Samson TROVIS 5575 Service manual

Automation System TROVIS 5500
Heating and District Heating Controller
TROVIS 5575
Mounting and
Operating Instructions
EB 5575 EN
Firmware version 1.6x
Edition January 2007
®
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 5575 EN
Disclaimer of liability

Table of contents
1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Rotary pushbutton and changeover key . . . . . . . . . . . . . . . . . 7
1.1.2 Rotary switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Displaying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Setting the controller time . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Setting the times-of-use . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Setting party mode . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Activating extended operating level . . . . . . . . . . . . . . . . . . 16
1.8.1 Setting public holidays . . . . . . . . . . . . . . . . . . . . . . . . 17
1.8.2 Setting vacation periods . . . . . . . . . . . . . . . . . . . . . . . . 18
1.9 Presetting room and DHW temperature set points. . . . . . . . . . . . 20
2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Setting the system code number . . . . . . . . . . . . . . . . . . . . 22
2.2 Activating and deactivating functions. . . . . . . . . . . . . . . . . . 23
2.3 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Calibrating the sensors . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Resetting to default values . . . . . . . . . . . . . . . . . . . . . . . 27
3 Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Functions of the heating circuit . . . . . . . . . . . . . . . . . . . . 50
5.1 Weather-compensated control . . . . . . . . . . . . . . . . . . . . . 50
5.1.1 Gradient characteristic . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1.2 4-point characteristic . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2 Fixed set point control . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Underfloor heating/drying of jointless floors . . . . . . . . . . . . . . 54
5.4 Deactivation depending on outdoor temperature . . . . . . . . . . . . 56
5.4.1 OT deactivation value in rated operation . . . . . . . . . . . . . . . . 56
5.4.2 OT deactivation value in reduced operation . . . . . . . . . . . . . . 56
5.4.3 OT activation value in rated operation . . . . . . . . . . . . . . . . . 56
5.4.4 Summer mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 Delayed outdoor temperature adaptation. . . . . . . . . . . . . . . . 57
5.6 Remote operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.7 Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Contents

5.8 Flash adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.8.1 Flash adaptation without outdoor sensor (room temperature dependent) . 61
5.9 Adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6 Functions of the DHW circuit. . . . . . . . . . . . . . . . . . . . . . 63
6.1 DHW heating in the storage tank system . . . . . . . . . . . . . . . . 63
6.1.1 DHW circuit additionally controlled by a globe valve . . . . . . . . . . 65
6.2 DHW heating in the storage tank charging system . . . . . . . . . . . 66
6.3 DHW heating in instantaneous heating system . . . . . . . . . . . . . 68
6.4 DHW heating with solar system . . . . . . . . . . . . . . . . . . . . 69
6.5 Intermediate heating operation . . . . . . . . . . . . . . . . . . . . 69
6.6 Parallel pump operation . . . . . . . . . . . . . . . . . . . . . . . . 70
6.7 Circulation pump operation during storage tank charging. . . . . . . . 70
6.8 Priority operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.8.1 Reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.8.2 Set-back operation . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.9 Forced charging of the DHW storage tank . . . . . . . . . . . . . . . 71
6.10 Thermal disinfection of the DHW storage tank . . . . . . . . . . . . . 72
7 System-wide functions . . . . . . . . . . . . . . . . . . . . . . . . 74
7.1 Automatic summer time/winter time changeover . . . . . . . . . . . . 74
7.2 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Forced operation of the pumps. . . . . . . . . . . . . . . . . . . . . 75
7.4 Return flow temperature limitation . . . . . . . . . . . . . . . . . . . 75
7.5 Condensate accumulation control . . . . . . . . . . . . . . . . . . . 76
7.6 Three-step control . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.7 On/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.8 Releasing a control circuit over the binary input. . . . . . . . . . . . . 77
7.9 Processing of external demand in Rk1 . . . . . . . . . . . . . . . . . 78
7.10 Flow rate/heat capacity limitation in Rk1. . . . . . . . . . . . . . . . 80
7.10.1 Limitation using pulse input . . . . . . . . . . . . . . . . . . . . . . 80
7.10.2 Limitation using 0/4 to 20 mA signal . . . . . . . . . . . . . . . . . 81
7.10.3 Creep feed rate limitation over binary input . . . . . . . . . . . . . . 82
7.10.4 Limitation of the calculated capacity . . . . . . . . . . . . . . . . . . 82
7.11 Device bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.11.1 Requesting and processing an external demand . . . . . . . . . . . . 84
7.11.2 Sending and receiving outdoor temperatures . . . . . . . . . . . . . . 85
7.11.3 Synchronizing the clock . . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.4 Priority over all controllers . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.5 Connecting a TROVIS 5570 Room Panel . . . . . . . . . . . . . . . . 87
7.11.6 Display error alarms issued by the device bus . . . . . . . . . . . . . 87
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Contents

7.12 Feeder pump operation . . . . . . . . . . . . . . . . . . . . . . . . 88
7.13 Locking manual level . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.14 Locking the rotary switches . . . . . . . . . . . . . . . . . . . . . . 88
7.15 Setting a customized key number . . . . . . . . . . . . . . . . . . . 89
8 Operational faults . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.2 Sensor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.3 Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . 91
9 Memory module . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.1 Data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 96
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.1 Function block lists . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.2 Parameter lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
12.3 Assignment of the rotary switches. . . . . . . . . . . . . . . . . . . 121
12.4 Sensor resistance tables . . . . . . . . . . . . . . . . . . . . . . . 122
12.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
12.6 Customer data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Frequently used abbreviations . . . . . . . . . . . . . . . . . . . . 137
EB 5575 EN 5
Contents

Controller versions
The TROVIS 5575 Heating Controller is available in various versions. The type designation
registered on the nameplate of the controller indicates the controller version:
Type designation (nameplate) Version
TROVIS 5575-000x Standard controller with illuminated display background and with
device bus
TROVIS 5575-001x Controller with illuminated display background, with device bus
and with an additional pump output
TROVIS 5575-002x Controller without illuminated display background and without
device bus
These instructions apply to all versions of the TROVIS 5575-00xx Heating Controller.
6EB 5575 EN
Controller versions

1 Operation
The controller is ready for use with the temperatures and operating 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 Operating elements
The operating controls are located in the front panel of the controller and protected by a
Plexiglas door.
1.1.1 Rotary pushbutton and changeover key
Rotary pushbutton
Turn q:
Display, select parameters and function blocks
Press :
Confirm adjusted selection or settings
Changeover key
(use pen or any other pointed item to press)
Press to switch between operating level and configuration/pa-
rameter level
EB 5575 EN 7
Operation
*

1.1.2 Rotary switches
Use the three rotary switches to adjust the desired operating mode (icons on the left) and the
relevant parameters (icons on the right).
The top and middle switches are assigned to the heating circuits (see page 121). The rotary
switch in the middle is not used in systems without a second heating circuit.
The bottom switch is assigned to the DHW circuit.
Rotary switch to adjust the operating modes of the heating circuit
Automatic/time-controlled operation
with switchover between day and night modes
Day mode (rated operation)
Night mode (reduced operation)
Control operation deactivated, frost protection only
Manual operation: correction value adjusted in percent
and activation/deactivation of the pumps
Rotary switch to adjust the parameters of the heating circuit
Day set point (rated room temperature)
Night set point (reduced room temperature)
Times-of-use for heating
Party mode
Controller time: setting current time, date and year
Rotary switch to adjust the operating modes of the DHW circuit
Automatic/time-controlled operation
with switchover between times when DHW heating
is permissible/impermissible
DHW heating deactivated, frost protection only
Manual operation: correction value adjusted in percent
and activation/deactivation of the pumps
8EB 5575 EN
Operation

Rotary switch to adjust the parameters of the DHW circuit
Set point for DHW temperature
Times-of-use for DHW heating
Times-of-use for DHW circulation pump
Party mode
Note!
If several rotary switches are set to “Parameter“ (right side), blinks on the display. The
controller cannot be operated.
1.2 Operating modes
Day mode (rated operation)
Regardless of the programmed times-of-use and summer mode, the set points relevant for
rated operation are used by the controller.
Night mode (reduced operation)
Regardless of the programmed times-of-use, the set points relevant for reduced operation are
used by the controller.
Automatic/time-controlled operation
During the programmed times-of-use, the controller works in rated operation. Outside these
times-of-use, the controller is in reduced operation, unless control operation is deactivated
depending on the outdoor temperature. The controller switches automatically between both
operating modes.
Manual operation
Valves and pumps can be controlled manually (–> section 3).
EB 5575 EN 9
Operation

1.3 Display
During operation, the display indicates the current time as well as information about the op-
eration of the controller. The times-of-use are represented by black squares below the row of
numbers at the top of the display. Icons indicate the operating status of the controller.
The controller status can be displayed in operating level (–> section 1.4).
TROVIS 5575-000x and TROVIS 5575-001x:
An illuminated display indicates that the controller is being operated or a fault exists.
TROVIS 5575-002x:
Version without illuminated display
10 EB 5575 EN
Operation
STOP
118
2
3
6
7
8
9
4
5
10 11 12 13 14 15 16 17
19
20
Fig. 1 · Icons
1 Automatic operation
2 Day mode
(rated operation)
3 Night mode
(reduced operation)
4 Vacation mode
5 Public holiday mode
6 Frost protection
7 Malfunction
8 Circulation pump UP1*
9 Valve Rk1: OPEN
10 Valve Rk1: CLOSED
11 Storage tank charging
pump SLP
12 Output bA9*
13 Circulation pump UP5*
14 DHW demand
15 Circulation pump UP2*
16 Valve Rk2: OPEN
17 Valve Rk2: CLOSED
18 Time-of-use
19 Control circuit assignment:
: Heating circuit 1
: Heating circuit 2
20 OT dependent control
deactivated
* UP1, UP2, SLP, UP5, bA9 indicate possible choices for pump selection in manual operating mode.

1.4 Displaying data
The time, date, public holidays and vacation periods as well as the temperatures of con-
nected sensors and their set points can be retrieved and displayed with the help of the rotary
pushbutton.
Note!
Data can also be viewed in manual operating mode .
To do so, select Info, confirm and proceed as described below.
Proceed as follows:
qSelect value.
Depending on the configuration of the controller, the different data points are dis-
played:
__:__ Time
Room temperature, heating circuit 1, 2
Outdoor temperature
Temperature at flow sensor VF, heating circuit 1, 2
Temperature at flow sensor VF1, primary heat exchanger circuit
Temperature at flow sensor VF2, DHW circuit
Temperature at solar collector sensor VF3
Temperature at return flow sensor RüF
Temperature at storage tank sensor SF1
Temperature at storage tank sensor SF2
Temperature at storage tank sensor SF2 of the solar circuit
Temperature at flow sensor VF4
Compare the set point/limit value and the actual value.
Press the rotary pushbutton to display the time and date.
EB 5575 EN 11
Operation

1.5 Setting the controller time
The current time and date need to be set immediately after start-up and after a power failure
of more than 24 hours has occurred. This is the case when the time blinks on the display.
Proceed as follows:
Turn the top rotary switch to position “Controller
time“ (right side).
Display shows: time
qEdit the controller time.
Confirm the adjusted time.
Display shows: year
qEdit the year.
Confirm the adjusted year.
Display shows: date (day.month)
qEdit the date.
Confirm the adjusted date.
Display shows: time
Return the rotary switch to the desired operating mode
(left side).
12 EB 5575 EN
Operation
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242322212019181716151413121110 9876543210

1.6 Setting the times-of-use
Three times-of-use can be set for each day of the week.
If only one time-of-use is required, the start and stop times of the second time-of-use must be
adjusted to identical values. In this case, the third time-of-use is not displayed.
If only two times-of-use are required, the start and stop times of the third time-of-use must be
adjusted to identical values.
The times-of-use for the different control circuits are adjusted at the rotary switches one after
the other:
Times-of-use Rotary switch Position
Heating circuit 1* Top
Heating circuit 2* Middle
DHW heating* Bottom
Circulation pump Bottom
* Refer to page 121 for assignment
Parameters WE* Range of values
Time period/day 1–7 1–7, 1, 2, 3, 4, 5, 6, 7 with 1–7 = daily,
1 = Monday, 2 = Tuesday, …, 7 = Sunday
Start first time-of-use 06:00 00:00 to 24:00 h; in steps of 15 minutes
Stop first time-of-use 22:00 00:00 to 24:00 h; in steps of 15 minutes
Start second time-of-use 22:15 00:00 to 24:00 h; in steps of 15 minutes
Stop second time-of-use 22:15 00:00 to 24:00 h; in steps of 15 minutes
Start third time-of-use – 00:00 to 24:00 h; in steps of 15 minutes
Stop third time-of-use – 00:00 to 24:00 h; in steps of 15 minutes
* Default values (WE) valid for heating circuit 1/primary heat exchanger circuit (top rotary switch)
EB 5575 EN 13
Operation

Proceed as follows: Turn appropriate rotary switch to position
“Times-of-use”.
Display shows:
1–7
qSelect period/day for which the times-of-use are to be
valid:
1–7 = every day,
1 = Monday, 2 = Tuesday, ..., 7 = Sunday
Activate editing mode for period/day.
Display shows:
START , blinks
qEdit start time (steps of 15 minutes).
Confirm start time.
Display shows:
STOP
qEdit stop time (steps of 15 minutes).
Confirm stop time.
Display shows:
START
The second time-of-use is set like the first time-of-use.
To set the times-of-use for each day, repeat the instructions in the fields highlighted in gray.
Return the rotary switch to the desired operating mode (left side).
Note!
Do not use the 1–7 menu to check the programmed times-of-use.
If this menu is opened after the times-of-use have been programmed, the schedule program-
med for Monday is also adopted for all other days of the week.
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Operation
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STOP
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START
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1.7 Setting party mode
Using the Party mode function, the controller continues or activates rated operation of the
controller during the time when the party timer is active, regardless of the adjusted
times-of-use. The party timer begins when the rotary switch has been returned to operating
mode “Automatic“. When the party timer has elapsed, the party function is reset to
00:00.
The party modes for the different control circuits are adjusted at the rotary switches one after
the other:
Party timer Rotary switch Position
Heating circuit 1* Top
Heating circuit 2* Middle
DHW circuit* Bottom
* Refer to page 121 for assignment
Parameter WE Range of values
Continue/activate rated operation 0 h 0 to 48 h
Proceed as follows:
Turn appropriate rotary switch to “Party mode“.
Display shows:
00:00 or the remaining time of the adjusted party timer
qEdit desired length of the one-off time-of-use.
Return the rotary switch to operating mode “Automatic“ (left side).
Note!
The time elapsing on the party timer is displayed in steps of 15 minutes.
EB 5575 EN 15
Operation

1.8 Activating extended operating level
After the key number 1999 has been adjusted, the following information can be viewed and
edited after the data points listed in section 1.4 have been displayed:
4Flow rate
4Heat capacity
4Public holidays “ “ (editable)
4Vacation periods “ “ (editable)
4Valve positions
4Switching states of the binary inputs
4Info 2 · The following data are shown in the same sequence as shown below:
Controller ID
Memory capacity of data logging module (section 9.1)
255
Operating hours of solar circuit pump (refer to section 6.4)
Water flowmeter (refer to section 6.3)
Opening the extended operating level:
Switch to configuration and parameter level.
Display shows:
0 0 0 0
qSet key number 1999.
Confirm key number.
Display shows: time
Note!
The additional information is no longer displayed when the key number 1999 is adjusted
again.
16 EB 5575 EN
Operation

1.8.1 Setting public holidays
On public holidays, the times-of-use specified for Sunday apply. A maximum of 20 public
holidays may be entered.
Parameter WE Level / Range of values
Public holidays –Extended operating level / 01.01 (1 Jan) to 31.12 (31 Dec)
Proceed as follows:
qIn extended operating mode, select “Public holidays“.
Display shows:
Open data point “Public holidays“.
qIf applicable, select
– – – – .
Activate editing mode for public holiday. blinks.
qEdit desired public holiday.
Confirm public holiday.
To enter additional public holidays, re-select
– – – – and repeat the steps in the fields high-
lighted in gray.
Exit data point “Public holidays“.
Note! Public holidays can also be adjusted in parameter level PA5 (–> section 2.3).
Deleting a public holiday:
qUnder data point “Public holidays“, select the holiday you wish to delete.
Confirm selection.
qSelect
– – – – .
Delete the public holiday.
Note!
Public holidays that are not assigned to a specific date should be deleted by the end of the
year so that they are not carried on into the following year.
EB 5575 EN 17
Operation
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1.8.2 Setting vacation periods
During vacation periods, the controller constantly remains in reduced operating mode. A
maximum of 10 vacation periods can be entered. Each vacation period can be assigned
separately to the heating circuits Rk1 to Rk2 and/or to the DHW circuit.
Parameter WE Level / Range of values
Vacation period (START, STOP) –Extended operating level / 01.01 to 31.12
Proceed as follows:
qIn extended operating level, select “Vacation periods“.
Display shows:
Open data point “Vacation periods“.
Display shows:
START , – –.– – (day.month)
qIf applicable, select
– – – – .
Activate editing mode for start date of vacation period.
blinks.
qEdit start date of vacation period.
Confirm start date of vacation period.
qEdit end of vacation period.
Display shows:
STOP, – –.– – (day.month)
Confirm end date of the vacation period.
Black squares under 1 to 4 at the top of the display
indicate the assignment of the vacation periods to the
individual heating circuits.
qSelect the control circuit to which the current vacation
period should apply.
Current vacation period applies to circuit Rk1
Current vacation period applies to circuit Rk2
–
Current vacation period applies to DHW circuit
The vacation period can be assigned to a single control
circuit or any combination of all three control circuits
(Rk1 to Rk2, DHW circuit).
To enter additional vacation periods, re-select
– – – – and repeat the steps in the fields
highlighted in gray.
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Operation
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Exit data point “Vacation periods“.
Note! Vacation periods can also be adjusted in parameter level PA5 (–> section 2.3).
Deleting vacation periods:
qUnder “Vacation periods“, select the start date of the period you wish to delete.
Confirm selection.
qSelect
– – – – .
Delete vacation period.
Note!
Vacation periods should be deleted by the end of the year so that they are not carried on
into the following year.
EB 5575 EN 19
Operation

1.9 Presetting room and DHW temperature set points
For the heating circuits, the desired room temperatures during the day ( Day set point ) and
during the night (
Night set point ) can be preset.
In the DHW circuit, the temperature you wish the DHW to be heated to can be adjusted.
The temperature set points for the different control circuits are adjusted at the rotary switches
one after the other:
Desired temperature set point Switch Position
Heating circuit 1*: Day set point Top
Heating circuit 1*: Night set point Top
Heating circuit 2*: Day set point Middle
Heating circuit 2*: Night set point Middle
DHW circuit*: DHW temperature set point Bottom
* Refer to page 121 for assignment
Parameter WE Rotary switch / Range of values
Day set point 20 °C Top, middle / 0 to 40 °C
Night set point 15 °C Top, middle / 0 to 40 °C
DHW temperature set point 55 °C Bottom / Min. to max. DHW temperature
Proceed as follows:
Turn appropriate rotary switch to “Set point temperature“.
Display shows: temperature value
qChange temperature value.
Return the rotary switch to the desired operating mode (left side).
20 EB 5575 EN
Operation