Samson TROVIS 6495 Series Service manual

Series 6495

Industrial Controller TROVIS 6495-2

Mounting and

Operating Instructions

EB 6495-2 EN

Firmware version 1.11

Edition December 2009

Electronics from SAMSON

2EB 6495-2 EN

DANGER!

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious injury.

NOTICE

NOTICE indicates a property damage mes-

sage.

Note: Supplementary explanations, informa-

tion and tips

Definitions of the signal words used in these instructions

Contents Page

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 5

2 Device version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.1 Operation structure . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Display and operator controls . . . . . . . . . . . . . . . . . . . . . 13

6 Operating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 Changing the set point. . . . . . . . . . . . . . . . . . . . . . . . . 16

6.2 Switching over to manual mode and changing the output . . . . . . . . . 16

6.3 Opening/closing cascade . . . . . . . . . . . . . . . . . . . . . . . 17

7 Info menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 Operating menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.1 Entering the operating menu . . . . . . . . . . . . . . . . . . . . . . 23

8.2 Changing the control parameters. . . . . . . . . . . . . . . . . . . . 23

8.3 Switching over internal/external set point. . . . . . . . . . . . . . . . 25

8.4 Switching over between internal set points and changing them . . . . . 25

9 Configuration menu. . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.1 Entering the configuration level . . . . . . . . . . . . . . . . . . . . 29

9.2 Configuring the controller . . . . . . . . . . . . . . . . . . . . . . . 30

9.2.1 Setting configuration items. . . . . . . . . . . . . . . . . . . . . . . 30

9.2.2 Configuration example . . . . . . . . . . . . . . . . . . . . . . . . 31

9.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.3.1 Changing the controller display . . . . . . . . . . . . . . . . . . . . 33

9.3.2 Setting up additional display. . . . . . . . . . . . . . . . . . . . . . 35

9.3.3 Switching Controller [1] and Controller [2] displays . . . . . . . . . . . 38

10 Locking the controller . . . . . . . . . . . . . . . . . . . . . . . . . 41

10.1 Locking the operating level. . . . . . . . . . . . . . . . . . . . . . . 41

10.2 Locking all keys over a digital input . . . . . . . . . . . . . . . . . . 42

10.3 Activating key number operation . . . . . . . . . . . . . . . . . . . 43

11 User calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.1 Calibrating analog inputs . . . . . . . . . . . . . . . . . . . . . . . 45

EB 6495-2 EN 3

Contents

11.2 Calibrating analog outputs. . . . . . . . . . . . . . . . . . . . . . . 45

12 Fault alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

13 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13.1 Infrared interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

13.2 Optional interface boards . . . . . . . . . . . . . . . . . . . . . . . 50

13.2.1 RS-232/USB interface board . . . . . . . . . . . . . . . . . . . . . 50

13.2.2 RS-485/USB interface board . . . . . . . . . . . . . . . . . . . . . 51

13.3 SAMSON memory pen . . . . . . . . . . . . . . . . . . . . . . . . 53

14 Setting and operation with TROVIS-VIEW software . . . . . . . . . . 55

14.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

14.1.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . 55

14.2 Installing TROVIS-VIEW software. . . . . . . . . . . . . . . . . . . . 56

14.3 Starting TROVIS-VIEW and performing settings . . . . . . . . . . . . . 57

14.3.1 Configuring the controller . . . . . . . . . . . . . . . . . . . . . . . 60

14.3.2 Reading information. . . . . . . . . . . . . . . . . . . . . . . . . . 62

14.4 Operational data graphs (Trend Viewer) . . . . . . . . . . . . . . . . 64

14.5 Data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

14.5.1 Setting up communication port . . . . . . . . . . . . . . . . . . . . . 66

14.5.2 Online operation (direct data transmission) . . . . . . . . . . . . . . . 67

14.5.3 Offline operation (indirect data transmission) . . . . . . . . . . . . . . 67

14.5.4 Data transmission between TROVIS-VIEW and memory pen. . . . . . . 68

15 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

15.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

15.2 Configuration list . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

15.3 Abbreviations used. . . . . . . . . . . . . . . . . . . . . . . . . . 145

15.4 Block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4EB 6495-2 EN

Contents

1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start-up and opera-

tion of the industrial controller:

4The industrial controller may only be mounted, started up or operated by trained and

experienced personnel familiar with the product.

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 possi-

ble dangers due to their specialized training, their knowledge and experience as well

as their knowledge of the relevant standards.

4The controller is intended for use in low-voltage installations.

For wiring and maintenance, you are required to observe the relevant safety regula-

tions.

To avoid damage to any equipment, the following also applies:

4Proper shipping and appropriate storage are assumed.

EB 6495-2 EN 5

Important safety instructions

2 Device version

2.1 Article code

Industrial Controller TROVIS 6495-2 x

Supply voltage

85 to 264 V AC

24 V AC/DC

2.2 Accessories

Accessories Order no.

TROVIS-VIEW Configuration

and Operator Interface.......... 6661-1033

Infrared adapter (RS-232)...... 8864-0900

Bracket for infrared adapter... 1400-9769

USB 1.1 serial adapter........... 8812-2001

RS-232/USB interface board.. 1400-9917

RS-485/USB interface board.. 1400-9918

USB cable (2 m) with type A

and 5-pin mini-B connectors... 8801-7301

Connecting cable

RJ 12/D-sub 9-pin (RS-232)... 1400-7699

Memory pen (RS-232)........... 1400-9753

Modular adapter

RJ 12/D-sub 9-pin................. 1400-7698

6EB 6495-2 EN

Device version

3 Installation

The TROVIS 6495-2 Industrial Controller is

designed for panel mounting. Its front case

has the dimensions 96 x 96 mm.

NOTICE

When installing several TROVIS 6495-2 In-

dustrial Controllers, the minimum distance

between each controller as shown in Fig. 1

must be kept!

1. Prepare a panel cut-out with the dimen-

sions 92+0.8 x 92+0.8 mm.

2. Push the industrial controller into the

panel cut-out from the front.

3. Insert the two mounting clips in the

notches on the top and bottom.

4. Turn the threaded rods in the direction

of the control panel using a screw-

driver, clamping the case against the

control panel.

EB 6495-2 EN 7

Installation

150 (5.90")

12 34

156 (6.14")

96 (3.78")

91.2 (3.59")

Fig. 1 · Installation

>15

92+0.8

(3.62"+0.3)

92+0.8

(3.62"+0.3)

>30

Panel cut-out and

minimum distances

when installing several

controllers Panel

cut-out

Mounting

clips Terminal strips

Slot for interface board

4 Electrical connection

Risk of electric shock!

When installing electric cables, you are re-

quired to observe the regulations governing

electrical power plant installation in the

country where the controller is to be in-

stalled.

Installation notes

•Install the power supply lines and the sig-

nal lines separately! Do not install them

parallel to each other! To improve noise

immunity, observe a minimum distance of

10 cm between the power line and the

measuring input line. The lines for the dig-

ital signals (bus lines) as well as the ana-

log signal lines (sensor lines, analog in-

puts and outputs) must also be routed

using separate cables.

•To avoid measurement errors or other dis-

turbances, use shielded cables for the an-

alog and binary signal lines and bus

lines. Ground the shield at one end, either

at the controller inlet or at the control cab-

inet outlet, using the largest possible

cross-section. Connect the central ground-

ing point and the PE grounding conductor

with a cable ≥10 mm² using the shortest

route.

•Inductances in the control cabinet, e.g.

contactor coils, are to be equipped with

suitable interference suppressors (RC ele-

ments).

•Control cabinet elements with high field

strength, e.g. transformers or frequency

converters, are to be shielded with sepa-

rators providing a good ground connec-

tion.

The controller has screw terminals for

1.5 mm² wires (0.5 to 1.5 mm² wire

cross-section).

The lines are connected to the terminal strips

1 to 4 as shown in the following connection

diagrams 2a to 2c.

Transmitter supply

The controller has a supply output to power

a maximum of four two-wire transmitters

(21 V DC, 90 mA).

Resistance thermometer

The analog inputs AI1 to AI4 are designed

for the connection of resistance thermome-

ters Pt 100 and Pt 1000 in a three-wire cir-

cuit. The resistance of each connection lead

must be the same and not exceed 15 Ω.

Lead calibration is not necessary.

Resistance thermometers can also be con-

nected in two-wire circuits. In this case,

connect a jumper between the controller ter-

minals. Take into account that the lead resis-

tance may reach several ohms over long

distances, causing the measured value to be

considerably distorted. This measured value

can be balanced out using a correction

value (configuration item

I.1.4/I.2.4/I.3.4/I.4.4 Input signal

increase/decrease, see section 15.2).

8EB 6495-2 EN

Electrical connection

Potentiometer

The analog input AI2 is designed for the

connection of a potentiometer. Potentiome-

ters between 50 and 1200 Ωcan be

connected.

A potentiometer is used, for example for po-

sition feedback of an electrical actuator or

for input of an external set point.

Generally, we recommend performing a

user calibration. To perform a calibration,

use the configuration items A.20.2.13

(zero) and A.20.2.14 (end), see section

11.

EB 6495-2 EN 9

Electrical connection

Fig. 2a · Electrical connection

Terminal strip 1



 















 ##

$

% 

" 









 

& 







"

 

 











&

( 

)

* & 







 

  

  !

DIP switches:

10 EB 6495-2 EN

Electrical connection

Fig. 2b · Electrical connection

Current

0/4 to 20 mA

Voltage

0/2 to 10 V

Digital input

with internal supply Digital input

with external supply

32Analog output AO1

–

24 V DC

Digital input DI4

Supply output

21 V DC

max. 90 mA

Digital input DI3

GND

36Analog output AO2

–

85 –

–

98Analog output AO3

–

Digital input DI2

Digital input DI1

GND

81 +

–

24 V DC

Terminal strip 2

ATR

BTR

2-Leiter4-Leiter

TX RX/TX

RS-485/USB interface (option, see section 13.2.2)

4-wire 2-wire

RS-232 interface (option, see section 13.2.1)

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