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
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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
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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.