Samson Trovis 6400, Trovis 6412, Trovis 6442 Mounting And Operating Instructions

Automation System TROVIS 6400

Process Control Stations TROVIS 6412 and 6442

Edition July 2007

Firmware C 1.3 Firmware Si 1.4

Mounting and Operating Instructions

EB 6412 EN

Contents

1. Notes on these mounting and operating instructions...................................... 5

1.1. Documentation ............................................................................................. 5

1.2. Abbreviations used in this manual.................................................................. 5

2. Description................................................................................................... 6

2.1. Features ....................................................................................................... 6

2.2. Versions ....................................................................................................... 6

2.3. The process control station (overview)............................................................. 7

2.4. Technical data .............................................................................................. 8

3. Installing the process control stations .......................................................... 11

3.1. TROVIS 6412 (panel-mounting unit)............................................................. 11

3.2. TROVIS 6442 (rack-mounting unit for 19inch racks)...................................... 12

3.3. Opening the controller case......................................................................... 12

4. Soldering jumpers...................................................................................... 14

4.1. Determining the input signals....................................................................... 14

4.1.1. Input board 1 (IB1)...................................................................................... 14

4.1.2. Input board 2 (IB2)...................................................................................... 15

4.1.3. Input board 3 (IB3)...................................................................................... 16

4.1.4. Input board 4 (IB4)...................................................................................... 17

4.2. Soldering jumpers on the logic board........................................................... 19

4.3. Soldering jumper for implementing the code number..................................... 19

4.4. Soldering jumpers on the interface board ..................................................... 20

5. Electrical connections.................................................................................. 22

5.1. TROVIS 6412 (panel-mounting unit)............................................................. 22

5.2. TROVIS 6442 (rack-mounting unit for 19inch racks)...................................... 24

5.3. Balancing the line resistance for the connection of Pt 100 sensors................... 26

5.4. Wiring technique with regard to electromagnetic compatibility....................... 26

6. Operation.................................................................................................. 28

6.1. Process display and control panel elements................................................... 28

6.2. OPERATING level........................................................................................ 28

6.2.1. Modifying the internal set point (reference variable) ...................................... 29

6.2.2. Power supply failure.................................................................................... 30

6.2.3. Manual adjustment of the output variable ..................................................... 30

6.3. PARAMETER level........................................................................................ 32

6.3.1. Operating the PARAMETER level .................................................................. 32

6.3.2. Example how to modify a parameter............................................................ 34

6.4. CONFIGURATION level .............................................................................. 36

6.4.1. Operating the CONFIGURATION level......................................................... 36

6.4.2. Example how to modify a configuration block............................................... 38

6.5. I-O level (displaying all input and output variables) ....................................... 40

6.6. Si level (setting the RS-485 interface)............................................................ 40

6.7. Ai level (adjustment and calibration) ............................................................ 41

6.8. Fir level (displaying the firmware number) .................................................... 43

6.9. CHE level (checking the display panel).......................................................... 43

6.10. PA level (code number for the PARAMETER level) ..............................44

6.11. CO level (code number for the CONFIGURATION level)....................44

6.12. Ini level (resetting the process control station to its default values) ....................45

6.13. AdP level (adaptation of the control parameters) ............................................46

6.13.1. Single adaptation (adaptation during the start-up phase)................................48

6.13.2. Scheduling dependent on the actual value signal or output variable signal.......51

6.13.3. Scheduling dependent on an external signal..................................................53

6.13.4. Notes on adaptation....................................................................................53

6.13.5. Summary of the adaptation parameters.........................................................54

7. TROVIS 6482 Configuration and Parameterization Program.........................56

8. COPA pen...................................................................................................58

9. Interface RS-485 .........................................................................................60

9.1. Interface mode ............................................................................................60

9.2. Network construction ...................................................................................60

9.3. Network interconnections .............................................................................62

9.4. Operation...................................................................................................62

9.5. Functions supported by the Modbus protocol .................................................62

9.5.1. Function code 01 (Read Coil Status)..............................................................62

9.5.2. Function code 02 (Read Input Status).............................................................63

9.5.3. Function code 05 (Force Single Coil).............................................................63

9.5.4. Function code 03 (Read Holding Register) .....................................................63

9.5.5. Function code 04 (Read Input Register)..........................................................64

9.5.6. Function code 06 (Preset Single Register).......................................................64

9.5.7. Function code 15 (Force Multiple Coils).........................................................64

9.5.8. Function code 16 (Preset Multiple Register) ....................................................65

9.5.9. Error messages ...........................................................................................65

9.5.10. Other functions............................................................................................66

9.6. Retrofitting the RS-485 interface....................................................................66

10. Start-up procedure......................................................................................67

10.1. Optimization (tuning the process control station to the controlled system) .........67

Appendix A Data point list for the RS-485 interface.......................................................71

Appendix B Error messages ..........................................................................................90

Appendix C Checklist....................................................................................................94

Notes on these mounting and operating instructions Documentation

1.Notes on these mounting and operating instructions

1.1.Documentation

Two manuals constitute the documentation for the TROVIS 6412 and 6442 Process Control Stations: Mounting and Operating Instructions EB 6412 EN and Configuration Manual KH

6412 EN. EB 6412 EN contains information about the installation, electrical connection and operation of

the control stations. Also introduced is how to work with the COPA pen, the COPA adapter and the associated TROVIS 6482 Configuration and Parameterization Program. In addition, the function of the RS-485 interface is described.

Configuration Manual KH 6412 EN presents a detailed description of the optional control modes of the process control station, which can be defined by selecting the corresponding configuration blocks and parameters.

1.2.Abbreviations used in this manual

The parameter names and input and output abbreviations used in this manual are those appearing on the front-panel display of the TROVIS 6412 Process Control Station. These are not always the same as the ones defined in the relevant DIN standards or often used in other documents.

Caution!

Assembly, commissioning and operation of this process control station may only be performed by experienced personnel.

2.Description

2.1.Features

The TROVIS 6412 and 6442 Process Control Stations are microprocessor-controlled devices used to automate industrial and process engineering plants. They are suitable not only for constructing simple control loops, but for solving complex control problems as well. The TROVIS 6412 and TROVIS 6442 Process Control Stations only differ from each other in their design (see section 2.2.).

Function blocks which are permanently stored in memory allow the user to easily define pre-configured control systems and select various functions. The control mode selected determines which configuration blocks can be set, and these configuration blocks in turn determine the adjustable parameters.

The process control stations are available with various input boards with either three or four analog inputs. Furthermore, each control station has three binary inputs.

The analog inputs of the input boards are suitable for either standardized current and voltage signals, potentiometers, Pt 100 temperature sensors, thermocouples or transmitter supply. The input board 4 in the Technical data (page 8 and following) is no longer available. As a result, the use of thermocouples is restricted.

Standard outputs include: One continuous control output, one on-off/three-step output and one binary output for error messages.

The functional range of the process control stations can be optionally enhanced with the following: One additional continuous control output, one analog output, two limit switches and two binary outputs.

The process control stations can be operated, configured, and parameterized directly on the control panel via several keys. The functions associated with the respective keys can be disabled.

An optional program - TROVIS 6482 - allows configuration and parameterization of the process control station via a PC (see page 56). Apart from this, all configuration blocks and parameters can also be transferred to the process control stations, using a configuration and parameterization pen (COPA pen) (see page 58).

The process control stations can be equipped with a RS-485 serial interface for use in a higher level process control system.

2.2.Versions

TROVIS 64 2 Panel-mounting unit

Rack-mounting unit

Features Description

Description The process control station (overview)

2.3.The process control station (overview)

Y +

Y -

Control elements

Control mode−Filtering, root extraction, func-

Software functions:

−

Ai 1

Ai 2

tion generation of input variables−Combination of input variables

Ai 3

Ai 4

(addition, subtraction, multiplica-

tion, calculation of mean value,

comparison, ratio)

Operation with two set points−Set point ramp and output

variable ramp

−

Optionally linear and non-linear

control algorithms and compen-

sation algorithms−Output signal limitation (fixed,

−

variable or by means of an input

variable)

Split-range operation−Definition of starting and

−

pen/

adapter

restart conditions, limit alarms

Adaptation of control parameters

or parameter control by an

external signal−Selection control (limiting control)

−

Optional equipment

Fig. 1 ⋅ Block diagram of the process control station

2.4.Technical data

Inputs

Input board 1 2 3 4

Input 1 mA, V,

potentiometer,

transmitter

supply

Pt 100 in 2/3 or 4-wire

circuit

Thermocouple

(int./ext.

reference

junction)

Input 2

mA, V input,

transmitter supply

Pt 100

in 2/3

or 4-wire

circuit

mA, V,

transmitter

supply

Input 3 mA or V

input

mA, V,

transm. supply

Omitted Omitted

Input 4

mA, V or potentiometer

mA, V,

potentiometer,

transmitter

supply

mA, V or

potentiometer

mA or V input

Measuring ranges 4(0) to 20 mA or

2(0) to 10 V; 0.2(0) to 1 V; 1(0) to 5 V Meas. range switch-over Soldering jumpers Max. permissible values

Current ± 50 mA, voltage ± 25 V Internal resistance

Current R

= 50 Ω; voltage Ri = 200 k

Permissible DC voltage

0 to 10 V

Error Zero point < 0.2 %, span < 0.2 %, linearity < 0.2 % Temperature influence Zero point < 0.1 %/10 K; span < 0.1 %/10 K

Pt 100 temperature sensors

Measuring ranges

−

50 to 100 °C; 0 to 200 °C; 100 to 600 °C Meas. range switch-over Soldering jumpers and configuration Line resistances

Two-wire R

+ R

< 10 Ω,

Three-wire R

= RL2 = RL3 < 50 Ω,

Four-wire, each R

< 100

Error Zero point, gain, linearity < 0.2 % Temperature influence Zero point < 0.2 %/10 K; span < 0.2 %/10 K

Potentiometer Measuring range

0 to 1kΩ, ± 100 Ω, three-wire

Line resistance

< 10 Ω each Error Zero point < 0.2 %, gain < 0.2 % Temperature influence Zero point < 0.1 %/10 K; gain < 0.2 %/10 K

Thermocouple

Specifications on request Transmitter supply 16 to 23 V, max. 50 mA, short-term short-circuit protected Binary inputs 3 binary inputs,

switching contacts (load 36 V DC, approx. 3 mA) or

external switching voltage (24 V DC, ± 30 %,

maximum 6 mA), selection via soldering jumpers

Technical data Description

Description Technical data

Outputs

Continuous control output

Signal range

Output control range

4(0) to 20(22) mA, permissible load < 750 Ω or 2(0) to 10 V, permissible load > 3 kΩ

−10 to 110 %

Error Zero point < 0.3 %, nominal end value < 0.3 %,

linearity < 0.3 %

Temperature influence Zero point < 0.1 %/10 K; nominal end value < 0.1 %/10 K

Switching output 1 on-off or three-step output,

250 V AC (1A AC, cos ϕ = 1)

Binary output (BO 3) Electrically isolated transistor output,

= 3 V DC,U

min

= 42 V DC, I

max

= 30 mA DC

max

Options Control output 1 continuous control output for split-range operation;

signal range, output control range, error and temperature influence same as first continuous control output (see above)

Analog output

4(0) to 20 mA, permissible load < 750 Ω or 2(0) to 10 V or −10 to 10 V, permissible load > 3kΩ

Error and temperature influence same as first continuous control output (see above)

Limit relay 2 relays, floating contacts, maximum 250 V AC

(1 A AC, cos ϕ = 1) or maximum 250 V DC (0.1 A DC)

Binary outputs 2; floating contacts; maximum 42 V AC (0.1 A AC);

42 V DC (0.05 A DC)

Interfaces

Serial interface on the front-panel

Communications protocol TROVIS 6482 SAMSON Protocol Number of stations 1

RS-232 in conjunction w. SAMSON cable no. 1170-1141

Length of cable < 2 m Transmittable data Configuration, parameters, input and output signals for

graphic display

COPA pen Read/write pen for transmitting the CONFIGURATION and

PARAMETER data to/from the process controls station via the front-panel serial interface

Serial interface RS-485 (optional)

Communications protocol Modbus RTU 584 Data transmission Asynchronous, half duplex, 4-wire or 2-wire Character format RTU (8 bit), 1 start bit, 8 data bits, 1(2) stop bit(s),

optional parity bit Baud rate 300 to 19200 bit/s Number of addressable

246 stations

Number of stations 32 (can be extended with repeater) Length of cable and

transmitting medium Transmittable data Configuration, parameters, operating state,

< 1200 m, with repeater maximum 4800 m, 4-wire (2

wires twisted, stranded in pairs, with static screen)

process variables, error messages

General specifications

Displays Read-off angle Readable from all sides, high-contrast and lighted

Liquid Crystal Display (LCD)

Displays

⁄

-digit set point (reference variable) display and

⁄

-digit controlled variable display; bar graph displays

for deviation (i.e. error) and output variable; LED displays for range exceeding, alarm messages when limits are exceeded, manual operation, faults etc.; parameter display (only in the PARAMETER level)

Configuration Permanently stored function blocks for fixed set point

control, follow-up control with or without internal/external set point change-over, cascade control, synchro control, ratio control, SPC control, limiting control, DDC backup fixed set point control via binary contact

Power supply 230 V AC (200 to 250 V AC),

120 V AC (102 to 132 V AC), 24 V AC (21.5 to 26.5 V AC), Option 24 V DC (19 to 34 V DC);

48 to 62 Hz Power consumption Approx. 18 VA Temperature range

0 to 50 °C (operation),

−

20 to 70 °C (shipping and storage)

Degree of protection

Panel-mounting unit: Front IP 54, case IP 30,

terminals IP 00;

Rack-mounting unit: IP 00 Overvoltage category II Degree of contamination 2 Conformance to European standards EN 61010, edition March 1994 Electrical

connection

Functional earthing Panel-mounting unit: On case w. Cu-flex. lead > 2.5 mm

Rack-mounting unit: Connector, Type F

(DIN 41 612), Cu-flex. lead > 2.5 mm

Power voltage and process signals

Panel-mounting unit: Screw terminals 1.5 mm2;

Rack-mounting unit: Two connectors, Type F

(DIN 41 612), soldering or crimp types

Total delay time

Approx. 100 ms Resolution Input and output, approximately 11 bits Dimensions See Fig. 3 and Fig. 4 Weight Panel-mounting unit, approx. 1.9 kg; rack-mounting unit, 1 kg

The input board 4 (thermocouple at input 1) is no longer available

Specific measuring ranges on request

Depending on how many functions are configured

Technical data Description

Installing the process control stations TROVIS 6412 (panel-mounting unit)

3.Installing the process control stations

3.1.TROVIS 6412 (panel-mounting unit)

The TROVIS 6412 Process Control Station is designed for panel-mounting and has the front-frame dimensions 72 x 144 mm. Perform the following steps in order to mount the controller:

1. Make a panel cut-out with the dimensions 68

+0.7

x 138

2. Push the process control station in the panel cut-out from the front side.

3. Install one supplied mounting bracket, both on the top and bottom of the control station following steps 1) and 2) shown in Fig. 2 .

4. Turn the threaded rods in the direction of the control panel, using a screwdriver so that the case is clamped against the panel ((step 3), Fig. 2 ).

16.5

(0.65)

+1.0

mm.

226

(8.90)

Fig. 3 ⋅ Dimensions (panel-mounting unit)

137.5

(5.41)

144

(5.67)

(2.83)

1 Label 2Screws

1) Insert on pin (pivot) and turn

Fig. 2 ⋅ Installation (panel-mounting unit)

2) Click into place

3) Screw tight

4 Mounting bracket 5Pin 6 Threaded rods 7 Front-panel bezel

TROVIS 6442 (rack-mounting unit for 19inch racks) Installing the process control stations

3.2.TROVIS 6442 (rack-mounting unit for 19inch racks)

The TROVIS 6442 Process Control Station is a rack-mounting unit designed for mounting in 19inch racks. It has to be installed as follows:

1. Push the control station along the guiding rails into the corresponding rack unit, making sure it does not become tilted. Push until the connectors connect.

2. Secure the process control station to the rack unit by fastening it from the front, using two screws (see 1, Fig. 4 ).

3 Press one protective nipple (enclosed in the delivery) into each bore made for the screws.

14.5

(0.57)

Fig. 4 ⋅ Dimensions of the 19inch rack-mounting unit

162.5

(6.40)

190

(7.48)

100 (3.94)

128.5

(5.06)

70.5

(14 HP)

(2.77)

1Screw with

protective nipple

3.3.Opening the controller case

ATTENTION!

The case may only be opened by experienced personnel when the power to the process control station has been cut off!

Re-jumpering (see section 4.) or retrofitting the process control station with an interface board requires that the case be opened as follows:

1. With panel-mounting cases, remove small paper labels (see 1, Fig. 3 ) if necessary. With 19inch rack-mounting units, remove the two protective nipples. Unscrew the two screws located on the front-panel of the case (see Fig. 3 or Fig. 4 , depending on the type of case).

2. Withdraw controller section towards the front. Then, proceed as described for the respective PCB to be modified.

Installing the process control stations Opening the controller case

Modify input (5, Fig. 5 ) or/ and interface board (6, Fig. 5 ):

3. Unscrew the four screws (1, 2) and remove the two distance bolts (4).

4. Carefully withdraw the input and/or interface board from the case.

5. Modify the board as desired (see sections 4.1., 4.4.).

6. Carefully reinstall the interface or/and input board by plugging it/them into the associated connectors. Make sure the connections are made correctly! Terminals 1 and 21 of each connector are marked.

7. Reinstall the two distance bolts (3) and the four screws (1, 2).

Proceed as described under 8. to 10.

Modify the logic board (7, Fig. 5 ) as follows:

3. Unscrew the two screws (1).

4. Remove cover plate (3).

5. Modify the board as desired (s. sections 4.2. and 4.3.).

6. Reinstall cover plate, making sure that its curved part bends towards the outside.

7. Reinstall the two screws (1).

Proceed as described under 8. to 10.

8. Record any modifications made on the label located on the cover plate. With panel-mounting units, additionally mark modifications on the label on the outside case wall!

9. Insert controller section and fasten it with the two associated screws.

10. If necessary, reinsert small labels and protective nipple on the front-panel of the control station.

1Screws 2Screws 3 Cover plates 4 Distance bolts 5Input board 6Interface board 7Logic board 8 Power supply board 9 Case section (only

panel-mount. unit)

Fig. 5 ⋅ Location of the boards in the controller case

Determining the input signals Soldering jumpers

4.Soldering jumpers

ATTENTION!

The soldering jumpers may only be modified by experienced personnel when the power to the process control station has been cut off!

Several functions of the process control station are determined by means of soldering jumpers. Open the case as described in section 3.3. to modify the jumpers. The soldering jumpers are marked on the soldering sides of the PCBs.

4.1.Determining the input signals

4.1.1.Input board 1 (IB1)

Note: Select the desired input signal and close the related soldering jumpers listed in line 3 or the following ones of the table below (depending on type of signal selected)! Open all remaining jumpers associated with the corresponding input (line 2)! See Fig. 5 for the location of the input board.

Input signal Input 1

(Ai 1)

Jumpers: 10 to 19

Current 0 to 20 mA 11 21 31 41, 45

4 to 20 mA 11, 14 21, 24 31, 34 41, 44, 45

−20 to 20 mA

Voltage 0 to 1 V11213141

0 to 5 V 12 22 32 42

0 to 10 V 13 23 33 43

0.2 to 1 V 11, 14 21, 24 31, 34 41, 44 1 to 5 V 12, 14 22, 24 32, 34 42, 44

2 to 10 V 13, 14 23, 24 33, 34 43, 44

Potentiometer

0 to 1kΩ

11, 15, 16 21, 25, 26

12, 17, 18

Input 2 (Ai 2)

Jumpers: 20 to 26

−−

Input 3 (Ai 3)

Jumpers: 31 to 34

−−

Input 4 (Ai 4)

Jumpers: 41 to 47

42, 46, 47

Transmitter supply 10, 11, 14, 19

Soldering jumpers associated with the binary inputs for all input boards:

Switching contact 50, 51 60, 61 70, 71 External switching voltage Jumpers mentioned above are open

Binary input 1 (bi 1)

Jumpers

20, 21, 24

Binary input 2 (bi 2)

Jumpers

−−

Binary input 3 (bi 3)

Jumpers

Soldering jumpers Determining the input signals

4.1.2.Input board 2 (IB 2)

Input signal Input 1

(Ai 1)

Input 2 (Ai 2)

Input 3 (Ai 3)

Input 4 (Ai 4)

Jumpers: 10 to 19

Current 0 to 20 mA

Jumpers: 20 to 26

Jumpers: 30 to 34

Jumpers: 41 to 47

21 31 41, 45

4 to 20 mA 21, 24 31, 34 41, 44, 45

−20 to 20 mA

21, 25, 26

−−

Voltage 0 to 1 V 213141

0 to 5 V 22 32 42

0 to 10 V 23 33 43

−

0.2 to 1 V 21, 24 31, 34 41, 44 1 to 5 V 22, 24 32, 34 42, 44

2 to 10 V 23, 24 33, 34 43, 44

Potentiometer

Transmitter supply

0 to 1kΩ−−

20, 21, 24

30, 31, 34

42, 46, 47

−

Pt 100 2 /3-wire 4-wire

10, 12, 13,

15, X

Measuring ranges

−50 to 100 °C 0 to 200 °C 100 to 600 °C

Select one measuring range and the corresponding soldering jumper. In the PA level, adjust the measuring range by means of the parameters GWK

For specific measuring ranges (on request), soldering jumper X must be open and soldering jum-

11, 14, 16,

and GWK1 .

−

per 17 must be closed.

Determining the input signals Soldering jumpers

4.1.3.Input board 3 (IB 3)

Input signal Input 1

(Ai 1)

Input 2 (Ai 2)

Input 4 (Ai 4)

Current 0 to 20 mA

4 to 20 mA 41, 44, 45

Jumpers: 10 to 19

−−

Jumpers: 20 to 29

Jumpers: 41 to 47

41, 45

−20 to 20 mA −

Voltage 0 to 1 V 41

0 to 5 V 42

0 to 10 V 43

0.2 to 1 V 41, 44 1 to 5 V 42, 44

2 to 10 V 43, 44

Potentiometer

0 to 1kΩ

42, 46, 47

Transmitter supply 40, 41, 44,

45, 48

Pt 100 2 /3-wire 4-wire 2 /3-wire 4-wire

10, 12, 13,

15, X

Measuring ranges

−50 to 100 °C 0 to 200 °C 100 to 600 °C

Select one measuring range and the corresponding soldering jumper. In the Pa level, adjust the measuring range by means of the parameters GWK

Select one measuring range and the corresponding soldering jumper. In the PA level, adjust the

measuring range by means of the parameters GWK

For specific measuring ranges (on request), soldering jumper X must be open and soldering jum-

19 18 17

11, 14, 16, X

20, 22, 23,

25, XX

and GWK1 .

and GWK2 .

21,24,

29 28 27

26,

−

per 17 must be closed.

For specific measuring ranges (on request), soldering jumper XX must be open and soldering jumper 27 must be closed.

4.1.4.Input board 4 (IB 4)

Input board 4 is no longer available.

Input signal

Input 1 (Ai 1)

Input 2 (Ai 2)

Input 3/4 (Ai 3/4)

Jumpers: 10 to 19

Jumpers: 20 to 26

Jumpers: 41 to 47

Current 0 to 20 mA

−

21 41, 45

4 to 20 mA 21, 24 41, 44, 45

−

20 to 20 mA

21, 25, 26

−

Voltage 0 to 1 V 21 41

0 to 5 V 22 42

0 to 10 V 23 43

0.2 to 1 V 21, 24 41, 44 1 to 5 V 22, 24 42, 44

2 to 10 V 23, 24 43, 44

0 to 50 mV 17

−−

0 to 100 mV 16

−

50 to 50 mV

−

100 to 100 mV

Potentiometer

0 to 1k

Ω− −

42, 46, 47

Transmitter supply

−

20, 21, 24, 29

40, 41, 44, 45, 49

Thermocouples

Type U

0 to 200 °C

−−

150 to 400 °C

300 to 600 °C

0 to 600 °C

Type R

0 to 700 °C

500 to 1200 °C

1000 to 1700 °C

0 to 1700 °C

Type T

0 to 150 °C

100 to 250 °C

200 to 400 °C

0 to 400 °C

Soldering jumpers Determining the input signals

Determining the input signals Soldering jumpers

Input signal Input 1

(Ai 1)

Jumpers: 10 to 19

Type S

Type L

Type B

Type J

0 to 700 °C

500 to 1200 °C

1000 to 1700 °C

0 to 1700 °C

0 to 350 °C 250 to 600 °C 500 to 900 °C

0 to 900 °C

200 to 1200 °C 1000 to 1500 °C 1300 to 1800 °C

200 to 1800 °C

0 to 400 °C

350 to 800 °C

17 16 15 14 17 16 15 14 17 16 15 14 17 16

Input 2 (Ai 2)

Jumpers: 20 to 26

Input 3/4 (Ai 3/4)

Jumpers: 41 to 47

−−

Type E

Type K

Reference junction temperature for external reference junction

700 to 1200 °C

0 to 1200 °C

0 to 400 °C

300 to 700 °C

600 to 1000 °C

0 to 1000 °C

0 to 500

°C

400 to 900 °C

800 to 1300 °C

0 to 1300 °C

0 °C

20 °C

50 °C

15 14 17 16 15 14 17 16 15 14 11

Soldering jumpers Soldering jumpers on the logic board

4.2.Soldering jumpers on the logic board

See Fig. 5 for the location of the logic board

Soldering jumper: X closed, 0 open

11 13 21 23 31 33 37 38 SZ LB 1 LB 2 LB 3

Continuous control output Y1

Continuous control output Y2

Analog output Ao1

Operation with code number X Operation with interface X X X

0(4) to 20 mA X 0

0(2) to 10 V 0 X

0(4) to 20 mA X 0

0(2) to 10 V 0 X

0(4) to 20 mA X 0 X 0

−10 to 10 V 0(2) to 10 V 0 X X 0

0X0X

4.3.Soldering jumper for implementing the code number

The CONFIGURATION level and the PARAMETER level can be protected against unauthorized use by means of code numbers. To activate this function, the soldering jumper SZ located on the logic board must be closed (see table in section 4.2.). This jumper SZ is open when the controller is delivered, meaning that the configuration and parameter data of the process control station can be modified without having to enter a corresponding code number. Refer to section 6.10 and 6.11 on how to define the code numbers for CONFIGURATION level and the PARAMETER level.

Soldering jumpers on the interface board Soldering jumpers

4.4.Soldering jumpers on the interface board

See. Fig. 5 for the location of the interface board and Fig. 6 for the location of the soldering jumpers.

Important! In the interface mode, the soldering jumpers LB1, LB2 and LB3 on the logic board must also be closed (see section 4.2., page 19). This must be observed when retrofitting the process control station with the interface board.

Soldering jumper (LB) Default setting:

X closed, 0 open Enable parity bit PARITAET 0 Parity odd UNGERADE 0 2 stop bits RES 0 Baud rate Modbus Select a soldering jumper

300 bit/s 300 0 600 bit/s 600 0 1200 bit/s 1200 0 2400 bit/s 2400 0 4800 bit/s 4800 0 9600 bit/s 9600 X

19200 bit/s 19200 0 Termination BUSABSCHLUSS (4 LBs) 0 Two-wire mode 2LEITER (2 LBs) 0 Four-wire mode 4LEITER (2 LBs) X

Soldering jumpers Soldering jumpers on the interface board

Fig. 6 ⋅ Location of the soldering jumpers on the interface board

TROVIS 6412 (panel-mounting unit) Electrical connections

5.Electrical connections

When making the electrical connections, note the VDE 0100 regulations and the regulations valid in the country where the control station is intended to be installed.

Use shielded cables for the signal lines of the analog and binary inputs, which are installed outside the control cabinets, in order to avoid measuring errors or other interferences. Inside the control cabinets, these lines have to be installed separately from the control and power supply lines.

The shieldings of the lines are to be grounded on one side at the neutral point of the measuring and control system.

5.1.TROVIS 6412 (panel-mounting unit)

The device has plug-in terminals for wires with cross-sections of 0.5 to 1.5 mm2 (DIN 45 140).

Binary inputs Switching contact External switching voltage

81 82

bi 1

bi 2

bi 3

81 82

bi 1

–

bi 2

–

bi 3

Continuous control outputs Switching output Analog output

Binary outputs Limit relay

88 89

bo 1

bo 2

–

bo 3

47 48

–

G1 G2

34 35

–

Ao 1

1),2)

Optional equipment

Power supply Serial interface RS-485

Fig. 7 ⋅ Terminal assignment of TROVIS 6412

T(A)

T(B)

R(B)

R(A)

For 2-wire bus Terminals 96 and 97

Electrical connections TROVIS 6412 (panel-mounting unit)

Inputs

Input board 1 (IB 1)

Input board 2 (IB 2)

Ai 1

–

0...1000

13 14

–

11 12

2-wire transmitter 2-wire transmitter

Ai 2

–

Ai 3

–

Ai 4

0...1000

–

Input board 3 (IB 3)

Input board 4 (IB 4)

With reference junction sensor (item no. 1070-8472)

–

mV source

Pt 100

2-wire transmitter 2-wire transmitter

–

2-wire transmitter

–

Pt 100

–

2-wire transmitter

0...1000

–

Fig. 8 ⋅ Terminal assignment of TROVIS 6412 (continued)

2-wire transmitter + −

–

TROVIS 6442 (rack-mounting unit for 19inch racks) Electrical connections

5.2.TROVIS 6442 (rack-mounting unit for 19inch racks)

The device has two plug connectors, style F (DIN 41612). The signal lines are assigned to one of these two connectors, whereas the power supply lines are assigned to the other one, meaning these lines are installed separately (see Fig. 9 and Fig. 10 ).

Binary inputs Switching contact External switching voltage

d 4

bi1

bi2

bi3

Binary output 3 Serial interface RS-485

–

bo3

R(B)

R(A)

For 2-wire bus terminals d 22 and d 24

T(A)

T(B)

bi1

–

bi2

Continuous control outputs Switching output Analog output

14 16

–

810

–

Ao 1

–

bi3

Power supply Binary outputs

z 24

d 6

Fig. 9 ⋅ Terminal assignment of TROVIS 6442

Limit relay

bo1

bo2

24 26 28

G1 G2L

20 22 24

Electrical connections TROVIS 6442 (rack-mounting unit for 19inch racks)

Inputs

Input board 1 (IB 1)

Input

board 2 (IB 2)

Ai 1

–

0...1000

28 26

32 30

–

2-wire transmitter 2-wire transmitter

Ai 2

–

Ai 3

–

Ai 4

z 6

–

0...1000

–

Input board 3 (IB 3)

Input board 4 (IB 4)

With reference junction sensor (item no. 1070-8472)

Pt 100

–

mV source

–

2-wire transmitter 2-wire transmitter

Pt 100

–

2-wire transmitter

–

2-wire transmitter

2-wi re transmit te r

0...1000

–

0...1000

–

0...1000

–

Fig. 10 ⋅ Terminal assignment of TROVIS 6442 (continued)

Balancing the line resistance for the connection of Pt 100 sensors Electrical connections

5.3.Balancing the line resistance for the connection of Pt 100 sensors

When Pt 100 sensors are connected to the control station in a two-wire circuit, the line resistance is to be balanced to 10 Ω at the external resistor Rj in order to avoid measuring errors:

1. Short-circuit the line at the Pt 100 sensor or potentiometer.

2. Switch the resistor R

in the line.

3. Measure the resistance in the total circuit, using a suitable ohmmeter.

4. Adjust the resistor R

until the line resistance is 10 Ω.

In three-wire circuits, the line resistance must not be balanced. Zero and span, however, should be checked and re-adjusted if necessary.

In four-wire circuits, balancing the line resistance is also not necessary.

5.4.Wiring technique with regard to electromagnetic compatibility

All input, output and data lines have to be run in shielded cables for reasons of electromagnetic compatibility (EMC).

The power supply lines, as well as the protective conductors and the functional earthing line (FE) are to be connected separately from each controller to the corresponding multi-terminal bus bar.

With 19inch racks, a conductive connection between the functional earthing line and the rack has to be made. The shielded cables are to be grounded at one end (see Fig. 11 and Fig. 12 ).

Electrical connections Wiring technique with regard to electromagnetic compatibility

L N PE

N PE

Controller 1 Controller n

Fig. 11 ⋅ Electrical connections for panel-mounting units

Cu-flex. lead ≥ 1.5 mm

Cu-flex. lead ≥ 2.5 mm

Cu-flex. lead ≥ 10 mm

d12

d18

z2 z4

d18

d12

d18

z2 z4

d18

Controller 1 Controller n

1Plug connector

Signal lines

2Plug connector

Control lines Cu-flex. lead

≥ 1.5 mm Cu-flex. lead

≥ 2.5 mm Cu-flex lead

≥ 10 mm

L N PE

Fig. 12 ⋅ Electrical connections for 19inch rack-mounting units

Process display and control panel elements Operation

6.Operation

This section describes how to operate the process control stations directly on the control panel. Unfold the last page of this manual to obtain a better understanding of this description!

The process control stations are designed according to a three-level, logic operating structure:

1) OPERATING level, 2) PARAMETER level and 3) CONFIGURATION level. These levels are described in sections 6.2. to 6.13. Depending on the selected level (mode), the visual displays on the LCD panel and the keys assume different functions.

6.1.Process display and control panel elements

The process control station is operated via eight front-panel keys. The front panel also contains a clear display field, which shows different variables and symbols, depending on the selected operating level. Note that some parameters available in the PARAMETER and ADAPTATION PARAMETER level can be a combination of several variables and symbols.

All process display and control panel elements are listed and explained on the last two pages of this manual. Optional error messages are described in Appendix B .

6.2.OPERATING level

This is the standard operating level of the process control station (control mode). In this level, the control station operates according to the pre-set control mode and the defined parameters.

The values of the set point (reference variable) (3) and the controlled variable (8) are numerically indicated on the display panel. The control deviation (error) (7) and the output variable (14) are represented as a percentage by means of bar graphs. In addition, a LED (19) indicates whether the control station is in the AUTOMATIC or MANUAL mode. If the F key is pressed, the numerical value of the output variable appears in the upper line of the display field (3).

The OPERATING level allows the operator to modify the value of the internal set point (reference variable), abort the restart condition option after a start-up procedure or a power supply failure has occurred, or open the cascade when the controller is in the follow-up control mode. The output variable can be modified manually when having changed over the process control station to the MANUAL mode. These functions are described in the following sections. All other levels can be accessed from the OPERATING level.

Operation OPERATING level

6.2.1.Modifying the internal set point (reference variable)

In the OPERATING level, the internal set point WIN can be modified by pressing the C or D key, provided that these keys have not been disabled in the CONFIGURATION level (C59-2 or C59-4). Pressing the respective key briefly modifies the last digit of the indicated number by one. The key must be held down to further advance the number. In this case, the displayed value changes more quickly. While this modification is made, W display. W be configured to display other values than W

disappears after approximately 3 s. Note that the digital display field (3) can also

(see configuration block C4).

Pressing the C key increases the set point (reference variable). Pressing the D key decreases the set point (reference variable).

is additionally indicated on the

Fig. 13 ⋅ Display of the set point (reference variable) in the OPERATING level

3 Set point (reference variable) 7 Control deviation (error) 8 Controlled variable 14 Manipulated variable display 16 Indicator "internal set point valid" 19 AUTOMATIC mode

OPERATING level Operation

6.2.2.Power supply failure

Configuration block C 43 (restart condition) defines the behaviour of the process control station after switching on the power supply in the start-up phase or after detecting a power supply failure (> approx. 1 s). This restart condition determines the operating mode, the set point (reference variable) and the output variable for output Y1 or Y2.

If one of the restart conditions C43-1 to C43-6 is set, it is necessary to confirm the setting by pressing the F key in order to return to the normal control mode. In both cases, the digital displays for the set point and the controlled variable flash until the F key is pressed. The settings C43-5 and C43-6 cause the process control station to remain in the MANUAL mode, even when the F key is pressed. This is indicated by the symbol in (19).

The settings C43-7 to C43-12 must not be confirmed in order to return to the normal control mode. The process control station automatically operates in the control mode according to the restart conditions implemented with configuration block C 43.

The following table is a short summary of the optional restart conditions.

C43 Set point Output variable Oper. mode Press F-key Comment

-1, -2 Last active Y

-3, -4 W

-5, -6 Last active Y1K1, Y2K

-7, -8 Last active Y

-9, -10 Internal Y

-11, -12 External Y

, Y2K

1K1

Y1K1, Y2K

, Y2K

1K1

, Y2K

1K1

, Y2K

1K1

Automatic Yes Automatic Yes WS overwrites W

Manual Yes

Automatic No Automatic No Automatic No

After pressing F, still MANUAL mode

6.2.3.Manual adjustment of the output variable

In MANUAL mode, the connected control valve can be manually moved to the desired position, using the G and H keys, provided that these keys have not been disabled in the configuration mode (C59-2 or C59-4). The corresponding key must be pressed until the desired output variable is adjusted. The bar graph (13) indicates the change in the output variable. If the F key is pressed, the numerical value of the output variable is also displayed in the digital display field (2).

Bumpless change-over from MANUAL to AUTOMATIC mode and vice versa is carried out via the MANUAL/AUTOMATIC key (E).

Pressing the G key increases the output variable. Pressing the H key decreases the output variable.

+ 69 hidden pages

Samson Trovis 6400, Trovis 6412, Trovis 6442 Mounting And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual