Samson TROVIS 5571, TROVIS 5500 Series Mounting And Operating Instructions

Automation System TROVIS 5500 Programmable Logic Controller (PLC) TROVIS 5571

Electronics from SAMSON

Mounting and Operating Instructions

EB 5571 EN

Firmware version 1.21 Edition March 2009

Disclaimer of liability

We are constantly developing our products and therefore, reserve the right to change the product or the information contained in this document at any time without notice.

We do not assume any liability for the accuracy or completeness of these mounting and operating instructions. Moreover, we do not guaranteethat thebuyer can use the product for an intended purpose. SAMSON rejects any liability for claims by the buyer, especially claims for compensation including lost profits or any other financial loss, except the damage was caused intentionally or by gross negligence. If an essential term of the contract is breached by negligence, SAMSON’s liability is limited to the foreseeable damage.

Safety instructions

The device may only be assembled, started up or operated by trained and

experienced personnel familiar with the product. Proper shipping and appropriate storage are assumed.

The device has been designed for use in electrical power systems. For wiring

and maintenance, you are required to observe the relevant safety regulations.

Modifications of the PLC firmware compared to the previous version

1.10 (old) 1.11 (new)

New default setting for parameter Expansion of the data logging function (see section 5.5)

1.11 (old) 1.21 and lower (new)

Internal modifications

2 EB 5571 EN

Gateway

= Off

Contents

Contents Page

1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1.1 Operating keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2.1 Adjusting the contrast of the display . . . . . . . . . . . . . . . . . . . 6

1.3 Displaying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Setting the system time . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2 Changing PLC settings. . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Configuring universal inputs . . . . . . . . . . . . . . . . . . . . . . 13

2.4 Resetting to default values . . . . . . . . . . . . . . . . . . . . . . . 15

3 Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Operational faults . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Modbus slave interface . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2 Modbus master interface . . . . . . . . . . . . . . . . . . . . . . . 20

5.3 Description of communication parameters to be adjusted . . . . . . . . 21

5.4 Meter bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.4.1 Activating the meter bus . . . . . . . . . . . . . . . . . . . . . . . . 23

5.5 Data logging module . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.5.1 Data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.5.2 Saving and loading firmware and applications . . . . . . . . . . . . . 26

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.1 Settings level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.3 Special key codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.4 Expansion modules . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.4.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.4.2 Terminal assignment. . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.4.3 Integrating the expansion modules . . . . . . . . . . . . . . . . . . . 37

8.5 Sensor resistance tables . . . . . . . . . . . . . . . . . . . . . . . . 38

8.6 Customer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

EB 5571 EN 3

Operation

1 Operation

The programmable logic controller (PLC) is freely programmable. The controller is delivered without an executable application in the memory. The application must be developed sepa

rately for the desired purpose on a personal computer using ISaGRAF

(programming as in

IEC 61131-1) and then transferred to the controller. On start-up, after transferring the generated application, the current time and date must be set

in the controller (–> section 1.4).

1.1 Operating elements

1.1.1 Operating keys

The keys are located in the front panel of the PLC and protected by a Plexiglas door.

Changeover key

(press with pen or other pointed item) Switch between levels (after entering the key code)

Reset key

(press with pen or other pointed item) Reset freely accessible parameters and function blocks to their default values (factory settings)

4 EB 5571 EN

Cursor key(s)

Pressing both keys together:

– Switch to information level

Pressing one of the keys separately: – Navigate in levels (also in the application developed with ISaGRAF – Set data points

Enter key

– Open levels (also in the application developed with ISaGRAF

– Activate editing mode for parameters and function blocks – Confirm entered settings

)

Operation

1.2 Display

The programmable logic controller has a plain text display. The display is automatically illuminated when entering or setting the controller.

After connecting the controller to the power supply, “System is being initialized…“ appears briefly on the display. Should the display not be illuminated or the contrast is too strong/weak, you can adapt the dis play illumination. Refer to section 1.2.1.

28.11.2005 10:00:05 V1.1xx

Application: … Version: … Date: … CRC: … Size: … kB Cycle time: … ms

The current status of the three communication interfaces “RS-232/Slave“, “RS-485/Master“ and “RS-232/Prog“ appears at the bottom of the display:

RS-232/Slave (left) RS-485/Master (middle) RS-232/Prog (right)

Interface inactive Interface inactive Interface inactive

If an application is not saved on the PLC, the normal display (left) contains the date, time and current firmware version.

If an application is saved on the PLC, the normal display contains application-related information.

blinking

SMS

Direct connection to control station

active

Modem inactive

Modem initializa

tion active

RING,

calling active

Connection estab

lished/canceled

Connection to con

trol station active

Error

SMS sending

active

Modbus master

active

Connection to

ISaGRAF

bench active

Data logging

active

EB 5571 EN 5

Work-

Operation

Note!

If no key is pressed for two minutes, the PLC returns to the normal display. The background illumination of the display is switched off automatically. Any settings that have not been confirmed are not saved and must be re-entered.

1.2.1 Adjusting the contrast of the display

Entering the key code

0000

Activate the editing mode. Display: Entering the key code

0000

blinks

Confirm the

0000

reading. Set the contrast. Confirm the changed setting.

Display: Normal display (depending on the application)

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1.3 Displaying data

Operation

The states of the inputs and outputs as well as information on the connected meter bus instru ments can be retrieved in the information level. In addition, the analog and binary outputs can be changed (refer to section 3 on manual operation). The information level is divided into individual menu items:

Analog inputs · Measured data from connected sensors

Analog outputs · Output data from four analog outputs *

Binary inputs · States of the binary sensors (on/off)

Binary outputs · States of the binary outputs (on/off) *

Meter bus · Output data of the meters connected over meter bus

*)The analog and binary output settings can be changed after entering the key code.

)

Proceed as follows:

Information level

Analog inputs

Analog outputs Binary inputs Binary outputs Meter bus System info

Back

Binary outputs

BA07=OFF BA08=OFF BA09=OFF BA10=OFF BA11=OFF BA12=OFF

Back

Information level

Analog inputs Analog outputs Binary inputs Binary outputs Meter bus System info

Back

Switch to the information level. Display: Information level The menu item “Analog inputs“ is highlighted.

Select required menu item, e.g. binary outputs. Activate the menu item. Select required data point.

Returning to the information level

Select

Back

to return to the information level.

Exit the menu item. Display: Information level

Exiting the information level

Select

Back

Exit the information level. Display: Normal display (depending on the application)

Note!

If no key is pressed for two minutes, the PLC automatically returns to the normal display.

EB 5571 EN 7

Operation

1.4 Setting the system time

The current time and date need to be set immediately after start-up and after a power failure lasting more than 24 hours.

Set the system time in the settings level under the menu item “Date / time”. The Automatic sum

mer time function can also be activated or deactivated in this menu item.

System time: Time-dependent functions of the saved application are based on the system

time set in the PLC. Automatic summer time: The summer time is automatically set on the last Sunday in

March at 02:00 h and the winter time on the last Sunday in October at 03:00 h.

Proceed as follows:

Entering the key code

0000

Settings level

Date / time

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Settings level

28.11.2005 10:00

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Activate the editing mode. Display: Entering the key code

0000

blinks

Enter the key code. Confirm the key code entered.

Display: Settings level The “Date / time“ menu item is highlighted.

Activate the menu item “Date / time“. Display: System time (DD.MM.YYYY HH:MM)

Activate the editing mode for the system time.

Display: Date (

) blinks. Enter date. Confirm date entered.

Display: Month (

) blinks.

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Settings level

Automatic summer time? On

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Settings level

28.11.2005 10:00

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Operation

Enter month. Confirm month entered.

YYYY

Display: Year (

) blinks. Enter year. Confirm year entered.

Display: Time (

) blinks. Enter hour. Confirm hour entered.

Display: Minutes (

) blink. Enter minutes. Confirm minutes entered.

Display: “Automatic summer time? __“ blinks If required, change the current setting (on/off) of the

Automatic summer time function. Activate function: Automatic summer time? On Deactivate function: Automatic summer time? Off Exit the menu item “Date / time“.

Display: Settings level

Settings level

Date / time RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Exiting the settings level

Select

Back.

Exit the settings level. Display: Normal display (depending on the application)

Note!

If no key is pressed for two minutes, the PLC automatically returns to the normal display.

EB 5571 EN 9

Start-up

2 Start-up

2.1 Programming

Programming the PLC requires a PC with ISaGRAF®software.

The ISaGRAF needs of your plant (ISaGRAF

software enables you to program a control system that is tailored to the specific

development environment 1400-7621). Programming must fol low the structures and rules stipulated in IEC 61131-3. The PLC may be programmed with the languages defined in the standard: Sequential Function Chart (SFC), Instruction List (IL), Flow Chart (FC), Function Block Diagram (FBD), Ladder Diagram (LD), and Structured Text (ST).

There are 128 KB of memory available in the PLC for the ISaGRAF

application.

The application is complied to machine code in the PC environment. This code is then trans ferred to the PLC over the front RJ-45 jack (connecting cable 1400-7620).

Programming languages:

Sequential Function Chart (SFC):

Instruction List (IL): Low-level textual language for logic and arithmetic operations Flow Chart (FC): High-level language used to visualize the data flow Function Block Diagram

(FBD): Ladder Diagram (LD): Simple graphics-based language for logical operations (boolean) Structured Text (ST): High level language similar to PASCAL and C especially designed for

Used to describe operations of a sequential process with a simple graphic representation

Graphics-based language for building and combining complex functions (logical, arithmetic)

control applications

For operation and application of the ISaGRAF®environment, refer to the documentation in cluded in the software package. To enable simple and clear programming, ready-made func tions and function blocks, e.g. for boiler systems, heat exchanger sequence control, ventilation systems, heating circuits or domestic hot water systems, are available from SAMSON.

Parameters* Station address 255 RS-232/Prog / 1 to 247, 255 Baud rate 9600 RS-232/Prog / 9600, 19200

WE Settings level / Range of values

* –> Section 5.3 (Description of communication parameters to be adjusted)

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Start-up

Note!

In ISaGRAF status or value of the internal variable is written to the associated holding or coil register and can be read or written over Modbus.

Important! The PLC application must be reloaded after a cold start.

, internal variables can be assigned (integer or bool) network addresses. The

2.2 Changing PLC settings

PLC settings can only be changed after entering the valid key code. The valid key code can be found on page 42. To avoid unauthorized use, remove the page or

make the key code unreadable. Change PLC settings in the settings level, which contains the following menu items:

Date / time, refer to section 1.4

RS-232/Slave, refer to section 5.1

RS-485/Master, refer to section 5.2

RS-232/Prog, refer to section 2.1

Meter bus, refer to section 5.4

Universal input type, refer to section 2.3

Proceed as follows:

Entering the key code

0000

Activate the editing mode. Display: Entering the key code

0000

blinks

Enter the valid key code.

EB 5571 EN 11

Start-up

Settings level

Date / time

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

RS-232/Slave

Modbus Slave Modem Baud rate

Back

Settings level

Date / time RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Confirm the key code. Display: Settings level The menu item “Date / time“ is highlighted.

Select the menu item in which the settings are to be changed, e.g. “RS-232/Slave“.

Activate the selected menu item. Select the data point which you want to change. Activate the editing mode of the data point.

Display: Data point blinks. Set the data point. Confirm the setting.

Returning to the settings level

Back

Select

to return to the settings level.

Exit the menu item. Display: Settings level

Exiting the settings level

Select

Back

to return.

Exit the settings level. Display: Normal display (depending on the application)

Note!

If no key is pressed for two minutes, the PLC automatically returns to the normal display.

12 EB 5571 EN

Start-up

2.3 Configuring universal inputs

There are 17 universal inputs, which may be used as binary inputs, analog inputs (0 to 10 V, 0/4 to 20 mA) or as sensor inputs. The hardware must be configured accordingly (sensor ini tialization).

Refer to page 38 for the resistance values of the PTC, Pt 100 and Pt 1000 sensors. You can also configure each universal input separately.

The following configurations are available: Pt 100/500/1000/2000, Ni 200/1000/2000, PTC, NTC, 1–2 kΩ, BE, 0/4 to 20 mA (with 50Ωparallel resistor) and 0 to 10 V.

Proceed as follows:

Entering the key code

0000

Settings level

Date / time

RS-232/Slave RS-485/Master RS-232/Prog Meter bus Universal input type

Back

Universal input type

UE01=PT100↔PT1000

UE02=PT100↔PT1000 UE03=PT100↔PT1000 UE04=PT100↔PT1000 UE05=PT100↔PT1000 UE06=PT100↔PT1000

Back

Activate the editing mode. Display: Entering the key code

0000

blinks

Enter the valid key code. Confirm the key code.

Display: Settings level The “Date / time“ menu item is highlighted.

Select the menu item “Universal input type“. Activate this selected menu item.

The first universal input UE01is highlighted. Select the universal input. Activate the universal input.

UE__

Display:

blinks.

EB 5571 EN 13

Manual operation

Select the type of universal input. The inputs are available in the following order: PT100↔PT1000, PT100↔PTC, NI2000, PT2000, PT500, 0 – 10V, BE, 1000 – 2000Ω, PT100, PT1000, NTC, PTC, NI1000, NI200, 4 – 20mA, 0 – 20mA

Note!

On selecting the universal input types PT100 PT100

PTC, this configuration applies then to all 17 uni

↔

PT1000 or

↔

versal inputs. Any inputs that have a different type need to be configured separately afterwards.

Binary inputs with terminal 10 functioning as GND are slow (delay of approx. 3 s). Binary inputs with terminal 9 functioning as GND are fast (ms).

If a resistance input has been selected:

(PT100↔PT1000, PT100↔PTC, NI2000, PT2000, PT500, PT100, PT1000, NTC, PTC, NI1000 or NI200)

Universal input type

Calibrate? No

UE02=PT100↔PT1000 UE03=PT100↔PT1000 UE04=PT100↔PT1000 UE05=PT100↔PT1000 UE06=PT100↔PT1000

Back

14 EB 5571 EN

Confirm the type of universal input. Display: ”Calibrate? No“ blinks.

If the temperature sensor connected at the input is not to be calibrated:

Exit the universal input.

If the temperature sensor connected at the input is to be calibrated:

Set to “Calibrate? Yes“. Confirm calibration.

Display:

Temperature measured

by the sensor blinks.

Compare the temperature measured by the sensor with the temperature measured by a reference ther mometer installed directly at the point of measure

ment.

+ 30 hidden pages

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