Samson Trovis 6493 Service manual

Translation of original instructions
EB 6493 EN
Firmware version 4.03
Edition August 2021
TROVIS6493 Compact Controller

Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 6493 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 6493 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-3
1.2 Notes on possible property damage.............................................................1-4
2 Markings on the device ..............................................................................2-1
2.1 Housing inscription .....................................................................................2-1
2.2 Article code................................................................................................2-2
2.3 Firmware versions.......................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Technical data ............................................................................................3-5
3.2 Dimensions.................................................................................................3-8
3.3 Values for resistance thermometers ...............................................................3-9
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the compact controller.....................................4-1
4.3 Transporting the compact controller ..............................................................4-1
4.4 Storing the compact controller......................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-1
5.3 Mounting the compact controller ..................................................................5-1
5.4 Electrical connection....................................................................................5-3
6 Operation..................................................................................................6-1
6.1 Device overview..........................................................................................6-1
6.2 Operating controls ......................................................................................6-2
6.3 Display ......................................................................................................6-3
6.4 Infrared interface ........................................................................................6-4
7 Start-upandcongurationatthedevice......................................................7-1
7.1 Conguration .............................................................................................7-1
7.1.1 Conguringthecompactcontroller...............................................................7-8
7.2 Entering the key number............................................................................7-14
7.3 Tuning the control parameters ....................................................................7-18
7.3.1 Empirical tuning method............................................................................7-18
7.3.2 Tuning according to the Ziegler and Nichols method....................................7-19
7.3.3 -CO- TUNE: Start-up adaptation................................................................7-23

Contents
EB 6493 EN
8 Start-upandcongurationwithTROVIS-VIEW .............................................8-1
8.1 Communication ..........................................................................................8-1
8.1.1 Interface.....................................................................................................8-1
8.1.2 Addressing.................................................................................................8-3
8.1.3 Communication readings on the display .......................................................8-3
8.2 Folders in TROVIS-VIEW..............................................................................8-4
8.2.1 Identication...............................................................................................8-4
8.2.2 Operation ..................................................................................................8-4
8.2.3 Functions and parameters............................................................................8-6
8.2.3.1 Control parameters [PAR] ............................................................................8-7
8.2.3.2 Input [IN] ...................................................................................................8-7
8.2.3.3 Set point [SETP] ..........................................................................................8-9
8.2.3.4 Controller [CNTR] .......................................................................................8-9
8.2.3.5 Output [OUT] .............................................................................................8-9
8.2.3.6 Limit relays [ALRM] .....................................................................................8-9
8.2.3.7 Additional functions [AUX] ..........................................................................8-9
8.2.3.8 Start-up adaptation [TUNE] .......................................................................8-10
8.2.3.9 Process data [I-O] .....................................................................................8-11
9 Operation..................................................................................................9-1
9.1 Setting the internal set point.........................................................................9-1
9.2 Switchover between set points......................................................................9-1
9.3 Switching over to manual mode and changing the manipulated variable.........9-3
9.4 AUX menu, -CO- ST.IN: Reset to default settings ............................................9-3
9.5 AUX menu, -CO- VIEW: Set viewing angle of the display...............................9-4
9.6 I-O menu: Process data ...............................................................................9-4
9.6.1 -CO- CIN: Firmware version ........................................................................9-4
9.6.2 -CO- S-No: Serial number...........................................................................9-4
9.6.3 -CO- ANA: Show analog inputs and outputs.................................................9-5
9.6.4 -CO- BIN: Show binary inputs and outputs ...................................................9-5
9.6.5 -CO- ADJ: Calibration of analog inputs and analog output ............................9-5
10 Malfunctions ............................................................................................10-1
10.1 Troubleshooting ........................................................................................10-1
10.2 Error messages generated by the compact controller....................................10-4
10.3 Emergency action .....................................................................................10-4
11 Servicing..................................................................................................11-1
12 Decommissioning .....................................................................................12-1
13 Removal ..................................................................................................13-1

Contents
EB 6493 EN
14 Repairs ....................................................................................................14-1
14.1 Returning devices to SAMSON ..................................................................14-1
15 Disposal...................................................................................................15-1
16 Certicates...............................................................................................16-1
17 AnnexA(congurationguide) ..................................................................17-1
17.1 Abbreviations...........................................................................................17-1
17.2 Congurationlist.......................................................................................17-2
17.3 Congurationprotocol.............................................................................17-20
18 Annex B...................................................................................................18-1
18.1 Accessories ..............................................................................................18-1
18.2 After-sales service.....................................................................................18-2

Contents
EB 6493 EN

EB 6493 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The TROVIS6493 Compact Controller is a digital controller to automate the industrial and
process plants. The controller is suitable for controlling continuous, on/off or pulsing nal
control elements.
The controller is designed to operate under exactly dened conditions. Therefore, operators
must ensure that the controller is only used in operating conditions that meet the specica-
tions used for sizing the controller at the ordering stage. In case operators intend to use the
controller in other applications or conditions than specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer to the technical data for limits and elds of application as well as possible uses. See
the 'Design and principle of operation' section.
Reasonably foreseeable misuse
The controller is not suitable for the following applications:
−Use outside the limits dened during sizing and by the technical data
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described
Qualications of operating personnel
The controller must be mounted, started up, serviced and repaired by fully trained and quali-
ed personnel only; the accepted industry codes and practices must be observed. According
to these mounting and operating instructions, trained personnel refers to individuals who are
able to judge the work they are assigned to and recognize possible hazards due to their spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

1-2 EB 6493 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the controller.
Revisions and other modications
Revisions, conversions or other modications of the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
The controller has a direct effect on the nal control element. To avoid personal injury or
property damage, plant operators and operating personnel must prevent hazards that could
be caused in the control valve by the process medium, the operating pressure, the signal
pressure or by moving parts by taking appropriate precautions. Plant operators and operat-
ing personnel must observe all hazard statements, warning and caution notes in the refer-
enced documents.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed to
any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

EB 6493 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
The TROVIS6493 Compact Controller with a CE marking fullls the requirements of the Di-
rectives 2014/30/EU and 2014/35/EU.
The TROVIS6493 Compact Controller with a EAC marking fullls the requirements of the
Regulations TRCU004/2011 and TRCU020/2011.
The 'Certicates' section contains this declaration of conformity and TR CU certicate.
The controller is designed for use in low voltage installations.
ÎFor wiring, maintenance and repair, observe the relevant safety regulations.
Referenced documentation
The documentation for the TROVIS6493 Compact Controller consists of the Mounting and
Operating Instructions EB6493 and the Conguration Manual uKH6493.
These mounting and operating instructions EB6493 describe the installation, electrical wiring
and operation of the controller. In addition, EB6493 includes a list of all conguration set-
tings.
The Conguration Manual KH6495-2 uKH6493 describes the controller's functions in de-
tail. The control modes are explained using examples of applications. The TROVIS-VIEW soft-
ware is explained in detail in the Operating Instructions uEB6661.
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to electric shock.
ÎBefore connecting wiring, performing any work on the device or opening the de-
vice, disconnect the supply voltage and protect it against unintentional reconnec-
tion. Make sure that the contacts of the digital outputs are voltage-free.
ÎOnly use power interruption devices that can be protected against unintentional re-
connection of the power supply.
ÎDo not remove any covers to perform adjustment work on live parts.

1-4 EB 6493 EN
Safety instructions and measures
1.2 Notes on possible property damage
NOTICE
!
Risk of damage to the controller due to the supply voltage exceeding the permissible
tolerances.
The controller is designed for use in low voltage installations.
ÎObserve the permissible tolerances of the supply voltage.
Controller damage caused by water.
The terminals and the controller housing are not protected against water (terminals:
IP00, housing: IP30). Only the front panel of the controller is protected against water
(IP65) when installed properly.
ÎProtect the terminals and the controller housing against drops, sprays and jets of
water.
Malfunction due to a conguration that does not meet the requirements of the appli-
cation.
The controller is congured for specic applications by setting conguration items and
parameters. Conguration and parameterization have an direct effect on nal control
elements.
ÎPerform the conguration for the specic application.
Manipulation of the conguration due to unauthorized access.
The controller can be protected against unauthorized access through entering a key
number.
ÎActivate key number operation (see the 'Operation' section).
ÎDo not pass the (service) key number on to unauthorized persons. Keep it in a safe
place inaccessible to unauthorized persons.
The operator keys can be protected against unauthorized access over a digital input.
ÎLock the operator keys over a digital input (see the 'Operation' section).

EB 6493 EN 2-1
Markings on the device
2 Markings on the device
2.1 Housing inscription
The details on the device version are lasered onto the nameplate on the side of the controller
housing.
SAMSON
TROVIS 6493
Made in Germany
1
6
5
2
3
4
7
8
9
10
1 Analog inputs (IN1 and IN2)
2 Binary input (BI)
3 Analog output (Y)
4 Binary outputs (BO1 to BO3)
5 Two-wire transmitter supply
6 Supply voltage
7 Firmware version
8 Model number
9 Serial number
10 Conguration ID

2-2 EB 6493 EN
Markings on the device
2.2 Article code
TROVIS6493-032 Compact
Controller x
Supply voltage
90 to 250VAC 4
24VAC/DC 5
2.3 Firmware versions
Firmware revisions
Old New
4.01 4.02
Internal revisions
4.02 4.03
Internal revisions

EB 6493 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The TROVIS6493 Compact Controller is a
panel-mounted digital controller to automate
the industrial and process plants. It is suit-
able for control of continuous, on/off or
pulsing nal control elements (e.g. electro-
pneumatic positioners, electric actuators,
heating systems, refrigerating machines etc.)
The controller is congured to adapt it to
control tasks. The controller settings are
saved in a non-volatile memory, even when
the power supply fails. It can be protected by
a key number.
Control modes
The compact controller is designed for xed
set point and follow-up control. Two internal
set points and one input for the external set
point are available.
Default settings
The default compact controller is a tempera-
ture controller for xed set point control with
the internal set point W that operates as a PI
controller.
The controlled variable is measured at the
analog input IN2 (Pt100 resistance ther-
mometer).
The 4 to 20mA control signal is issued at the
analog output Y.
Analog inputs
The analog inputs IN1 and IN2 can be ad-
justed to the following ranges:
−0 to 20mA, 4 to 20mA, 0 to 10V, 2 to
10V
−Pt100, Pt1000, Ni100, Ni1000 resis-
tance thermometers in three-wire circuits:
The resistance of each connection lead
must be the same and not exceed 15Ω.
Resistance thermometers can also be
connected in two-wire circuits.
In two-wire circuits, take into account that the
lead resistance may reach several ohms over
long distances, causing the measured value
to be considerably distorted. This measured
value can be compensated for by a correc-
tion value (see '-CO- F.FOR Feedforward
control' in the Conguration Manual
uKH6493).
−Potentiometer 1kΩ (resistance transmit-
ter) in three-wire circuit:
A potentiometer is used, for example for
position feedback of an electrical actua-
tor or for input of an external set point.
The controller is congured to assign an in-
put to the controlled variable X and the other
input to the input variable WE. The input
variable WE can be used as an external set
point, feedforward control input value (auxil-
iary controlled variable) or external position
feedback. The '-CO-F.FOR Feedforward
control' function allows two input variables
to be added or subtracted. For example, a
Note

3-2 EB 6493 EN
Design and principle of operation
differential control can be implemented by
subtracting two inputs.
Binary input
The binary input BI1 is activated by a volt-
age signal (4 to 31VDC) and can be used
as follows:
−Start set point ramp
−Switchover between set points
−Increase/decrease actual value
−Activation of the constant output value
(e.g. for enabling control)
−Manual/automatic switchover
−Start output ramp
−Locking manipulated variable
−Activate binary outputs
−Lock control keys
ÎuKH6493.
Several functions can be assigned to the bi-
nary input.
Analog output
The following ranges can be adjusted for the
analog output Y:
−0 to 20mA, 4 to 20mA, 0 to 10V, 2 to
10V
The manipulated variable Y is issued at the
analog output by default. Alternatively, the
input variables X and WE as well as the er-
ror Xd can be issued.
Binary outputs
The binary outputs BO1 and BO2 are de-
signed as relays with double-throw contacts.
They can either used as a three-step output,
on/off output or to monitor limit values and
issue status alarms.
The binary output BO3 is designed as a gal-
vanically isolated transistor output to indicate
collective error messages. If an internal error
exists or the congured signal monitoring of
the inputs responds, the externally connected
voltage signal (3 to 50VDC, max. 30mA)
is generated.
Supply output – Transmitter supply
The supply output (20VDC, max. 45mA)
can be used to supply two two-wire transmit-
ters and the binary input.
Infrared interface
The infrared interface is used to exchange
data between the controller and the TRO-
VIS-VIEW software.
Conguration
The compact controller can either be cong-
ured and operated directly at the controller
using the keys on the front panel (see the
'Operation' section) or on a computer using
the TROVIS-VIEW software (uT6661 and
uEB6661).

EB 6493 EN 3-3
Design and principle of operation
TROVIS-VIEW provides a uniform user
interface that allows users to congure and
parameterize various SAMSON devices
using device-specic database modules. The
device module 6493 can be downloaded
free of charge from our website at
uwww.samsongroup.com > SERVICE &
SUPPORT > Downloads > TROVIS-VIEW.
Further information on TROVIS-VIEW (e.g.
system requirements) is available on our
website and in the Data Sheet uT6661.
Note

3-4 EB 6493 EN
Design and principle of operation
IN 1
BI 1
Y
BO 1
IR
IN 2
mA, V
BO 2
BO 3
PWM 3-step
ON/OFF 3-step
PWM
TROVIS 6493
mA, V Pt 100 Pt 1000 Ni 100 Ni 1000 Pot. 1 k
TROVIS-
VIEW
Analog inputs
Binary input
Inter- face
Supply voltage
Limit alarms
Transistor output
Fault alarm
Supply output
Analog output
Relay outputs
On/off and three-step output
Fig.3-1: Wiring diagram (inputs and outputs)

EB 6493 EN 3-5
Design and principle of operation
3.1 Technical data
Table3-1: Technical data · TROVIS6493
Inputs
Analog input IN1
Analog input IN2
Two analog inputs, optionally for controlled variable
X or external set point WE
0/4 to 20mA or 0/2 to 10V, resistance
thermometer Pt100, Pt1000, Ni100, Ni1000 or
potentiometer 1kΩ
Input for cur-
rent and volt-
age
Nominal signal range 0/4 to 20mA or 0/2 to 10V
Max. permissible values Current ±50mA, voltage ±25V
Internal resistance Current Ri = 50Ω, voltage Ri = 20kΩ
Permissible common
mode voltage 0 to 5V
Error Zero <0.2%, span <0.2%, linearity <0.2%
Effect of temperature <0.1%/10K for zero and span1)
Resolution <0.0024mA
<1.2mV
(<0.012% with 0 to 20mA)
(<0.015% with 4 to 20mA)
(<0.012% with 0 to 10V)
Transmitter supply According to DINIEC381 (NAMUR Recommenda-
tion NE06) 20VDC, max. 45mA, resistant to
short circuiting
Resistance
thermometer
For sensor Pt100, Pt1000 according to DINEN60751
Ni100, Ni1000 according to DIN43760
Nominal measuring
range
Pt100, Pt1000: –100 to +500°C
Ni100, Ni1000: –60 to +250°C
Wire resistance Three-wire RL1= RL2= RL3 < 15Ω
Error Zero < 0.2%, span < 0.2%, linearity < 0.2%
Pt100, Pt1000 in the
range between –40 and
+150°C
Zero < 0.1%, span < 0.1%, linearity < 0.1%
Effect of temperature <0.2%/10K for zero and span1)
Resolution <0.04°C (<0.007% at –100 to +500°C)
1) Based on 20°C

3-6 EB 6493 EN
Design and principle of operation
Inputs
Resistance
transmitters
(potentiome-
ters)
Nominal value 1kΩ, three-wire
Wire resistance RL < 15Ω per wire
Error Zero <0.2%, span <0.2%
Effect of temperature Zero <0.1%/10K, span <0.2%/10K 1)
Resolution <0.07Ω (<0.007%)
Binary input Switching contact
−With external supply 24VDC (4 to 31VDC)
or
−Powered by the controller over terminals 14, 15
(20VDC)
Signal state OFF with 0 to 2V
Signal state ON with 4 to 31V
Current draw <6mA at 24VDC
<5.5mA at 20VDC
1) Based on 20°C
Outputs
Analog output Nominal signal range 0/4 to 20mA, load <740Ω
0/2 to 10V, load >3kΩ
Max. permissible signal
range 0 to 22mA, 0 to 11V
Error <0.2%
Effect of temperature Zero <0.1%/10K, span <0.1%/10K
Resolution <0.0015mA (<0.0075% with 0 to 20mA)
(<0.0094% with 4 to 20mA)
<0.75mV (<0.0075% with 0 to 10V)
Binary output BO1
Binary output BO2
Two relays with oating switching contact, max.
250VAC, max. 250VDC,
max. 1AAC, max. 0.1ADC, cosφ= 1
Spark suppression Connected in series C = 2.2nF and varistor
300VAC, in parallel to each relay contact
Binary output BO3 for fault alarms Isolated transistor output, external supply 3 to
50VDC, max. 30mA
Infrared interface Transmission protocol: SAMSON protocol (SSP)
Transmission rate: 9600bit/s
Angle of reected beam: 50°
Distance between infrared adapter and controller:
max. 0.7m

EB 6493 EN 3-7
Design and principle of operation
Generalspecications
Display Backlit LCD
Display range –999 to +9999; start value, end value and decimal sep-
arator can be adjusted
Conguration Functions saved in read-only memory for xed set point
and follow-up control, one control circuit
Supply voltage 90 to 250VAC; 47 to 63Hz
24VAC/DC (20 to 30VAC/DC), 47 to 63Hz
Power consumption 13VA (90 to 250VAC), external fuse >630mA (slow)
7VA (24VAC/DC), external fuse >1.25A (slow)
Type of connection Screw clamp terminals
Wire cross-section Max. 1.5mm²
Temperature Ambient: 0 to 50°C
Storage and transport: –20 to +70°C
Mechanical environmental conditions af-
fecting storage, transport and operation
Sinusoidal vibration according to IEC60068-2-6:
2 to 9Hz; 3.5mm amplitude
9 to 200Hz; 10m/s² acceleration
200 to 500Hz; 15m/s² acceleration
Random and guidance vibration according to IEC60068-
2-64:
1.0m²/s³; 10 to 200Hz
0.3m²/s³; 200 to 2000Hz
Shocks according to IEC60068-2-27:
Acceleration 100m/s²; duration 11ms
Degree of protection IP65 (front), IP30 (housing), IP00 (terminals) according
to EN60529
Device safety According to EN61010-1:
Class of protection II
Overvoltage category II
Degree of contamination 2
Design and testing according to EN61010-1
Electromagnetic compatibility Requirements according to EN61000-6-2, EN61000-6-
3 and EN61326-1
Cycle time ≤80ms
Weight Approx. 0.5kg
Conformity

3-8 EB 6493 EN
Design and principle of operation
3.2 Dimensions
158 (6.18)
142 (5.59)1048 (1.89)
96 (3.78)
91,5 (3.60)
Fig.3-2: Dimensions in mm (inch)