Samson TROVIS 5571 Service manual

Automation System TROVIS 5500
Programmable Logic Controller (PLC)
TROVIS 5571
®
Electronics from SAMSON
Mounting and
Operating Instructions
EB 5571 EN
Firmware version 1.21
Edition March 2009

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 5571 EN
Disclaimer of liability
Modifications of the PLC firmware compared to the previous version
1.10 (old) 1.11 (new)
New default setting for parameter
Gateway = Off
Expansion of the data logging function (see section 5.5)
1.11 (old) 1.21 and lower (new)
Internal modifications

Contents Page
1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.1 Operating keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Adjusting the contrast of the display . . . . . . . . . . . . . . . . . . . 6
1.3 Displaying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Setting the system time . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Changing PLC settings. . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Configuring universal inputs . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Resetting to default values . . . . . . . . . . . . . . . . . . . . . . . 15
3 Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Operational faults . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Modbus slave interface . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Modbus master interface . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Description of communication parameters to be adjusted . . . . . . . . 21
5.4 Meter bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.1 Activating the meter bus . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5 Data logging module . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5.1 Data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5.2 Saving and loading firmware and applications . . . . . . . . . . . . . 26
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Settings level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.3 Special key codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.4 Expansion modules . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.4.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.4.2 Terminal assignment. . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.4.3 Integrating the expansion modules . . . . . . . . . . . . . . . . . . . 37
8.5 Sensor resistance tables . . . . . . . . . . . . . . . . . . . . . . . . 38
8.6 Customer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EB 5571 EN 3
Contents

1 Operation
The programmable logic controller (PLC) is freely programmable. The controller is delivered
without an executable application in the memory. The application must be developed sepa-
rately for the desired purpose on a personal computer using ISaGRAF®(programming as in
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 (after entering the key code)
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)
Pressing both keys together:
– Switch to information level
Pressing one of the keys separately:
– Navigate in levels (also in the application developed with ISaGRAF®)
– Set data points
Enter key
– Open levels (also in the application developed with ISaGRAF®)
– Activate editing mode for parameters and function blocks
– Confirm entered settings
4EB 5571 EN
Operation

1.2 Display
The programmable logic controller has a plain text display.
The display is automatically illuminated when entering or setting the controller.
After connecting the controller to the power supply, “System is being initialized…“ appears
briefly on the display.
Should the display not be illuminated or the contrast is too strong/weak, you can adapt the dis-
play illumination. Refer to section 1.2.1.
If an application is not saved on the PLC, the normal display
(left) contains the date, time and current firmware version.
If an application is saved on the PLC, the normal display
contains application-related information.
The current status of the three communication interfaces “RS-232/Slave“, “RS-485/Master“
and “RS-232/Prog“ appears at the bottom of the display:
RS-232/Slave (left) RS-485/Master (middle) RS-232/Prog (right)
Interface inactive Interface inactive Interface inactive
Direct connection
to control station
active
Modbus master
active Connection to
ISaGRAF®Work-
bench active
Modem inactive Data logging
active
blinking Modem initializa- tion active
RING,
calling active
blinking Connection estab- lished/canceled
Connection to con-
trol station active
Error
SMS sending
active
EB 5571 EN 5
Operation
28.11.2005 10:00:05 V1.1xx
Application: …
Version: …
Date: …
CRC: …
Size: … kB
Cycle time: … ms
SMS

Note!
If no key is pressed for two minutes, the PLC returns to the normal display. The background
illumination of the display is switched off automatically.
Any settings that have not been confirmed are not saved and must be re-entered.
1.2.1 Adjusting the contrast of the display
Activate the editing mode.
Display: Entering the key code
0000 blinks
Confirm the
0000 reading.
Set the contrast.
Confirm the changed setting.
Display: Normal display (depending on the
application)
6EB 5571 EN
Operation
Entering the key code
0000

1.3 Displaying data
The states of the inputs and outputs as well as information on the connected meter bus instru-
ments can be retrieved in the information level. In addition, the analog and binary outputs can
be changed (refer to section 3 on manual operation).
The information level is divided into individual menu items:
4Analog inputs · Measured data from connected sensors
4Analog outputs · Output data from four analog outputs *)
4Binary inputs · States of the binary sensors (on/off)
4Binary outputs · States of the binary outputs (on/off) *)
4Meter bus · Output data of the meters connected over meter bus
*)The analog and binary output settings can be changed after entering the key code.
Proceed as follows:
Switch to the information level.
Display: Information level
The menu item “Analog inputs“ is highlighted.
Select required menu item, e.g. binary outputs.
Activate the menu item.
Select required data point.
Returning to the information level
Select
Back to return to the information level.
Exit the menu item.
Display: Information level
Exiting the information level
Select
Back .
Exit the information level.
Display: Normal display (depending on the
application)
Note!
If no key is pressed for two minutes, the PLC automatically returns to the normal display.
EB 5571 EN 7
Operation
Information level
Analog inputs
Analog outputs
Binary inputs
Binary outputs
Meter bus
System info
Back
Information level
Analog inputs
Analog outputs
Binary inputs
Binary outputs
Meter bus
System info
Back
Binary outputs
BA07=OFF
BA08=OFF
BA09=OFF
BA10=OFF
BA11=OFF
BA12=OFF
Back

1.4 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 24 hours.
Set the system time in the settings level under the menu item “Date / time”. The Automatic sum-
mer time function can also be activated or deactivated in this menu item.
4System time: Time-dependent functions of the saved application are based on the system
time set in the PLC.
4Automatic summer time: The summer time is automatically set on the last Sunday in
March at 02:00 h and the winter time on the last Sunday in October at 03:00 h.
Proceed as follows:
Activate the editing mode.
Display: Entering the key code
0000 blinks
Enter the key code.
Confirm the key code entered.
Display: Settings level
The “Date / time“ menu item is highlighted.
Activate the menu item “Date / time“.
Display: System time (DD.MM.YYYY HH:MM)
Activate the editing mode for the system time.
Display: Date (
DD ) blinks.
Enter date.
Confirm date entered.
Display: Month (
MM ) blinks.
8EB 5571 EN
Operation
Entering the key code
0000
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back
Settings level
28.11.2005 10:00
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back

Enter month.
Confirm month entered.
Display: Year (
YYYY ) blinks.
Enter year.
Confirm year entered.
Display: Time (
HH ) blinks.
Enter hour.
Confirm hour entered.
Display: Minutes (
MM ) blink.
Enter minutes.
Confirm minutes entered.
Display: “Automatic summer time? __“ blinks
If required, change the current setting (on/off) of the
Automatic summer time function.
Activate function: Automatic summer time? On
Deactivate function: Automatic summer time? Off
Exit the menu item “Date / time“.
Display: Settings level
Exiting the settings level
Select
Back.
Exit the settings level.
Display: Normal display (depending on the
application)
Note!
If no key is pressed for two minutes, the PLC automatically returns to the normal display.
EB 5571 EN 9
Operation
Settings level
Automatic summer time? On
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back
Settings level
28.11.2005 10:00
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back

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 specific
needs of your plant (ISaGRAF®development environment 1400-7621). Programming must fol-
low the structures and rules stipulated in IEC 61131-3. The PLC may be programmed with the
languages defined in the standard: Sequential Function Chart (SFC), Instruction 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 application is complied to machine code in the PC environment. This code is then trans-
ferred to the PLC over the front RJ-45 jack (connecting cable 1400-7620).
Programming languages:
Sequential Function Chart
(SFC): Used to describe operations of a sequential process with a simple gra- phic 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 func-
tions and function blocks, e.g. for boiler systems, heat exchanger sequence control, ventilation
systems, heating circuits or domestic hot water systems, are available from SAMSON.
Parameters*WE Settings level / Range of values
Station address 255 RS-232/Prog / 1 to 247, 255
Baud rate 9600 RS-232/Prog / 9600, 19200
* –> Section 5.3 (Description of communication parameters to be adjusted)
10 EB 5571 EN
Start-up

Note!
In ISaGRAF®, internal variables can be assigned (integer or bool) network addresses. The
status or value of the internal variable is written to the associated holding or coil register and
can be read or written over Modbus.
Important! The PLC application must be reloaded after a cold start.
2.2 Changing PLC settings
PLC settings can only be changed after entering the valid key code.
The valid key code can be found on page 42. To avoid unauthorized use, remove the page or
make the key code unreadable.
Change PLC settings in the settings level, which contains the following menu items:
4Date / time, refer to section 1.4
4RS-232/Slave, refer to section 5.1
4RS-485/Master, refer to section 5.2
4RS-232/Prog, refer to section 2.1
4Meter bus, refer to section 5.4
4Universal input type, refer to section 2.3
Proceed as follows:
Activate the editing mode.
Display: Entering the key code
0000 blinks
Enter the valid key code.
EB 5571 EN 11
Start-up
Entering the key code
0000

Confirm the key code.
Display: Settings level
The menu item “Date / time“ is highlighted.
Select the menu item in which the settings are to be
changed, e.g. “RS-232/Slave“.
Activate the selected menu item.
Select the data point which you want to change.
Activate the editing mode of the data point.
Display: Data point blinks.
Set the data point.
Confirm the setting.
Returning to the settings level
Select
Back to return to the settings level.
Exit the menu item.
Display: Settings level
Exiting the settings level
Select
Back to return.
Exit the settings level.
Display: Normal display (depending on the
application)
Note!
If no key is pressed for two minutes, the PLC automatically returns to the normal display.
12 EB 5571 EN
Start-up
RS-232/Slave
Modbus Slave
Modem
Baud rate
Back
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back

2.3 Configuring universal inputs
There are 17 universal inputs, which may be used as binary inputs, analog inputs (0 to 10 V,
0/4 to 20 mA) or as sensor inputs. The hardware must be configured accordingly (sensor ini-
tialization).
Refer to page 38 for the resistance values of the PTC, Pt 100 and Pt 1000 sensors.
You can also configure each universal input separately.
The following configurations are available: Pt 100/500/1000/2000, Ni 200/1000/2000,
PTC, NTC, 1–2 kΩ, BE, 0/4 to 20 mA (with 50 Ωparallel resistor) and 0 to 10 V.
Proceed as follows:
Activate the editing mode.
Display: Entering the key code
0000 blinks
Enter the valid key code.
Confirm the key code.
Display: Settings level
The “Date / time“ menu item is highlighted.
Select the menu item “Universal input type“.
Activate this selected menu item.
The first universal input UE01is highlighted.
Select the universal input.
Activate the universal input.
Display:
UE__ blinks.
EB 5571 EN 13
Start-up
Entering the key code
0000
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back
Universal input type
UE01=PT100↔PT1000
UE02=PT100↔PT1000
UE03=PT100↔PT1000
UE04=PT100↔PT1000
UE05=PT100↔PT1000
UE06=PT100↔PT1000
Back

Select the type of universal input.
The inputs are available in the following order:
PT100↔PT1000, PT100↔PTC, NI2000, PT2000,
PT500, 0 – 10V, BE, 1000 – 2000Ω, PT100,
PT1000, NTC, PTC, NI1000, NI200, 4 – 20mA,
0 – 20mA
Note!
On selecting the universal input types PT100
↔
PT1000 or
PT100
↔
PTC, this configuration applies then to all 17 uni-
versal inputs. Any inputs that have a different type need to
be configured separately afterwards.
Binary inputs with terminal 10 functioning as GND are slow
(delay of approx. 3 s).
Binary inputs with terminal 9 functioning as GND are fast
(ms).
If a resistance input has been selected:
(PT100↔PT1000, PT100↔PTC, NI2000, PT2000,
PT500, PT100, PT1000, NTC, PTC, NI1000 or NI200)
Confirm the type of universal input.
Display: ”Calibrate? No“ blinks.
If the temperature sensor connected at the input is not to be
calibrated:
Exit the universal input.
If the temperature sensor connected at the input is to be
calibrated:
Set to “Calibrate? Yes“.
Confirm calibration.
Display:
Temperature measured by the sensor blinks.
Compare the temperature measured by the sensor
with the temperature measured by a reference ther-
mometer installed directly at the point of measure-
ment.
14 EB 5571 EN
Manual operation
Universal input type
Calibrate? No
UE02=PT100↔PT1000
UE03=PT100↔PT1000
UE04=PT100↔PT1000
UE05=PT100↔PT1000
UE06=PT100↔PT1000
Back

If both temperatures are not the same:
Correct the sensor temperature.
Confirm corrected temperature.
If another type of universal input is selected:
Confirm the universal input type.
Returning to the settings level
Select
Back to return to the settings level.
Exit the menu item.
Display: Settings level
Exiting the settings level
Select
Back to return.
Exit the settings level.
Display: Normal display (depending on the
application)
2.4 Resetting to default values
The values in the settings level can be reset to their default values.
Important!
Resetting to default values causes a application saved in the PLC to be deleted.
Proceed as follows:
1. Cut the power supply to the PLC.
2. Restart the PLC, while pressing down the reset key with a pointed object.
“System is being initialized… Cold start values loaded!“ appears briefly on the display
before the normal display with the current firmware version (displays on page 5) ap-
pears.
The values of the setting level are the same as the default values (see section 8.1).
EB 5571 EN 15
Appendix
Universal input type
UE12=PT100↔PT1000
UE13=PT100↔PT1000
UE14=PT100↔PT1000
UE15=PT100↔PT1000
UE16=PT100↔PT1000
UE17=PT100↔PT1000
Back
Settings level
Date / time
RS-232/Slave
RS-485/Master
RS-232/Prog
Meter bus
Universal input type
Back

3 Manual operation
All outputs configured in manual operating mode. Refer to the wiring plan (–> section 7).
Note!
If the analog and binary output menus are activated without entering the key code before-
hand, the key icon appears at the top of the display when you press the enter key to con-
firm the setting. This setting is locked.
You can only change this setting after entering the key code first.
Proceed as follows:
Activate the editing mode.
Display: Entering the key code
0000 blinks
Enter the valid key code.
Confirm the key code.
Display: Settings level
The “Date / time“ menu item is highlighted.
Select
Back to return.
Exit the editing mode.
Display: Normal display (depending on application )
Switch to the information level.
Display: Information level
“Analog inputs“ menu item is highlighted.
Select required menu item “Analog outputs” or
“Binary outputs”.
Activate the menu item.
Select the required output.
Activate the selected output.
Display:
AA... or BA... blinks.
16 EB 5571 EN
Manual operation
Entering the key code
0000
Information level
Analog inputs
Analog outputs
Binary inputs
Binary outputs
Meter bus
System info
Back

Analog output setting: 0 to 10 V
Increase the value.
Reduce the value.
Setting with binary outputs: on/off
Binary input = on
Binary input = off
Exit the output.
Display: indicates manual intervention.
Exiting the information level
Select
Back to return.
Exit the information level.
Display: Normal display (depending on application)
4 Operational faults
Displaying errors in the error status register and sending fault alarms to a mobile phone over
the SMS function or to a fax machine can be configured in ISaGRAF®to match the applica-
tion.
The corresponding function blocks exist for this purpose.
EB 5571 EN 17
Operational faults
Information level
Analog inputs
Analog outputs
Binary inputs
Binary outputs
Meter bus
System info
Back

5 Communication
5.1 Modbus slave interface
The PLC can communicate with a control system using the RS-232 Modbus slave interface. To-
gether with the suitable process visualization software and communication software, a com-
plete control system can be implemented.
The following interface settings are possible:
–Operation with a dial-up modem on the RS-232 Modbus slave interface
Basically, communication is only established automatically when the application has been con-
figured to dial when a fault occurs. The controller works autonomously. Nevertheless, the mo-
dem can dial up to the controller at any time to read data from it or change settings, if neces-
sary. The use of the modem connecting cable (1400-7139) is recommended.
–Operation with a leased line modem on the RS-232 Modbus slave interface
Communication is established over a permanent connection between two leased line modems.
This setup is applied for long-distance transmissions or when different signal level converters
are used. The connection between the controller and the modem can also be established over
the modem connecting cable (1400-7139).
–Operation on a four-wire bus
To link the controller and the bus line, the signal level needs to be converted by an appropriate
converter (SAMSON cable converter 1400-7308).
18 EB 5571 EN
Communication
Fig. 1 · Network structure

Modbus slave interface RS-232
The Modbus connection is located on the rear panel of the controller housing (RJ 12 jack). The
controller can be connected either directly to the serial interface of a PC (point-to-point connec-
tion) or to a (dial-up) modem. A dial-up modem is required if the controller is to be connected to
the telecommunications network. In this case, the controller operates autonomously and issues
an alarm to the building control station (GLT) when faults occur. In addition, the building control
station can dial up to the controller and read data from it.
Parameters*WE Settings level / Range of values
Station address
16-bit addressing?
Control system
monitoring
255
No
30 min
RS-232/Slave > Modbus Slave / 1 to 247, 255
RS-232/Slave > Modbus Slave > Station address / Yes, No
RS-232/Slave > Modbus Slave / 1 to 300 min
Modem Off RS-232/Slave
Modem = On: PLC connected to telecommunications network
Modem = Off: PLC directly connected to a computer
Cyclical initialization 30 min RS-232/Slave > Modem = On / 1 to 300 min
Automatic disconnection 5 min RS-232/Slave > Modem = On / 1 to 300 min
Baud rate 9600 RS-232/Slave / 9600, 19200
* –> Section 5.3 (Description of communication parameters to be adjusted)
EB 5571 EN 19
Communication
GND TD DTR RTSRDDCD
Fig. 2 · Pin assignment, RJ-12 system bus interface

Modbus slave interface
in combination with RS-232/RS-485 cable converters (for four-wire bus)
Operating the PLC in combination with cable converters requires a permanent bus connec-
tion (data cable). The bus line links the devices/control units in an open ring. At the end of
the bus line, the data cable is connected to the control station using an RS-485/RS-232 con-
verter (e.g. TROVIS 5484). The maximum extension (cable length) of the bus line is 1,200 m.
A maximum of 32 devices can be connected to such a segment. If you wish to use more than
32 devices or need to bridge greater distances, make sure repeaters (e.g. TROVIS 5482) are
installed to replicate the signal. In all, a maximum of 246 devices can be connected to a bus
line.
Caution!
Make sure that the relevant standards and regulations concerning lightning and overvoltage
protection are observed upon installation.
Parameters*WE Settings level / Range of values
Station address
16-bit addressing?
Control system
monitoring
255
No
30 min
RS-232/Slave > Modbus Slave / 1 to 247, 255
RS-232/Slave > Modbus Master > Station address / Yes, No
RS-232/Slave > Modbus Slave / 1 to 300 min
Modem Off RS-232/Slave / Modem = Off
Baud rate 9600 RS-232/Slave / 9600, 19200
* –> Section 5.3 (Description of communication parameters to be adjusted)
5.2 Modbus master interface
Modbus instruments can be connected to the PLC using the RS-485 Modbus master interface.
The maximum bus line is 1,200 m. If you need to bridge greater distances, make sure repeaters
(e.g. TROVIS 5482) are installed to replicate the signal.
Terminals 1 and 2 are used for connection (see Fig. 4). Up to four expansion modules can also
be connected in parallel to these terminals. Refer to section 8.4.3 for more details.
Caution!
Make sure that the relevant standards and regulations concerning lightning and overvoltage
protection are observed upon installation.
20 EB 5571 EN
Communication
!
!