ontroller on the basis of the relevant terminal diagrams of the asso iated system
ode numbers (Fig. 3 to 10).
The power supply se tion of the ontroller  terminals 14 to 26  must be onne ted using wires
with a ross-se tion of 1.5 mm2 at the minimum.
Kno k out the holes marked on the rear asing for the able entries and insert the en losed self-
sealed grommets or suitable glands.
3.3 Connecting the sensors
Conne t the ables with a ross-se tion of min. 0.5 mm2 to the terminal strip  terminals 1
to 13  on the rear asing. See hapter 7.1.4 for Pt100 (Pt1000/PTC) on sensor alibration.
3.4 Terminal wiring diagrams
Legend for ir uit diagrams:
AF Outdoor sensor SLP Storage tank harging pump
RF Room sensor UP Cir ulation pump of heating ir uit
RÜF Return flow sensor ZP Cir ulation pump of drinking water ir uit
SF Storage tank sensor WMZ Heat meter
VF Flow sensor Solar ir uit:
TW Drinking water ir uit CF Solar ir uit olle tor sensor
HK Heating ir uit CP Solar ir uit pump
2 PKT On/off


With 0 …20 mA
50 Ω onne t in parallel
Fig. 3
System ode no. 1 Option Type 5244
Type 5257-4
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Fig. 6
System ode no. 3.0
Fig. 4
System ode no. 2.0
Fig. 5
System ode no. 2.1
Option Type 5244
Type 5257-4
Stage1
Stage 2

With 0 …20 mA
50 Ω onne t in parallel

Thermostat
Option Type 5244
Type 5257-4

With 0 …20 mA
50 Ω onne t in parallel

Thermostat
Changeover
valve
Option Type 5244
Type 5257-4


With 0 …20 mA
50 Ω onne t in parallel
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