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

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 5757 EN

Contents
EB 5757 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 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 Operating controls .......................................................................................12
3.1.1 LEDs ...........................................................................................................12
3.1.2 Handwheel..................................................................................................14
3.1.3 Travel indicator............................................................................................14
3.2 Accessories .................................................................................................14
3.3 Technical data .............................................................................................15
3.4 Dimensions in mm........................................................................................16
4 Preparation.................................................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.2.1 Transporting ................................................................................................18
4.2.2 Lifting..........................................................................................................18
4.3 Storage.......................................................................................................18
5 Mounting and start-up.................................................................................19
5.1 Mounting the actuator onto the valve.............................................................19
5.2 Installing the control valve into the pipeline ....................................................19
5.3 Electrical connections ...................................................................................19
5.4 Conguringtheelectricactuator....................................................................20
6 Operation...................................................................................................20
6.1 Manually changing the stem position.............................................................20
7 Servicing.....................................................................................................24
7.1 Preparation for return shipment.....................................................................24
8 Malfunctions ...............................................................................................24
8.1 Emergency action ........................................................................................24

Contents
4 EB 5757 EN
9 Decommissioning and disassembly ..............................................................26
9.1 Decommissioning.........................................................................................26
9.2 Removing the actuator from the valve ............................................................26
9.3 Disposal......................................................................................................26
10 Appendix....................................................................................................27
10.1 After-sales service........................................................................................27
10.2 Congurationlistandcustomersettings .........................................................28
10.3 Customer setting ..........................................................................................30
10.4 EU declaration of conformity.........................................................................31
Firmware revisions
Old New
1.0x 2.0x/2.1x
Additional features:
–Switchingoutput(seesection10.2)
– Data logging function (uKH5757)
– Command mode (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section10.2anduKH5757).
Newpumpprotectionfunction(F17).Seesection10.2anduKH5757.

EB 5757 EN 5
Safety instructions and measures
1 Safety instructions and measures
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owofliquidsorvaporsinthepipeline.
The electric actuator with process controller is suitable for throttling service in DHW applica-
tions.
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3.3.
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 servicing 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 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 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
None
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.Theymustobserveallhazardstatements,warningandcaution
notes in these mounting and operating 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 as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, operators must ensure that operating personnel or third persons are not ex-
posed 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,warningand
caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

EB 5757 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 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 following documents apply in addition to these mounting and operating instructions:
−CongurationmanualuKH5757forTROVIS5757-3ElectricActuatorwithProcess
Controller (detailed description of all functions and parameters)
−Mounting and operating instructions of the valve on which the electric actuator is mount-
ed, e.g. for SAMSON valves:
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
uEB5895forType3267ValvewithJetPump

8 EB 5757 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 open the back housing cover.
The electric actuators with process controllers are protected against dripping water fall-
ingatanangle(IP42).
ÎAvoid contact with spray water or water jets.
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 5757 EN 9
Safety instructions and measures
1.2 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
reset to default settings.

10 EB 5757 EN
Markings on the device
2 Markings on the device
2.1 Actuator 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 Power supply
f Power line frequency
P Power consumption
2.2 Valve nameplate
See associated valve documentation.

EB 5757 EN 11
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 be
mountedontoSAMSONType3213,
Type3222,Type3222N,Type2488,and
Type3267Valves(DN15to25)andonto
specialversionsofType3260and
Type3226Valves.
The electric actuator with process controller
hasaninputforaPt1000temperaturesen-
sor.Itcanfunctionasaxedsetpointcon-
troller with this input. Alternatively, the elec-
tric actuator can be used for domestic hot
water in instantaneous heating system. In
thiscase,eitherawaterowsensorora
owswitchmustbeused.Theowswitch
recognizeswhenthehotwaterisbeing
tapped.Thewaterowsensorcanaddition-
ally 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 current input. This can be
used either instead of the temperature sensor
or to connect an external set point. For ver-
sionswithaswitchingoutput(rmwarever-
sion2.0x/2.1x),thisoutputcanbecong-
ured as either a pump output (circulation
pump for the DHW circuit or heating circuit),
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extensioncable
6Returnowtodistrictheatingnetwork(RL)
7Valve,e.g.Type3222
VL Flow pipe
RL Returnowpipe
WW Hot water
KW Cold water
VSTW Flow sensor
WSS Waterowsensor
Fig.1: Sample application: domestic hot water heating with Pt1000 sensor and water ow sensor

12 EB 5757 EN
Design and principle of operation
a fault alarm output or an output to report
when hot water is tapped.
18
2
4
3
6
7
5
1.1
1 Electric actuator
with process
controller
1.1Connecting cable
2 Handwheel
3 Actuator stem
4 Coupling nut
5 Travel indicator
6 Plug stem
7 Valve spring
8Cover,serialRJ-12
jack
Fig.2: Functional diagram
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 ac-
tuator or using a memory pen. The con-
trolled variable, control behavior, and the
actuator's direction of action can also be
changed in TROVIS-VIEW.
The output signal of the controller functions
as a three-step signal on the motor of the ac-
tuator 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 po-
sition is reached or in case the motor is over-
loaded.
The actuator is mounted onto the valve using
a coupling nut (4). When the actuator stem
extends, the globe valve is closed, opposing
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.
3.1 Operating controls
3.1.1 LEDs
The actuator has a red and a yellow LED
which indicate the operating state of the ac-
tuator. The LEDs are located underneath the
transparent cover on top of the actuator.
Blinking pattern of the yellow LED
−Device off, no communication with
memory pen or command pen inserted
On
Off
Time [s]
−Device switched on or memory pen in-
serted: memory pen action completed
On
Off
Time [s]

EB 5757 EN 13
Design and principle of operation
−Memory pen inserted: preparing to read
from memory pen
On
Off
246
135
Time [s]
−Memory pen inserted: preparing to
write data to memory pen
On
Off
2.4 4.8
7.2
1.2 3.6
6.0
Time [s]
−Memory pen inserted: plausibility error
in memory pen
On
Off
246810
Time [s]
−Memory pen inserted: EEPROM error in
memory pen
On
Off
2 4 6810
Time [s]
Blinking pattern of the red LED
−Normal operation or memory pen in-
serted
On
Off
Time [s]
−Restarting device after reset or
torque-dependent limit switch error
On
Off
Time [s]
−Temperature too high (upper limit
(GWH)exceeded)
On
Off
246810
Time [s]
−EEPROM error in device
On
Off
2 4 6810
Time [s]
−Zero calibration in progress
On
Off
2 4
6
8
10
Time [s]
−Transit time measurement in progress
On
Off
2 4 6810
Time [s]
−Wire breakage at temperature input
On
Off
4.5
9
Time [s]

14 EB 5757 EN
Design and principle of operation
−Wire breakage at current input
On
Off
5.5
11
Time [s]
−Flowrateatwaterowsensorexceeds
measuring range
On
Off
6.5
13
Time [s]
3.1.2 Handwheel
The valve can be moved to any position in
the de-energized state by the handwheel (2,
Fig.1).
3.1.3 Travel indicator
Travel and direction of action can be read
offthetravelindicator(5,Fig.1)ontheside
of the actuator housing.
3.2 Accessories
Accessories for communication:
The TROVIS-VIEW software for revi-
sion2oftheTROVIS5757-3ElectricAc-
tuator with Process Controller is required.
The TROVIS-VIEW software can be down-
loaded free of charge from our website
(uwww.samson.de at Services > Software
> TROVIS-VIEW). The software can also be
supplied on a CD-ROM. Further details can
be found in Data Sheet uT6661.
Accessories for domestic hot water heating
in instantaneous heating systems:
−Type5207-0060 Temperature Sensor
(fast-responsePt1000sensor)
−Sensor pocket
To provide the best positioning of the
Pt1000sensorattheheatexchanger,
order no. 1400-9249
−Water ow sensor
Axialturbineowmeter,orderno.1400-
9246
−Flow switch
Torecognizewhenhotwaterisbeing
tapped using an NO contact

EB 5757 EN 15
Design and principle of operation
3.3 Technical data
TROVIS5757-3 Electric Actuator with Process Controller
Connection to valve Force-locking
Rated travel 6mm
Transit time for rated travel 20s
Thrust 300N
Power supply 230V(±10%)/50Hz
Power consumption Approx. 3 VA
Manual override Yes
Permissible temperatures1)
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
Electromagnetic compatibility AccordingtoEN61000-6-2,EN61000-6-3and
EN61326
Mounting position Any position except suspended
Compliance ·
Weight Approx.0.7kg
Inputs and outputs
BinaryinputBI12) Setpointswitchover(W1andW2,seesection10.2)
BinaryinputBI22) Flow switch
Version with switching output (rmware version 2.0x/2.1x)
Switching output 230V,50Hz,max.1A
Accessories
Temperature sensor Pt1000,fastresponse:–50to150°C
Waterowsensor 530 pulses/l
Flow switch Floating contact
Control input 0/4to20mA
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.
2) Recommendation: use devices with gold contacts when using relays.

16 EB 5757 EN
Design and principle of operation
3.4 Dimensions in mm
Ø 12
55
80
11
32 70 eL Stem retracts
aL Stem extends
114
70
50
G¾ G¾
13 13 G¼
G1
35
G¾
65
39
G1
G¾
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
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
Fig.3: Electric actuator with process controller and accessories (part 1)

EB 5757 EN 17
Design and principle of operation
Ø3.3
Ø5.4
10.5
15
52 ±1 2000
approx.
50
G¼
G¾
35
G¾
65
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
Sensor pocket (including gasket)
forheatexchangerwithG¾
Order no. 1400-9249
38
G¾
G¾
G¼
G¾
35
G¾
65
Connecting piece (including
gasket)forvalveG¾
Order no. 1400-9236
Circulation pipe
connection (including
gasket)
Order no. 1400-9232
Fig.4: Electric actuator with process controller and accessories (part 2)

18 EB 5757 EN
Preparation
4 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

EB 5757 EN 19
Mounting and start-up
5 Mounting and start-up
Risk of malfunction due to incorrectly per-
formed start-up.
Perform start-up following the described
sequence.
5.1 Mounting the actuator onto
the valve
Risk of actuator damage due to excessively
high tightening torques.
Observe the specied tightening torques.
The actuator has a force-locking connection
tothevalveinde-energizedstate.
ÎTurnthehandwheel(2,Fig.1on
page11)counterclockwisetoretract
the actuator stem as far as it will go.
ÎPlace the actuator on the valve con-
nection and tighten the coupling nut
(Fig.1onpage11)(tighteningtorque
20Nm).
5.2 Installing the control valve
into the pipeline
Degree of protection not achieved due to in-
correct mounting position.
Do not install the valve with the actuator
suspended downwards.
ÎInstall the valve into the pipeline accord-
ingthespecicationsinthemounting
and operating instructions of the valve.
5.3 Electrical connections
Risk of electric shock.
−Upon installation of the electric cables, you
are required to observe the regulations
concerning low-voltage installations ac-
cording to DINVDE0100 as well as the
regulations of your local power supplier.
−Use a suitable power supply which guar-
antees that no dangerous voltages reach
the device in normal operation or in the
event of a fault in the system or any other
system parts.
−Connect the actuator to the electrical net-
work only after the power supply is rst
switched off. Make sure the power cannot
be switched on unintentionally.
The actuator requires a fast-response
Pt1000temperaturesensortobeconnected
for it to function.
The binary input can be used to change be-
tween the two set points W1 and W2.
Alternatively,insteadofthePt1000sensor,
thecurrentinput0/4to20mAcanbeused
for control purposes.
Inaddition,awaterowsensororaow
switchcanbeconnectedtoquicklyrecognize
when hot water is being tapped.
Connect the ends of both connecting leads
asshowninFig.5andFig.6.
NOTICE
!
NOTICE
!
NOTICE
!
DANGER
!

20 EB 5757 EN
Operation
Insulate any wires that are not used.
The initialization process starts immediately
after the actuator has been connected to the
electrical power supply.
The actuator stem extends (when the direc-
tion of action increasing/increasing has
been set) and the red and yellow LEDs un-
derneath the cover on top of the actuator are
illuminated. As soon as the actuator stem has
reached the nal position, the red LED is
turned off. The yellow LED remains illuminat-
ed and indicates that the actuator is ready
for use.
Error indication
A wire breakage at the temperature input or
at the current input is indicated by a slowly
blinkingredLED.Seesection3.1.1.
A faulty sensor line cannot be detected when
a 0 to 20mA input signal is used.
5.4 Conguring the electric
actuator
Theactuatorisconguredwiththe
TROVIS-VIEW software. All the functions and
parametersarelistedinsection10.2.
The conguration manual uKH5757 can
be found in the Help menu of the
TROVIS-VIEW software. The manual con-
tains a detailed description of each function
and parameter.
6 Operation
Immediately after completing mounting and
start-up, the valve with electric actuator is
ready for use.
6.1 Manually changing the
stem position
A manual adjustment of the stem position
only makes sense when the power supply is
switched off as the stem position is deter-
mined by the actuator in closed-loop opera-
tion, meaning any manual adjustment would
be automatically corrected by the actuator.
The stem position is changed at the hand-
wheel:
ÎSwitch off the power supply.
ÎTurn clockwise to extend the actuator
stem(approx.4turnsfor1mmtravel).
ÎTurn counterclockwise to retract the
actuatorstem(approx.4turnsfor1mm
travel).
Note
Note
Note