Series 6495
TROVIS 6495-2 Industrial Controller
For panel mounting (front frame 96 x 96 mm/3.78 x 3.78 inch)
Application
Digital controller to automate industrial and process plants for
general and more complex controltasks · Suitablefor control of
continuous, on/off or pulsing final control elements (pneumatic
actuators with i/p positioners, electric actuators, electric heat
ing systems, refrigerating machines etc.)
The TROVIS 6495-2 Industrial Controller has two independent
internal controllers with common input and output sections.
By setting theconfigurationitemsandparameters,thecontroller
can be adapted to a control task quickly. Preset basicconfigura
tions for each control type minimize setup work for standard ap
plications. The controller can be set up directly at the controller
or using the optional TROVIS-VIEW software.
The controllersettings are saved in a non-volatile memory, even
when the power supply fails. The two internal controllers can be
operated directly without switching over. The plain-text display
(German, English, French) facilitates configuration and
parameterization.
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Electronics from SAMSON
®
Special features
• Simple menu structure with plain text readings
• Four analog inputs with filtering, root extraction and function
generation as well as measuring range monitoring
• Four digital inputs for set point switchover, constant output
value, reversal of operating action, output tracking (DDC
backup), ramps etc.
• Three analog outputs
•
Four relay outputs for two on-off/three-step outputs or limit
alarms
•
Two transistor outputs for status alarms
•
One transistor output for fault alarms
•
Optional RS-232/USB and RS-485 Modbus RTU/USB inter
face boards for SSP and Modbus RTU
•
Degree of protection (front) IP 65
•
Plug-on screw terminals
•
Fixed set point control, one or two channels, internal/exter
nal switchover
•
Follow-up control, one or two channels, internal/external
switchover
•
Ratio control
•
Cascade control, consisting of master and slave controller
•
Override control
•
Mixing control
•
Linking of input variables (addition, subtraction, multiplica
tion, division, meanvalue,minimumand maximum selection)
for feedforward control or control with max. four input vari
ables (multi-component control)
Fig. 1 · TROVIS 6495-2 Industrial Controller
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Operation withmax. four internal set pointsand one external
set point, either analog or over interface (SPC mode)
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Set point ramp and output ramp
•
Split-range operation
•
Control mode switchover P/PI or PD/PID
•
KP or TN adapted using the controlled variable, reference
variable, manipulated variable or error
•
Adjustable limitation of integral-action component
•
Operating point determined by set point or digital input
•
Control signal limitation (fixed or floating according to input
variable)
•
Operation with key number or key locking over the digital in
put
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Edition December 2009
Data Sheet T 6495-2 EN
Inputs and outputs (Fig. 3)
Four analog inputs (AI 1 to AI 4) · DIP switches at the side of
–
the case are used to initially select current or resistance in
puts. The signal type is set depending on the configuration:
0 (4) to 20 mA, 0 (2) to 10 V, Pt 100, Pt 1000; input 2 addi
tionally for potentiometer.
Four digital inputs (DI 1 to DI 4) · The digital inputs are con
–
trolled either by a 24 V DC voltage signal or by the transmit
ter supply using a floating contact. The digital outputs can
only becontrolledingroups, with DI 1 andDI 2 being the first
group, and DI 3 and DI 4 being the second group.
Example: internal supply for digital inputs DI 1 and DI 2, and
external supply for digital inputs DI 3 and DI 4.
Three analog outputs (AO1 to AO3) · The signal type is set
–
depending on the configuration: 0 (4) to 20 mA, 0 (2) to
10 V. Outputs AO1 and AO3 can optionally be used for
other signals as well.
Seven digital outputs · Four relay and three transistor outputs
–
The relay outputscanbeused to implement on/off, three-step
(SO1 and SO2) or limit outputs (DO 1 to DO 4). The transis
tor outputs DO 5 and DO 6 can be used to issue status
alarms; fault alarms can be issued at transistor output DO 7.
Supply voltage
The controller comes with two different power supply units.
Specify the required version in your order:
85 to 264 V AC
–
24 V AC/DC
–
Supply output (auxiliary voltage)
A maximumof four two-wire transmitters and four digital inputs
can be supplied by this output (21 V DC, 90 mA).
Infrared interface (Fig. 2)
Data are transmitted between the controller and the
TROVIS-VIEW Configuration and Operator Interface over an
infrared interface integrated into the controller and an infrared
adapter (order no. 8864-0900) connected to a PC.
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˚
25
0.7 m
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2
1
1 Infrared adapter
2 Port of the computer
(COM or with USB 1.1
serial adapter at the
USB port)
Fig. 2 · Connecting an infrared adapter
Communications interface
The controller canoptionallybefittedwith one of the two follow
ing interface boards. The boards can be retrofitted.
RS-232/USB interface board with
– RS-232 interface (RJ 12 connector) and
– USB interface (5-pin mini-B connector)
RS-232 data transmission uses SSP or Modbus RTU protocol.
RS-485/USB interface board with
– RS-485 interface (four terminals) and
– USB interface (5-pin mini-B connector)
RS-485 data transmission uses SSP or Modbus RTU protocol.
The two-/four-wire operation and the active bus termination
can be set over slide switches.
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mA, V, Pt 100, Pt 1000
mA, V, Pt 100, Pt 1000,
Analog-
potentiometer
inputs
mA, V, Pt 100, Pt 1000
mA, V, Pt 100, Pt 1000
Digitalinputs
Interfaces
Fig. 3 · Overview of inputs and outputs
2
TROVIS 6495-2
TROVIS 6495
AI1
AI2
AI3
AI4
DI1
DI2
DI3
DI4
IR
Interface
Supply voltage Supply output for transmitter
AO1
mA,V
AO2
mA,V
AO3
mA,V
DO1
DO2
1
DO3
DO4
2
DO5
DO6
DO7
ON/OFF
Analogoutputs
Digital outputs
(relay)
Limit
alarms
Digital outputs
(transistor)
Status alarms
Fault alarms
PWM 3-step 3-step
PWM
+
On/off or three-step
switching output SO1
–
+
On/off or three-step
switching output SO2
–
T 6495-2 EN
Operation
Display and operating controls (Figs. 4)
The device has nine operator keys, of which three are assigned
to each controller.Depending on the selected control mode, one
or two controllers are activated. Controller [1] is displayed and
operated on the left, Controller [2] on the right, or optionally
vice versa. The row of keys in the middle is used for both
controllers.
Operating level
After the supply voltage has been switched on, the controller is
in the operating level.
The readings of the controlled variable, the reference variable
and the manipulated variable for each controller as well as a
bar graphfor error areindicated on the display(1). Depending
on the configuration, status alarms of the digital inputs and out
puts can be shown. The operating menu allows set points to be
switched and control parameters to be changed.
The two rows at the bottom of the display can be assigned as de
sired. The user can choose between various signals and inter
mediate calculationsinside the controller. For example, the val
ues or a bar graph of two outputs in split-range operation can
be displayed.
Configuration and parameterization
In theconfiguration level, the controller is adapted to the control
task to becompleted. The functions are arranged in hierarchical
menus. All settings are displayed as plain text.
9
1
1.1
3.1
4.1
2
5.1
6 5.2
1.2
3.2
8
4.2
7
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1 Display
1.1/1.2 Bar graph for error, controller [1]/[2]
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2 Infrared interface
3.1/3.2 Manual/automatic key, controller [1]/[2]
4.1/4.2 Cursor key, controller [1]/[2]
5.1/5.2 Cursor key, controller [1]/[2]
6 Escape key
7 Enter key
8 Info key
9 Label area
Fig. 4 · Display and operating controls
Key
Manual/
automatic
key
Cursor
keys
Enter key
Info key
Escape
key
Key functions in the levels
Operating level Info menu Operating menu Configuration level
–
Switch between manual and
automatic control mode
–
Cascade control: Open/close
controller cascade
–
Automatic mode: Change set
point
–
Manual mode: Change
output value
–
Enter main menu (operating
menu and configuration level)
–
Open info menu
–
Confirm restart after supply
voltage failure
–
No function –
–
Browse through menu and
information
–
Enter menu
–
No function –
–
Return to the operating level step
by step
–
No function –
–
Browse through a menu
–
Change set point and control
parameters
–
Confirm settings
–
Switch over set point
–
No function –
–
Return to the operating level step
by step
–
Edit individual items of
parameters
–
Browse through menu, submenu,
configuration items and
parameters
–
Change configuration items and
parameters
–
Enter menu and submenu,
activate configuration items and
parameters
–
Confirm setttings
–
No function –
–
Return to the operating level step
by step
3
T 6495-2 EN
Operation using TROVIS-VIEW
Controller settings (Fig. 5)
Configuration settings and parameters can conveniently be ad
justed, documented and transmitted using the optional
TROVIS-VIEW software. Working in TROVIS-VIEW is similar to
working in Windows Explorer.
TROVIS-VIEW includes a trend viewer for start-up that records
the process data. Input and output variables are displayed in a
clear structure.
The TROVIS-VIEWsoftware is delivered on a CD-ROM. For fur
ther information on TROVIS-VIEW refer to Data Sheet
T 6661 EN.
Data transmission (Fig. 6)
See section on accessories on page 8 for order numbers.
Data can be transmitted between TROVIS-VIEW and the con
troller in different ways:
Data transmission using the infrared interface (11) and an
–
infrared adapter (14)
Data transmission using the optional interface board with
–
RS-232 and USB connections: data can be transmitted over a
conventional cable, either a USB cable (13) or a connecting
cable (15), and a memory pen (16).
The controller can be fitted with the optional RS-485 interface
–
board to integrate it into a communications network. This in
terface board has a USB port used to transmit data over
TROVIS-VIEW.
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Fig. 5 · Operation using TROVIS-VIEW
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10
TROVIS 6495-2
TROVIS 6495
11
12
10 RJ 12 jack
11 Infrared interface
12 USB interface
13 USB cable (mini-B, 5-pin – USB type A)
14 Infrared adapter (RS-232)
15 Connecting cable RJ 12/D-sub 9-pin (RS-232)
16 Memory pen (RS-232)
17 Modular adapter RJ 12/D-sub 9-pin (RS-232)
18 COM port (RS-232) on the computer
19 USB port on the computer
Fig. 6 · Data transmission
15
16
13
14
17
USB 1.1 serial adapter
It can be connected under Windows
Windows
puter or over the USB 1.1 serial adapter.
®
XP either over the COM port of the com
18
®
2000 or
19
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4
T 6495-2 EN
Technical data · TROVIS 6495-2
Inputs
4 analog inputs mA, V, Pt 100, Pt 1000, input 2 also for potentiometer
mA or V
inputs
Resistance
thermometer
Potentiometer Nominal values 100, 200, 500, 1000
General
specifications
4 digital inputs
Outputs
3 analog outputs
7 digital outputs
Relay outputs 4 relays with floating NO contact, can be inverted
Transistor
outputs
Interfaces
Infrared
interface
Version Differential input
Nominal signal range 0 to 20 mA, 4 to 20 mA, 0 to 10 V, 2 to 10 V
Resolution < 0.007 %, based on nominal signal range
Permissible signal range –1 to 22 mA or –0.5 to 11 V
Input resistance 50Wwith current; 10 kWwith voltage
Static destruction limit
For sensor Pt 100, Pt 1000, according to DIN EN 60751
Nominal signal range –50 to 300 °C (–58 to 572 °F), can be limited
Connection Three-wire circuit (resistance per lead < 15W), two-wire circuit
Resolution < 0.02 K (0.006 % based on nominal signal range)
Connection Three-wire circuit, resistance per lead < 15
Resolution < 0.006 %
Measuring error of inputs < ± 0.2 % of nominal signal range for zero, span, linearity
Ambient temperature influence < ± 0.1 %/10 K for zero and span, based on 20 °C
Input filter Adjustable
Function generation Adjustable using 7 points
Signal increase/drop Adjustable
User calibration Adjustable
Transmitter fault alarm Adjustable, input signal < –5 % or > 105 %
Transmitter supply Supply output, terminals 89 and 90, 21 V DC, max. 90 mA, resistant to short-circuiting
Control Switching contact with external supply 24 V DC (17 to 31 V DC) or supplied by the
Nominal signal range 0 to 20 mA, 4 to 20 mA, 0 to 10 V, 2 to 10 V
Max. permissible signal range 0 (2.4) to 22 mA or 0 (1.2) to 11 V
Load < 750Wfor current; > 3 kWfor voltage
Error of outputs < ± 0.2 % of the nominal signal range for zero, span, linearity
Ambient temperature influence < ± 0.1 %/10 K for zero and span, based on 20 °C
Resolution < 0.03 %, based on nominal signal range
Static destruction limit ±30 V
Permissible contact load 264 V AC, 1 A AC, cosf= 1 or 250 V DC, 0.1 A DC
Spark suppression Connected in series C = 2.2 nF and varistor 300 V AC, in parallel to each relay contact
3 electrically isolated transistor outputs
External supply 3 to 42 V DC, max. 30 mA
Transmission protocol SAMSON-specific protocol (SSP)
Data that can be transmitted Controller settings, process variables, operating status
Transmission rate 9600 bit/s
Angle of deflection 50°
Distance IR adapter – controller£70 cm
30 V, 50 mA
±
W
W
controller over terminals 89 and 90 (21 V DC)
Signal state 'OFF' at 0 to 10 V, signal state 'ON' at 17 to 31 V, signal inversion can
be configured
Current consumption 3.1 mA at 24 V DC and 2.4 mA at 21 V DC
DI1 and DI2 as well as DI3 and DI4 are galvanically connected on one side
5
T 6495-2 EN
Technical data (continued)
RS-232/USB
(accessories)
RS-485/USB
(accessories)
General specifications
Voltage supply 85 to 264 V AC, 47 to 63 Hz or 24 V AC/DC (20 to 30 V), 47 to 63 Hz
Power consumption
Temperature Ambient: 0 to 50 °C · Storage: – 20 to 70 °C
Storage temperature –20 to 70 °C
Degree of protection (EN 60529) IP 65 (front), IP 30 (housing), IP 00 (terminals)
Device safety According to EN 61010-1: Class of protection II
Electromagnetic compatibility Requirements according to EN 61000-6-2, EN 61000-6-3 and EN 61326-1
Relative humidity Max. 95 %, non-condensing
Electrical connection Plug-on screw terminals 1.5 mm² (cross-section of the line 0.5 to 1.5 mm²)
Display Dot matrix display with 132 x 49 pixels
Display range –999 to 9999; start value, end value and decimal separator can be adjusted
Total delay time < 100 ms
Configuration Functions saved in read-only memory, configuration saved in non-volatile memory
Control types One or two fixed set point/follow-up control, one ratio control, one cascade control,
Weight 0.5 kg
RS-232 with electrical isolation, USB (slave)
Connection USB: 5-pin mini-B · RS-232: RJ 12
Transmission protocol USB: SAMSON-specific protocol (SSP) · RS-232: SSP and Modbus RTU
Data that can be transmitted Controller settings, process variables, operating status, fault alarms
RS-485 with electrical isolation, USB (slave)
Connection USB: 5-pin mini-B · RS-485: 4-pin screw terminals
Transmission protocol USB: SAMSON-specific protocol (SSP) · RS-485: SSP and Modbus RTU
Data that can be transmitted Controller settings, process variables, operating status, fault alarms
Transmission rate/
format
SSP: 9600 bit/s, 8 bit, no partity bit, 1 start bit
Modbus: 300 to 115200 bit/s, 8 bit, parity bit adjustable, 1 (2) stop bits
Type of transmission RS-485: Asynchronous, half duplex, 4-wire or 2-wire
Number of connected devices RS-485: 32 (can be extended when a repeater is used)
Number of addressable
stations
Modbus: 246
Line length RS-485: < 1200 m, max. 4800 m with repeater
Bus termination RS-485: Active, selectable
Transmission medium RS-485: 2 or 4 cores (twisted-pair cabling, stranded in pairs, with static shield)
85 to 264 V AC: max. 19 VA, fuse 630 mA (slow)
20 to 30 V AC/DC: max. 15 VA, fuse 1.25 A (slow)
Overvoltage category II
Degree of contamination 2
one ratio and fixed set point/follow-up control, one limitation control
Dimensions in mm (inch)
96 (3.78")
96 (3.78")
6
Mounting clips
91.2 (3.59")
150 (5.90")
156 (6.14")
Terminal strips
12 34
Slot for interface
board
Panel cut-out and minimum
distances when installing several
TROVIS 6495-2 Controllers
+0.8
92
+0.3
(3.62"
Panel
cut-out
>30
>15
T 6495-2 EN
)
)
+0.3
+0.8
92
(3.62"
Electrical connection
Terminal strip 1
Supply output
21 V DC, max. 90 mA
Input AI1
Input AI2
Input AI3
Input AI4
Current
0/4to20mA
89
90
11
12
13
15
16
17
19
20
21
23
24
25
Current
2-wire
transmitter
0/4 to 20 mA
+
–
–
+
–
+
–
+
–
+
+
–
+
–
+
–
+
–
Voltage
0/2 to 10 V
Resistance thermometer
Pt 100/Pt 1000
+
–
J
+
–
J
+
–
J
+
–
J
Potentiometer
100/200/500/1000
+
100 %0%
W
Terminal strip 2
Supply output
21 V DC, max. 90 mA
Digital input DI1
Digital input DI2
Digital input DI3
Digital input DI4
GND
GND
89
90
Current
0/4 to 20 mA
+
–
31
32Analog output AO1
33
+
81
–
82
+
83
35
36Analog output AO2
37
97
98Analog output AO3
99
+
85
–
86
+
87
+
–
+
–
+
–
Voltage
0/2 to 10 V
–
+
–
+
–
+
Digital input
with internal supply
Digital input
with external supply
24VDC
–
24VDC
–
+
+
7
T 6495-2 EN
Electrical connection (continued)
Terminal strip 3
Digital output DO5
Digital output DO6
Digital output DO7
Terminal strip 4
Supply voltage
Switch output SO1 (+)
Digital output DO1
Switch output SO1 (–)
Digital output DO2
61
62
63
64
65
66
Supply
3 to 42 V DC, max. 30 mA
L
N
42
43
52
53
–
+
–
+
–
+
L
85 to 264 V AC 24 V AC/DC (20 to 30 V)
N
Three-step output
for motor-driven actuator
+
L1
–
L+
L–
On/off output with
pulse-position modulation
+
N
L1
Digital output:
limit values, alarms, on/off output
Switch output SO2 (+)
Digital output DO3
Switch output SO2 (–)
Digital output DO4
Electrical isolation
Analog inputs
Digital inputs
Internal supply
Digital inputs
External supply
Interface
Supply voltage
45
46
55
56
+
L1 L1
–
Analog outputs
Digital outputs (relay)
for three-step, on/off, limit alarms
Digital outputs (transistor)
for fault and status alarms
Transmitter supply
N
Electrical isolation
+
Article code
Industrial controller TROVIS 6495-2
Supply voltage
85 to 264 V AC
24 V AC/DC
Accessories Order no.
–
TROVIS-VIEW Operator Interface............. 6661-1033
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Infrared adapter (RS-232)........................ 8864-0900
–
Bracket for infrared adapter...................... 1400-9769
–
USB 1.1 serial adapter............................. 8812-2001
–
Interface board RS-232/USB.................... 1400-9917
–
Interface board RS-485/USB.................... 1400-9918
–
USB cable (2 m) with type A and
5-pin mini-B connectors...........................
–
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
x
1
2
8801-7301
Specifications subject to change without notice.
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
:
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
T 6495-2 EN
2011-11
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