Samson Type 5824 Service manual

Electric Actuators
with LON Interface
Type 5824 without 
Type 5825 with fail-safe action
Mountin and
operatin instructions
EB 5824-1 EN
Edition June 2003
Fig. 1 ⋅Type 5824 Actuator

Contents Page
1. Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 6
2. Connection to the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Type 5824 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Force-locking connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Form-fit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Type 5825 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Force-locking connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2 Form-fit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Tra el indicator scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. Installing the control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Connecting the supply oltage . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Connection to the LON® bus . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Identifying the actuator on a LON® . . . . . . . . . . . . . . . . . . . . . 11
5.2 Initializing the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 Form-fit actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2 Force-locking actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. Description of closed loop actuator object . . . . . . . . . . . . . . . . . . 13
6.1. Description of network ariables . . . . . . . . . . . . . . . . . . . . . . . 14
6.1.1 Initialization procedure for force-locking actuators . . . . . . . . . . . . . . . 15
6.1.2 Initialization procedure for form-fit actuators . . . . . . . . . . . . . . . . . 15
6.2 Description of configuration properties . . . . . . . . . . . . . . . . . . . . 16
7. Convenient start-up using a plug-in . . . . . . . . . . . . . . . . . . . . . 17
8. Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Contents
2EB 5824-1 EN

Safety instructions
Assembly, start-up and operation of this de ice may only be performed by
trained and experienced personnel familiar with the product.
According to these mounting and operating instructions, trained personnel
refers to indi iduals 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.
Any hazards which could be caused in the connected al e by the process
medium, operating pressure or mo ing parts are to be pre ented by means
of the appropriate measures.
Proper transportation and storage are assumed.
The actuators ha e been designed for use in electrical power installations.
For wiring and maintenance, you are required to obser e the rele ant safety
regulations.
The actuator must be protected against unintentional reconnection of the
power supply.
Note: The de ice with a CE marking fulfils the requirements of the Directi es
94/9/EC and 89/336/EEC.
The declaration of conformity can be iewed and downloaded on the Internet
at http://www.samson.de.
EB 5824-1 EN 3

Technical data
Actuator Without fail-safe action With fail-safe action
Type 5824-20 5824-30 5825-20 5825-25 5825-30 5825-35
Type of connection to al e Force-lock. Form-fit Force-locking Form-fit
Rated tra el 12 (6) mm
1)
15 mm 12 (6) mm
1)
15 mm
Actuating time for rated tra el 70 s 90 s 70 s 90 s
Actuating time in case of failure  6 s 7 s
Fail-safe action
Actuator stem  Extends Retracts Extends Retracts
Nominal thrust 700 N 
Nominal thrust of safety spring  500 N 280 N
Operating oltage 24 V AC / 50 Hz
Power consumption Approx. 5 VA Approx. 7 VA
Transformer FTT10A Free Topology Transcei er, LTP-10 compatible
Configuration LNS
TM
plug-in for LON binding tools
Handwheel Yes Optional
2)
Permissible ambient temperature:
Permissible storage temperature:
Perm. temp. at connecting stem:
0 to +50 °C
20 to +70 °C
0 to +130 °C
Degree of protection
( ertical installation) IP 54
Noise immunity EN 50082-2
Noise emission EN 50081-1
Weight 0.75 kg 1 kg
1)
Tra el of 6 mm possible by installing a tra el stop according to Fig. 2 in chapter 2.
2)
Manual adjustment using a 4 mm hexagonal wrench after the housing lid has been remo ed;
after the fail-safe action has been acti ated, the al e returns to the fail-safe position.
4EB 5824-1 EN

EB 5824-1 EN 5

1. Design and principle of operation
The electric actuators consist of a re ersible
synchronous motor and a maintenance-free
gear incorporated in a plastic housing.
The actuator is connected to the al e by
means of a coupling nut (4), which pro ides
a force-locking connection, or by means of
a stem connector, which pro ides a form-fit
connection between the actuator stem and
the plug stem.
The rotary motion of the actuator motor is
transmitted to the actuator stem (3), and
hence to the plug stem of the connected
al e ia a crank disc.
The motor is disconnected ia torque-
dependent switches (10) when the al e
has reached either of its final positions or
an o erload occurs.
Type 5824 without fail-safe action
In case of a force-locking connection be-
tween actuator and al e, the spring in-
stalled in the al e causes the plug stem to
follow the mo ement of the actuator stem
when the actuator stem retracts.
The al e can be manually mo ed to the
desired position by means of a handwheel (2).
Type 5825 with fail-safe action
The actuators with fail-safe action largely
comply with the Type 5824 ersion illus-
trated in Fig. 2. In addition, they contain a
spring mechanism (8) and an electromagnet.
If the control oltage applied to the electro-
magnet is interrupted, the actuator mo es to
the fail-safe position.
When de-energized in this way, the magnet
disengages the coupling between gear and
actuator motor. This causes the spring mech-
anism to mo e the actuator stem fully in the
operating direction OUT (or IN). The con-
nected (globe) al e is mo ed to the closed
position.
CAUTION! Do not use the magnet for con-
trol tasks.
The Type 5825 is not equipped with a hand-
wheel (2) on the housing co er.
Manual adjustment ia a hexagonal wrench
is only possible after the front co er has
been remo ed.
Typetest
The electric actuators with fail-safe action
ha e been typetested by the German
Technical Inspectorate TÜV according to
DIN 32730.
The register no. is indicated on the name
plate.
6EB 5824-1 EN
Desi n and principle of operation

CAUTION
Do not open the rear housing
co er!
Fig. 2 ⋅Type 5824/5825 Actuator (force-locking connection to al e)
8 9 1 1.1210 2.1 1.29.1
4
3
0
12
6
15
0
6
12
15
a
9.1
9.2
9.2
11mm
Tra el stop
Version
obsolete
new
1Housing
1.1 Front housing co er
1.2 Cable entry
2 Handwheel, only on
Type 5824
2.1 Actuating shaft
3Actuator stem
4Coupling nut
8 Spring mechanism, only
on Type 5825
9 Scale for tra el indication
9.1 Dri ing pin
9.2 Stopping pin (11 mm)
10 Torque switch (internal)
Installing the travel stop
1. Remo e the front housing co er (1.1) and then the tra el scale (9)
2. Place a hexagonal wrench into the actuating shaft (2.1) and
turn it to mo e the dri ing pin into the area termed
a.
3. Slide the tra el stop, with the stopping pin of 11 mm (9.2)
suspended downward, o er the dri ing pin (9.1) acc. to Fig. 2.
4. Re-install the tra el scale in the correct position acc. to chapter 2.3.
If tra el limitation is not required, remo e the tra el stop.
EB 5824-1 EN 7
Desi n and principle of operation

2. Connection to the valve
Note regarding the travel stop:
The rated tra el of 12 mm in force-locking
actuators can be reduced to 6 mm by install-
ing a tra el stop. The tra el reduction allows
the force-locking actuators to be used for
smaller al es. A tra el stop is supplied with
the de ice and has to be installed according
to Fig. 2.
2.1 Type 5824 Actuator
2.1.1 Force-locking connection
1. Turn handwheel (2) counterclockwise to
retract the actuator stem.
2. Position the actuator on the al e con-
nection and tighten coupling nut (4)
using a tightening torque of 20 Nm.
2.1.2 Form-fit connection
1. Position actuator on the yoke and
tighten coupling nut (4) using a tightening
torque of 20 Nm.
2. Position actuator with yoke (15) on the
al e and tighten nut (17) using a mini-
mum tightening torque of 150 Nm.
3. Pull plug stem all the way up to the actu-
ator stem or extend actuator stem using
the handwheel (2).
4. Position coupling clamps of the stem
connector (16) included in the acces-
sories and screw tight.
Fig. 3 ⋅Connections between actuator and control al e
3
4
0
0
2
15
4
16
17
2Handwheel
3Actuator stem
4Coupling nut
15 Rod-type yoke
16 Stem connector
17 Nut
Form-fit connection with stem connector
to a al e with rod-type yoke
Force-locking connection with coupling nut, e.g.
to a Type 3222 Val e
8EB 5824-1 EN
Connection to the valve

2.2 Type 5825 Actuator
2.2.1 Force-locking connection
Fail-safe action "Actuator stem extends":
1. Unscrew front co er and place 4 mm
hexagonal wrench into the red actuat-
ing shaft (Fig. 2, 2.1).
2. Use the wrench to retract the actuator
stem. Howe er, turn counterclockwise
only and only to the point where the
internal torque switch (Fig. 2, 10) is
acti ated.
3. Keep the wrench positioned and con-
nect al e and actuator using the
coupling nut (tightening torque 20 Nm).
Reinstall the front co er and carefully fix
it using the screws.
Fail-safe action "Actuator stem retracts":
Position the actuator on the al e connec-
tion and tighten coupling nut using a
tightening torque of 20 Nm.
2.2.2 Form-fit connection
Proceed as described in chapter 2.1.2 for
ersions both with fail-safe action "Actuator
stem retracts" and "Actuator stem extends."
2.3 Travel indicator scale
The tra el indicator scale has two opposing
scales to satisfy different al e ersions.
Upon deli ery (default), the scale is placed
so that the dri ing pin is at position 0. This
position is used for globe al es and three-
way di erting al es.
For three-way mixing al es, remo e the
scale, turn it by roughly 180° and reposi-
tion it so that the appropriate bore (12 or
15 according to the rated tra el) is placed
o er the dri ing pin.
3. Installing the control valve
The control al e must be installed in the
pipeline with the actuator on top so as to
ensure the stated degree of protection.
Fig. 4 ⋅Mounting of tra el indicator scale
0
0
6
6
12
15
12
15
0
15
12
6
Bores for pin for three-way
mixing al es
Pin in position 0:
scale positioned for globe al es
and three-way di erting al es (default)
EB 5824-1 EN 9
Installin the control valve

4. Electrical connections
When installing electric lines, you
are required to obser e the regula-
tions go erning electrical power
plant installation according to DIN
VDE 0100 as well as the regulations
of your local power supply company.
Use a suitable power supply which
guarantees that no dangerous olt-
ages reach the de ice in standard
operation or in case of a fault in the
system or any other system parts.
We recommend installing a discon-
nector (e.g. automatic circuit
breaker). This allows the actuator to
be connected separately from the
power supply network. Once the in-
stallation has been completed, the
actuator can be started up ia
switchbox or similar equipment.
Make sure the power cannot be
switched on unintentionally.
4.1 Connecting the supply voltage
The electrical connection must be estab-
lished ia the cable entries (see Fig. 2, 1.2)
in such a manner that the actuator is sup-
plied with 24 VAC / 50 Hz ia terminals L1
and N1.
4.2 Connection to the LON® bus
The LON® Free Topology Transcei er
(FTT10A) pro ides a polarity insensiti e con-
nection to the bus.
The LON® bus cables must be connected to
the two actuator terminals marked "LON"
on the board (see Fig. 5). Note that specific
LON® bus cables are a ailable to meet dif-
ferent requirements.
NOTE:
The "LONWORKS FTT-10A Transcei er
Users Guide" lists a number of cables quali-
fied by Echelon® to work with the TP/FT-10
network. The guide also specifies the physi-
cal properties of the cables.
Fig. 5 ⋅Electrical connection
24V~ 24V~ LON-BUS
FTT 10A
L2 N2 L1 N1
LON
Supply
Magnet
for Type 5825
10 EB 5824-1 EN
Electrical connections

5. Start-up
5.1 Identifying the actuator on a
LON®
Each actuator has a unique Neuron ID which
allows the actuator to be identified on the
LON® (Local Operating Network). You can
either find it on the label on the actuator hous-
ing and enter it in LonMaker manually, or
you can use the actuator to transmit it o er the
LON® network as a ser ice message. In the
latter case, the actuator must already be in-
stalled and electrically wired.
When you press the ser ice button (Fig. 6),
the red ser ice LED lights up and the control
electronics transmit a ser ice message o er
the LON® bus.
5.2 Initializing the actuator
During the initialization, the final positions
of the actuator are determined and sa ed.
Fig. 6 shows the operator controls and dis-
play elements for identification and initiali-
zation.
Fig. 6 ⋅Operator controls and display elements
Initialization button Ser ice button Operation LED Ser ice LED
Potentiometer gear
EB 5824-1 EN 11
Start-up

5.2.1 Form-fit actuators
With form-fit actuators, the clamped connec-
tion between the actuator stem and the
al e eliminates the possibility of lost motion.
To start the initialization, press the initializa-
tion button for 3 seconds.
The green operation LED indicates the cur-
rent status as follows:
LED off Actuator stem extends,
final position = 0 %
LED on Actuator stem retracts,
final position = 100 %
LED blinks Standard operation
When initialization is acti ated, the operation
LED goes out and the actuator mo es the actu-
ator stem to the final position (0 %).
When the final position is reached, the oper-
ation LED lights up, the operating direction is
re ersed and the actuator mo es the actuator
stem to the final position (100 %).
Shortly after completion of the initialization
routine, the actuator is reset to standard
operation, and the operation LED blinks.
CAUTION!
Changes in the position of the white poten-
tiometer gear lead to an incorrect position
feedback and thus to a faulty initialization.
If you ha e changed the position of the
gear, proceed as follows for correction:
Extend the actuator stem fully (zero posi-
tion). Using a screwdri er, turn the poten-
tiometer shaft counterclockwise until it does
not go any further, then turn back clockwise
by approx. 10°.
Following this, a new initialization routine is
required to determine the final positions.
5.2.2 Force-locking actuators
In case of a force-locking connection be-
tween actuator and al e ia a coupling
nut, the actuator stem is not firmly con-
nected to the plug stem, but only contacts it.
If the tra el range of the actuator is wider
than the al e tra el, the actuator stem is
lifted off the al e stem during the initializa-
tion. As a result, the final positions are not
determined correctly. Therefore, it is impera-
ti e that the actuator be mo ed manually to
the al es final positions of 0 % and 100 %
tra el.
The initialization procedure is explained in
chapter 6.1. For LNS-based configuration
tools, the actuator can also be initialized
con eniently by means of software using a
plug-in such as Plug-in Version 1.5 as
described in TV-SK 6328.
12 EB 5824-1 EN
Start-up

. Description of closed loop actuator object
nvi01
nviSoll
S
NVT_lev_percent
nvi10
nvi_Auswahl
nci11 - nciLocation (SNVT_str_asc)
nci12 - nciLow2 (SNVT_lev_percent)
nci13 - nciLow1 (SNVT_lev_percent)
nci14 - nciHigh1 (SNVT_lev_percent)
nci15 - nciHigh2 (SNVT_lev_percent)
nci16 - nciMinRnge (SNVT_lev_percent)
nci17 - nciMaxRnge (SNVT_lev_percent)
nci18 - nciInvert (SNVT_lev_disc)
nci19 - nciSollDef (SNVT_lev_percent)
nci20 - nciHeartBeatIn (SNVT_time_sec)
nci21 - nciHeartBeatOut (SNVT_elapsed_time)
nci22 - nciDriveTime (SNVT_time_sec)
nci23 - nciSendTime (SNVT_time_sec)
unsigned char
nvo02
nvoSollFb
S
NVT_lev_percent
nvoSollPosi
S
NVT_lev_percent
nvoIstPosi
S
NVT_lev_percent
nvoMinMax
S
NVT_lev_disc
nvoStellAusg
S
NVT_lev_disc
nvoSicher
S
NVT_lev_disc
nvo04
nvo03
nvo05
nvo07
nvo06
Mandatory Network
Variables
Optional Network
Variables
Optional
Configuration
Properties
Closed Loop Actuator Object, Object Type 4
nvoElapsedTime
S
NVT_time_f
nvo08
nvoMotorTime
S
NVT_time_f
nvo09
nvo_xy
unsigned long
nvo24
EB 5824-1 EN 13
Description of closed loop actuator object

.1. Description of network variables
Variable Type Function
nviSoll SNVT_le _percent Set point input of position 0 to 100 %
nvoSollFb SNVT_le _percent Feedback of set point input
nvoSollPosi SNVT_le _percent Set position calculated from data points
nciMin Rnge, nciMaxRnge and nciln ert
nvolstPosi SNVT_le _percent Actual status of actuator
nvoMinMax ST_OFF
ST_LOW
ST_MED
ST_HIGH
ST_ON
SNVT_le _disc Output ariable of limit alue monitoring
istPosi < nciLow2
istPosi < nciLow1
istPosi < nciHigh1
istPosi < nciHigh2
istPosi ≥ nciHigh2
nvoStellAusg ST_OFF
ST_HIGH
ST_LOW
SNVT_le _disc Actual status of actuator
Down
Up
Stop
nvoSicher ST_OFF
ST_ON
SNVT_le _disc Feedback of safety monitoring
nvoElapsedTime SNVT_time_sec Absolute uptime of the actuator (s)
nvoMotorTime SNVT_time_sec Absolute uptime of the motor (s)
nviAuswahl
0
1
2
3
77
88
99
unsigned char Input ariable for start-up /manual adjustment
Note: manual adjustment has priority o er
standard operation
Automatic
Manual stop
Manual up
Manual down
Acceptance 100 % initialization alue
Acceptance 0 % initialization alue
Start initialization routine
14 EB 5824-1 EN
Description of closed loop actuator object

.1.1 Initialization procedure for force-locking actuators
1. Select ariable, enter alue "3" for command "manual down", press the return key and
wait for the actuator to mo e to zero position.
2. Enter alue "1" for command "manual stop" and press the return key.
3. Enter alue "88" for command "initialization 0 %" and press the return key.
4. Enter alue "2" for command "manual up" and press the return key. Wait until the
actuating time of the actuator has elapsed (6 mm = 35 s, 12 mm = 70 s).
5. After the actuating time has elapsed, enter alue "1" for command "manual stop" and
press the return key.
6. Enter alue "77" for command "initialization 100 %" and press the return key.
.1.2 Initialization procedure for form-fit actuators
1. Enter "99" and press the return key or press the initialization button of the actuator.
Note:
The acti ation of any of the initialization commands "77, 88 and 99" causes the operating
mode to be automatically set to automatic operation.
EB 5824-1 EN 15
Description of closed loop actuator object

.2 Description of configuration properties
Variable Type Function
nciLocation SNVT_str_asc Description (location etc.)
nciMinRnge
nciMaxRnge
nciInvert
SNVT_le _percent
SNVT_le _percent
SNVT_le _disc
Minimum and maximum alues and re ersion of the
"split range" function
nciSollDef SNVT_le _percent Standard set point input if the bus does not pro ide any
set point input. Is also used after "HeartBeatIn" time has
elapsed
nciHeartBeatIn SNVT_time_sec Heartbeat time of the set point input (0 = no HeartBeat)
nciHeartBeatOut SNVT_elapsed_time Time needed to output the actual position if there has
been no change in the position
nciDriveTime SNVT_time_sec Actuating time of the actuator (for monitoring purposes)
nciSendTime SNVT_time_sec Time needed to update the uptimes
(see n oElapsedTime and n oMotorTime)
nvo_xy unsigned char Actual measured alue (position feedback) for
manufacturing test only
16 EB 5824-1 EN
Description of closed loop actuator object

7. Convenient start-up using a plug-in
A plug-in can be used to supplement an LNS-based configuration tool. This allows for a
more con enient start up of the LON actuators. The plug-in software can be iewed and
downloaded on the Internet at http://www.samson.de.
EB 5824-1 EN 17
Convenient start-up usin a plu -in

8. Dimensions in mm
146
40
113
8
82
44 103
6
6
Ø10
Type 5824-20 / Type 5825-20/25
Type 5824/25 -30
Type 5825-30
18 EB 5824-1 EN
Dimensions in mm

EB 5824-1 EN 19

SAMSON AG ⋅ MESS- UND REGELTECHNIK
Weismüllerstraße 3 ⋅ 60314 Frankfurt ⋅ Germany
Phone: [phone] ⋅ Fax: [phone]
Internet: http://www.samson.de
S/Z 2003-06
EB 5824-1 EN