Samson TROVIS 6495-2 Service manual

Translation of original instructions
EB 6495-2 EN
Firmware version 1.11 to 1.21
Edition September 2022
TROVIS6495-2 Industrial 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 6495-2 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 6495-2 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 Block diagrams...........................................................................................3-4
3.2 Technical data ..........................................................................................3-12
3.3 Dimensions...............................................................................................3-16
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the industrial controller....................................4-1
4.3 Transporting the industrial controller.............................................................4-1
4.4 Lifting the industrial controller ......................................................................4-1
4.5 Storing the industrial controller.....................................................................4-2
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-1
5.3 Mounting the industrial controller .................................................................5-1
5.4 Installing the interface board........................................................................5-2
5.5 Electrical connection....................................................................................5-3
6 Operation..................................................................................................6-1
6.1 Device overview..........................................................................................6-1
6.2 Operating controls......................................................................................6-3
6.3 Operating structure.....................................................................................6-4
7 Start-upandconguration..........................................................................7-1
7.1 Conguration .............................................................................................7-1
7.1.1 Enteringthecongurationmenu...................................................................7-5
7.1.2 Conguringthecontroller ............................................................................7-5
7.1.1.1 Settingcongurationitems...........................................................................7-6
7.1.2.1 Congurationexample................................................................................7-7
7.1.3 Adapting the display direction .....................................................................7-8
7.1.3.1 Changing the controller display....................................................................7-9
7.1.3.2 Setting up additional display......................................................................7-11

Contents
EB 6495-2 EN
7.1.3.3 Switching Controller [1] and Controller [2] displays.....................................7-15
7.2 CongurationusingtheTROVIS-VIEWsoftware ..........................................7-17
7.3 User calibration........................................................................................7-17
7.3.1 Calibrating analog inputs..........................................................................7-17
7.3.2 Calibrating analog outputs ........................................................................7-18
8 Operation..................................................................................................8-1
8.1 Operating level...........................................................................................8-1
8.1.1 Adjusting the set point.................................................................................8-2
8.1.2 Switching over to manual mode and changing the output...............................8-2
8.1.3 Opening/closing cascade ...........................................................................8-3
8.2 Info menu...................................................................................................8-4
8.3 Operating menu .........................................................................................8-8
8.3.1 Entering the operating menu........................................................................8-8
8.3.2 Changing the control parameters ...............................................................8-10
8.3.3 Switchingoverinternal/externalsetpoint ...................................................8-11
8.3.4 Switching over and changing internal set points ..........................................8-12
8.4 Locking the controller ................................................................................8-14
8.4.1 Locking the operating level ........................................................................8-14
8.4.2 Locking all keys over a digital input............................................................8-15
8.4.3 Activating key number operation................................................................8-16
8.5 Data transmission .....................................................................................8-18
8.5.1 TROVIS-VIEW...........................................................................................8-18
8.5.2 Infrared interface ......................................................................................8-19
8.5.3 RS-232/USB interface board.....................................................................8-19
8.5.3.1 Memory pen.............................................................................................8-21
8.5.3.2 Data transmission between the controller and memory pen...........................8-22
8.5.4 RS-485/USB interface board.....................................................................8-22
9 Malfunctions ..............................................................................................9-1
9.1 Troubleshooting ..........................................................................................9-1
9.2 Emergency action .......................................................................................9-3
10 Servicing..................................................................................................10-1
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
13 Repairs ....................................................................................................13-1
13.1 Returning devices to SAMSON ..................................................................13-1
14 Disposal...................................................................................................14-1

Contents
EB 6495-2 EN
15 Certicates...............................................................................................15-1
16 AnnexA(congurationguide) ..................................................................16-1
16.1 Abbreviations...........................................................................................16-1
16.2 Congurationlist·Functionsandparameters ..............................................16-2
17 Annex B...................................................................................................17-1
17.1 Accessories ..............................................................................................17-1
17.2 After-sales service.....................................................................................17-2

EB 6495-2 EN

EB 6495-2 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The TROVIS6495-2 Industrial 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
controllers in applications or conditions other than those 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 6495-2 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 6495-2 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
The TROVIS6495-2 Industrial Controller with a CE marking fullls the requirements of the
Directives 2014/30/EU and 2014/35/EU.
The TROVIS6495-2 Industrial Controller with an 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6495-2 Industrial Controller consists of the Mounting and
Operating Instructions EB6495-2 and the Conguration Manual uKH6495-2.
These instructions EB6495-2 describe the installation, electrical wiring and operation of the
controller. In addition, EB6495-2 includes a list of all conguration settings.
The Conguration Manual uKH6495-2 describes the controller's functions in detail. The
control modes are explained using examples of applications. The TROVIS-VIEW4 software 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 6495-2 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
application.
The controller is congured for specic applications by setting conguration items and
parameters. Conguration and parameterization have a 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).