Samson TROVIS 5431 Service manual

Automation System TROVIS 5400

Heating and District Heating Controller

TROVIS 5431

Mounting and

operating instructions

EB 5431 EN

Electronics from SAMSON

Firmware Version 1.20

Edition February 2001

Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Whats new compared to the previous version? . . . . . . . . . . . . . 5

2 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Operating controls on the front panel . . . . . . . . . . . . . . . . . . 7

3.1.1 Control switch (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1.2 Mode selector switch (B) . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1.3 Arrow keys and enter key (E, F) . . . . . . . . . . . . . . . . . . . . . 8

3.2 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Control levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3.1 Info levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3.2 Changing the system code number . . . . . . . . . . . . . . . . . . . 16

3.3.3 Parameter levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3.4 Configuration levels . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 System descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Functional descriptions . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1.1 Selecting the sensor (CO-SYS F02) . . . . . . . . . . . . . . . . . . . 36

5.1.2 Calibrating the sensor (CO-SYS F08). . . . . . . . . . . . . . . . . . 36

5.1.3 Binary input for storage tank thermostat . . . . . . . . . . . . . . . . 36

5.1.4 Analog input AI (CO1 F08; CO-SYS F10, F11) . . . . . . . . . . . . . 36

5.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.2.1 Outputs to the control valve (CO-SYS F05, F15) . . . . . . . . . . . . 37

5.2.2 Limiting the system deviation for OPEN signal (CO-SYS F06, F16) . . . . 37

5.2.3 Transmitting the outdoor temperature (CO-SYS F12) . . . . . . . . . . 37

5.2.4 Pump management (CO1 F09). . . . . . . . . . . . . . . . . . . . . 38

5.2.5 Collective error message (CO-SYS F13) . . . . . . . . . . . . . . . . 38

5.3 Time-controlled functions . . . . . . . . . . . . . . . . . . . . . . . 38

5.3.1 Time, date, year (PA-SYS) . . . . . . . . . . . . . . . . . . . . . . . 38

5.3.2 Delayed outdoor temperature adaptation (CO1 F05) . . . . . . . . . . 38

5.3.3 Automatic clock reset summer time/winter time (CO-SYS F03). . . . . . 39

5.3.4 Summer time operation (PA1, CO1 F06) . . . . . . . . . . . . . . . . 39

5.3.5 Public holidays and vacations (PA-SYS, CO2 F07) . . . . . . . . . . . 40

5.3.6 Times-of-use (PA1, PA2) . . . . . . . . . . . . . . . . . . . . . . . . 40

5.4 Control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2EB 5431 EN

Contents

5.4.1 Characteristic (CO1 F04) . . . . . . . . . . . . . . . . . . . . . . . 41

5.4.2 Reduced operation (PA1) . . . . . . . . . . . . . . . . . . . . . . . 42

5.4.3 Limitation of return flow temperature (CO-SYS F01) . . . . . . . . . . . 43

5.4.4 External request (CO-SYS F10, F11) . . . . . . . . . . . . . . . . . . 43

5.4.5 Optimize (CO1 F02) . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.4.6 Flash adaptation (CO1 F03, only with room sensor) . . . . . . . . . . 46

5.5 Drinking water heating system (systems 2 to 5) . . . . . . . . . . . . . 47

5.5.1 Storage tank sensor/Storage tank thermostat (CO2 F01, F02) . . . . . . 47

5.5.2 Forced charging of drinking water storage tank. . . . . . . . . . . . . 47

5.5.3 Intermediate heating for drinking water charging (CO2 F10) . . . . . . 48

5.5.4 Switchover of control for drinking water heating in the storage tank charging

system (CO2 F03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.5.5 Build-up of charging temperature via the return flow sensor with deactivated

heating circuit (CO2 F08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.5.6 Priority of drinking water heating system (CO2 F09) . . . . . . . . . . 49

5.5.7 Circulation pump for storage tank charging (CO2 F04) . . . . . . . . . 50

5.5.8 Parallel pump operation (CO2 F06) . . . . . . . . . . . . . . . . . . 50

5.5.9 Thermal disinfection of drinking water storage tank (CO2 F05) . . . . . 50

5.5.10 Times-of-use for the drinking water heating system (PA2) . . . . . . . . 51

5.5.11 Vacation and public holidays for drinking water heating (CO2 F07) . . 51

5.5.12 Control in systems with an instantaneous water heater (CO2 F11) . . . . 51

5.5.13 Recognition of drinking water tapping in systems with an instantaneous

water heater (CO2 F12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.6 Controller response in case of faults . . . . . . . . . . . . . . . . . . 52

5.6.1 Defective sensor and malfunctions . . . . . . . . . . . . . . . . . . . 52

5.6.2 Setting the default values (CO-SYS F09) . . . . . . . . . . . . . . . . 52

5.6.3 Monitoring the temperature (CO-SYS F14) . . . . . . . . . . . . . . . 53

5.7 Protective functions . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7.1 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7.2 Blocking manual operation (CO-SYS F04) . . . . . . . . . . . . . . . 54

5.7.3 Forced operation of the pumps. . . . . . . . . . . . . . . . . . . . . 54

6 Memory pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.1 Data exchange between heating controller and memory pen . . . . . . 55

7 Installing the heating controller . . . . . . . . . . . . . . . . . . . . 56

8 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 58

9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

EB 5431 EN 3

Contents

Appendix A Function block lists . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Appendix A.1 Function block list for heating circuit CO1 . . . . . . . . . . . . . . . 64

Appendix A.2 Function block parameters CO1 . . . . . . . . . . . . . . . . . . . . 65

Appendix A.3 Function block list for drinking water heating circuit CO2 . . . . . . . . 66

Appendix A.4 Function block parameter CO2 . . . . . . . . . . . . . . . . . . . . 67

Appendix A.5 Function block list CO-SYS. . . . . . . . . . . . . . . . . . . . . . . 68

Appendix A.6 Function block parameters CO-SYS . . . . . . . . . . . . . . . . . . 69

Appendix B Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Appendix B.1 Level PA1 (heating circuit) parameters . . . . . . . . . . . . . . . . . 71

Appendix B.2 Level PA2 (drinking water heating circuit) parameters . . . . . . . . . . 77

Appendix B.3 Level PA-SYS parameters . . . . . . . . . . . . . . . . . . . . . . . 80

Appendix C Info levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Appendix C.1 InFO 1 level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Appendix C.2 InFO 2 level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Appendix D Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Appendix E Resistance values of temperature sensors . . . . . . . . . . . . . . . 86

Appendix F Configured data . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Code number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Important display symbols . . . . . . . . . . . . . . . . . . . . . . 99

Front view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

EB 5431 EN 4

Contents

1 General

The TROVIS 5431 Heating and District

Heating Controller is designed for weather-

compensated flow temperature control of

heating systems. These Mounting and oper-

ating instructions describe how to operate

the controls including the controller switches

and keys as well as describe the electrical

connection and the mechanical installation.

In addition, they describe the comprehensive

configuration and parameterization options.

Please note, however, that you require expert

knowledge to change the configuration and

parameterization of the heating control

system. Once you have connected it to the

mains and the controller is supplied with aux-

iliary power, it is basically ready for opera-

tion. Since its operation is based on time

schedules, however, it is absolutely required

that you set the current time and date. To do

this, follow the step-by-step instructions start-

ing on page 20.

The controller stores configuration and

parameterization data even over prolonged

periods of storage without being connected

to a power supply source. Only time, date

and year must be reset after an extended

power failure.

The factory default is set to heating operation

from 7 a.m. to 10 p.m. and, if applicable, to

provide hot drinking water twenty-four hours

a day. (The heating and district heating con-

troller does not necessarily control the drink-

ing water heating in all systems!) If you want

different operating times, you have to

change the time-of-use. For a detailed

description of how to change the time-of-use,

refer to page 23 ff.

The index in the back makes it easier for you

to quickly access information on a specific

subject.

To simplify reading, the device is referred to

as heating controller instead of heating

and district heating controller hereafter.

1.1 Whats new compared to the previous version?

For Version 1.20, the external request function was revised (see chapter 5.4.4.).

EB 5431 EN 5

General

2 Warning

4Assembly, start-up and operation of the

device may only be performed by trained

and experienced personnel familiar with

this product. Proper shipping and appro-

priate storage are assumed.

4The heating controller is designed for use

in power installations. For connection and

maintenance you are required to observe

the relevant safety regulations.

4In automatic operating mode (time-

controlled operation), the device ensures

that all protective functions that are vital

for the system are monitored. Safety fea-

tures, such as frost protection monitoring

and excess temperature monitoring, how-

ever, are not active in the following cases:

defective heating controller and failure of

functions; defective or not connected sen-

sors, or sensors which were not

deactivated; missing auxiliary power sup-

ply to the heating controller.

4The installation of the controller and its

electrical connection described in the

following, must be carried out by autho-

rized personnel only.

4In addition, changing function blocks and

function block parameters (see chapter

3.3.4 and Appendix A) requires special-

ized knowledge of heating systems and

should only be performed by an expert.

6EB 5431 EN

Warning

3 Operation

For an easier understanding of how to oper-

ate this controller, please unfold the last page

of these Mounting and operating instruc-

tions! Switches and keys are used to oper-

ate the controller. You can access them by

opening the transparent front door. Use

switch (B) to change operating modes. Use

switch (A) and keys (E) and (F) to prompt

parameters such as temperature and setpoint

as well as to determine the selectable

controller functions and parameters. This will

take you to different levels which are

described in chapter 3.3. All the entered set-

tings and the information you require are rep-

resented by symbols in the display (D).

You have the option of feeding the controller

with configuration and parameterization

data using a memory pen (see chapter 6).

The individual switches and keys as well as

the operation on the different levels are

described in the following chapters.

3.1 Operating controls on the front panel

3.1.1 Control switch (A)

Use this switch to prompt several temperature

values and set the most important

parameters.

For a detailed description on the functions of

this switch, refer to the Quick Guide

KA 5431 EN.

Displays outdoor temperature

Displays flow and return flow temper-

ature of the heating circuit

Displays storage temperature and

charging temperature of the drinking

water circuit depending on the config-

uration

Displays and changes the time and

date

Displays and changes the parameters

of the heating circuit, depending on

the configuration

Displays and changes the time sched-

ule of the heating circuit

Displays and changes the parameters

of the drinking water circuit, depend-

ing on the configuration

Standard operation via menus,

operation via arrow and enter keys,

see chapter 3.3.

EB 5431 EN 7

Operation

3.1.2 Mode selector switch (B)

Use this switch to select the operating mode:

Automatic operation: The controller

operates on a time schedule and

switches between heating and set-back

mode. Select this mode as default

switch position!

Rated operation: The controller contin-

uously operates in heating mode.

Reduced operation: The controller con-

tinuously operates in set-back mode.

−

Manual operation: The control valve is

operated in manual mode:

+ open, 0 maintain, −close

Use these switch positions for start-ups

and repairs only!

Drinking water heating operation: The

drinking water is heated up according

to the demand. The heating system is

off.

Standby: Heating and drinking water

heating systems are off. The frost pro-

tection is active.

3.1.3 Arrow keys and enter key (E, F)

Use the arrow keys to access the dif-

ferent levels up and down, select

parameters and function blocks,

increase and decrease values

Use the enter key to activate levels,

parameters, function blocks, to

acknowledge changed values

8EB 5431 EN

Operation

3.2 Manual operation

CAUTION

In manual operation, all outputs can be manipulated by the operator as desired. When

you enter the manual operating mode, all limiting temperature values and logic interlock

signals are inactive. The operator is responsible for the interaction between all outputs

and the outcome!

Accessing the manual level

EB 5431 EN 9

Operation

Press Display Comment

Set the control

switch (A) to If you want to operate the control valve

only, this switch position is not required. To

manually operate the pumps, however, you

must select this switch position to gain

access.

Set the mode

switch (B) to

+, 0

or −

This allows you to operate the control valve

(open, maintain position, or close). At the

same time, the manual symbol appears on

the display.

until You reach the pump level.

10 EB 5431 EN

Operation

Press Display Comment

You now have access to this level. On the

display, you can see the heating pump HCP

(PU 1). In this example, the pump is active:

-1

either

or Use the arrow keys to select the output you

want to activate:

PU 2 Heat exchanger charging pump HEP

PU 3 Storage charging pump SCP

PU 4 Circulation pump CP

PU 5 Binary output BO1

PU 6 Binary output BO2

PU 7 Binary output BO3

You have activated the selected output, PU

blinks.

either

Activate the desired output, observing the

following:

Activate pump/binary output,

display indicates, e.g. PU 1-1 or

Deactivate pump/binary output,

display indicates, e. g. PU 1-0.

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