Samson TROVIS 5724-3 Service manual

Translation of original instructions
EB 5724 EN
Firmware version 2.20
Edition August 2016
TROVIS5724-3 (without fail-safe action)
TROVIS5725-3 (with fail-safe action)
Electric Actuators with Process Controller
for domestic hot water heating

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 5724 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 5724 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 ................................................................1-4
1.3 Notes on possible property damage.............................................................1-5
2 Markings on the device ..............................................................................2-1
2.1 Nameplate .................................................................................................2-1
2.2 Device code................................................................................................2-2
2.3 Firmware versions.......................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe action ...........................................................................................3-2
3.2 Communication ..........................................................................................3-3
3.3 Technical data ............................................................................................3-4
3.4 Dimensions.................................................................................................3-6
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 Aligning the travel indication scale...............................................................5-2
5.4 Mounting the actuator .................................................................................5-2
5.4.1 TROVIS5724-3(force-lockingattachment) ...................................................5-2
5.4.2 TROVIS5724-3(form-tattachment)............................................................5-3
5.4.3 TROVIS5725-3(force-lockingattachment) ...................................................5-4
5.4.4 TROVIS5725-3(form-tattachment)............................................................5-4
5.5 Installing the control valve into the pipeline ...................................................5-4
5.6 Installing the accessories..............................................................................5-5
5.7 Electricalconnection....................................................................................5-5
6 Operation..................................................................................................6-1
6.1 Device overview and operating controls........................................................6-1
6.2 Indication with LEDs ....................................................................................6-2
6.3 Automatic set point potentiometer.................................................................6-2
6.4 Serial interface ...........................................................................................6-2

Contents
EB 5724 EN
7 Start-up and conguration..........................................................................7-1
7.1 Initializingtheactuator................................................................................7-1
7.2 Conguringtheactuator..............................................................................7-1
7.3 Quickcheck ...............................................................................................7-2
8 Operation..................................................................................................8-1
8.1 Closed-loop control.....................................................................................8-1
8.2 LED blinking pattern....................................................................................8-1
8.3 Change set point at the device .....................................................................8-3
8.4 Manual mode.............................................................................................8-4
8.4.1 Mechanical override ...................................................................................8-4
8.5 Operation using memory pen ......................................................................8-5
8.5.1 Copying function ........................................................................................8-7
8.5.2 Command mode.........................................................................................8-8
8.6 Readings in TROVIS-VIEW...........................................................................8-8
8.6.1 Operating values ........................................................................................8-8
8.6.2 Operating states .........................................................................................8-8
8.6.3 Functions....................................................................................................8-8
8.6.4 Status messages..........................................................................................8-9
8.6.5 Statistics...................................................................................................8-10
9 Malfunctions ..............................................................................................9-1
9.1 Troubleshooting ..........................................................................................9-1
9.2 Error indication by LEDs ..............................................................................9-2
9.3 Emergency action .......................................................................................9-3
10 Servicing..................................................................................................10-1
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
12.1 Force-locking attachment ...........................................................................12-1
12.2 Form-tattachment ...................................................................................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......................................................................................................16-1
16.1 Accessories ..............................................................................................16-1
16.2 After-sales service.....................................................................................16-2
16.3 Congurationandparameterlist................................................................16-3
16.4 Customer-specicdata ..............................................................................16-5

EB 5724 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheTROVIS5724-3andTROVIS5725-3ElectricActuatorswithProcessControllerareelec-
tric actuators with an integrated digital controller. They are designed for operating a mount-
ed globe valve. In combination with the valve, the electric actuators with process controller
areusedtocontroltheowofliquidsinthepipeline.Theelectricactuatorswithprocesscon-
troller are suitable for closed-loop operation in DHW applications.
Theactuatorsaredesignedtooperateunderexactlydenedconditions(e.g.thrust,travel).
Therefore, operators must ensure that the actuators are 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an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 electric actuators with process controller are 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 electric actuators with process controller must be mounted, started up, serviced and re-
pairedbyfullytrainedandqualiedpersonnelonly;theacceptedindustrycodesandprac-
tices are to 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 rec-
ognizepossiblehazardsduetotheirspecializedtraining,theirknowledgeandexperienceas
well as their knowledge of the applicable standards.

1-2 EB 5724 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of electric actuators.
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.
Safety features
The limit switches switch off the motor in the end positions.
Uponsupplyvoltagefailure,theTROVIS5725-3ElectricActuatorwithProcessController
causes the valve to move to a certain fail-safe position. The direction of the fail-safe action is
speciedonthenameplateofSAMSONactuators.
Warning against residual hazards
Theelectricactuatorwithprocesscontrollerhasadirectinuenceonthevalvewhenitis
mounted on the valve. 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 operating 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, espe-
cially 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 as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed to
any danger.

EB 5724 EN 1-3
Safety instructions and measures
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards, directives and regulations
TheTROVIS5724-3andTROVIS5725-3ElectricActuatorswithaCEmarkingcomplywith
the requirements of the Directives 2014/30/EU and 2014/35/EU.
TheTROVIS5724-3andTROVIS5725-3ElectricActuatorswithanEACmarkingcomply
with the requirements of the Regulations TR CU 004/2011 and TR CU 020/2011.
The electric actuators are 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:
− CongurationManualforTROVIS5724-3andTROVIS5725-3ElectricActuatorswith
Process Controller uKH5724
− Mounting and operating instructions of the valve on which the electric actuator is
mounted, e.g. for SAMSON valves:
uEB5861forType3260Three-wayValve
uEB5863forType3226Three-wayValve
uEB5866forType3222GlobeValve
uEB5867forType3222NGlobeValve
uEB5868forType3213andType3214GlobeValves
uEB8111forType3321GlobeValve
uEB8113forType3323Three-wayValve
uEB8131forType3531GlobeValveforHeatTransferOil
uEB8135forType3535Three-wayValveforHeatTransferOil
uEB3018forType42-36EPressure-independentControlValve(PICV)withelectric
actuator

1-4 EB 5724 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andperforminganyworkonthedevice,disconnectthe
supply voltage and protect it against unintentional reconnection.
ÎOnly use power interruption devices that can be protected against unintentional re-
connection of the power supply.
ÎDo not open the back housing cover.
Theelectricactuatorswithprocesscontrollerareprotectedagainstspraywater(IP54).
ÎAvoid jets of water.
The switching output L' may be live after the supply voltage has been connected.
ÎDo not touch the switching output L'.
ÎWhen the switching output is not used, deactivate it in function F16 ('Not active'
setting uKH5724).
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
Theform-tversionoftheelectricactuatorscontainsmovingparts(actuatorandplug
stems),whichcaninjurehandsorngersifinsertedintotheactuator.
ÎDonotinserthandsorngerintotheyokewhilethevalveisinoperation.
ÎDisconnect the supply voltage before performing any work on the control valve.
ÎDo not impede the movement of the actuator or plug stem by inserting objects into
their path.

EB 5724 EN 1-5
Safety instructions and measures
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 actuator damage due to the supply voltage exceeding the permissible toler-
ances.
The 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 incorrect wiring of the inputs.
Incorrect wiring of the inputs may lead to excessively high voltages and damage the
electric actuator with process controller.
ÎWire the inputs range according to the technical data.
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 actuator by turning it too far.
The actuator stem of the electric actuators can be adjusted manually.
ÎMove the actuator stem only as far as the bottom or top end position.

1-6 EB 5724 EN
NOTICE
!
Malfunction due to a conguration that does not meet the requirements of the appli-
cation.
Theelectricactuatorwithprocesscontrollerisconguredforthespecicapplicationby
settingcongurationitemsandparameters.
ÎPerformthecongurationforthespecicapplicationduringstart-upandafterare-
set to default settings.
Risk of damage to the screw heads on the front cover due to the use of the wrong
tool.
The actuator housing cover is fastened using TORX PLUS®screws,size10IP.
ÎTo screw or unscrew the screws, only use the following screwdrivers:
− TORX®T10
− TORX PLUS®10IP
− Flat-bladescrewdriverwith0.8mmbladethicknessand4.0mmbladewidth