Samson TROVIS 5757-7 Service manual

Controller with Electric Actuator
Type 5757-7
for heating and cooling applications
Mounting and
Operating Instructions
EB 5757-7 EN
Firmware version 2.00
Edition July 2009
Fig. 1 · Type 5757-7 Controller with Electric Actuator

2EB 5757-7 EN
DANGER!
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING!
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
NOTICE
NOTICE indicates a property damage
message.
Note: Supplementary explanations,
information and tips
Definitions of the signal words used in these instructions

Contents Page
1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 5
2 Design and principle of operation . . . . . . . . . . . . . . . . . . . 6
2.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 LED blinking pattern . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Connection to the valve . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Outdoor temperature compensated control . . . . . . . . . . . . . . . 17
6.1.1 Override using potentiometer . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Summer mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.3 Delayed outdoor temperature adaptation. . . . . . . . . . . . . . . . 20
6.2 Fixed set point control . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.1 Control with reference variable (room temperature) . . . . . . . . . . . 21
6.3 Changing the operating modes . . . . . . . . . . . . . . . . . . . . 22
6.3.1 Switchover via binary input . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2 Switchover via room panel . . . . . . . . . . . . . . . . . . . . . . 23
6.3.3 Switchover via binary input in room panel . . . . . . . . . . . . . . . 24
6.4 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Return flow temperature limitation . . . . . . . . . . . . . . . . . . . 24
6.6 Pump forced operation . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 External request for heat demand . . . . . . . . . . . . . . . . . . . 25
6.8 Control principle . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.9 Direction of action. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.10 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.10.1 Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.10.2 Command mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.10.3 Function block F13 for manual operation. . . . . . . . . . . . . . . . 28
6.10.4 Manual level in TROVIS-VIEW . . . . . . . . . . . . . . . . . . . . . 28
7 Configuration and operation using TROVIS-VIEW interface . . . . . . 30
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Installing TROVIS-VIEW software . . . . . . . . . . . . . . . . . . . 31
7.3 Starting TROVIS-VIEW and performing settings . . . . . . . . . . . . 32
3EB 5757-7 EN
Contents

7.4 Changing the user level . . . . . . . . . . . . . . . . . . . . . . . . 34
7.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.5.1 Activating/deactivating functions . . . . . . . . . . . . . . . . . . . 35
7.5.2 Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.6 Reading operation data . . . . . . . . . . . . . . . . . . . . . . . . 37
7.7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.7.1 Additional diagnostics folders in
Specialist user level . . . . . . . . . . 39
7.7.2 Operational data graph (Trend Viewer) . . . . . . . . . . . . . . . . 41
8 Data transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1 Data transmission between TROVIS-VIEW and the actuator
(connecting cable). . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.1 Offline operation (indirect data transmission) . . . . . . . . . . . . . . 45
8.1.2 Online operation (direct data transmission). . . . . . . . . . . . . . . 45
8.2 SAMSON memory pen . . . . . . . . . . . . . . . . . . . . . . . . 46
8.2.1 Data transfer between TROVIS-VIEW and memory pen . . . . . . . . . 46
8.2.2 Data transmission between actuator and memory pen. . . . . . . . . . 47
8.2.3 Copy function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2.4 Command mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.3 Data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4 Functional test assistant . . . . . . . . . . . . . . . . . . . . . . . . 51
9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.1 Function block list . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.2 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3 Resistance values with Pt 1000 resistors . . . . . . . . . . . . . . . . 54
9.4 Customer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4EB 5757-7 EN
Contents
Note: These Mounting and Operating Instructions EB 5757-7 EN are valid for firmware ver-
sions 2.00 to 2.09.
The latest edition of these instructions, detailing the firmware version and modifications com-
pared to the previous version, is available on the Internet at http://www.samson.de.

1 General safety instructions
For your own safety, follow these instructions concerning the mounting, start up and opera-
tion of the actuator:
4Mounting, start-up and operation of this device may only be performed by trained and
experienced personnel familiar with the product.
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 specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.
4Any hazards that could be caused by the process medium, operating pressure or by
moving parts are to be prevented by means of the appropriate measures.
4The actuators has been designed for use in low voltage installations.
For wiring and maintenance, you are required to observe the relevant safety regulations.
Take necessary measures to ensure that the power supply cannot be reconnected
inadvertently.
4Before wiring the controller with electric actuator, disconnect it from the power supply.
To avoid damage to any equipment, the following also applies:
4Proper shipping and appropriate storage are assumed.
Note: Actuators with a CE marking fulfill the requirements of the Directives 2004/108/EC
and 2006/95/EC.
The Declaration of Conformity is available on request.
EB 5757-7 EN 5
General safety instructions

2 Design and principle of
operation
The Type 5757-7 consists of a digital con-
troller integrated into the housing of an elec-
tric actuator.
The combination is especially designed for
heating applications as well as for fixed set
point control of heating systems in small to
medium-sized buildings. It is particularly
suitable for mounting to SAMSON
Type 3222, Type 3222 N, Type 2488 and
Type 3267 Valves (DN 15 to 25) and to
special versions of Type 3226 and
Type 3260 Valves.
The digital controller is connected to a flow
sensor on the input side, which can be op-
tionally upgraded by a return flow, outdoor
or room sensor.
In addition to the Pt 1000 input, the digital
controller has a potentiometer input (1000
to 1100 Ωor 1000 to 2000 Ω) to measure
the flow temperature. This input influences
the heating characteristic in the case of out-
door temperature compensated control and
the room temperature set point in the case of
fixed set point control with room tempera-
ture influence.
Heating characteristic and set point parame-
ters can be changed over the TROVIS-VIEW
Operator Interface.
The output signal of the integrated digital
controller is applied as a three-point step-
ping signal to the synchronous motor of the
actuator. The signal is transferred over the
connected gear to the actuator stem (3) and
used as the positioning force.
The motor is switched off by torque switches
when an end position is reached or in case
the motor is overloaded. The actuator is
mounted onto the valve using a coupling nut
(4).
When the actuator stem extends, the 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) fol-
lows the motion of the return spring.
The valve can be moved to any position by
the handwheel (2) when the power supply
is disconnected. Travel and direction of ac-
tion can be read off the travel indicator (5)
on the side of the actuator housing.
6EB 5757-7 EN
Design and principle of operation
182
4
3
6
7
5
1.1
Fig. 2 · Functional diagram
Stem retracts
Stem extends 5
1 Controller with
electric actuator
1.1 Connecting lead
2 Handwheel (only use
when power is dis-
connected)
3 Actuator stem
4 Coupling nut
5 Travel indicator
6 Plug stem
7 Valve spring
8 Cover, serial
interface connection,
slide switch and LEDs

Slide switch
The slide switch allows you to switch be-
tween two different configurations #1 and
#2. In position #1, the slide switch points to-
wards the outside of the housing and in po-
sition #2 towards the middle of the housing.
In both levels #1 and #2, the functions de-
scribed in section 6 can be activated and
the associated parameter settings made.
The default settings is the same for both lev-
els #1 and #2, except for function block
F13.
Changes to functions and parameters can
be made over the TROVIS-VIEW software.
Refer to section 7.
The position of the slide switch determines
which function and parameter settings (level
#1 or #2) is used for closed loop operation.
2.1 Accessories
Heating applications, see section 6
4Type 5267-2 Pt 1000 Contact Sensor
Permissible temperatures:
Medium –20 to 120 °C
Ambient –20 to 120 °C
Degree of protection IP 42
4Type 5257-2 Pt 1000 Room Sensor
with potentiometer (remote adjuster)
Permissible temperatures:
Medium –35 to 70 °C
Ambient –35 to 70 °C
Degree of protection IP 20
4Type 5257-7 Room Panel with
potentiometer and mode selector switch
Permissible temperatures:
Medium –20 to 60 °C
Ambient –20 to 60 °C
Degree of protection IP 30
4Type 5227-2 Pt 1000 Outdoor Sensor
Permissible temperatures:
Medium –35 to 85 °C
Ambient –35 to 85 °C
Degree of protection IP 44
Communication, refer to section 7
4TROVIS-VIEW Configuration and Opera-
tor Interface for Type 5757-7 Controller
with Electric Actuator
4Hardware package
Accessories for direct and indirect data
transmission (including a memory pen
(1400-7697), connecting cable and
modular adapter), order no. 1400-7704
4Memory pen
Indirect data transmission,
order no. 1400-7697
EB 5757-7 EN 7
Design and principle of operation
Fig. 3 · Location of the slide switch
Slide switch (red)

4Memory pen – 64
For indirect data transmission and data
logging, order no. 1400-9753
2.2 Technical data
Type 5757-7 Controller with Electric Actuator
Temperature sensor Max. 3 x Pt 1000
Measuring range –40 to 150 °C
Binary inputs
BE1 (instead of
potentiometer) Floating contact
BE2 (instead of
return flow sensor Floating contact
Potentiometer input 1000 to 1100 Ωor
1000 to 2000 Ω
Switching output 230 V/50 Hz/1 A
Circulation pump or
external heat demand
Rated travel 6 mm
Transit time for
rated travel 20 s
Nominal thrust 300 N
Supply voltage 230 V (±10 %) / 50 Hz
Power consumption Approx. 3 VA
Class of protection II
Permissible temperatures
Ambient 0 to 50 °C
Storage –20 to 70 °C
Degree of protection IP 42
Mounting position Any, but not suspended
Noise immunity EN 61000-6-2
Noise emission EN 61000-6-3
Weight Approx. 0.7 kg
2.3 LED blinking pattern
The device has a red and a yellow LED
which indicate the operating states of the
device.
The LEDs are located underneath the cover
on top of the circuit board.
Blinking pattern of the yellow LED
• Device switched off or command mode:
• Device switched on or memory pen ac-
tion completed:
• Active return flow temperature limitation
or validity error in memory pen:
• Preparing to read data from memory
pen:
8EB 5757-7 EN
Design and principle of operation
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]

• Preparing to write data to memory pen:
• Preparing data logging:
• Data logging in progress:
• EEPROM error in memory pen:
Blinking pattern of the red LED
• Device switched off, normal operation or
command mode:
• Device is starting up or limit switch error:
• Exceptional error or sensor line break-
age:
• EEPROM error in device:
• Stem synchronization:
EB 5757-7 EN 9
Design and principle of operation
ON
OFF Time [s]
ON
OFF Time
[
s
]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]

• Internal transit time measurement:
• Flow sensor defective:
• Outdoor/room sensor defective:
• Return flow sensor defective:
• Potentiometer defective:
3 Connection to the valve
The actuator has a force-locking connection
to the valve in de-energized state.
4Turn the handwheel (2) counterclockwise
to retract the actuator stem as far as it
will go.
4Place the actuator on the valve connec-
tion and screw coupling nut (4) tight
(tightening torque 20 Nm).
3.1 Mounting position
Any mounting position may be used, how-
ever, the actuator may not be installed in a
suspended position.
10 EB 5757-7 EN
Connection to the valve
2 Handwheel
3 Actuator stem
4 Coupling nut
ON
OFF Time [s]
ON
OFF Time [s]
ON
OFF Time [s]
3
2
4
Fig. 4 · Mounting the actuator onto the valve
OFF
ON
Time [s]
ON
OFF Time [s]