Samson 5857 Service manual

Translation of original instructions
EB 5857 EN
Firmware version 1.04
Edition September 2018
Type5857 Electric Actuator
Three-step version · Version with digital positioner

Definition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 5857 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 5857 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-5
2 Markings on the device ..............................................................................2-1
2.1 Nameplate .................................................................................................2-1
2.2 Firmware versions.......................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Additional equipment (positioner) ................................................................3-1
3.1.1 Communication ..........................................................................................3-3
3.2 Technical data ............................................................................................3-4
3.3 Dimensions.................................................................................................3-5
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the actuator ...................................................4-1
4.3 Transporting the actuator.............................................................................4-1
4.4 Lifting the actuator ......................................................................................4-1
4.5 Storing the actuator.....................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-1
5.3 Mounting the actuator .................................................................................5-1
5.4 Installing the control valve into the pipeline ...................................................5-2
5.5 Electrical connection....................................................................................5-3
5.5.1 Three-step version .......................................................................................5-3
5.5.2 Version with digital positioner ......................................................................5-3
6 Operation..................................................................................................6-1
6.1 Device overview and operating controls........................................................6-1
6.1.1 Three-step version .......................................................................................6-1
6.1.2 Version with positioner ................................................................................6-2
6.1.2.1 Indication with LEDs ....................................................................................6-3
6.1.2.2 Direction of action switch.............................................................................6-3
6.1.2.3 Initialization key .........................................................................................6-4

Contents
EB 5857 EN
7 Start-up and conguration..........................................................................7-1
7.1 Putting the actuator with three-step signal into operation ................................7-1
7.2 Putting the actuator with positioner into operation..........................................7-1
7.2.1 Initializing the actuator................................................................................7-1
7.3 Conguringtheactuatorwithpositioner .......................................................7-2
8 Operation..................................................................................................8-1
8.1 Three-step version .......................................................................................8-1
8.2 Version with positioner ................................................................................8-1
8.2.1 LED blinking pattern....................................................................................8-1
8.3 Manual mode.............................................................................................8-4
8.3.1 Mechanical override ...................................................................................8-4
8.4 Operation using memory pen ......................................................................8-6
8.4.1 Copying function ........................................................................................8-8
8.4.2 Data logging ..............................................................................................8-8
8.4.3 Command mode.........................................................................................8-9
8.5 Readings in TROVIS-VIEW.........................................................................8-10
8.5.1 Operating values ......................................................................................8-10
8.5.2 Operating states .......................................................................................8-10
8.5.3 Status messages........................................................................................8-10
8.5.4 Statistics...................................................................................................8-11
9 Malfunctions ..............................................................................................9-1
9.1 Error indication by LEDs (version with positioner)...........................................9-1
9.2 Emergency action .......................................................................................9-2
10 Servicing..................................................................................................10-1
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
13 Repairs ....................................................................................................13-1
13.1 Returning the actuator to SAMSON............................................................13-1
14 Disposal...................................................................................................14-1
15 Certicates...............................................................................................15-1
16 Annex A (conguration instructions)..........................................................16-1
16.1 Input signal ..............................................................................................16-1
16.1.1 Split-range operation ................................................................................16-1
16.2 Position feedback signal ............................................................................16-2
16.3 Functions..................................................................................................16-2
16.3.1 Detect input signal failure ..........................................................................16-2

Contents
EB 5857 EN
16.3.2 End position guiding .................................................................................16-3
16.4 Blockage ..................................................................................................16-4
16.4.1 Blockage detection....................................................................................16-4
16.4.2 Blockage removal .....................................................................................16-4
16.4.3 Indicate blockage......................................................................................16-5
16.4.4 Blocking protection....................................................................................16-5
16.5 Travel.......................................................................................................16-6
16.5.1 Limited travel range...................................................................................16-6
16.5.2 Travel adjustment ......................................................................................16-6
16.5.3 Idle time during end position guiding..........................................................16-7
16.5.4 Velocity....................................................................................................16-7
16.5.5 Dead band (switching range).....................................................................16-8
16.5.6 Characteristic ...........................................................................................16-8
16.5.7 Start-up..................................................................................................16-10
16.5.8 Functions ('Service' folder).......................................................................16-10
16.5.8.1 Manual level...........................................................................................16-10
16.5.8.2 Functions................................................................................................16-11
17 Annex B...................................................................................................17-1
17.1 Accessories ..............................................................................................17-1
17.2 After-sales service.....................................................................................17-2
17.3 Congurationlistandcustomer-specicdata...............................................17-3

EB 5857 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
TheType5857ElectricActuatorisdesignedtooperateamountedglobevalveusedinheat-
ing, ventilation and air-conditioning systems. In the version with digital positioner, the posi-
tioner ensures a predetermined assignment of the valve position to the input signal.
Theactuatorisdesignedtooperateunderexactlydenedconditions(e.g.thrust,travel).
Therefore, operators must ensure that the actuator is only used in operating conditions that
meetthespecicationsusedforsizingtheactuatorattheorderingstage.Incaseoperators
intendtousetheactuatorinotherapplicationsorconditionsthanspecied,contact
SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataforlimitsandeldsofapplicationaswellaspossibleuses.See
the 'Design and principle of operation' section.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:
− Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described
Qualications of operating personnel
The actuator must be mounted, started up, serviced and repaired by fully trained and quali-
edpersonnelonly;theacceptedindustrycodesandpracticesmustbeobserved.According
to these mounting and operating instructions, trained personnel refers to individuals who are
able to judge the work they are assigned to and recognize possible hazards due to their spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

1-2 EB 5857 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the electric actuator.
Work on the control valve may be necessary when mounting or removing the device.
ÎObservetherequirementsforpersonalprotectiveequipmentspeciedinthevalvedocu-
mentation.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the control valve by the process medium, the operat-
ing pressure, the signal pressure or by moving parts by taking appropriate precautions. Plant
operators and operating personnel must observe all hazard statements, warning and caution
notes in these mounting and operating instructions, especially for installation, start-up and
service work.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions to the operating per-
sonnel and to instruct them in proper operation. Furthermore, operators must ensure that op-
erating personnel or third parties are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthespeciedhazardstatements,warningandcautionnotes.Furthermore,operating
personnel must be familiar with the applicable health, safety and accident prevention regula-
tions and comply with them.

EB 5857 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
TheType5857ElectricActuatorwithaCEmarkingfulllstherequirementsoftheDirectives
2014/30/EU and 2014/35/EU.
TheType5857ElectricActuatorwithanEACmarkingfulllstherequirementsoftheRegula-
tionsTRCU004/2011andTRCU020/2011.
The'Certicates'sectioncontainsthisdeclarationofconformityandTRCUcerticate.
TheType5857ElectricActuatorisdesignedforuseinlow-voltageinstallations.
ÎFor wiring, maintenance and repair, observe the relevant safety regulations.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions of the valve on which the electric actuator is mount-
ed, e.g. for SAMSON valves:
uEB5866forType3222GlobeValve
uEB5867forType3222NGlobeValve
uEB3135-1forType2488Pressure-independentControlValve(PICV)
uEB3136forType2488NPressure-independentControlValve(PICV)
uEB5861forType3260Three-wayValve
uEB5863forType3226Three-wayValve

1-4 EB 5857 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to electric shock.
ÎBefore connecting wiring, performing any work on the device or opening the de-
vice, disconnect the supply voltage and protect it against unintentional reconnec-
tion.
ÎOnly use power interruption devices that can be protected against unintentional re-
connection of the power supply.
ÎDo not remove any covers to perform adjustment work on live parts.
ÎDo not open the actuator housing.
Theelectricactuatorisprotectedagainstdrippingwaterfallingatanangle(IP42).
ÎAvoid sprays and jets of water.
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Improper opening can lead to valve
components bursting.
ÎBefore starting any work on the control valve, depressurize all plant sections affect-
ed as well as the valve.
ÎDrain the process medium from all the plant sections affected and from the valve.
ÎWear recommended personal protective equipment. See associated valve docu-
mentation.

EB 5857 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
No personal injury can be caused by moving parts.
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the actuator being illegible.
Over time, markings, labels and nameplates on the actuator may become covered with
dirt or become illegible in some other way. As a result, hazards may go unnoticed and
the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the electric actuator due to the supply voltage exceeding the per-
missible tolerances.
TheType5857ElectricActuatorisdesignedforuseaccordingtoregulationsfor
low-voltage installations.
ÎObserve the permissible tolerances of the supply voltage.
Risk of actuator damage due to excessively high tightening torques.
The connection of the electric actuator must be tightened with certain torques. Excessive
tightening torques lead to parts wearing out more quickly.
ÎObservethespeciedtighteningtorques.
Risk of damage to the electric actuator by turning it too far.
The actuator stem of the electric actuator can be adjusted manually.
ÎMove the actuator stem only as far as the bottom or top end position.

1-6 EB 5857 EN

EB 5857 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
1CongurationID
2 Serial number
3 Thrust
4 Rated travel
5 Transit time for rated
travel
6 Supply voltage
7 Power line frequency
8 Power consumption
9 Input signal
10 Firmware version
Made in Germany
754
6
8s: t: f:U: P
Var.-ID
Serial-No.
1
2
F: 3
:
SAMSON 5857
Electric Actuator
Made in Germany
94
6
8
SAMSON 5857
Electric Actuator
with digital positioner
Var.-ID
Serial-No.
1Firmware-Version: 10
2
3s: In: U: PF:
:
Three-step version
Version with digital positioner

2-2 EB 5857 EN
Markings on the device
2.2 Firmware versions
Firmware revisions1)
Old New
1.00 Up to 1.04
Internal revisions
1) Only in the version with digital positioner

EB 5857 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1.
The three-step version of the electric actuator
consists of a reversible synchronous motor
and a maintenance-free gear. In the version
with digital positioner, a stepper motor al-
lows for supply by frequency-independent
voltages.
The control signal of the controller is connect-
ed to the terminals eL and aL of the actuator.
If voltage is applied to eL, the actuator motor
retracts the actuator stem. If voltage is ap-
plied to aL, the actuator motor extends the
actuator stem.
The actuator is connected to the valve by a
coupling nut (4) which provides a force-lock-
ing connection between the actuator stem
and the plug stem of the valve.
The control signal from the input side is
transferred over the motor and the connected
gear and used as the positioning force to
move the actuator stem. When the actuator
stem (3) extends, the valve is closed, oppos-
ing the force of the valve spring (7). When
the actuator stem retracts, the valve is
opened as the plug stem (6) follows the mo-
tion of the return spring.
The motor is switched off by torque-depen-
dent limit switches when an end position is
reached or in case the motor is overloaded.
Travel and direction of action can be read
off the travel indicator (5) on the side of the
actuator housing.
The actuator has a handwheel that is used to
manually position the valve when the actua-
tor is de-energized.
TheType5857Actuatorcanbecombined
preferablywithSAMSONTypes3222,
3222N,2488and2488NValvesaswell
asspecialversionsofType3260and
Type3226Valves.
3.1 Additional equipment
(positioner)
The actuator is available with a digital posi-
tioner.
The positioner ensures a predetermined as-
signment of the valve position to the input
signal.A0to10Vsignalcanbepickedup
at the brown (BN) and green (GN) wires for
position indication (see the 'Installation' sec-
tion for connection).
The characteristic and the input and output
signal settings can be changed using the
TROVIS-VIEW software (uEB6661).
The version with positioner allows the char-
acteristic to be reversed and is suitable for
split-range operation.

3-2 EB 5857 EN
Design and principle of operation
1 Actuator
1.1 Cable
2 Handwheel
3 Actuator stem
4 Coupling nut
5 Travel indicator
6 Plug stem
7 Valve spring
8 Cover 1) (serial interface, direction of action switch, initialization button and LEDs)
1) Only in the version with digital positioner
18
2
4
eL
aL
3
6
7
5
1.1
Fig.3-1: Valve with actuator

EB 5857 EN 3-3
Design and principle of operation
3.1.1 Communication
Serial interface
Theactuatorwithpositioneristtedwithan
RS-232 serial interface. This allows commu-
nication with TROVIS-VIEW using SSP proto-
col(seeFig.3-2).
Serial interface
Fig.3-2: Serial interface
Conguration
Theactuatorwithpositioneriscongured
with the TROVIS-VIEW software. In this case,
the serial interface on the actuator is used to
connect the actuator to the computer. The
TROVIS-VIEW software enables the user to
easilycongurethepositioneraswellas
view process parameters online.
TROVIS-VIEW can be downloaded free of
charge from our website at
uwww.samsongroup.com > Service &
Support > Downloads > TROVIS-VIEW.
Further information on TROVIS-VIEW (e.g.
system requirements) is available on our
website and in the Data Sheet uT6661 as
well as the Operating Instructions
uEB6661.
ÎSeethe'Start-upandconguration'sec-
tion.
Note

3-4 EB 5857 EN
Design and principle of operation
3.2 Technical data
Table 3-1: Technical data · Type 5857
Type5857 Actuator Version Three-step With digital positioner
Connection to valve Force-locking
Rated travel 6mm
Transit time for rated travel 20s 30/201)/10s
Stroking speed 0.3mm/s 0.2/0.31)/0.55mm/s
Thrust 300N
Supply voltage 230V(±10%),50Hz
24V(±10%),50Hz
24V( ± 10%),50Hz,60HzandDC2)
Power consumption Approx. 3 VA 5VA
Manual override Yes
Permissible temperature ranges
Ambient 0to50°C
Storage –20to+70°C
Process medium3) 0to120°C
Degree of protection IP42accordingtoEN60529
Class of protection IIaccordingtoEN61140
Device safety AccordingtoEN61010-1
Noise immunity AccordingtoEN61000-6-2andEN61326-1
Noise emission AccordingtoEN61000-6-3andEN61326-1
Conformity ·
Weight Approx.0.7kg
Digital positioner
Input signal
–
0to10V1), Ri=20kΩ
Position feedback (output signal) 0to10V1), RB=1kΩ
Characteristic Linear 1), equal percentage, reverse
equalpercentage,user-dened
1) Default setting
2) 10sappliesto24VDC(0%,+10%)forTransittimeforratedtravelsetting.
3) The permissible medium temperature depends on the valve on which the electric actuator is mount-
ed. The limits in the valve documentation apply.

EB 5857 EN 3-5
Design and principle of operation
3.3 Dimensions
Ø 12
55
80
11
32
70
114
70
114
70
Three-step version
eL: Actuator stem retracts
aL: Actuator stem extends
eL
Version with digital positioner
aL
Fig.3-3: Dimensions in mm

3-6 EB 5857 EN