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).

EB 6495-2 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 side of the controller housing (see
Fig.2-1). No nameplate is used.
SAMSON
TROVIS 6495-2
Made in Germany
1
6
5
4
10
9
8
7
2
3
11
Fig.2-1: Information on the housing
1 Supply voltage
2 Analog inputs (AI 1 to 4)
3Digital inputs (DI 1 to 4)
4 Analog outputs (AO 1 to 3)
5Digital outputs (DO 1 to 4)
6Digital outputs (DO 5 to 7)
7 Two-wire transmitter supply
8Firmware
9 Model
10 Serial number
11 Conguration ID

2-2 EB 6495-2 EN
Markings on the device
2.2 Article code
TROVIS6495-2IndustrialController x
Supply voltage
85 to 264VAC 1
24VAC/DC 2
2.3 Firmware versions
Firmware revisions
Old New
1.11.064 1.11.066 (09-2009)
O.1.6 'Constant output value 1 with DI' now also functions in combination with C.4.1-6
'Operation mode after restart, Manual, start AO= AO.K1'.
In rmware version1.11.066, the use of 1.C.2.2.3-1 to 1.C.2.2.3-4 'Open cascade
with DI' results in a memory error. These functions must not be congured.
1.11.066 1.11.068 (06-2011)
In rmware version1.11.068, the error after the use of 1.C.2.2.3-1 to 1.C.2.2.3-4
'Open cascade with DI' is rectied. In addition, the MSP now has a voltage monitor to
ensure that data is not lost after a power voltage failure.
1.11.068 1.11.070 (06-2012)
In rmware version1.11.070, the communication parameters 'Station number',
'Transmission rate', 'Parity' and 'Stop bit' remain saved after a warm or cold start.
1.11.070 1.21.027 (06-2015)
The rmware version1.21 has a 50ms scanning time, making it twice as fast and better
suited for fast control systems.
We recommend updating the controller to rmware version1.21. By performing the
update using one of the optional plug-in interface boards, device settings remain saved.
Note on updating to rmware version1.21: if feedforward control to YPID was
congured with C.3.2.3-3 and C.3.2.9, note that disturbance variable B no longer refers
to the measuring range of PV; it is now calculated without reference to the measuring
range.
The following section references refer to the Configuration Manual uKH6495-2)

EB 6495-2 EN 2-3
Markings on the device
Firmware revisions
Old New
1.11.070 Section C.3.1.3 Error signal:
−E.TZ Operating threshold [0.00 to 110.00%],
firmware version1.11 and lower [0.0 to 110.0 %]
Section C.3.2.9 Arithmetic operation output YPID:
−In rmware version1.21 and higher, the disturbance variable B is linked to YPID
over C.3.2.9 as an unscaled value. In rmware version1.11 and lower, the
disturbance variable B, scaled according to the measuring range of PV, is linked to
the output signal YPID of the control algorithm over C.3.2.9.
Section D Communication data point list:
−AI1 to AI4, PV, PV0, SPE, DV, TR, FB: in rmware version1.21 and higher, it is
transferred as a physical value (unscaled). In rmware version1.11 and lower, it is
transferred as a percentage in relation to the measuring range.
Section D Communication data point list:
−Output Y can be written in manual mode and only read in automatic mode in
rmware version1.21 and higher. It can only be read in rmware version1.11
and lower.
Section D Communication data point list:
−Manual/automatic, internal/external set point, open/close cascade can be written
and read in rmware version1.21 and higher. They can only be read in rmware
version1.11 and lower.
Section D Communication data point list:
−Internal set point (0)/external set point (1) in rmware version1.11 and lower,
action reversed: internal (1), external (0)
Section D Communication data point list:
−Internal/external set point can be written in rmware version1.21 and higher if the
function is not switched by a digital input.
Section D Communication data point list:
−The internal set points can be switched over the Modbus holding register HR 55
(Controller [1]) und HR 115 (Controller [2]) in rmware version1.21 and higher.
Section C.2.3.1 Set point ramp, wait condition:
−Monitoring of deviation band SP.RH only has a one-sided effect in rmware
version1.21 and higher. Additionally the range of the deviation band [0.1 to
1000.0%] and the default setting 1000.0 % have been changed (in rmware
version1.11 and lower: [0.1 to 100.0%] and 100.0% respectively)

2-4 EB 6495-2 EN
Markings on the device
Firmware revisions
Old New
1.11.070 Section D.1.1 Communication monitoring:
−An entry is made in the error list and event list in the event of timeout in rmware
version1.21 and higher. The fault indication icon is also indicated in the display.
−Changing the conguration of the input signal source in the I.x.1 conguration item
does not cause the measuring range to be reset any more in rmware version1.21
and higher.
1.21.027 1.21.030 (10-2015)
The output of the input variables PV, PV0, DV, SPE, TR, FB and SP0 to the outputs AOx is
scaled again to the associated measuring range (in comparison to rmware
version1.21.027).
The limitation of YM in a cascade controller now also has an effect on the controller
output Y.

EB 6495-2 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The TROVIS6495-2 Industrial Controller has
two independently working controllers with
shared input and output sections.
By setting the functions and parameters, the
controller can be adapted to a control task
quickly. Preset basic congurations for each
control type minimize setup work for stan-
dard applications. The controller can be set
up using the keys on the housing or the op-
tional TROVIS-VIEW software without requir-
ing any additional accessories.
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 for TROVIS6495-2 can be
downloaded free of charge from our website
at www.samsongroup.com > Services >
Software > TROVIS-VIEW. Further
information on TROVIS-VIEW (e.g. system
requirements) is available on our website
and in the Data Sheet uT6661.
The controller settings are saved in a
non-volatile memory, even when the power
supply fails. The two internal controllers can
be operated directly without switching. The
plain-text display in English, German and
French facilitates conguration and parame-
terization.
Note
Control modes
− Fixed set point control, one or two chan-
nels, internal/external switchover
− Follow-up control, one or two channels,
internal/external switchover
− Ratio control (mixing control)
− Cascade control, consisting of master
and slave controller
− Limiting or override control
Control
− Linking of input variables (addition, sub-
traction, multiplication, division, mean
value, minimum and maximum selection)
for feedforward control or control with
one to four input variables (multi-compo-
nent control)
− Operation with up to four internal set
points and oneexternal set point, either
analog or via interface (SPC mode)
− Set point ramp and output ramp
− Split-range operation
− Control mode selection P/PI or PD/PID
− KP and TN adapted using the controlled
variable, reference variable, manipulat-
ed variable or error signal
− Adjustable limitation of integral-action
component
− Operating point preset by set point or
digital input
− Control signal limitation (xed or oating
according to an input variable)
− Operation with code number or key lock-
ing by a digital input

3-2 EB 6495-2 EN
Design and principle of operation
Inputs
− 4 analog inputs (AI1 to AI4)
DIP switches at the side of the housing to
select current or resistance inputs. The
signal type is set depending on the con-
guration:
− 0/4 to 20mA
− 0/2 to 10V
− Pt100 or Pt1000 resistance ther-
mometer
− Filter, root extraction, function gener-
ation and measuring range monitor-
ing
− Input 2 additionally for potentiome-
ters
− 4 digital inputs (DI1 to DI4)
The digital inputs are controlled either by
a 24VDC voltage signal or by the
transmitter supply using a oating con-
tact. The digital outputs can only be con-
trolled in groups, with DI1 and DI2 being
the rst group and DI3 and DI4 being
the second group.
Example: internal supply for digital in-
puts DI1 and DI2 and external supply for
digital inputs DI3 and DI4.
− Set point switchover, constant output val-
ue, reversal of operating action, output
tracking (DDC backup), ramps etc
The following functions that have been de-
ned over the C Controller, O Output
and A General settings menus can be as-
signed to a digital input (see the 'Start-up
and conguration' section):
− Invert digital input
− Switchover between internal set points
− Switchover to external set point
− Open/close cascade
− Incremental/decremental set point
change
− Set point increase/decrease by constant
− Start set point ramp
− Hold set point ramp
− Invert error signal
− Control mode selection P(D)/PI(D)
− Activate operating point for P/PD con-
troller
− Manual/automatic switchover
− Hold output
− Activate output tracking
− Increase/decrease actual value
− Activate constant output value
− Start output ramp
− Limit output rate
− Lock control keys
Outputs
− 3 analog outputs (AO1 to AO3)
The signal type is set depending on the
conguration.
− 0/4 to 20mA
− 0/2 to 10V
The outputs AO1 to AO3 can optionally
be used for other signals as well.

EB 6495-2 EN 3-3
Design and principle of operation
− 7 digital outputs (4 relay outputs and 3
transistor outputs)
The relay outputs can be used as follows:
− SO1 and SO2 as on/off or three-
step output
− DO1 to DO4 as limit output
− DO5 and DO6 (transistor output) for
status messages
− DO7 (transistor output) for fault
alarms
− 4 relay outputs
for two on/off or three-step outputs or
four limit alarms
− 2 transistor outputs
for status messages
− 1 transistor output
for fault alarms
− One supply output
The supply output can be used to supply
a voltage for up to 4 two-wire transmit-
ters and 4 digital inputs (21VDC, max.
90mA).
Infrared interface
Data are transmitted between the controller
and the TROVIS-VIEW software over an in-
frared interface, by default integrated into
the controller and an infrared adapter (order
no. 8864-0900) connected to a computer
(see the 'Operation' section).
Communication interface
Optionally, the controller can be equipped
with one of the following interface boards.
The boards can also be retrotted.
− RS-232/USB interface board
− One RS-232 interface with RJ-12
jack
− One USB interface with 5-pin mini-B
port
The RS-232 data transfer uses an SSP or
Modbus RTU protocol. The memory pen-
64 can be used with controllers tted
with an RS-232/USB interface board to
load data congured in TROVIS-VIEW or
transferred from another controller.
− RS-485/USB interface board
− RS-485 interface (4 terminals) and
− USB interface (5-pin mini-B port)
The RS-485 data transfer uses an SSP or
Modbus RTU protocol. Slide switches are
used to set the two-/four-wire operation
and to activate bus termination.

3-4 EB 6495-2 EN
Design and principle of operation
1) Digital outputs
(relay)
PWM 3-step 3-step
PWM +
–
+
–
On/off and three-step switching output SO1
On/off and three-step switching output SO2
AI1
AI2
AI3
AI4
mA, V, Pt 100, Pt 1000
mA, V, Pt 100, Pt 1000,
mA, V, Pt 100, Pt 1000
mA, V, Pt 100, Pt 1000
DI1
DI2
DI3
DI4
IR
Interface
AO1 mA,V
AO2 mA,V
AO3 mA,V
DO1
ON/OFF
DO2
DO3
DO4
DO5
DO7
DO6
TROVIS 6495-2
1
2
Analog outputs
Limit alarms
Digital outputs
(transistors)
Status messages
Fault alarm
Supply outputSupply voltage
Interfaces
Digital
inputs
Analog
inputs
Digital outputs
(relay)1)
Potentiometers
Fig.3-1: Overview of inputs and outputs
3.1 Block diagrams
Simplied block diagrams are shown for
each control mode on the following pages.
The Conguration Manual uKH6495-2
contains detailed block diagrams.

EB 6495-2 EN 3-5
Design and principle of operation
+PID
-
SPE
SPC
PV
C.2.2.2
C.2.1.2
C.3.1.1
PV0
SP0
e
C.1.1.1 C.1.2.1
M.1-1
C.2.1.1
SP1/2/3/4
Y
I.1.111
12 13
AI1
I.2.115
16 17
AI2
I.3.119
20 21
AI3
I.4.123
24 25
AI4
AO1 AO2
AO3 SO1 SO2
mA/V
O.3.3O.3.2 O.4.3O.4.2 O.5.3O.5.2
31
32 33
O.1.3 O.1.2
mA/V
mA/V
O.2.3O.2.2 35
36 37 97 98 99 42 43 52 53 45 46 55 56
O.1.1 O.2.1 O.3.1 O.5.1 O.4.1
Pt 100/ Pt 1000/ mA/V/R Pt 100/ Pt 1000/ mA/V Pt 100/ Pt 1000/ mA/V
Pt 100/ Pt 1000/ mA/V
Terminals
External set point
Internal set point
Ext, set point (interface)
Controlled variable
1x Fixed set point/follow-up control
Controller [1]
Terminals

3-6 EB 6495-2 EN
Design and principle of operation
Terminals
+PID
-
SPE
SPC
PV Y
C.2.2.2
C.2.1.2
C.3.1.1
PV0
SP0
e
C.1.1.1 C.1.3.1
M.1-2
DV
PV R
C.1.2.1
C.2.1.1
SP1/2/3/4
C.2.1.3-1
PV DV * K11
=
K11
I.1.111
12 13
AI1
I.2.115
16 17
AI2
I.3.119
20 21
AI3
I.4.123
24 25
AI4
AO1 AO2
AO3 SO1 SO2
mA/V
O.3. 3O.3.2 O.4. 3O.4.2 O.5. 3O.5.2
31
32 33
O.1. 3 O.1. 2
mA/V
mA/V
O.2. 3O.2.2 35
36 37 97 98 99 42 43 52 53 45 46 55 56
O.1. 1 O.2. 1 O.3. 1 O.5. 1 O.4. 1
1
K11
SPR
Pt 100/ Pt 1000/ mA/V
Pt 100/ Pt 1000/ mA/V/R
Pt 100/ Pt 1000/ mA/V
Pt 100/ Pt 1000/ mA/V
Ratio control
Terminals
Actual value Set point
Actual ratio
Controlled variable
Leading process variable
Set point ratio
External set point (set point ratio)
Ext. set point (interface)
Internal set point (set point ratio)
Ratio formula
Ratio
Ratio controller [1]
Other ratio formulas can be selected.
Note