Samson TROVIS 5757-3 Service manual

Translation of original instructions
EB 5757 EN
Firmware version 2.20
Edition September 2016
TROVIS5757-3 Electric Actuator 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 5757 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 5757 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 Firmware versions.......................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Communication ..........................................................................................3-3
3.2 Technical data ............................................................................................3-4
3.3 Dimensions.................................................................................................3-5
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the actuator ...................................................4-1
4.3 Transporting the actuator.............................................................................4-1
4.4 Lifting the actuator ......................................................................................4-1
4.5 Storing the actuator.....................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-1
5.3 Mounting the actuator .................................................................................5-1
5.4 Installing the control valve into the pipeline ...................................................5-2
5.5 Installing the accessories..............................................................................5-2
5.6 Electrical connection....................................................................................5-3
6 Operation..................................................................................................6-1
6.1 Device overview and operating controls........................................................6-1
6.2 Indication with LEDs ....................................................................................6-1
6.3 Serial interface ...........................................................................................6-1
7 Start-up and conguration..........................................................................7-1
7.1 Initializing the actuator................................................................................7-1
7.2 Conguringtheactuator..............................................................................7-1
8 Operation..................................................................................................8-1
8.1 Closed-loop control.....................................................................................8-1
8.2 LED blinking pattern....................................................................................8-1
8.3 Manual mode.............................................................................................8-3
8.4 Operation using memory pen ......................................................................8-4

Contents
EB 5757 EN
8.4.1 Copying function ........................................................................................8-5
8.4.2 Command mode.........................................................................................8-5
8.5 Readings in TROVIS-VIEW...........................................................................8-6
8.5.1 Operating values ........................................................................................8-6
8.5.2 Operating states .........................................................................................8-6
8.5.3 Functions....................................................................................................8-7
8.5.4 Status messages..........................................................................................8-7
8.5.5 Statistics.....................................................................................................8-8
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
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list.......................................................................................16-3
16.4 Customer-specicdata ..............................................................................16-5

EB 5757 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The TROVIS 5757-3 Electric Actuator with Process Controller is an electric actuator with an
integrated digital controller. It is designed for operating a mounted globe valve. In combina-
tion with the valve, the actuator is used to control the temperature of liquids or vapors in the
pipeline. The electric actuator with process controller is suitable for throttling service in DHW
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
SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataforlimitsandeldsofapplicationaswellaspossibleuses.See
the 'Design and principle of operation' section.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:
− Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described
Qualications of operating personnel
The actuator must be mounted, started up, serviced and repaired by fully trained and quali-
edpersonnelonly;theacceptedindustrycodesandpracticesmustbeobserved.According
to these mounting and operating instructions, trained personnel refers to individuals who are
able to judge the work they are assigned to and recognize possible hazards due to their spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

1-2 EB 5757 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 limit switches switch off the motor in the end positions.
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.
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.

EB 5757 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
TheTROVIS5757-3ElectricActuatorwithProcessControllerwithaCEmarkingfulllsthere-
quirements of the Directives 2014/30/EU and 2014/35/EU.
TheTROVIS5757-3ElectricActuatorwithProcessControllerwithanEACmarkingfulllsthe
requirementsoftheRegulationsTRCU004/2011andTRCU020/2011.
The'Certicates'sectioncontainsthisdeclarationofconformityandTRCUcerticate.
The electric actuator with process controller is designed for use in low-voltage installations.
ÎFor wiring, maintenance and repair, observe the relevant safety regulations.
Referenced documentation
The documentation for the TROVIS 5757-3 Electric Actuator with Process Controller consists
oftheMountingandOperatingInstructionsEB5757andtheCongurationManual
uKH5757.
The following documents also apply in addition to these mounting and operating instructions:
uEB3135-1forType2488Pressure-independentControlValve(PICV)
uEB3136forType2488NPressure-independentControlValve(PICV)
uEB5861forType3260Three-wayValve
uEB5863forType3226Three-wayValve
uEB5866forType3222GlobeValve
uEB5867forType3222NGlobeValve
uEB5868forType3213GlobeValve

1-4 EB 5757 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 housing cover.
The electric actuator with process controller is protected against dripping water falling
atanangle(IP42).
ÎAvoid sprays and jets of water.
The wires of the switching output L' may be live after the supply voltage has been con-
nected.
ÎDo not touch the wires of the switching output L'.
ÎWhen the switching output is not used, deactivate it in function F16 ('Not active'
setting uKH5757).Insulatethewireends.
1.2 Notes on possible personal injury
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.

EB 5757 EN 1-5
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 TROVIS 5757-3 Electric Actuator with Process Controller is designed for use ac-
cording to regulations for low-voltage installations.
ÎObserve the permissible tolerances of the supply voltage.
Risk of actuator damage due to excessively high tightening torques.
The connection of the TROVIS 5757-3 Electric Actuator with Process Controller 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.
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.

1-6 EB 5757 EN

EB 5757 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
F: 300 N Firmware: 2.xx
Var.-ID xxxxxxx Serial no. xxxx *xxxxxx*
U: 230 V f: 50 Hz P: 3 VA Made in Germany
s: 6 mm v: 0.3 mm/s
Electric Actuator
with Process Controller
TROVIS 5757-3
F Thrust
s Rated travel
v Stroking speed
U Supply voltage
f Power line frequency
P Power consumption

2-2 EB 5757 EN
Markings on the device
2.2 Firmware versions
Firmware revisions
Old New
1.0x 2.0x/2.1x
Additional features:
− Switching output (see Annex).
− Dataloggingfunction(seeCongurationManualuKH5757).
− Commandmode(seeCongurationManualuKH5757).
2.0x/2.1x 2.20
Extension of function of switching output (F16) to additional setting option "Circulation
pump(heating)reversed"(seeAnnexandCongurationManualuKH5757).
Newpumpprotectionfunction(F17)(seeAnnexandCongurationManualuKH5757).

EB 5757 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The TROVIS 5757-3 Electric Actuator with
Process Controller is an electric actuator with
an integrated digital controller. It can mount-
edonSAMSONTypes3213,3222,
3222N,2488and3267Valves(DN15to
25)aswellasspecialversionsofType3260
andType3226Valves.
Design
ÎSeeFig.3-1andFig.3-2.
The actuator is mounted onto the valve using
a coupling nut (4). When the actuator stem
extends, the globe valve is closed, opposing
1
2
3
4
5
6
1 Heat exchanger
2 Temperature sensor including sensor pocket, VSTW
3 Supply from district heating network (VL)
4TROVIS5757-3ElectricActuatorwithProcessController
5Waterowsensorwithconnectingcable
6Returnowtodistrictheatingnetwork(RL)
7Valve,e.g.Type3222
Sales Flow pipe
RL Returnowpipe
WW Hot water
KW Cold water
VSTW Flow sensor
WSS Waterowsensor
Fig.3-1: Sample application: domestic hot water heating with Pt1000 sensor and water ow sensor
the force of the valve spring (7). When the
actuator stem retracts, the valve is opened as
the plug stem (6) follows the motion of the
return spring.
When connected to a three-way mixing
valve, the extending actuator stem causes the
valve (A → AB) to open.
The output signal of the controller functions
as a three-step signal on the motor of the
actuator and is transferred over the
connected gear to the actuator stem (3) and
used as the stroke. The motor is switched off
by torque-dependent switches when an end
position is reached or in case the motor is
overloaded.

3-2 EB 5757 EN
Design and principle of operation
18
2
4
3
6
7
5
1.1
1 Electric actuator
with process
controller
1.1Connecting cable
2 Manual adjuster
3 Actuator stem
4 Coupling nut
5 Travel indicator
6 Plug stem
7 Valve spring
8 Cover, serial RJ12
jack
Fig.3-2: Design of TROVIS5757-3
Manual adjuster
The travel can be adjusted using the manual
adjuster when the actuator is in the de-ener-
gized state (see the 'Operation' section).
Inputs
The electric actuator with process controller
hasaninputforafast-responsePt1000
temperaturesensor.Itcanfunctionasaxed
set point controller with this input. Alterna-
tively, the electric actuator can be used for
domestic hot water in instantaneous heating
system.Inthiscase,eitherawaterowsen-
sororaowswitchmustbeusedforfastde-
tection.Theowswitchrecognizeswhenthe
hotwaterisbeingtapped.Thewaterow
sensor can additionally record the quantity
of hot water being tapped. An optimization
function adapts the control to the changing
network conditions.
In addition to the temperature sensor input,
theactuatorhasa0/4to20mAcurrentin-
put. This can be used either instead of the
temperature sensor (measured value) or to
connect an external set point.
The binary input can be used to change be-
tween the set points W1 and W2.
Output
Theswitchingoutputcanbeconguredas
either a pump output (circulation pump for
the DHW circuit or heating circuit), a fault
alarm output or an output to report when hot
water is tapped.
Setting
The set point of the digital controller is set to
60°CandcanbechangedinTROVIS-VIEW
using a connecting cable connected to the
RS-232 interface (serial interface) on the
actuator or using a memory pen (see
section3.1).Thecontrolledvariable,control
behavior and the actuator's direction of
action can also be changed in TROVIS-
VIEW.
All the functions and parameters are listed in
the Annex.

EB 5757 EN 3-3
Design and principle of operation
3.1 Communication
Serial interface
TheactuatoristtedwithanRS-232serial
interface. This allows communication with
TROVIS-VIEW using SSP protocol.
Conguration
TheactuatorisconguredusingtheTROVIS-
VIEW software that enables the user to easily
congurethecontrolleraswellasview
process parameters online.
TROVIS-VIEW can be downloaded free of
charge from our website at
uwww.samsongroup.com > Service &
Support > Downloads > TROVIS-VIEW.
Further information on TROVIS-VIEW (e.g.
system requirements) is available on our
website and in the Data Sheet uT6661 as
well as the Operating Instructions
uEB6661.
Note

3-4 EB 5757 EN
Design and principle of operation
3.2 Technical data
Table 3-1: Technical data · TROVIS 5757-3
TROVIS5757-3
Connection to valve Force-locking
Rated travel 6mm
Manual override Yes
Transit time for rated travel 20s
Thrust 300N
Supply voltage 230V(±10%),50Hz
Power consumption Approx. 4 VA
Sensor input Pt1000
Current input 0/4to20mA
Binary input BI1 1) Set point switchover (W1 and W2)
Binary input BI2 1) Flow switch
Inputforwaterowsensor 530pulses/l,measuringrange1to30l/min
Switching output 230V,50Hz,max.1A
Permissible temperature ranges1)
Ambient 0to50°C
Storage –20to+70°C
Degree of protection IP42accordingtoEN60529
Class of protection IIaccordingtoEN61140
Device safety AccordingtoEN61010-1
Noise immunity AccordingtoEN61000-6-2andEN61326-1
Noise emission AccordingtoEN61000-6-3andEN61326-1
Conformity
Materials
Housing Plastic(PPOwithglassberreinforcement)
Coupling nut M32x1.5 Brass
Weight Approx.0.7kg
1) Recommendation: use devices with gold contacts when using relays.
2) 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 5757 EN 3-5
Design and principle of operation
3.3 Dimensions
Ø 12
55
80
11
32 70
114
70
Fig.3-3: Dimensions in mm · Electric actuator with process controller

3-6 EB 5757 EN
Design and principle of operation
Ø3.3
Ø5.4
10.5
15
52 ±1 2000
approx.
50
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:90°C
Water ow sensor with exten-
sion 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
Sensor pocket (including gas-
ket) for heat exchanger with
G¾
Order no. 1400-9249
Sensor pocket (includ-
ing gasket) for heat ex-
changerwithG1
Order no. 1400-9252
Fig.3-4: Dimensions in mm · Accessories for the electric actuator with process controller (sensors)

EB 5757 EN 3-7
Design and principle of operation
Circulation pipe connection (in-
cluding gasket)
Order no. 1400-9232
Connecting piece (including
gasket)forvalveG1
Order no. 1400-9237
Connecting piece (including
gasket)forvalveG¾
Order no. 1400-9236
Fig.3-5: Dimensions in mm · Accessories for the electric actuator with process controller
(connections)

3-8 EB 5757 EN