Samson TROVIS 5724-8 Service manual

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

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
at www.samson.de > Service & Support > Downloads > Documentation.
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
2 EB 5724-8 EN

Contents
EB 5724-8 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..............................................................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........................................................................................19
4 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.................................................................................22
5.1 Mounting the actuator onto the valve.............................................................22
5.1.1 Force-locking attachment..............................................................................22
5.1.2 Form-tattachment ......................................................................................22
5.2 Installing the control valve into the pipeline ....................................................22
5.3 Electrical connections ...................................................................................22
5.4 Starting initialization....................................................................................25
5.5 Conguringtheelectricactuator....................................................................26
5.6 Setting up Modbus communication................................................................26

Contents
4 EB 5724-8 EN
5.6.1 Protocol.......................................................................................................26
5.6.2 Connection with control station......................................................................28
5.6.3 Congurationoftheelectricactuator .............................................................29
5.7 Quick check ................................................................................................29
6 Operation...................................................................................................30
6.1 Adjusting the set point..................................................................................30
6.2 Starting/end closed-loop operation...............................................................30
6.3 Increasing/decreasing set point ....................................................................31
6.4 Selecting the external/internal set point .........................................................32
6.5 Start and stop program controller..................................................................32
6.6 Manually changing the stem position.............................................................33
7 Maintenance ...............................................................................................33
7.1 Preparation for return shipment.....................................................................33
8 Malfunctions ...............................................................................................34
8.1 Emergency action ........................................................................................34
9 Decommissioning and disassembly ..............................................................35
9.1 Decommissioning.........................................................................................35
9.2 Removing the actuator from the valve ............................................................35
9.2.1 Force-locking attachment..............................................................................35
9.2.2 Form-tattachment ......................................................................................35
9.3 Disposal......................................................................................................36
10 Appendix....................................................................................................36
10.1 After-sales service........................................................................................36
10.2 Congurationandparameterlist...................................................................37
10.3 Excerpt from Modbus list ..............................................................................46
10.4 Default settings ............................................................................................52
10.5 Customer setting ..........................................................................................56
10.6 Electrical connection.....................................................................................60
10.7 Declaration of conformity .............................................................................61

EB 5724-8 EN 5
Safety instructions and measures
1 Safety instructions and measures
TheTROVIS5724-8andTROVIS5725-8ElectricActuatorswithProcessControllers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 controllers are suitable for closed-loop operation in heating and cool-
ing 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3.6.
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 5724-8 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 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:
−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. 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, operators must ensure that
operating personnel or third persons 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,theoper-
ating personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
Referenced standards and regulations
The electric actuators with process controllers comply with the requirements of the European
Pressure Equipment Directive 2014/30/EU and 2014/34/EU. 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5724-8andTROVIS5725-8ElectricActuatorswith
Process Controllers uKH5724-8
−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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 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 supply voltage.
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 M4 (‘None’ setting).
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 and the valve.
ÎDrain the process medium from all the plant sections concerned as well as 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 toler-
ances.
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-
ly tightened torques lead to parts wearing out quicker.
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 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.
Unauthorized change of settings at the electric actuator.
The electric actuator with process controller has a communication interface to transfer
datausingTROVIS-VIEWsoftware(rmware1.1x:Bluetooth®, firmware 2.1x:
Modbus-RTU). The communication interface is active upon delivery.
ÎWhen the data exchange is not used, deactivate the communication interface at the
operating keys or in the ‘Protocol’ parameter (‘None’ setting).