Samson TROVIS 5724-3 Service manual

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

2 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.
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
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition 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

Contents
EB 5724 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................10
2.1 Actuator nameplate......................................................................................10
2.2 Valve nameplate ..........................................................................................10
3 Design and principle of operation ................................................................11
3.1 Fail-safe positions ........................................................................................12
3.2 Operating controls .......................................................................................12
3.3 Accessories .....................................................................................................
3.4 Technical data .............................................................................................15
3.5 Dimensions in mm........................................................................................17
4 Measures for preparation............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................20
4.2.2 Lifting..........................................................................................................20
4.3 Storage.......................................................................................................20
4.4 Aligning the travel indication scale................................................................21
5 Mounting and start-up.................................................................................21
5.1 Mounting the actuator onto the valve.............................................................21
5.1.1 Force-locking attachment ..............................................................................21
5.1.2 Form-t attachment ......................................................................................22
5.2 Installing the control valve into the pipeline ....................................................22
5.3 Electrical connections ...................................................................................22
5.4 Conguring the electric actuator....................................................................24
5.5 Quick check ................................................................................................24
6 Operation...................................................................................................27
6.1 Manually changing the stem position.............................................................27

4 EB 5724 EN
Contents
7 Servicing.....................................................................................................29
7.1 Preparation for return shipment.....................................................................29
8 Malfunctions ...............................................................................................30
8.1 Emergency action ........................................................................................30
9 Decommissioning and disassembly ..............................................................30
9.1 Decommissioning.........................................................................................30
9.2 Removing the actuator from the valve ............................................................31
9.2.1 Force-locking attachment ..............................................................................31
9.2.2 Form-t attachment ......................................................................................31
9.3 Disposal......................................................................................................31
10 Appendix....................................................................................................31
10.1 After-sales service........................................................................................31
10.2 Conguration and parameter list...................................................................32
10.3 Parameter list...............................................................................................33
10.4 Customer setting ..........................................................................................34
10.5 EU declaration of conformity.........................................................................35
Firmware revisions
2.11
(old)
2.13 (new)
Additional setting option 'Circulation pump (heating) reversed' in Function of switching
output (F16). See section10.2 and uKH 5724.
2.13
(old)
2.20 (new)
New pump protection function (F17). See section10.2 and uKH 5724.

EB 5724 EN 5
Safety instructions and measures
1 Safety instructions and measures
The TROVIS5724-3 and TROVIS5725-3 Electric Actuators with Process Controllers are a
combination of an electric actuator and an integrated digital controller. They are designed
for operating a mounted globe valve. In combination with the valve, the actuator is used to
control the ow of liquids in the pipeline. The electric actuators with process controllers are
suitable for DHW heating applications.
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 applications 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, SAMSON must be con-
tacted.
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
section3.4.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:
−Use outside the limits dened during sizing and in 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 in these instructions
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 are to be observed. Accord-
ing 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
specialized training, their knowledge and experience as well as their knowledge of the appli-
cable standards.

6 EB 5724 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the electric actuator
with process controller. Work on the valve on which the electric actuator is mounted may be
necessary when mounting or removing the actuator from the valve.
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 to 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 following safety features exist:
−Upon power supply failure, the TROVIS5725-3 Electric Actuator causes the valve to
move to a certain fail-safe position. The fail-safe action of SAMSON actuators is speci-
ed on the actuator nameplate.
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. They
must observe all hazard statements, warning and caution notes in these mounting and oper-
ating instructions, especially for installation, start-up, and maintenance.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions to the operating
personnel and to instruct them in proper operation. Furthermore, the operator must ensure
that operating personnel or third persons 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, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

EB 5724 EN 7
Safety instructions and measures
Referenced standards and regulations
The electric actuators with process controllers comply with the requirements of the Directives
2014/30/EU and 2014/35/EU. The declaration of conformity includes information about
the applied conformity assessment procedure. This declaration of conformity is included in
the Appendix of these instructions.
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 Controllers uKH5724
−Mounting and operating instructions of the valve on which the electric actuator is mount-
ed, 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 ac-
tuator

8 EB 5724 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of electric shock.
ÎBefore connecting wiring, performing any work on the device or opening the de-
vice, disconnect the power supply and protect it against unintentional reconnection.
ÎOnly use power interruption devices that are protected against unintentional recon-
nection of the power supply.
ÎDo not remove any covers to perform adjustment work on live parts.
ÎDo not open the back housing cover.
The electric actuators with process controllers are protected against spray water
(IP54).
ÎAvoid jets of water.
The switching output L' might 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 ('Passive' set-
ting).
Risk of bursting in pressure equipment.
Control 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 con-
cerned as well as the valve.
ÎDrain the process medium from all the plant sections concerned and from the valve.
ÎWear recommended personal protective equipment. See associated valve docu-
mentation.

EB 5724 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The form-t version of the electric actuator with process controller 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 power supply 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.
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to the power supply exceeding the permissible toler-
ances.
The electric actuators are designed for use according to regulations for low-voltage in-
stallations.
ÎObserve the permissible tolerances of the power supply.
Risk of actuator damage due to excessively high tightening torques.
The connection of the electric actuator must be tightened with certain torques. Excessive-
ly tightened torques lead to parts wearing out quicker.
ÎObserve the specied tightening torques.
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.

10 EB 5724 EN
Markings on the device
2 Markings on the device
2.1 Actuator nameplate
12
Var.-ID
Serial no.
3
5
15
16
SAMSON
Controller with
Model
0062
4
6
F:
7
10 11
U:
f:
9
t:
12
P:
13
8
s:
Electric Actuator
Firmware - Version:
:
:
14
1 Type designation
2 Year of manufacture
3Conguration ID
4Model designation (TROVIS5725-3 only)
5 Serial number
6DIN registration number (TROVIS5725-3
only)
7 Thrust
8 Rated travel
9 Transit time for rated travel
10 Power supply
11 Power line frequency
12 Power consumption
13 Fail-safe action (TROVIS5725-3 only)
Actuator
stem re-
tracts
Actuator
stem extends
14 Firmware version
15 Inputs
16 Outputs
2.2 Valve nameplate
See associated valve documentation.
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 loosen and tighten 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

EB 5724 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The TROVIS5724-3 and TROVIS5725-3
Electric Actuators with Process Controller
consist of a linear actuator with an integrat-
ed digital controller.
They are especially designed for DHW heat-
ing in instantaneous heating systems for
small to medium-sized buildings and for
xed set point control circuits in mechanical
engineering applications. They are particu-
larly suitable for mounting to SAMSON
Types3213, 3214, 3260, 3222, and 3226
Valves.
A special version of Type3222 (DN25) and
Type3222N DN15) with a special plug de-
sign is available for small installations
(apartment or house). As a result, even small
tapping amounts can be controlled.
The integrated digital controller must be con-
nected to a temperature sensor on the input
side, which can be optionally upgraded by a
water ow sensor or a ow switch.
Alternatively, a current signal can be used
for mechanical engineering applications.
The set point of the digital controller is set
to 60°C and can be changed manually at
the set point potentiometer (11) or in the
TROVIS-VIEW software.
The actuator contains a reversible synchro-
nous motor and a maintenance-free gear.
The synchronous motor is switched off by
torque-dependent switches in the end posi-
tions or in case of overload. The force of the
electric motor is transmitted via gearing and
crank disk to the actuator stem (3) and to the
plug stem of the mounted valve.
0
100
50
891 1.1212 1.2
11
0
6
12
15
15
12
6
0
0
6
12
15
4
3
1 Electric actuator with process
controller
1.1 Front cover
1.2 Cable entry
2Handwheel (TROVIS5724-3 only)
3 Actuator stem
4 Coupling nut
8Spring assembly (TROVIS5725-3
only)
9 Travel indication scale
11 Set point potentiometer
12 Serial interface (RJ-12 port)
ÎDo not open the back housing cover.
Fig.1: TROVIS5724-3 and 5725-3 Electric Actuators with Process Controller, force-locking valve
connection

12 EB 5724 EN
Design and principle of operation
When the actuator stem extends, it presses
on the plug stem (10) of the valve. When the
actuator stem retracts, the plug stem follows
the movement of the return spring in the
valve.
Actuator and valve are connected by the
coupling nut (4).
TROVIS 5724-3
The electric actuator without fail-safe action
has a handwheel (2) used to manually posi-
tion the valve (only when the actuator is dis-
connected from the power supply). Travel
and direction of action can be read off the
travel indication scale (9).
TROVIS 5725-3
The electric actuator with fail-safe action
contains a spring assembly (8) and an elec-
tromagnet, which move the connected valve
to its fail-safe position when de-energized.
ÎThe fail-safe action must not be used to
control the valve position.
The TROVIS 5725-3 Electric Actuator
with Process Controller with "actuator
stem extends" fail-safe action is tested by
the German Technical Inspectorate (TÜV)
according to DIN EN 14597 in combination
with various SAMSON valves. The register
number is available on request.
3.1 Fail-safe positions
TROVIS5724-3
The TROVIS5724-3 Electric Actuator with
Process Controller does not have fail-safe ac-
tion. When a valve is mounted on this actua-
tor, the valve remains in the last position af-
ter the power supply fails.
TROVIS5725-3
The TROVIS5725-3 Electric Actuator with
Process Controller has fail-safe action. When
a valve is mounted on this actuator, the valve
is moved to the fail-safe position specied on
the nameplate (12 in Fig.1) after the power
supply fails:
−Actuator stem extends: upon power sup-
ply failure, the actuator stem extends.
−Actuator stem retracts: upon power sup-
ply failure, the actuator stem retracts.
3.2 Operating controls
Travel indicator
Handwheel
Fig.2: Operating controls on the actuator

EB 5724 EN 13
Design and principle of operation
Travel indicator
Travel and direction of action can be read
off the scale of the travel indicator.
The scale must be turned when a three-way
mixing valve is used so that the travel and
scale reading match. See section4.4.
Handwheel (TROVIS5724-3 only)
The valve position can be changed manually
using the handwheel. See section6.1.
LEDs
The device has a red and a yellow LED
which indicate the operating states of the de-
vice.
The LEDs are located underneath the front
cover on top of the circuit board.
Risk of damage to the screw heads on the
front cover due to the use of the wrong tool.
To loosen and tighten the screws, only use
TORX®T10, TORXPLUS®10IP, or a at-
blade screwdriver with 0.8mm blade thick-
ness and 4.0mm blade width.
We recommend screwing the bottom screws
of the open housing front cover into the top
holes of the housing.
Blinking pattern of the yellow LED
−Device switched off or command mode
ON
OFF
Time [s]
−Device switched on or memory pen
action completed
ON
OFF
Time [s]
−Plausibility error in memory pen
ON
OFF
Time [s]
−Preparing to read data from memory
pen
ON
OFF
Time [s]
−Preparing to write data to memory pen
ON
OFF
Time [s]
−Preparing data logging
ON
OFF
Time [s]
Note
NOTICE
!
Tip

14 EB 5724 EN
Design and principle of operation
−Data logging in progress
ON
OFF
Time [s]
−EEPROM error in memory pen
ON
OFF
Time [s]
Blinking pattern of the red LED
−Normal operation or memory pen insert-
ed
ON
OFF
Time [s]
−Device starting up
ON
OFF
Time [s]
−Temperature too high (upper limit (GWH)
exceeded)
ON
OFF
Time [s]
−EEPROM error in device
ON
OFF
Time [s]
−Zero calibration in progress
ON
OFF
Time [s]
−Internal transit time measurement
ON
OFF
Time [s]
−Wire breakage at temperature input
OFF
ON
Time [s]
−Wire breakage at current input
ON
OFF
Time [s]
−Flow rate at water ow sensor exceeds
measuring range
ON
OFF
Time [s]

EB 5724 EN 15
Design and principle of operation
3.3 Accessories
Communication
−TROVIS-VIEW software (6661-1060) for
revision 2 of the TROVIS5724-3 and
TROVIS5725-3 Electric Actuator with
Process Controller is required. The
TROVIS-VIEW software can be down-
loaded free of charge from our website
(uwww.samson.de at Services > Soft-
ware > TROVIS-VIEW). The software can
also be supplied on a CD-ROM. Further
details in Data Sheet u T6661.
−Hardware package
Accessories for data transmission (in-
cluding memory pen-64, connecting ca-
ble and modular adapter), order no.
1400-9998
−Memory pen-64
For indirect data transmission, order no.
1400-9753
DHW heating in instantaneous heating
system
−Type5207-0060 Temperature Sensor,
optimized Pt1000 temperature sensor
with fast response which is simple to in-
stall
−Sensor pocket
For Type5207-0060 Pt1000 Sensor for
mounting to heat exchangers with G¾
for optimal positioning instantaneous
heating systems, order no. 1400-9249
−Water ow sensor
Axial turbine owmeter for liquids and
associated extension cable with mating
connector, order no. 1400-9246)
−Flow switch
To recognize when hot water is being
tapped using an NO contact
3.4 Technical data
Electric actuator with
process controller
TROVIS 5724 5725
-310 -313 -320 -323 -330 -333 -310 -313 -320 -323 -330 -333
Fail-safe action Without With
Operating direction – Extends
Rated travel mm 6 6 12 12 15 15 6 6 12 12 15 15
Transit time for rated travel s 35 18 70 36 90 45 35 18 70 36 90 45
Transit time for fail-safe action s – 4 4 6 6 7 7
Thrust N 700 500 280
Thrust in the event of fail-safe
action N – 500 280
Attachment Force-locking •••• ••••
Form-t • • • •
Handwheel Yes Possible 1)

16 EB 5724 EN
Design and principle of operation
Electric actuator with
process controller
TROVIS 5724 5725
-310 -313 -320 -323 -330 -333 -310 -313 -320 -323 -330 -333
Fail-safe action Without With
Operating direction – Extends
Power supply 230V (±10%), 50Hz 230V (±10%), 50Hz
Power consumption Approx. VA 4 7.7 4 7.7 4 7.7 5.5 9.2 5.5 9.2 5.5 9.2
Permissible temperatures5)
Ambient 0 to 50°C 0 to 50°C
Storage –20 to +70°C –20 to +70°C
Safety
Degree of protection IP54 4) IP54 4)
Class of protection II (according to EN 61140)
Overvoltage category II (according to EN60664)
Degree of contamination 2 (according to EN60664)
Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326
Vibration According to EN61000-6-2 and EN60068-2-27
Compliance ·
Inputs and outputs
Binary input BI1 3) Floating contact for internal set point switchover or to deactivate the func-
tion to maintain the heat exchanger at a constant temperature
Binary input BI2 3) Floating contact to connect a ow switch
Switching output 230V/50Hz, max. 1A
Weight kg (approx.) 1.1 1.3
Accessories
Temperature sensor Pt1000, fast response
Water ow sensor 530 pulses/l, measuring range 1 to 30l/min
Flow switch 2) Yes · Alternative to water ow sensor
1) Manual override using 4mm Allen key (after removing the front cover); actuator always returns to fail-safe position
after release.
2) The ow switch or water ow sensor is not required in DHW heating in instantaneous systems with a constant circu-
lation.
3) Recommendation: use devices with gold contacts when using relays.
4) Up to device index .03 only when the actuator is installed in the upright position. See last two gures of the congu-
ration ID written on the nameplate (see page10), e.g. Var.-ID xxxxxxx.xx, for the device index.
5) The permissible medium temperature depends on the valve on which the electric actuator with process controller is
mounted. The limits in the valve documentation apply.

EB 5724 EN 17
Design and principle of operation
3.5 Dimensions in mm
TROVIS5724-313/-323
TROVIS5725-313/-323
12
18
Ø70
51
(33)
136
146
48 44
103
82
113
TROVIS5724-310/-320
TROVIS5725-310/-320
146
82
113
48 44
103
TROVIS5724-333
TROVIS5725-333
12
51
Ø10
46.5
6
18
Ø70
(33)
136
44
103

18 EB 5724 EN
Design and principle of operation
Ø10
46.5
6
146
82
113
48
TROVIS5724-330
TROVIS5725-330
Type 5207-0060 Pt1000 Sensor
Time response: t0.5 < 1s, t0.9 < 3s; in
water 0.4m/s
PN 16
Max. medium temperature: 80°C
Accessories for domestic
hot water heating
Ø3.3
Ø5.4
10.5
15
52 ±1 2000
approx.
50
Water ow sensor with extension
cable
Order no. 1400-9246
Measuring range 1 to 30l/min,
DN10, PN10, IP54
max. medium temperature: 70°C
Extension cable length: 2m
50
G¾ G¾
13 13

EB 5724 EN 19
Design and principle of operation
G¼
G¾
35
G¾
65
G¼
G¾
35
G¾
65
G¼
G1
35
G¾
65
38
G¾
G¾
39
G1
G¾
Sensor pocket (including gasket)
for heat exchanger with G¾
Order no. 1400-9249
Connecting piece (including
gasket) for valve G¾
Order no. 1400-9236
Circulation pipe connection
(including gasket)
Order no. 1400-9232
Sensor pocket (including gasket)
for heat exchanger with G1
Order no. 1400-9252
Connecting piece (including
gasket) for valve G1
Order no. 1400-9237

20 EB 5724 EN
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received against the deliv-
ery note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent (re-
fer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before mounting and start-up.
1. Remove the packaging from the electric
actuator.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transporting and lifting
4.2.1 Transporting
−Protect the electric actuator against exter-
nal inuences (e.g. impact).
−Protect the electric actuator against mois-
ture and dirt.
−Observe the permissible transportation
temperature of –20 to +70°C.
4.2.2 Lifting
Due to the low service weight, lifting equip-
ment is not required to lift the electric actua-
tor.
4.3 Storage
Risk of actuator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
We recommend regularly checking the elec-
tric actuator and the prevailing storage con-
ditions during long storage periods.
Storage instructions
−Protect the electric actuator against exter-
nal inuences (e.g. impact).
−Protect the electric actuator against mois-
ture and dirt.
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe the permissible storage tem-
perature from –20 to +70°C.
−Do not place any objects on the electric
actuator.
Note
NOTICE
!
Note