Samson TROVIS 5724-8 Service manual

Translation of original instructions
EB 5724-8 EN
Firmware version 1.1x/2.1x
TROVIS5724-8 Electric Actuator with Process Controller without fail-
safe action and TROVIS5725-8 with fail-safe action
For heating and cooling applications
Edition August 2019

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 5724-8 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]).
The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at www.samsongroup.com > Service & Support > Downloads >
Documentation.

Contents
EB 5724-8 EN
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..............................................................10
2 Markings on the device ...............................................................................11
2.1 Actuator nameplate......................................................................................11
2.2 Valve nameplate ..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................12
3.2 Operating controls .......................................................................................13
3.3 Readings and their meaning .........................................................................13
3.4 Versions ......................................................................................................14
3.5 Accessories .................................................................................................15
3.6 Technical data .............................................................................................16
3.7 Dimensions in mm........................................................................................20
4 Measures for preparation............................................................................21
4.1 Unpacking ..................................................................................................21
4.2 Transporting and lifting ................................................................................21
4.2.1 Transporting ................................................................................................21
4.2.2 Lifting..........................................................................................................21
4.3 Storage.......................................................................................................21
4.4 Aligning the travel indication scale................................................................22
5 Mounting and start-up.................................................................................23
5.1 Mounting the actuator onto the valve.............................................................23
5.1.1 Force-locking attachment ..............................................................................23
5.1.2 Form-tattachment ......................................................................................23
5.2 Installing the control valve into the pipeline ....................................................23
5.3 Electrical connection.....................................................................................25
5.4 Starting initialization ....................................................................................26
5.5 Conguringtheelectricactuator....................................................................27
5.6 Setting up Modbus communication................................................................27
5.6.1 Protocol.......................................................................................................29
5.6.2 Connection with control station......................................................................29
5.6.3 Congurationoftheelectricactuator .............................................................30
5.7 Quick check ................................................................................................30

Contents
EB 5724-8 EN
6 Operation...................................................................................................30
6.1 Adjusting the set point..................................................................................31
6.2 Starting/end closed-loop operation...............................................................31
6.3 Increase/decrease set point ..........................................................................32
6.4 Selecting the external/internal set point .........................................................32
6.5 Start and stop program controller..................................................................33
6.6 Manually changing the stem position.............................................................33
7 Servicing.....................................................................................................34
7.1 Preparation for return shipment.....................................................................34
8 Malfunctions ...............................................................................................35
8.1 Emergency action ........................................................................................35
9 Decommissioning and removal ....................................................................36
9.1 Decommissioning.........................................................................................36
9.2 Removing the actuator from the valve ............................................................36
9.2.1 Force-locking attachment ..............................................................................36
9.2.2 Form-tattachment ......................................................................................36
9.3 Disposal......................................................................................................37
10 Annex.........................................................................................................37
10.1 After-sales service........................................................................................37
10.2 Congurationandparameterlist...................................................................38
10.3 Excerpt from Modbus list ..............................................................................48
10.4 Default settings ............................................................................................54
10.5 Customer-specicdata .................................................................................58
10.6 Electrical connection.....................................................................................62
10.7 EU declaration of conformity.........................................................................63

EB 5724-8 EN 5
Safety instructions and measures
1 Safety instructions and measures
TheSAMSONTROVIS5724-8andTROVIS5725-8ElectricActuatorswithProcessControl-
ler are a combination of an electric actuator and an integrated digital controller with two PID
control modules. They are designed for operating a mounted globe valve. In combination
withthevalve,theactuatorisusedtocontroltheowofliquidsorvaporsinthepipeline.The
electric actuators with process controller are suitable for closed-loop operation in heating
and cooling 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 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SAM-
SON.
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3.6.
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.

6 EB 5724-8 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 control valve may be necessary when mounting or re-
moving 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 following safety features exist:
−Anactiveblockingprotection(A8.3congurationitem=1,seesection10.2)intheelec-
tric actuator with process controller prevents the valve from seizing up.
−Uponsupplyvoltagefailure,theTROVIS5725-8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. 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.

EB 5724-8 EN 7
Safety instructions and measures
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.
Referenced standards and regulations
The electric actuators with process controller 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 annex 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5724-8andTROVIS5725-8ElectricActuatorswith
Process Controller uKH5724-8
−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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

8 EB 5724-8 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 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controller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 M4 ('None' set-
ting).
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 5724-8 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 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.

10 EB 5724-8 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to the supply voltage exceeding the permissible
tolerances.
The electric actuators are designed for use according to regulations for low-voltage in-
stallations.
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.
The display does not work due to an interrupted cable connection.
The cable connection for the display is located underneath the front housing cover.
ÎOnly open the front housing cover to perform actions described in these instructions.
ÎDo not disconnect the connecting cable between the actuator and housing cover.
Malfunction due to a conguration that does not meet the requirements of the
application.
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.
Manipulation of settings at the electric actuator with process controller due to
unauthorized access.
The electric actuator with process controller has a communication interface for data
transmissionwiththeTROVIS-VIEWsoftware(rmware1.1x:Bluetooth®,rm-
ware2.1x:ModbusRTU).Thecommunicationinterfaceisactiveinthedeliveredstateof
the electric actuator with process controller.
ÎWhen data transmission is not used, deactivate the communication interface with
the operating keys or by setting the 'Protocol' parameter to 'None'.

EB 5724-8 EN 11
Markings on the device
2 Markings on the device
2.1 Actuator nameplate
1F144/11
2015
0062
TROVIS 5724-820
Electric Actuator
with Process Controller
Var.-ID 4150511.04
Serial no. 1085 *000000*
f: 50 Hz
F: 500 N
U: 230 V
s: 12 mm
v: 0.18 mm/s
P: 5 VA
Made in Germany
Firmware: 1.14
1
2
3
4 5
6
78 9
10
11 12
13
1 Type
2CongurationID
3 Serial number
4 Thrust
5 Rated travel
6 Stroking speed
7 Supply voltage
8 Power line frequency
9 Power consumption
10 Firmware version
11 DIN testing with registration number
(TROVIS5725-8only)
12 Fail-safe action
Actuator stem
extended
Actuator stem
retracted
13 Year of manufacture
2.2 Valve nameplate
See associated valve documentation.

12 EB 5724-8 EN
Design and principle of operation
3 Design and principle of oper-
ation
TheTROVIS5724-8andTROVIS5725-8
Electric Actuators with Process Controller
contain two integrated digital controllers, re-
ferredtoascontroller[1]andcontroller[2]
inthefollowing.TheTROVIS5724-8iswith-
outfail-safeactionandtheTROVIS5725-8
has fail-safe action.
The electric actuators with process controller
aremountedontoSAMSONTypes3222,
3213,3214,2488,42-36E,3226and
3260 Valves as well as Series V2001 Valves
uptovalvesizeDN50.
The actuator contains a reversible synchro-
nous motor and a maintenance-free gear.
The force of the motor is transmitted to the
actuator stem via gearing and cam disk.
When the actuator stem extends, it pushes
against the valve's plug stem. When the ac-
tuator stem retracts, the return spring in the
valve causes the plug stem to follow the
movement (force-locking connection). The
valve and actuator have a force-locking con-
nection.Aform-tconnectionisusedfor
special valve models, e.g. Series V2001
valves.
The user can read and change the set point
and operating values at the control panel.
All other parameters can be changed in the
TROVIS-VIEW software. Data between the
actuator and computer is transferred either:
−OverBluetooth(rmwareversion1.1x)
−OverModbus(rmwareversion2.1x)
After a power supply failure, the electric ac-
tuator starts again by performing a zero cal-
ibration and uses the last valid setting.
TheTROVIS5725-8ElectricActuatorswith
fail-safe action largely corresponds to the
previouslydescribedTROVIS5724-8.How-
ever, they also include a spring mechanism
and an electromagnet.
3.1 Fail-safe positions
TROVIS5724-8
TheTROVIS5724-8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 supply voltage fails.
TROVIS5725-8
TheTROVIS5725-8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(seeitem12insection2.1)
after the supply voltage 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.

EB 5724-8 EN 13
Design and principle of operation
3.2 Operating controls
TROVIS5724-8:
handwheel
Travel indicator
Display Operating
keys
Fig.1: Operating elements on the actuator
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5724-8 only)
The valve position can be changed manually
usingthehandwheel.Seesection6.6.
Operating keys
In closed-loop operation, the operating keys
havethefunctionlistedinTable2.
Reading
The actual value (process variable) before
thecomparatorforcontroller[1]or[2]is
shown on the display during closed-loop op-
eration. The setting is performed in the A3.1
congurationiteminTROVIS-VIEW.Seesec-
tion10.2.
3.3 Readings and their
meaning
Non-blinking readings on the display
Displayed value (see A.2.2) lower than
–9°C
Displayed value (see A.2.2) greater
than99°C
Zero calibration in progress
Initialization in progress
Transit time measurement in progress
Blockingprotectionactive
Manual level in TROVIS-VIEW active
Long-term test in progress
Internal limit LIM1 reached
Internal limit LIM2 reached
Program controller active
Blinking readings on the display
Signal failure AI1 (4)
Signal failure AI2 (5)
Signal failure AI3 (6)
Limit contact (1) error
No basic setting (2)
Noconguration(3)
Note

14 EB 5724-8 EN
Design and principle of operation
No initialization (7)
No calibration (8)
Stem extension/retraction canceled (9)
Manual level active
Initialization in progress
Update in progress
The number in brackets indicates the priority
of the E0 to E9 errors (highest priority = 1).
If several errors have occurred, only the
error with the highest priority is shown. The
error with the next highest priority is shown
when the error with highest priority is
remedied.
Information indicated by the decimal point
on the bottom right-hand corner of the dis-
play
−Programmedfunctionof[I]keyactivated
by digital input.
−Programmedfunctionof[O]keyactivat-
ed by digital input.
−Programmedfunctionof[I]keyactivated
by on-site operation.
−Programmedfunctionof[O]keyactivat-
ed by on-site operation.
−Program (program controller) active.
−Program (program controller) stopped.
−Program(programcontroller)nished.
3.4 Versions
The electric actuator with process controller
isavailableinfourversions[A],[B],[C]and
[D].Theseversionsaretailoredtothe
ready-conguredapplications.Inmanycas-
es, it is also possible to use the electric actu-
ator with process controller with another de-
vice version for other applications. See Ta-
ble1.
The ready-congured applications are de-
ned in M0 conguration item. They are de-
scribed in the Conguration Manual
uKH5724-8.
Note
Time
ON
OFF
Time
ON
OFF
1 s 1 s
Time
ON
OFF
1 s 1 s 1 s
Time
ON
OFF
1 s 1 s
Time
ON
OFF
Time
ON
OFF
1 s 1 s 1 s
Time
ON
OFF
Note

EB 5724-8 EN 15
Design and principle of operation
−Device version [A] with two-wire con-
necting cable (voltage supply) and two
Pt1000sensors
−Device version [B] with three-wire con-
necting cable (voltage supply and switch-
ingoutput)andtwoPt1000sensors
−Device version [C] with two-wire con-
necting cable (voltage supply), two
Pt1000sensorsandafour-wirecontrol
line for two further inputs
−Device version [D] with three-wire con-
necting cable (voltage supply and switch-
ingoutput),twoPt1000sensorsanda
four-wire control line for two further in-
puts
3.5 Accessories
Accessories for communication
−TROVIS-VIEW software
The TROVIS-VIEW software can be
downloaded free of charge from our
website (uwww.samsongroup.com>
Service&Support>Download>
TROVIS-VIEW). The software can also be
supplied on a CD-ROM. Further details
in Data Sheet uT6661.
−BusconnectingcableforModbusRTU
communication with 3-pin round connec-
tor,5m,orderno.1380-2689
−USB-RS485adapterR3fordirectcong-
uration over TROVIS-VIEW and Modbus
interface, order no. 1402-1300
Accessories for control
−Single-channel digital time switch with
weeklyprogram,ThebenTR610top2G,
order no. 1402-1017
Table1: Device versions ([A], [B], [C], [D]) and their possible implementation
Version[A] Version[B] Version[C] Version[D]
System code numbers 20, 60 • • • •
System code numbers 1, 10, 21, 30, 50, 70,
80 o•o•
System code numbers 65, 66 – – • •
System code numbers 35, 55, 95 – – o •
• Recommended o Possible when the switching output is not used
• Possible – Not possible

16 EB 5724-8 EN
Design and principle of operation
Accessories for sensors
−MountingkitforaPt1000cablesensor
as contact sensor, order no. 8524-0020
−Brassthermowell,G½,immersionlength
80 mm, PN 16, order no. 1099-0807
−CrNiMosteelthermowell,G½,immer-
sionlength80mm,PN40,orderno.
1099-0805
−CrNiMosteelthermowell,G½,immer-
sionlength250mm,PN40,orderno.
1099-0806
−Brassthermowell,G½,immersionlength
160mm,PN16,orderno.8525-5005
−CrNiMosteelthermowell,G½,immer-
sionlength160mm,PN40,orderno.
8525-5011
3.6 Technical data
Electric actuator with process
controller TROVIS 5724- 810
5725-
810
5724-
820
5725-
820
5724-
830
5725-
830
Fail-safe action With-
out With With- out With With- out
With
Actuator stem – Ex-
tends –Ex- tends –Ex-
tends
Connection to valve Force-locking Form-t
Rated travel 6mm 12mm 15mm
Transit time for rated travel 35s 70s 90s
Stroking speed 0.18mm/s
Thrust 700N 500N 700N 500N 700N 280N
Supply voltage 230V(±10%),50Hz
Power consumption 6VA
Manual override With With-
out With With- out With With- out
Permissible temperatures1)
Ambient 0 to +50°C
Storage –20 to +70°C
Degree of protection (not installed
suspended) IP54
Electromagnetic compatibility AccordingtoEN61000-6-2,EN61000-6-3and
EN61326
Connecting cable length Two-wire,5m ·Three-wire,2.5m

EB 5724-8 EN 17
Design and principle of operation
Weight Approx.1.1kg
Compliance ·
Operating time Up to 10 years (depending on the operating conditions
of the device)
We recommend checking whether the device functions
properly every 5 years.
Intended lifetime Normally 15 years (depending on the operating condi-
tions of the device)
Maximum storage period 24months(providedthestorageconditionsspeciedin
the associated mounting and operating instructions are
observed)
Deviceversion[A] • Two-wire connecting cable with open end for connection to voltage supply
(5m)
• 2Pt1000sensors(2mblueand3mred)
Deviceversion[B] • Three-wire connecting cable with open end for connection to voltage
supplyandswitchingoutput(2.5m)
• 2Pt1000sensors(2mblueand3mred)
Deviceversion[C] • Two-wire connecting cable with open end for connection to voltage supply
(5m)
• 2Pt1000sensors(2mblueand3mred)
• Four-wirecontrollinefortwoadditionalinputs(3m)
Deviceversion[D] • Three-wire connecting cable with open end for connection to voltage
supplyandswitchingoutput(2.5m)
• 2Pt1000sensors(2mblueand3mred)
• Four-wirecontrollinefortwoadditionalinputs(3m)
1) The permissible medium temperature depends on the valve on which the electric actuator with pro-
cess controller is mounted. The limits in the valve documentation apply.

18 EB 5724-8 EN
Design and principle of operation
Sensors
Type 5277-2 5277-3
NumberofPt1000
resistors 1 1
Accuracy ClassB
Sensor length 50mm 50mm
Perm. temperature range –50to+180°C
Degree of protection acc. to
EN60529 IP54
Weight Approx.0.23kg
Connecting cable length 2m 3m
Marking Blue Red
Wiring AI2 AI1
Connecting cable
Version Two-wire Three-wire
Length 5m 2.5m
Wire coding N ↔Blue N↔Blue
L↔Brown L↔Brown
L' ↔Black
Switching output
Amperage Max.1A
Voltage Depending on the supply volt-
age:230V·120V
Control line
Version AI3 AI4
Wire
coding
+↔Orange + ↔Red
–↔Brown –↔Black

EB 5724-8 EN 19
Design and principle of operation
Table2: Function of the operating keys
Key Function
Briey pressing the key
DependingonhowA2.1congurationitemisset,asetpoint,whichcanbeadjust-
ed,isdisplayed(seesection10.2).
Briey pressing the key
DependingonhowA2.2congurationitemisset,adifferentvalueisdisplayed
(seesection10.2).
Briey pressing the key
ThefunctiondependsonhowA1.1congurationitemisset(seesection10.2).
Key held pressed for three seconds
ReadingHA
Open manual level.
Key held pressed for six seconds
Reading I n
Startinitialization(seesection5.4).
Key held pressed for nine seconds
Reading C P
Firmwareversion1.1x:switchoffBluetoothcommunication(seeTable3)
Firmwareversion2.1x:seecommunicationparameters(seesection5.6.2)
Key held pressed for twelve seconds
Reading U P
Startrmwareupdate.
Briey pressing the key
ThefunctiondependsonhowA1.1congurationitemisset(seesection10.2).

20 EB 5724-8 EN
Design and principle of operation
3.7 Dimensions in mm
TROVIS5724-810/-820 and TROVIS5725-810/-820
146
82
113
48
44
103
40
TROVIS 5724-830 and TROVIS 5725-830
Ø10
46.5
Ø15.8