Samson Type 5824 Service manual

Electric Actuators
Type 5824 without fail-safe action
Type 5825 with fail-safe action
Fig. 1 · Type 5824 Actuator
Mounting and
Operating Instructions
EB 5824 EN
Edition July 2008

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4
1.1 Additional electrical equipment . . . . . . . . . . . . . . . . . . . . . 5
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Attachment to valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Type 5824 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Force-locking attachment . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Form-fit attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Type 5825 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Force-locking attachment . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2 Form-fit attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Travel indicator scale . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Operation and settings . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Changing the travel position . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Setting additional equipment. . . . . . . . . . . . . . . . . . . . . . 12
4.2.1 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.2 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.3 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.4 Priority circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2EB 5824 EN
Contents

EB 5824 EN 3
Safety instructions
4
The actuators may only be mounted, started up or operated by trained and
qualified personnel familiar with the product.
According to these instructions, trained personnel refers to individuals who
are able to judge the work they assigned to and recognize possible dangers
due to their specialized training, their knowledge and experience as well as
their knowledge of the applicable standards.
4
Any hazards which could be caused in the mounted valve by the process
medium, the operating pressure, the signal pressure or by moving parts are
to be prevented by means of the appropriate measures.
4
Proper shipping and appropriate storage of the actuator are assumed.
4
The electric actuators have been designed for use in electrical power
installations. For wiring and maintenance, you are required to observe the
relevant safety regulations. Only use power interruption devices which are
protected against unintentional reconnection of the power supply.
4
Note! The electric actuators fulfill the requirements of the directives
2004/108/EC and 2006/95/EC. The declaration of conformity is availa-
ble on request.

1 Design and principle of
operation
The electric actuators basically consist of a
reversible synchronous motor and a mainte-
nance-free gear in a plastic housing. A cou-
pling nut (4) provides a force-locking con-
nection between the actuator and the plug
stem of the valve. For form-fit attachment, a
stem connector is used.
Type 5824 without fail-safe action
The rotary motion of the actuator motor is
transmitted to the actuator stem (3) and the
plug stem of the connected valve over a
crank disk.
When the final positions are reached or in
case of overload, the motor is switched off
by torque-dependent switches (10).
When the actuator stem retracts in actuators
with force-locking connection, the plug stem
follows the movement of the spring installed
in the valve, causing it to retract.
The valve can be manually moved to the re-
quired position with the handwheel (2).
Type 5825 with fail-safe action
The actuators with fail-safe action largely
comply with the Type 5824 illustrated in
Fig. 2. In addition, they contain a spring
mechanism (8) and an electromagnet.
When the control voltage at the electromag-
net is interrupted, the actuator moves to
fail-safe position because the electromagnet
voltage drops, causing the coupling be-
tween gear and actuator motor to
disengage. The actuator stem is completely
moved in the direction OUT or IN by the
spring mechanism.
4EB 5824 EN
Design and principle of operation
Fig. 2 · Type 5824/5825 Actuator (front cover open), with force-locking attachment to the valve
Caution!
Do not open the back housing cover!
1 Housing
1.1 Front cover
1.2 Cable entry
2 Handwheel,
Type 5824 only
2.1 Actuating shaft
3 Actuator stem
4 Coupling nut
5 Cam disk
6 Limit switch
7.1 Adjuster for limit contact
7.2 Adjuster for limit contact
8 Spring mechanism,
Type 5825 only
9 Scale for travel indication
9.1 Driving pin
10 Torque switch
OUT
IN

A connected globe valve is moved to the fi-
nal position (valve CLOSED) with the
fail-safe action “Actuator stem extends”.
Caution!
Do not use the magnet for control tasks.
In Type 5825, there is no handwheel (2) on
the housing cover. Manual override is possi-
ble, after removing the front cover, using a
4 mm Allen key.
Typetesting
The Type 5825 Electric Actuators with
fail-safe action “Actuator stem extends” in
the force-locking version are typetested by
the German Technical Inspectorate (TÜV)
according to DIN 14597 in conjunction with
various SAMSON valves. The register num-
ber is available on request.
1.1 Additional electrical
equipment
The actuators can be equipped with a
positioner, if required. In addition, all actua-
tors can be equipped with two overridable
limit switches. The three-point stepping actu-
ator version can optionally be delivered with
a potentiometer.
Electric positioner
24 V actuators can optionally be fitted with
a positioner.
Positioners compare the 0 (2) to 10 V or
4 (0) to 20 mA signal issued by the electric
control equipment with the position of the
potentiometer, which is proportional to
travel, and issue a three-point stepping out-
put signal to control the synchronous motor.
The positioner is suitable for normal and
split-range operation. The characteristic is
reversible (increasing >> or decreasing <>).
A 0 to 10 V signal can be taken at terminals
32 and 33 for position feedback.
Potentiometer
The potentiometer is linked to the gearing
and provides a resistance signal between 0
to approx. 1000 Ωin proportion to the
travel. The resistance between approx. 0 to
800 Ωcan be used for feedback of the valve
travel.
Limit switches
The limit switches are activated by two cam
disks. The limit switches cannot be retrofit-
ted.
Priority circuit
The positioner version in conjunction with
limit switches can optionally be fitted with a
priority circuit (terminals 82 and 83).
EB 5824 EN 5
Design and principle of operation

1.2 Technical data
6EB 5824 EN
Design and principle of operation
Actuator Type 5824 5825
-10 -12 -13 -20 -23 -30 -10 -13 -20 -23 -30 -15 -25 -35
Fail-safe action – Stem extends Stem retracts
Rated travel mm 6 1) 6 6 12 12 15 6 1) 6 1212156
1) 12 15
Transit time f. rated travel s 35 1) 18 18 70 36 90 35 1) 18 70 36 90 35 1) 70 90
Transit time in case of
fail-safe action s – 44667467
Nominal
thrust
Stem extends N 700 300 700 700 700 700 500 280 500 280
Stem retracts N – 700 – 280 – 280
Nominal thrust of safety
spring N – 500 280 3) 280
Attach-
ment
Force-locking ••••• •••• ••
Form-fit • • •
Power supply
24V,50Hz •• • •• • ••••
230 V, 50 Hz ••••••••••••••
120 V, 60 Hz • • • • • • ••••
Power consumption, apprx. VA 33636348484444
Manual override Yes Optional 2)
Permissible temperatures
Ambient 0 to 50 °C
Storage –20 to 70 °C
At connecting stem 0 to 130 °C
Degree of protection IP 54 (upright position, acc. to DIN IEC 529)
Class of protection II (acc. to VDE 0106)
Overvoltage category II (acc. to VDE 0110)
Degree of contamination 2 (acc. to VDE 0110)
Noise immunity EN 61000-6-2
Noise emission EN 61000-6-3
Weight Approx. kg 0.75 0.75 1 0.75 1 0.75 1 1.25 1 1.25 1111
1) Actuators with 6 mm travel can also be used for valves with 7.5 mm travel.
2) Manual override using a 4 mm Allen key after removing housing cover, always returns to fail-safe position after
release
3) Safety spring pulls the actuator stem into the retracted final position; valve operated over the valve spring

EB 5824 EN 7
Design and principle of operation
Actuator Type 5824 5825
-10 -12 -13 -20 -23 -30 -10 -13 -20 -23 -30 -15 -25 -35
Fail-safe action – Stem extends Stem retracts
Materials
Housing, housing cover Plastic (PPO glass fiber reinforced)
Coupling nut Brass
Additional electrical equipment
Positioner 4) · For 24 V only;
Input 0 (2) to 10 V or 0 (4) to
20 mA, output 0 to 10 V,
reversible characteristic, split-
range (0 to 5 V, 5 to 10 V)
•• • •• • ••••
2 limit switches · Max. 230 V,
3 A; cannot be retrofitted! ••••••••••••••
1 potentiometer · 0 to 1000 Ω
±15 % (90 % of final value at
rated travel); max. 1 mA, 5 V •• • •• • ••••
4) Supply voltage; inputs and outputs are not electrically isolated.
Maximum 2 current inputs may be connected in series.
Ri(10 V) = 10 kΩ,R
i(20 mA) = 50 Ω,R a(min) = 1 kΩ

2 Attachment to valve
Depending on the version of the valve, the
actuator is connected to the valve either di-
rectly or over a rod-type yoke (Fig. 3).
2.1 Type 5824 Actuator
2.1.1Force-locking attachment
1. Retract the actuator stem by turning the
handwheel (2) counterclockwise.
2. Position the actuator on the valve con-
nection and tighten coupling nut (4) with
a tightening torque of 20 Nm.
2.1.2Form-fit attachment
1. Position actuator on the rod-type yoke
and tighten the coupling nut (4) with a
tightening torque of 20 Nm.
2. Position actuator with yoke (15) on the
valve and tighten the nut (17) with a
minimum tightening torque of 150 Nm.
3. Pull plug stem until it reaches the actua-
tor stem or extend actuator stem using
the handwheel (2).
4. Position the clamps of the stem connector
(16) included in the accessories on the
ends of the actuator stem and plug stem
and screw tight.
8EB 5824 EN
Attachment to valve
Force-locking attachment with a coupling nut,
e.g. on Type 3222 Valve Form-fit attachment with stem connector, e.g. with rod-type yoke on Series V2001 Valve
Fig. 3 · Attaching actuator and valve
2 Handwheel
3 Actuator stem
4 Coupling nut
15 Rod-type yoke
16 Stem connector
17 Nut

2.2 Type 5825 Actuator
2.2.1Force-locking attachment
Fail-safe action “Actuator stem extends”
1. Unscrew front cover and place a 4 mm
Allen key on the red actuating shaft.
2. Retract the actuator stem: Turn Allen key
counterclockwise only and only up to the
final travel value which is at the point
where the torque switch is activated
(switching off the synchronous motor).
Caution!
Turning the actuator too far will destroy it.
3. Keep Allen key in place and fasten valve
and actuator together using the coupling
screw (tightening torque 20 Nm). Re-
move Allen key and carefully screw the
front cover back on.
While taking the necessary safety pre-
cautions, the actuator stem can also be
retracted electrically when a voltage
signal is applied to the terminal eL con-
nected to N.
Fail-safe action “Actuator stem retracts”
Position the actuator on the valve connection
and tighten coupling nut with a tightening
torque of 20 Nm.
2.2.2Form-fit attachment
For fail-safe action “Actuator stem retracts”
or “Actuator stem extends”, attach actuator
as described in section 2.1.2.
2.3 Mounting position
The control valve must be mounted in the
pipeline with the Type 5824/5825 Actuator
on top to achieve the stated degree of pro-
tection.
2.4 Travel indicator scale
The travel indicator scale has two opposed
scales for adaptation to different valve ver-
sions. Which scale should be used depends
on the valve version (Fig. 4)
Globe and three-way diverting valves · The
driving pin is in position 0 (delivered state)
Three-way mixing valves · Remove scale,
turn it and replace it so that the pin is posi-
tioned over the appropriate hole (6, 12 or
15) corresponding to the rated travel
(6 mm, 12 mm or 15 mm travel).
Replacement scales for older actuators are
available on request.
EB 5824 EN 9
Attachment to valve
Fig. 4 · Scale for travel indication
Hole for
driving pin
with three-way
mixing valve
Driving pin
in position 0,
location of scale with globe or three-way diverting
valves (standard)

3 Electrical connection
For installation of the electric cables,
you are required to observe the regula-
tions for electrical power systems ac-
cording to DIN VDE 0100 as well as
the regulations of your local power
supplier.
Use a suitable power supply which
guarantees that no dangerous voltages
from the system or parts of the system
reach the device in standard operation
or in the event of a fault.
Caution!
Only connect the device to the main
power network when the power is
switched off. Make sure the power
cannot be switched on unintentionally!
Particularly for 24 V, 50 Hz actuators,
use wires with a sufficiently large
cross-section to guarantee that the per-
missible voltage tolerances of
±
10 %
are not exceeded.
1. Establish electrical connection over the
cable entries (1.2 in Fig. 2) as illustrated
in Fig. 5 while observing the following
important instructions.
The control signals of the controller are con-
nected to the terminals eL and aL:
4If voltage is applied to eL, the actuator
motor retracts the actuator stem in oper-
ating direction "IN" (into the actuator).
4Voltage applied to aL causes the actua-
tor stem to extend in operating direction
"OUT" (out of the actuator).
Important instructions:
4The interference suppression capacitors
Ceinstalled in the output circuit of the
connected controllers may not exceed a
value of 2.5 nF, otherwise the proper
functioning of the actuator cannot be
guaranteed.
When actuators are to be connected to
controllers with larger interference sup-
pression capacitors, a special version is
available on request.
4Actuators operated in parallel must be
connected over separate contacts to pre-
vent the actuators hunting in the end po-
sitions due to a shared OPEN or
CLOSED contact.
4The 0 (2) to 10 V control signal must be
connected to the terminals 12 and 13,
whereas a 0 (4) to 20 mA control signal
must be connected to terminals 11 and
12 in versions with continuous-action
signal input.
4Do not connect more than two mA in-
puts in series.
4If more than two actuators are to be con-
nected to one controller, use 10 V inputs
and convert 20 mA signals into 10 V by
using resistors (RTotal = 500 Ω) connected
in parallel.
Use two-core cables for voltage supply,
signal input and output.
The “–“ inputs (terminals 12 and 32) can
be combined.
10 EB 5824 EN
Electrical connection

EB 5824 EN 11
Electrical connection
Version for three-point stepping signal
Version with positioner for continuous-action signals
Controller
Three-step signal
Stem retracts
Stem extends
Electromagnet in version
with fail-safe action
Potentiometer
(only with three-step signal)
Limit switches
Priority circuit
in version with positioner
(only in combination with limit switches)
Output Control signal
Fig. 5 · Electrical connections

4 Operation and settings
4.1 Changing the travel position
Direction of action and travel can be read
off the travel indication scale (Fig. 6).
Type 5824 Actuator
Use the handwheel to adjust the travel
(approx. 4 turns for 1 mm):
4Turn clockwise ⇒Actuator stem extends
4Turn counterclockwise ⇒Actuator stem
retracts
Type 5825 Actuator
Caution!
The actuator is live.
1. Unscrew front cover and place a 4 mm
Allen key on the red actuating shaft.
2. Retract the actuator stem: For version
with fail-safe action “Actuator stem ex-
tends”, turn Allen key counterclockwise
only. For version with fail-safe action
“Actuator stem retracts”, turn the Allen
key clockwise only and only up to the fi-
nal travel value which is at the point
where the torque switch is activated
(switching off the synchronous motor).
Caution!
Turning the actuator too far will destroy
it.
After the safety release of the magnet,
the actuator cannot hold the position.
The spring assembly pushes the actuator
stem back into the fail-safe position.
3. Remove Allen key and carefully screw
the front cover back on.
4.2 Setting additional equipment
4.2.1Limit switches
The limit switches (6 in Fig. 2) can optionally
be used as double-throw, make or break
contacts.
Terminal assignment (Fig. 5):
Terminals 41, 44, 42: Bottom cam disk,
Adjuster 7.1
Terminals 51, 54, 52: Top cam disk,
Adjuster 7.2
Caution!
The actuator is live.
1. Unscrew front housing cover.
2. Move the actuator to the appropriate
travel position to set the required switch-
ing point.
12 EB 5824 EN
Operation and settings
Fig. 6 · Type 5824 Electric Actuator
Travel
indication
scale
Handwheel
Type 5824 only

3. Use a 4 mm Allen key to turn the adjust-
ers (7.1 or 7.2 in Fig. 2) until contact is
made. The angle of rotation of the cam
disks is limited. Therefore, the top
adjuster (7.1) should preferably be used
for the upper travel range and the bot-
tom adjuster (7.2) for the lower travel
range.
4.2.2Potentiometer
As the valve passes through its travel range,
the resistance value changes from 0 Ωto
max. 80 % of its nominal value.
Place a screwdriver on the slotted shaft (11
in Fig. 8) to calibrate the potentiometer.
Calibrating actuator with extended actua-
tor stem at 0 Ω
1. Connect ohmmeter to terminals 61 and
62.
2. Extend actuator stem as far as it will go
to its final position.
3. Turn the potentiometer counterclockwise
as far as it will go. The ohmmeter indi-
cates the initial value of approx. 0 Ω.
Calibrating actuator with retracted actuator
stem at 0 Ω
1. Connect ohmmeter to terminals 61 and
63.
2. Retract actuator stem as far as it will go
to its final position.
3. Turn the potentiometer clockwise as far
as it will go. The ohmmeter indicates the
initial value of approx. 0 Ω.
4. Only for actuators with 6 or 12 mm
travel: Slowly turn the potentiometer
counterclockwise up to the point where
the resistance just changes from 0 Ω.
4.2.3Positioner
The actuator is optionally controlled by a
DC current signal or a DC voltage signal as
the reference variable.
This reference variable, a 0 (2) to 10 V or
0 (4) to 20 mA signal, must be assigned to
the valve travel (0 to 100 %).
EB 5824 EN 13
Operation and settings
Fig. 7 · Characteristic increasing >> and
decreasing <>
Actuator stem
retracted
Actuator stem
extended
Travel
Span Span
Zero Zero
Reference variable
Input signal

Adjusters
The adjusters for adapting the reference va-
riable and the travel range are located un-
der the housing cover on the main circuit
board.
Adjust zero (starting point) at the slotted po-
tentiometer shaft (11) and the span (upper
range value) at the potentiometer (12).
Set the range of the reference variable, the
characteristic and split-range operation ac-
cording to the table at the DIL switch (14).
14 EB 5824 EN
Operation and settings
Fig. 8 · Adjusters in version with positioner
2.1 Shaft of handwheel
7.1 Adjuster for limit switch
7.2 Adjuster for limit switch
9 Travel indication scale
9.1 Driving pin
9.2 Travel marker
10 Torque switch
11 Zero adjuster
(potentiometer calibration in
three-point stepping version)
11.1 Driving gear wheel
12 Span adjuster
13 LED
14 DIL switch
DIL switch (14)
ON
OFF
Switch (14, Fig. 8) S4 S3 S2 S1
Input signal
4… 20 mA · 2… 10 V ON
0… 20 mA · 0… 10 V OFF
Characteristic
<> Actuator stem extends
Three-way mixing valves ON
>> Actuator stem retracts
Globe, three-way diverting valves OFF
Split-range operation function
Activated ON
Deactivated OFF
Split-range operation range
50…100 % ON
0…50 % OFF

Setting at the valve
Example:
A globe valve with a travel of 12 mm should
move from the closed to open position with
an input signal of 0 to 10 V.
Characteristic increasing >> as per Fig. 7.
1. Set switch S1 to OFF at the DIL switch
(for 0...10 V input signal).
2. Set switch S2 to OFF (for characteris-
tic >>) as the actuator stem needs to re-
tract to open the valve as the voltage in-
put increases.
3. Set switch S3 to OFF to deactivate split-
range operation
4. Turn Zero adjuster (11) all the way to the
right.
5. Set Span adjuster (12) with the arrow in
horizontal position pointing to the middle
of the adjustment range.
6. Connect the input for the reference vari-
able (terminals 12 and 13) to a voltage
source (or controller) and set it to 0 V.
7. Switch on the 24 V AC voltage supply.
The actuator stem must extend according to
the actuating time of the motor, and close
the valve.
On reaching the closed position, the motor
of the actuator is switched off by the torque
switch.
Adjusting zero and span
Zero (starting point):
Note!
The adjustment of zero always refers to the
closed position of the control valve.
1. Slowly turn Zero adjuster (11) from all
the way on the right to the left until the
LED next to the DIL switch turns off.
Slightly turn back adjuster until LED is
switched back on again to indicate that
the actuator motor is running.
2. Slowly increase the voltage at the volt-
age source from 0 V to check the starting
point. On doing so, the LED lights up
and the plug stem leaves its lower end
position.
The starting point should be raised
slightly to approx. 0.3 V to ensure that
the valve is closed tightly at an input sig-
nal of 0 V.
3. Correct a starting point that starts too
early or too late with the Zero adjuster
as previously described until the LED
lights up at approx. 0.3 V and the actua-
tor stem starts to retract.
Span (upper range value):
1. Set the input signal at the voltage source
to the upper range value of 10 V.
Depending on the transit time of the ac-
tuator, the actuator stem retracts and the
plug stem moves to its upper end posi-
tion.
2. Check the travel indicator to determine
whether the required travel has been
EB 5824 EN 15
Operation and settings

reached. The travel marker (9.2) indi-
cates the travel.
If the travel is not reached, turn Span ad-
juster (12) slightly towards the left or
right until the required travel is reached
and at the point where the LED is turned
off. The motor switches off and the plug
stem remains in the final position.
Note!
If the characteristic is decreasing <>, zero
(starting point) must be adjusted to 10 V.
Set the final value of the travel to 0 V using
the Span adjuster.
To ensure that the valve closes tight at 10 V,
set span to a slightly lower input signal
value of 9.8 V.
Caution!
Position feedback of the positioner at termi-
nals 32 and 33 functions independent of the
set characteristic and the input signal range
of 0 V (actuator stem extended) to 10 V (ac-
tuator stem retracted).
Adjustment for split-range operation
Prior to activating split-range operation,
zero and span need to be adjusted at the
positioner as previously described.
Afterwards, set switch S3 to ON to activate
split-range operation. For split-range opera-
tion between 0 and 50 %, set switch S4 to
OFF and for a split range of 50 to 100 %,
set the switch to ON.
4.2.4Priority circuit
Actuators with a positioner can be equipped
with a priority circuit when used in combi-
nation with limit switches.
If the connection between terminals 82/83
is interrupted, the priority circuit is activated.
As long as the connection is interrupted, the
actuator stem moves in the direction of
100 % of the input signal and beyond until
the torque switch switches off the motor to a
priority position depending on the adjusted
characteristic.
4In globe valves (adjusted characteristic
>>), the actuator stem retracts and the
valve opens.
4In three-way valves (adjusted character-
istic <>), the actuator stem extends.
If the contact at terminals 82 and 83 is
made again, the control signal of the control
equipment determines the valve position
again.
Note!
The functioning of the fail-safe action in the
Type 5825 Actuator remains unaffected by
the priority circuit.
16 EB 5824 EN
Operation and settings

5 Dimensions in mm
EB 5824 EN 17
Dimensions in mm
Types 5824-13/-23 and 5825-13/-23 (version with faster motor)
Faster motor
Types 5824-10/-20, 5825-10/-20/ -15/-25 (without faster motor)

18 EB 5824 EN
Dimensions in mm
6
10
46.5
Types 5824-30, 5825-30/-35
Travel 15
Actuator without yoke
Travel 15
Actuator with yoke 1400-7414

EB 5824 EN 19

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: [phone] · Fax: [phone]
Internet: http://www.samson.de EB 5824 EN
2008-07