Samson TROVIS 5757-7 Service manual

Mounting and
Operating Instructions
EB 5757-7 EN
Firmware version 2.04
Translation of original instructions
Edition September 2016
TROVIS5757-7 Electric Actuator with
Process Controller
For heating and cooling applications

2 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.
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
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
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

Contents
EB 5757-7 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
3.2 LED blinking pattern.....................................................................................12
3.2.1 Handwheel..................................................................................................14
3.2.2 Travel indicator............................................................................................14
3.3 Accessories .................................................................................................14
3.4 Technical data .............................................................................................15
3.5 Dimensions in mm........................................................................................16
4 Measures for 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...................................................................................................23
6.1 Manually changing the stem position.............................................................23
7 Servicing.....................................................................................................24
7.1 Preparation for return shipment.....................................................................24
8 Malfunctions ...............................................................................................24

4 EB 5757-7 EN
Contents
8.1 Emergency action ........................................................................................24
9 Decommissioning and disassembly ..............................................................24
9.1 Decommissioning.........................................................................................25
9.2 Removing the actuator from the valve ............................................................26
9.3 Disposal......................................................................................................26
10 Appendix....................................................................................................26
10.1 After-sales service........................................................................................26
10.2 Conguration list and customer settings .........................................................27
10.2.1 Customer setting ..........................................................................................29
10.3 Resistance values with Pt 1000 resistors .........................................................30
10.4 EU declaration of conformity.........................................................................31

EB 5757-7 EN 5
Safety instructions and measures
1 Safety instructions and measures
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 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3.4.
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 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 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, the operator 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 5757-7 EN 7
Safety instructions and measures
Referenced standards 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 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5757-7 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

8 EB 5757-7 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.
The switching output L' is live after the power supply has been connected.
ÎDo not touch the switching output L'.
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 as well as the valve.
ÎDrain the process medium from all the plant sections concerned and from the valve.
ÎWear recommended personal protective equipment. See associated valve docu-
mentation.

EB 5757-7 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
installations.
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 re-
set to default settings.

10 EB 5757-7 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 5757-7
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 5757-7 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The TROVIS5757-7 Electric Actuator with
Process Controller is a combination of a lin-
ear actuator and an integrated digital con-
troller. The combination is especially de-
signed for heating applications as well as for
xed set point control of heating systems in
small to medium-sized buildings. It is partic-
ularly 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.
The digital controller is connected to a ow
sensor on the input side, which can be op-
tionally upgraded by a return ow, outdoor
or room sensor. In addition to the Pt1000
input, the digital controller has a potentiome-
ter input (1000 to 1100Ω or 1000 to 2000
Ω) to measure the ow temperature. This in-
put inuences the heating characteristic in
the case of outdoor-temperature-controlled
control and the room temperature set point
in the case of xed set point control with
room temperature inuence. The heating
characteristic and set point can be changed
over the TROVIS-VIEW conguration soft-
ware.
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) and used as the positioning
force.
The motor is switched off by torque-depen-
dent 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.
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 Handwheel (only
use when power is
disconnected)
7 Valve spring
8 Cover, serial
interface
connection,
slider switch,
and LEDs
3 Actuator stem
Fig.1: Functional diagram

12 EB 5757-7 EN
Design and principle of operation
The valve can be moved to any position in
the de-energized state by the handwheel
(2). Travel and direction of action can be
read off the travel indicator (5) on the side of
the actuator housing.
Slider switch
Slider switch (red)
Fig.2: Position of the slider switch
The slider switch allows you to switch be-
tween two different congurations #1 and
#2. In position #1, the slider switch points
away from the housing and in position #2
towards the middle of the housing. In both
levels #1 and #2, the functions described in
section10.2 can be activated and the asso-
ciated parameter settings made. The default
settings is the same for both levels #1 and
#2, except for function block F13. Changes
to functions and parameters can be made
over the TROVIS-VIEW software.
The position of the slider switch determines
which function and parameter settings (level
#1 or #2) is used for closed-loop operation.
3.1 Operating controls
3.1.1 LEDs
3.2 LED blinking pattern
The device has a red and a yellow LED
which indicate the operating states of the ac-
tuator.
The LEDs are located underneath the cover
on top of the circuit board.
Blinking pattern of the yellow LED
−Actuator switched off or command mode
ON
OFF
Time [s]
−Actuator switched on or memory pen
action completed
ON
OFF
Time [s]
−Active return ow temperature limitation
or plausibility error in memory pen
ON
OFF
Time [s]

EB 5757-7 EN 13
Design and principle of operation
−Preparing to read data from memory
pen
ON
OFF
Time [s]
−Preparing to write data to memory pen
ON
OFF
Time [s]
−Preparing data logging
ON
OFF
Time [s]
−Data logging in progress
ON
OFF
Time [s]
−EEPROM error in memory pen
ON
OFF
Time [s
]
Blinking pattern of the red LED
−Device switched off, normal operation or
command mode
ON
OFF
Time [s]
−Device start-up or torque-dependent limit
switch error
ON
OFF
Time [s]
−Exceptional error or sensor line break-
age
ON
OFF
Time [s]
−EEPROM error in device
ON
OFF
Time [s]
−Zero calibration
ON
OFF
Time [s]

14 EB 5757-7 EN
Design and principle of operation
−Internal transit time measurement
ON
OFF
Time [s]
−Flow sensor defective
OFF
ON
Time [s]
−Outdoor/room sensor defective
ON
OFF
Time [s]
−Return ow sensor defective
ON
OFF
Time [s]
−Potentiometer defective
ON
OFF
Time [s]
3.2.1 Handwheel
The valve can be moved to any position in
the de-energized state by the handwheel (2,
Fig.1).
3.2.2 Travel indicator
Travel and direction of action can be read
off the travel indicator (5, Fig.1) on the side
of the actuator housing.
3.3 Accessories
Accessories for communication
The TROVIS-VIEW software is re-
quired for the TROVIS5757-7 Elec-
tric Actuator with Process Controller. The
TROVIS-VIEW software can be down-
loaded free of charge from our web-
site (uwww.samson.de > Services >
Software > TROVIS-VIEW). The software can
also be supplied on a CD-ROM. Further de-
tails can be found in Data Sheet uT6661.
Accessories for heating and cooling appli-
cations
−Type5267-2 Contact Sensor (Pt1000)
Conguration ID: 1058683
Permissible temperatures:
Medium –20 to 120°C
Ambient –20 to 120°C
Degree of protection IP42

EB 5757-7 EN 15
Design and principle of operation
3.4 Technical data
TROVIS5757-7 Electric Actuator with Process Controller
Temperature sensor Max. 3 x Pt1000
Operating temperature range –40 to 150°C
Binary inputs
BI1 1) (instead of 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 external demand
Rated travel 6mm
Transit time for rated travel 20s
Thrust 300N
Power supply 230V (±10%)/50Hz
Power consumption 5VA
Class of protection II
Permissible temperatures2)
Ambient 0 to 50°C
Storage –20 to 70°C
Degree of protection IP42
Mounting position Any position except suspended
Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326
Compliance ·
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.
−Type5257-7 Room Panel (Pt1000) with
potentiometer and mode selector switch
Conguration ID: 1180319
Permissible temperatures:
Medium –20 to 60°C
Ambient –20 to 60°C
Degree of protection IP30
−Type5227-2 Outdoor Sensor (Pt1000)
Conguration ID: 1043862
Permissible temperatures:
Medium –35 to 85°C
Ambient –35 to 85°C
Degree of protection IP44

16 EB 5757-7 EN
Design and principle of operation
3.5 Dimensions in mm
Ø 12
55
80
11
32 70
eL Stem retracts
aL Stem extends
114
2.5 m
70
Fig.3: TROVIS5757-7 Electric Actuator with Process Controller

EB 5757-7 EN 17
Design and principle of operation
21
Ø4
50
36
75
60
22
28
82 32
20
86
Type5257-7 Room Panel (Pt1000)
Conguration ID: 1180319
Color: Cover and knobs RAL 9016 · Base RAL 7047
Continuous day mode (rated operation)
Continuous night mode (reduced operation)
Off/frost protection
Type5227-2 Outdoor Sensor (Pt1000)
Conguration ID: 1043862
Color: RAL 9016
50
2
32
30
Type5267-2 Contact Sensor (Pt1000)
(ow and return ow temperature
measurement)
Conguration ID: 1058683
Fig.4: Accessories for heating applications

18 EB 5757-7 EN
Measures for preparation
4 Measures for 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.
Information
NOTICE
!
Information

EB 5757-7 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 switching output L' is live. Do not touch
the switching output L'.
The actuator requires a Pt1000 temperature
sensor (e.g. Type5267-2) to be connected to
measure the ow temperature.
Depending on the control task, an outdoor
sensor (e.g. Type5227-2) or room panel
(Type5257-7 only) can be connected. They
can all be combined with a return ow sen-
sor (e.g. Type5267-2).
Additionally, the actuator has a potentiome-
ter input 1000 to 1100Ω (e.g. Type5257-
7) or 1000 to 2000Ω. This input is used to
correct the room set point (±5K) in case of
NOTICE
!
NOTICE
!
NOTICE
!
DANGER
!

20 EB 5757-7 EN
Mounting and start-up
xed set point control with room temperature
inuence (uKH5757-7). On using an out-
door sensor, it can change the adjusted heat-
ing characteristic (uKH5757-7). The
non-oating switching output can alterna-
tively be used as an output for an external
demand for heat.
The connected sensors are monitored for line
breakages. A fault in the line of a sensor is
indicated by the red LED blinking (under-
neath the cover on top of the circuit board).
Each sensor has its own blinking pattern (see
section3.2). In the event that several sensors
are defective, the LED blinks using the se-
quence for the sensor with the highest priori-
ty:
Highest priority Flow sensor
Outdoor sensor or
room sensor
Return ow sensor
Lowest priority Potentiometer
Example: In the event that the ow sensor
and outdoor sensor are defective, the LED
initially blinks to indicate that the ow sensor
is defective. When this fault is eliminated, the
LED then blinks to indicate that the outdoor
sensor is defective.
ÎPerform the electrical connection depend-
ing on the heating application according
to one of the following wiring diagrams
(Fig.5 to Fig.7). As soon as the actuator
is connected to the power supply, the ini-
tialization procedure starts.
The actuator stem extends and the red and
yellow LEDs are illuminated located under
the cover on top of the circuit board.
As soon as the actuator stem has reached
the nal position, the red LED is turned off.
The yellow LED remains illuminated and indi-
cates that the actuator is ready for use.
5.4 Conguring the electric ac-
tuator
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5757-7
can be found in the Help menu of the
TROVIS-VIEW software. The manual con-
tains a detailed description of each function
and parameter.
Information