Samson TROVIS 5757-7 Service manual

Translation of original instructions
EB 5757-7 EN
Firmware version 2.04
Edition January 2020
TROVIS 5757-7 Electric Actuator with Process Controller
For heating and cooling applications

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 5757-7 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 5757-7 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.......................................................................................2-1
3 Design and principle of operation ...............................................................3-1
3.1 Communication ..........................................................................................3-2
3.2 Technical data ............................................................................................3-3
3.3 Dimensions.................................................................................................3-4
3.4 Values for resistance thermometers ...............................................................3-6
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....................................................................................5-2
6 Operation..................................................................................................6-1
6.1 Device overview and operating controls........................................................6-1
6.2 Indication with LEDs ....................................................................................6-1
6.3 Slider switch...............................................................................................6-1
6.4 Serial interface ...........................................................................................6-2
6.5 Control mode switchover with a room panel..................................................6-2
7 Start-upandconguration..........................................................................7-1
7.1 Initializing the actuator................................................................................7-1
7.2 Conguringtheactuator..............................................................................7-1

Contents
EB 5757-7 EN
8 Operation..................................................................................................8-1
8.1 Closed-loop control.....................................................................................8-1
8.1.1 Switchingoverthecongurationandparameterlevels...................................8-1
8.2 LED blinking pattern....................................................................................8-1
8.3 Manual mode.............................................................................................8-3
8.4 Operation using memory pen ......................................................................8-3
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....................................................................................................8-6
8.5.4 Status messages..........................................................................................8-7
8.5.5 Statistics.....................................................................................................8-7
9 Malfunctions ..............................................................................................9-1
9.1 Troubleshooting ..........................................................................................9-1
9.2 Error priority ..............................................................................................9-2
9.3 Error indication by LEDs ..............................................................................9-2
9.4 Emergency action .......................................................................................9-4
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andcustomer-specicdata...............................................16-3

EB 5757-7 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheTROVIS5757-7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 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
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 5757-7 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,warningand
caution notes. Furthermore, operating personnel must be familiar with the applicable health,
safety and accident prevention regulations and comply with them.

EB 5757-7 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
Theelectricactuatorwithprocesscontrollerfullls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 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5757-7forTROVIS5757-7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

1-4 EB 5757-7 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5757-7).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 5757-7 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 actuator is designed for use according 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 electric actuator 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 5757-7 EN

EB 5757-7 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 5757-7
F Thrust
s Rated travel
v Stroking speed
U Supply voltage
f Power line frequency
P Power consumption
2.2 Firmware versions
Firmware revisions
Old New
1.0x 2.0x
Sliderswitchtoswitchbetweentwodifferentcongurationsandparametersatthedevice
ProgrammingisonlypossiblewithTROVIS-VIEW4.

2-2 EB 5757-7 EN

EB 5757-7 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
TheTROVIS5757-7ElectricActuatorwith
Process Controller is an electric actuator with
an integrated digital controller. The combina-
tion is especially designed for heating appli-
cationsaswellasforxedsetpointcontrol
of heating systems in small to medium-sized
buildings. It is particularly suitable for
mountingtoSAMSONTypes3222,
3222N,2488and3267Valves(DN15to
25) as well as to special versions of
Type3226andType3260Valves.
Design
ÎSeeFig.3-1.
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.
Principle of operation
The output signal of the integrated digital
controller acts over the positioner on the syn-
chronous motor of the actuator and is trans-
ferred over the connected gear to the actua-
torstem(3inFig.3-1)andusedastheposi-
tioning force.
The motor is switched off by torque-depen-
dent switches when an end position is
reached or in case the motor is overloaded.
Inputs
Aowsensorneedstobeconnectedonthe
input side, which can be optionally upgrad-
edbyareturnow,outdoororroomsensor.
Theycanallbecombinedwithareturnow
sensor.
InadditiontothePt1000input,thedigital
controller has a potentiometer input (1000 to
1100Ωor1000to2000Ω)tomeasure
theowtemperature.Thisinputinuences
the heating characteristic in the case of out-
door-temperature-controlled control and the
room temperature set point is corrected in
thecaseofxedsetpointcontrolwithroom
temperatureinuence(±5K,uKH5757-7).
When an outdoor sensor is used, the adjust-
ed heating characteristic can be changed us-
ing the potentiometer (uKH5757-7).
The heating characteristic and set point can
be entered over the TROVIS-VIEW software.
The connected sensors are monitored for line
breakages (see the 'Malfunctions' section).
Outputs
A circulation pump (heating) can be control
withthe230Vswitchingoutput(seesec-
tion3.2).
The switching output can alternatively be
used as control for an external demand for
heat.

3-2 EB 5757-7 EN
Design and principle of operation
182
4
3
6
7
5
1.1
182
4
3
6
7
5
1.1
5
retracted
Actuator stem
extended
1 Electric actuator
with process
controller
4 Coupling nut
5 Travel indicator
1.1 Connecting cable 6 Plug stem
2 Manual adjuster
(only use when
power is
disconnected)
7 Valve spring
8 Cover, serial
interface
connection,
slider switch and
LEDs
3 Actuator stem
Fig.3-1: Functional diagram
Manual override
ÎSee the 'Operation' section.
In the de-energized state, the manual adjust-
er can be used to change the position of the
actuator stem.
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

EB 5757-7 EN 3-3
Design and principle of operation
3.2 Technical data
TROVIS5757-7
Connection to valve Force-locking
Rated travel 6mm
Transit time for rated travel 20s
Thrust 300N
Supply voltage 230V(±10%)/50Hz
Power consumption 5VA
Temperature sensor max.3xPt1000
Operating temperature range –40to+150°C
Binaryinputs
BI11) (instead of the
potentiometer) Floatingcontact,contactload5V/1mA
BI21)(insteadofreturnow
sensor) Floatingcontact,contactload5V/1mA
Potentiometer input 1000to1100Ωor1000to2000Ω
Switching output 230V/50Hz/1A;circulationpumpordemandforexternally
required signal
Permissible temperature ranges2)
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 ·
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.

3-4 EB 5757-7 EN
Design and principle of operation
3.3 Dimensions
Ø 12
55
80
11
32 70
eL Stem retracts
aL Stem extends
114
2.5 m
70
Fig.3-2: Dimensions in mm · TROVIS5757-7

EB 5757-7 EN 3-5
Design and principle of operation
50 25
80
82 32
20
86
Type5227-4OutdoorSensor Type5257-7RoomPanel
50
2
32
30
Type5267-2ContactSensor
Fig.3-3: Dimensions in mm · Accessories for heating applications

3-6 EB 5757-7 EN
Design and principle of operation
3.4 Values for resistance thermometers
Pt1000sensors
°C –35 –30 –25 –20 –15 –10 –5 0 +5 +10
Ω862.5 882.2 901.9 921.6 941.2 960.9 980.4
1000.0 1019.5 1039.0
°C +15 +20 +25 +30 +35 +40 +45 +50 +55 +60
Ω
1058.5 1077.9 1097.3 1116.7 1136.1 1155.4 1174.7 1194.0 1213.2 1232.4
°C +65 +70 +75 +80 +85 +90 +95 +100 +105 +110
Ω
1251.6 1270.7 1289.8 1308.9 1328.0 1347.0 1366.0 1385.0 1403.9 1422.9
°C +115 +120 +125 +130 +135 +140 +145 +150
Ω
1441.7 1460.6 1479.4 1498.2 1517.0 1535.8 1554.5 1573.1

EB 5757-7 EN 4-1
Shipment and on-site transport
4 Shipment and on-site trans-
port
The work described in this section is only to
be performed by personnel appropriately
qualiedtocarryoutsuchtasks.
4.1 Accepting the delivered
goods
After receiving the shipment, proceed as fol-
lows:
1. Compare the shipment received with the
delivery note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.2 Removing the packaging
from the actuator
Do not remove the packaging until immedi-
ately before mounting and start-up.
1. Remove the packaging from the electric
actuator.
2. Checkscopeofdelivery(seeFig.4-1).
3. Dispose of the packaging in accordance
with the valid regulations.
1x TROVIS5757-7ElectricActuatorwith
Process Controller
1x DocumentIP5757-7
(Important Product Information)
Fig.4-1: Scope of delivery
Note
4.3 Transporting the actuator
− 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.
4.4 Lifting the actuator
Due to the low service weight, lifting equip-
ment is not required to lift the electric actua-
tor.
4.5 Storing the actuator
Risk of electric actuator damage due to
improper storage.
ÎObserve the storage instructions.
ÎAvoid long storage times.
ÎContact SAMSON in case of different
storage conditions or longer storage
times.
We recommend regularly checking the elec-
tric actuator and the prevailing storage con-
ditions during long storage periods.
NOTICE
!
Note

4-2 EB 5757-7 EN
Shipment and on-site transport
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.