Samson 3222/5724 Service manual

Electric Control Valves/

Controller with Electric Actuator

Type 3222/5724, Type 3222/5725 and Type 3222/5757

Mounting and

Operating Instructions

EB 5766 EN

Edition July 2008

Type 3222/5725 Globe Valve mounted on

Controller with Electric Actuator

Type 3222/5757 Globe Valve mounted on

Controller with Electric Actuator

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4

1.1 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Additional installation instructions . . . . . . . . . . . . . . . . . . . . 9

3 Attaching the actuator to the valve . . . . . . . . . . . . . . . . . . 10

3.1 Type 5757/-7 Controller with Electric Actuator . . . . . . . . . . . . . 10

3.2 Type 5724/5725 Controller with Electric Actuator . . . . . . . . . . . 10

4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 Type 5757-7 Controller with Electric Actuator. . . . . . . . . . . . . . 11

4.2 Type 5757 Controller with Electric Actuator. . . . . . . . . . . . . . . 11

4.3 Type 5724/5725 Controller with Electric Actuator . . . . . . . . . . . 12

5 Manual override . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1 Type 5757/-7 Controller with Electric Actuator . . . . . . . . . . . . . 13

5.2 Type 5724/5725 Controller with Electric Actuator . . . . . . . . . . . 13

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8 Dimensions in mm and weights . . . . . . . . . . . . . . . . . . . . 16

9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9.1 Wiring for Type 5757-7 . . . . . . . . . . . . . . . . . . . . . . . . 18

9.2 Wiring for Type 5757 . . . . . . . . . . . . . . . . . . . . . . . . . 20

9.3 Wiring for Type 5724/5725 . . . . . . . . . . . . . . . . . . . . . 22

2EB 5766 EN

Contents

Typetest

The Type 5725 Controller with Electric Actuators with safety function used in

conjunction with Type 3222 Valves are typetested according to DIN 32730

by the German technical inspectorate TÜV.

EB 5766 EN 3

General safety instructions

The control valves may only be mounted, started up or serviced by fully

trained and qualified personnel, observing the accepted industry codes and

practices. Make sure employees or third persons are not exposed to any

danger.

All safety instructions and warnings in these mounting and operating

instructions, particularly those concerning assembly, start-up and

maintenance, must be observed.

The control valves fulfill the requirements of the European Pressure Equip-

ment Directive 97/23/EC. Valves with a CE marking have a declaration of

conformity which includes information about the applied conformity assess-

ment procedure. The declaration of conformity is available on request.

For appropriate operation, make sure that the control valve is only used in

applications where the operating pressure and temperature do not exceed

the operating values which are based on the valve sizing data submitted in

the order.

The manufacturer does not assume any responsibility for damage caused by

external forces or any other external influence!

Any hazards which could be caused in the control valve by the process

medium, the operating pressure, the signal pressure or by moving parts are

to be prevented by means of the appropriate measures.

Proper shipping and appropriate storage of the control valve are assumed.

Caution!

For installation and maintenance, make sure the relevant section of the

pipeline is depressurized and, depending on the process medium, drained

as well. If necessary, allow the control valve to cool down or warm up to

reach ambient temperature prior to starting any work on the valve.

The electric actuators have been designed for use in electrical power

installations. For wiring and maintenance, you are required to observe the

relevant safety regulations.

Only use power interruption devices which are protected against

unintentional reconnection of the power supply.

Take special care when making adjustments on live parts. Do not remove

any covers!

1 Design and principle of

operation

The control valves consist of a single-seated

Type 3222 Globe Valve and either a

Type 5757, Type 5757-7 or Type 5724

Controller with Electric Actuator or a Type

5725 Controller with Electric Actuator with

safety function.

The process medium flows through the globe

valve in the direction indicated by the arrow

on the body. The position of the valve plug

determines the flow rate over the cross-sec-

tional area of flow released between the

plug (3) and valve seat (2). The plug stem

(4) with plug is connected with the stem of

the actuator (10) by a force-locking connec-

tion. The valve is opened by the valve spring

(5) following the retracting movement of the

actuator stem. A special version is required

for water above 150 °C and for steam

(Fig. 1). The plug is moved by a change in

the control signal acting on the actuator.

The electric actuator with safety function

(Type 5725) has a spring mechanism and

an electromagnet that can be connected to a

safety control circuit. When the control cir-

cuit is interrupted or the power supply fails,

the magnet disengages the gear from the

self-locking motor and releases the spring

mechanism. The valve is closed in the event

of a safety situation (fail-safe action

“actuator stem extends”).

The electric actuators contain a digital con-

troller integrated into the actuator. The con-

trolled variable is recorded over the directly

connected Pt 1000 sensor (see Table 2).

The output signal of the digital controller

acts as a three-point stepping signal on the

synchronous motor of the actuator and is

transferred over the connected gear as a

positioning force onto the actuator stem.

The Type 5757, Type 5724 and Type 5725

are particularly suitable for DHW heating in

instantaneous heating systems and for fixed

set point control circuits in mechanical engi-

neering applications.

Type 5757-7 is suitable for heating applica-

tions.

1.1 Versions

PN DN EB 1)

Electric control valve/Controller with electric

actuator

Type 3222/5757 2) 25 15 to 25 5757

Type 3222/5757-7 3) 25 15 to 25 5757-7

Type 3222/5724 2) 25 15 to 50 5724

… with safety function

Type 3222/5725 2) 25 15 to 50 5724

1) Refer to the listed Mounting and Operating

Instructions (EB) for details on the controllers

with electric actuators

2) Controller with electric actuator for domestic

hot water heating in instantaneous heating

systems and for fixed set point control circuits

in mechanical engineering applications

3) Controller with electric actuator for heating

applications

4EB 5766 EN

Design and principle of operation

EB 5766 EN 5

Design and principle of operation

Type 3222/5724

Special version for temperatures up to 200 °C and

with plug balanced by a bellows

Type 3222/5757

1 Valve body

2 Seat

3 Plug

4 Plug stem

5 Valve spring

6 Guide nipple

7 Balancing bellows

8 Balancing piston

10 Controller with electric

actuator

Fig. 1 · Type 3222/5757 and Type 3222/5724 Electric Control Valves/Controller with Electric Actuator

1.2 Technical data

6EB 5766 EN

Design and principle of operation

1. Single-seated Type 3222 Globe Valve

Nominal size DN 15 20 25 32 40 50

Version with threaded ends

with flanges

as flanged body ••••••

Thread size G½¾1 –––

Version with female thread • • • – – –

Nominal pressure PN 25

Seat/plug sealing Metal sealing for KVS ≤2.5 · Soft sealing for KVS ≥3.6

Rated travel mm 6 12

Rangeability 50 : 1

Leakage class acc. to DIN EN 1349 Class I (< 0.05 % of KVS coefficient)

Version for water, oil and other liquids

Max. permissible temperature 150 °C 1, 2)

Max. permissible differential pressure Δp in bar

Types 5724 and 5725 20 12

Type 5757 20 –

Version for water and steam

Max. permissible temperature 200 °C

Max. permissible differential pressure Δp in bar

Types 5724 and 5725 20 · 10 for 3.6 ≤KVS ≤88

Type 5757 20 3) · 5 4) 5–

Materials

Valve body Red brass CC491K · EN-JS1049 (flanged body)

Seat Stainless steel 1.4104

Plug 1.4104/CW509L with soft sealing · 1.4104 for 0.1 ≤KVS ≤2.5

Valve spring Stainless steel 1.4310 K

Packing EPDM/FPM (FKM) · Oil-resistant version: FPM

Welding ends St 37

Threaded ends Red brass CC491K

Screwed-on flanges St 37.2

EB 5766 EN 7

Design and principle of operation

Nominal size DN 15 20 25 32 40 50

Thread size G½¾1–––

KVS coefficients

Version with female thread 3.6 5.7 7.2 – – –

Version with male thread 4 6.3 8 16 20 25

Reduced KVS coefficients 0.1· 0.16 · 0.25 · 0.4

0.63 · 1.0 · 1.6 · 2.5 1.0 · 1.6 · 2.5

45) · 3.6 6) –––

Rated travel mm 6 12

1) Use an intermediate insulating piece for temperatures above 130 °C to protect the actuator

2) DN 15 to 25 with Type 5757 Actuator:

Use an intermediate insulating piece for temperatures above 110 °C to protect the actuator

3) Differential pressure for KVS = 1 and 1.6

4) Differential pressure for KVS = 2.5 and 4

5) Version with male thread

6) Version with female thread

2. Controllers with electric actuators

8EB 5766 EN

Design and principle of operation

Type 5757 5724 5725

5757-7 5757 -10 -13 -20 -23 -10 -13 -20 -23

Nominal size DN 15 to 25 15 to 25 15 to 25 32 to 50 15 to 25 32 to 50

Scope of application Heating DHW heating in instantaneous heating systems,

fixed set point control circuits in mechanical engineering

Safety function Without Without With

Rated travel mm 6 6 6 12 12 6 6 12 12

Transit time for rated travel s 20 35 18 70 35 35 18 70 35

Transit time upon fail-safe

action s – – 4466

Fail-safe action – – Stem extends

Nominal thrust kN 0.3 0.7 0.5

Manual override Yes Yes Possible 1)

Power supply 230 V (±10 %), 50 Hz

Power consumption approx. VA 3 3 37375959

Permissible temperatures

Ambient °C 0 to 50 0 to 50 0 to 50

Storage °C –20 to 70 –20 to 70 –20 to 70

At connecting rod °C 0 to 110 0 to130 0 to 130

Degree of protection IP 42 IP 54 (upright position, acc. to DIN IEC 529)

Inputs and outputs of the digital controller

Temperature sensor Pt 1000 3 x 1 x 1 x 1 x

Setting range °C 1 to 150 0 to 150 1 to 150 1 to 150

Potentiometer input 1000 to

1100/2000 Ω–– –

Water flowmeter input – 530 pulses/l 530 pulses/l 530 pulses/l

Current input – 4 (0) to 20 mA 4 (0) to 20 mA 4 (0) to 20 mA

Binary input BE1 2) Op. mode

switchover Switching between internal set points/

Deactivation of function to maintain temperature constant

Binary input BE2 2) – Flow switch

Binary output BA 230 V/50 Hz

Cir. pump/Ex-

ternal demand –– –

1) Manual override using a 4 mm hex screwdriver (after removing the housing cover);

always returns to fail-safe position after safety release.

2) Recommendation for Type 5724, Type 5725 and Type 5757: With gold contacts

2 Installation

Caution!

Versions designed to handle temperatures

up to 200 °C must be fitted with the dark

gray graphite supplied with the valve. Do

not use the UDP seals available as accesso-

ries as they are only suitable for tempera-

tures up to 150 °C.

2.1 Mounting position

4Choose the place of installation where

the ambient temperature does not ex-

ceed or fall below the permissible limits

specified for the actuator and that allows

you to freely access the control valve

even after the entire plant has been com-

pleted.

4Flush the pipeline thoroughly before in-

stallation.

4Do not install the valve with the actuator

suspended downwards.

Install versions for water and steam up to

200 °C with the actuator installed up-

right in a horizontal pipeline.

4If you wish to insulate the control valve,

install an intermediate insulating piece

between valve and actuator. Make sure

the insulation ends 25 mm above the

valve body. Do not insulate the actuator

and coupling nut as well.

4Install a strainer (SAMSON Type 2 NI)

upstream of the control valve to prevent

any sealing parts, weld spatter or other

foreign matter carried along by the pro-

cess medium from impairing the proper

functioning of the valve, in particular, the

tight shut-off.

4The valve must be installed free of stress.

If necessary, support the piping near the

connections.

2.2 Strainer

4Install the strainer with the filter element

facing downwards upstream of the valve

inlet.

4Choose the place of installation to allow

enough space to remove the filter.

4Install the strainer with the direction of

flow as indicated by the arrow on the

body.

2.3 Additional installation

instructions

We recommend to install a hand-operated

shut-off valve both upstream of the strainer

and downstream of the control valve to be

able to shut down the plant for cleaning and

maintenance, and when the plant is not

used for longer periods of time.

EB 5766 EN 9

Installation

3 Attaching the actuator to the

valve

If the actuator has not already been

mounted on the valve by the manufacturer

or when the original actuator on a valve is

to be replaced with a controller with electric

actuator, proceed as follows.

Note!

Fasten the actuator and valve together either

at the valve connection or at the intermedi-

ate insulating piece, depending on the valve

version, with a tightening torque of 20 Nm.

3.1 Type 5757/-7 Controller

with Electric Actuator

1. Turn the handwheel (see section 5.1)

counterclockwise when the actuator is

disconnected from the power supply to

retract the actuator stem as far as it will

go.

2. Place the actuator on the connection

piece and secure with the coupling nut.

3.2 Type 5724/5725 Controller

with Electric Actuator

Type 5724

1. Turn the handwheel (see section 5.2)

counterclockwise to retract the actuator

stem as far as it will go.

2. Place the actuator on the connection

piece and secure with the coupling nut.

Type 5725 with fail-safe action “Actuator

stem extends”

1. Unfasten the front cover and place a

4 mm hex screwdriver on the actuator

stem (see section 5.2).

2. Turn the screwdriver counterclockwise

only and only until the travel final value

is reached at the maximum, which acti-

vates the bottom torque switch.

Caution!

Turning the actuator too far will destroy

it.

3. Hold the screwdriver in place. Secure the

actuator and connection piece with the

coupling nut.

4. Remove screwdriver and carefully

refasten the front cover.

10 EB 5766 EN

Attaching the actuator to the valve

4 Electrical connections

Upon installing the electrical cables,

you are required to observe the regula-

tions concerning electrical power in-

stallations according to DIN VDE 0100

as well as the regulations of your local

power supplier.

Use a suitable power supply to ensure

that no dangerous voltages from the

system or parts of the system reach the

device in standard operation or in case

of a fault.

Warning!

Only connect the device to the main

power network when the power is

switched off. Make sure the power

cannot be switched on unintentionally!

4Perform the electrical wiring as required

depending on the application (refer to

section 4.1 to 4.3).

As soon as the actuator is connected to the

power supply, the initialization procedure

starts:

The actuator stem extends and the red and

yellow LEDs located under the cover on top

of the actuator light up. As soon as the actu-

ator stem has reached the final position, the

red LED is turned off. The yellow LED re-

mains illuminated and indicates that the

controller with electric actuator is ready for

operation.

4.1 Type 5757-7 Controller with

Electric Actuator

Heating application: The controller with

electric actuator requires a Pt 1000 temper-

ature sensor to be connected to measure the

flow temperature. Depending on the control

task, an outdoor sensor or a room sensor or

a room panel can be connected. Combining

one of these sensors with a return flow sen-

sor is usually possible. Additionally, the con-

troller with electric actuator has a potenti-

ometer input 1000 to 1100/2000 Ω. The

non-floating pump output can alternatively

be used as an binary output for an external

request for heat demand.

The default setting (WE) is configured for an

application with a flow sensor, outdoor sen-

sor and return flow sensor as well as with

an active binary input to switchover the op-

erating modes (see Fig. 2).

4.2 Type 5757 Controller with

Electric Actuator

Domestic hot water heating in instanta-

neous heating system: The controller with

electric actuator requires a Pt 1000 temper-

ature sensor to be connected for it to func-

tion. Two set points W1 and W2 can be

used for control. A binary input BE1 is used

to switch between them.

In addition, a water flowmeter or a flow

switch can be connected to quickly recog-

nize when hot water is being tapped.

The 0(4) to 20 mA current input can be used

in place of the Pt 1000 sensor for control

purposes.

EB 5766 EN 11

Electrical connections

The default setting (WE) is configured for an

application with a Pt 1000 flow temperature

sensor and water flowmeter (see Fig. 3).

4.3 Type 5724/5725 Controller

with Electric Actuator

Domestic hot water heating in instanta-

neous heating system: The electric wiring

options are the same as for the Type 5757

Controller with Electric Actuator, (see

section 4.2). In addition, the pump control

output can be configured as a fault alarm

output.

The default setting (WE) is configured for an

application of the electric actuator with a

Pt 1000 flow temperature sensor, water

flowmeter and pump control output (see

Fig. 4).

Note!

Refer to the appendix of these instructions

for other possible circuits with the necessary

configuration settings or refer to the Mount-

ing and Operating Instructions

EB 5757-7 EN, EB 5757 EN and

EB 5724 EN of the corresponding controller

with electric actuator.

12 EB 5766 EN

Electrical connections

or ye rd br blk gr br bl blk

34 6521LL´N

230 V, 50 Hz

Pt 1000

ASRüS

Fig. 2 · Wiring of Type 5757-7 (default)

*Caution! Live wires!

or ye rd br gr blk

230V, 50Hz

Pt 1000

5V GND L N

Fig. 3 · Wiring of Type 5757 (default)

LL1 N 5V INS1 S2

230V, 50Hz

Pt 1000

Fig. 4 · Wiring of Type 5724/5725 (default)

blk black

bl blue

br brown

gr green

or orange

rd red

ye yellow

1) Water flowmeter

3) Pump control output or fault alarm output

4) Electromagnet, Type 5725 only

5 Manual override

The direction of action and travel can be

read off the travel indication scale.

5.1 Type 5757/-7 Controller

with Electric Actuator

Caution!

Only activate the handwheel when the actu-

ator is disconnected from the power supply.

4Turn handwheel clockwise to extend the

actuator stem

4Turn handwheel counterclockwise to

retract the actuator stem

5.2 Type 5724/5725 Controller

with Electric Actuator

Type 5724

Adjust the travel by turning the handwheel

(approx. 4 turns for 1 mm travel):

4Turn clockwise to extend the actuator

stem

4Turn counterclockwise to retract the

actuator stem

Type 5725

Caution!

The actuator is live!

1. Undo the front cover and place a 4 mm

hex screwdriver onto the red actuating

shaft.

2. Turn the screwdriver counterclockwise

only, and only until the travel final value

is reached at the maximum, which acti-

vates the bottom torque switch (switching

off the motor).

Caution!

Turning the actuator too far will destroy

it.

After the fail-safe action has been trig-

gered by the magnet, the spring mecha-

nism pushes the actuator stem out and the

valve always move to its fail-safe position.

3. Remove screwdriver and carefully

refasten the front cover.

EB 5766 EN 13

Manual override

Handwheel

Travel indication Travel indication

Travel indication

Fig. 5 · Manual override of Type 5757/-7, Type 5724 and Type 5725 (from left to right)

6 Operation

The controllers with electric actuators are

adapted to the required control task by

configuration and parameterization per-

formed in TROVIS-VIEW Operator Interface:

4Type 5757-7: TROVIS-VIEW

6661-1066

4Type 5757: TROVIS-VIEW 6661-1062

4Type 5724 and Type 5725: TROVIS-

VIEW 6661-1060

Note!

Instructions on how to operate the

TROVIS-VIEW Operator Interface as well as

on the function and parameter settings are

contained in the Mounting and Operating

Instructions EB 5757-7 EN, EB 5757 EN

and EB 5724 EN for the corresponding con-

troller with electric actuator.

14 EB 5766 EN

Operation

7 Maintenance

The control valve is subject to natural wear.

Depending on the conditions the valve is op-

erated in, it needs to be checked at regular

intervals.

If leakage to the atmosphere occurs, remove

the valve from the pipeline and replace the

damaged parts.

Warning!

For maintenance work on the valve,

make sure the relevant section of the

pipeline is depressurized and,

depending on the process medium,

drained as well.

For high medium temperatures, allow

the section of the pipeline to cool down

before you start.

Make sure the control signal for the

actuator is switched off.

EB 5766 EN 15

Maintenance

8 Dimensions in mm and weights

16 EB 5766 EN

Dimensions in mm and weights

Nominal size DN 15 20 25 32 40 50

Thread size G½¾1 –––

Pipe Ød 21.3 26.8 33.7 42 48 60

Threadsize RG¾ G1G1¼G1¾G2G2½

Width across flats SW 30 36 46 59 65 82

Length L 65 70 75 100 110 130

Length with welding ends L1 210 234 244 268 294 330

Height H2 45.5 94