Samson Type 5824 Service manual

Mounting and
Operating Instructions
EB 5824-2 EN
Firmware version 1.04
Translation of original instructions
Edition January 2015
Electric Actuators
Type 5824 without fail-safe action
Type 5825 with fail-safe action
Version with positioner

2 EB 5824-2 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 5824-2 EN 3
1 Safety instructions and measures ...................................................................6
1.1 Notes on possible severe personal injury .........................................................9
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
2 Markings on the device ...............................................................................11
2.1 Nameplate ..................................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe action ............................................................................................13
3.2 Cover screws ...............................................................................................13
3.3 Additional functions .....................................................................................13
3.4 Device overview and operating controls.........................................................14
3.4.1 Type5824 (24V version).............................................................................14
3.4.2 Type5824 (85 to 264V version) ..................................................................15
3.5 Technical data · Type5824...........................................................................16
3.6 Technical data · Type5825...........................................................................18
3.7 Accessories .................................................................................................20
3.8 Dimensions in mm........................................................................................21
4 Measures for preparation............................................................................22
4.1 Unpacking ..................................................................................................22
4.2 Transporting and lifting ................................................................................22
4.2.1 Transporting ................................................................................................22
4.2.2 Lifting..........................................................................................................22
4.3 Storage.......................................................................................................22
4.4 Aligning the travel indication scale................................................................23
5 Mounting and start-up.................................................................................24
5.1 Mounting the actuator onto the valve.............................................................24
5.1.1 Type5824: force-locking attachment .............................................................24
5.1.2 Type5824: form-t attachment .....................................................................24
5.1.3 Type5825: force-locking attachment .............................................................24
5.1.4 Type5825: form-t attachment .....................................................................26
5.2 Installing the control valve into the pipeline ....................................................27
5.3 Electrical connections ...................................................................................28
5.3.1 Connecting the power supply........................................................................28
6 Additional functions ....................................................................................30
6.1 Adjusting the limit contacts ...........................................................................30

4 EB 5824-2 EN
Contents
7 Handwheel .................................................................................................31
7.1 Manual override of Type5825 Actuator ........................................................31
8 Operation...................................................................................................32
8.1 LEDs ...........................................................................................................32
8.1.1 Explanations to the blinking pattern of the LEDs..............................................33
8.1.2 Blinking pattern of the yellow LED..................................................................33
8.1.3 Blinking pattern of the red LED......................................................................34
8.2 Operating direction switch............................................................................35
8.3 Function switch ............................................................................................37
8.4 Initializing the actuator.................................................................................38
8.5 Serial interface ............................................................................................38
8.5.1 TROVIS-VIEW..............................................................................................38
8.5.2 Memory pen................................................................................................38
9 CongurationandoperationusingTROVIS-VIEW..........................................39
9.1 General ......................................................................................................39
9.1.1 System requirements.....................................................................................39
9.2 Installing the software...................................................................................40
9.3 Starting and setting the software ...................................................................41
9.4 Setting parameters in TROVIS-VIEW..............................................................42
9.4.1 Changing settings ........................................................................................42
9.5 Inputs and outputs........................................................................................44
9.5.1 Input signal .................................................................................................44
9.5.2 Position feedback signal ...............................................................................45
9.6 Actuator......................................................................................................46
9.6.1 Functions/actuator.......................................................................................46
9.6.2 Blockage.....................................................................................................48
9.6.3 Travel..........................................................................................................48
9.6.4 Characteristic ..............................................................................................51
9.7 Operating values .........................................................................................53
9.8 Service........................................................................................................54
9.8.1 Start-up.......................................................................................................54
9.8.2 Operating states ..........................................................................................54
9.8.3 Service/Functions ........................................................................................55
9.8.4 Status messages...........................................................................................57
9.8.5 Statistics......................................................................................................58
9.9 Trend-Viewer ...............................................................................................59
9.9.1 Settings .......................................................................................................59

EB 5824-2 EN 5
Contents
10 Transferdata ..............................................................................................61
10.1 Data transmission between TROVIS-VIEW and the actuator (connecting cable) .62
10.1.1 Ofine mode (indirect data transmission).......................................................63
10.1.2 Online mode (direct data transmission)..........................................................63
10.2 SAMSON memory pen ................................................................................64
10.2.1 Data transmission between TROVIS-VIEW and memory pen............................66
10.2.2 Data transmission between the actuator and memory pen...............................67
10.2.3 Copying function .........................................................................................68
10.2.4 Data logging ...............................................................................................68
10.2.5 Conguring the command mode ...................................................................70
11 Servicing.....................................................................................................71
11.1 Preparation for return shipment.....................................................................71
12 Malfunctions ...............................................................................................72
12.1 Emergency action ........................................................................................72
13 Decommissioning and disassembly ..............................................................73
13.1 Decommissioning.........................................................................................73
13.2 Removing the actuator from the valve ............................................................73
13.2.1 Force-locking attachment ..............................................................................73
13.2.2 Form-t attachment ......................................................................................73
13.3 Disposal......................................................................................................73
14 Annex.........................................................................................................74
14.1 After-sales service........................................................................................74
14.2 Conguration list and customer settings .........................................................75
Index ..........................................................................................................78
Firmware revisions
1.03
(old)
1.04 (new)
Changed default setting of End position guiding (stem extends) parameter
(new: 97.0%, old: 99.0%)
Changed default setting of Dead band parameter (new: 2.0%, old: 1.0%)

6 EB 5824-2 EN
Safety instructions and measures
1 Safety instructions and measures
The Type5824/5825 Electric Actuator is designed to operate a mounted globe valve used in
heating, ventilation and air-conditioning systems as well as in process engineering and in-
dustrial energy transfer systems. The digital positioner ensures a predetermined assignment
of the valve position to the input signal.
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, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the
device 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3.5 and section3.6.
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 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.

EB 5824-2 EN 7
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the electric actuator.
Work on the control valve may be necessary when mounting or removing the electric actua-
tor.
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
Upon power supply failure, the Type5825 Electric Actuator causes the valve to move to a
certain fail-safe position. The fail-safe action of SAMSON actuators is specied on the actua-
tor nameplate.
Warningagainstresidualhazards
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 operat-
ing 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 oper-
ating instructions, especially for installation, start-up and service work.
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 to the operating
personnel and to instruct them in proper operation. Furthermore, the operator must ensure
that operating personnel or third persons are not exposed to any danger.

8 EB 5824-2 EN
Safety instructions and measures
Responsibilitiesofoperatingpersonnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specied hazard statements, warning and caution notes. Furthermore, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
Referencedstandardsandregulations
The Type5824/5825 Electric Actuators comply with 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 Type5824/5825 Electric Actuators are 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:
−Mounting and operating instructions of the valve on which the electric actuator is mount-
ed, e.g. for SAMSON valves:
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5868 for Type3213 and Type3214 Globe Valves
uEB8111 for Type3321 Globe Valve
uEB8113 for Type3323 Three-way Valve
uEB8131 for Type3531 Globe Valve for Heat Transfer Oil
uEB8135 for Type3535 Three-way Valve for Heat Transfer Oil

EB 5824-2 EN 9
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 remove any covers to perform adjustment work on live parts.
ÎDo not open the back housing cover.
The electric actuator is protected against spray water (IP54).
ÎAvoid jets of water.
Riskofburstinginpressureequipment.
Valves and pipelines are pressure equipment. Improper opening can lead to valve
components bursting.
ÎBefore starting any work on the valve, depressurize all plant sections concerned 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.
1.2 Notes on possible personal injury
WARNING
!
Crushhazardarisingfrommovingparts.
The form-t version of the electric actuator contains moving parts (actuator and plug
stems), which can injure hands or ngers if inserted into the actuator.
ÎDo not insert hands or ngers into the yoke while the valve is in operation.
ÎDisconnect the power supply before performing any work on the control valve.
ÎDo not impede the movement of the actuator or plug stem by inserting objects into
their path.

10 EB 5824-2 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Riskofdamagetotheelectricactuatorduetothepowersupplyexceedingtheper-
missible tolerances.
The Type5824/5825 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.
Observe the specied torques on tightening the Type5824/5825 Electric Actuators.
Excessively tightened torques lead to parts wearing out quicker.
ÎObserve the specied tightening torques.
Riskofdamagetotheelectricactuatorbyturningittoofar.
The actuator stem of the electric actuator can be adjusted manually.
ÎOnly retract the actuator stem as far as the nal travel value.

EB 5824-2 EN 11
Markings on the device
2 Markings on the device
2.1 Nameplate
SAMSON
Electric Actuator
U:
v:
1
0062
Made in Germany
2
Var.-ID.
3
Model
4
Serial no.
5
Digital Positioner Firmware
13
F:
7
s:
8
9
10
P:
12
18
6
15
16
17
:
:
1 Type designation
2 Year of manufacture
3 Conguration ID
4 Model designation (Type5825 only)
5 Serial number
6 DIN registration number (Type 5825 only)
7 Thrust
8 Rated travel
9 Stroking speed
10 Power supply
12 Power consumption
13 Fail-safe action (Type5825 only)
Extends Retracts
15 Limit contact
16 Inputs
17 Outputs
18 Firmware version

12 EB 5824-2 EN
Design and principle of operation
3 Design and principle of oper-
ation
A stepper motor allows for supply by fre-
quency-independent voltages. The force of
the motor is transmitted to the actuator stem
(3) via gear and crank disk. When the actu-
ator stem extends, the actuator piston (3)
pushes against the valve's plug stem. When
the actuator stem retracts, the return spring
in the valve causes the plug stem to follow
the movement (force-locking connection). Ac-
tuator and valve are connected by the cou-
pling nut (4).
The positioner ensures a predetermined as-
signment of the valve position to the input
signal. For position feedback, an 0 to 10V
signal can be picked off at terminals 32 and
33.
The characteristic and the input and output
signal settings can be changed over the
TROVIS-VIEW software.
Type5824withoutfail-safeaction
The actuator without fail-safe action has a
handwheel (2) used to manually position the
valve. Travel and direction of action can be
read off the travel indication scale (9).
Type5825withfail-safeaction
The actuators with fail-safe action largely
corresponds to the Type5824 described
above. However, they also include a spring
mechanism (8) and an electromagnet.
0
6
12
15
15
12
6
0
1099.18
7.2
2 1.17.1 1.2
4
5 6
3
1 2.1
ON
OFF
1Housing
1.1 Front cover
1.2 Cable entry
2Handwheel (Type 5824 only)
2.1 Actuating shaft
3 Actuator stem with actuator
piston
4 Coupling nut
5Cam disk
6Limit contact
7.1 Adjuster for limit contact
(bottom contact cam)
7.2 Adjuster for limit contact
(top contact cam)
8 Spring assembly (Type5825
only)
9 Travel indication scale
9.1 Follower pin
10 Torque-dependent limit switch
Do not open the back
housing cover.
Fig.1: Type 5824/5825 Actuator (front cover open), with force-locking attachment to the valve

EB 5824-2 EN 13
Design and principle of operation
3.1 Fail-safe action
The actuator moves to the fail-safe position
when the electromagnet is de-energized. This
causes the actuator stem to be completely re-
tracted or extended by the spring mecha-
nism.
The Type5825 Actuator is available with the
fail-safe action:
Actuatorstemextends: Upon power supply
failure, the actuator stem extends.
Actuatorstemretracts: Upon power supply
failure, the actuator stem retracts.
ÎThefail-safeactionmustnotbeusedto
control the valve position.
The Type 5825 Actuator does not have a
handwheel (2) on the housing cover. Manual
override is possible, after removing the front
cover, using a 4mm Allen key. The actuator
returns to its original position as soon as the
Allen key is released.
TestingaccordingtoDINEN14597
The Types5825 Electric Actuator with fail-
safe action "actuator stem extends" is tested
by the German technical surveillance associ-
ation (TÜV) according to DINEN14597 in
combination with various SAMSON valves.
The register number is available on request.
3.2 Cover screws
The actuator housing cover is fastened using
TORX PLUS® screws, size 10IP.
ÎTo loosen and tighten the screws, the fol-
lowing screwdrivers can be used:
−TORX®T10
−TORX PLUS®10IP
−Flat-blade screwdriver with 0.8mm
blade thickness and 4.0mm blade width
3.3 Additional functions
Devices in 24V version can be tted with
limit contacts as additional function:
−On request, the actuators can be tted
with two limit contacts. Optionally, the
actuators can be equipped with two limit
contacts, which are actuated by continu-
ously adjustable cam disks.
−The power supply as well as the inputs
and outputs are not galvanically isolated.
−The two additional limit contacts are not
suitable for retrotting.

14 EB 5824-2 EN
Design and principle of operation
3.4 Device overview and operating controls
2
11 Travel indication scale
2Handwheel (Type5824 only)
Fig.2: Location of external operating elements
3.4.1 Type5824(24Vversion)
7
6
3
4
5
3 Actuating shaft
4 Serial interface
5Operating direction switch
6 Red and yellow LEDs
7 Function switch
Fig.3: Location of operator controls under the front cover of Type5824 (24V version)

EB 5824-2 EN 15
Design and principle of operation
3.4.2 Type5824(85to264Vversion)
3 Actuating shaft
4 Serial interface
5Operating direction switch
6 Red and yellow LEDs
7 Function switch
5
4
6
3
7
Fig.4: Location of operator controls under the front cover of Type5824 (85 to 264V version)

16 EB 5824-2 EN
Design and principle of operation
3.5 Technicaldata·Type5824
Type 5824
-10 -20 -30
Fail-safe action Without
Rated travel mm 6 1) 12 15
Stroking speed 2), 3) Slow mm/s 0.13 0.13 0.13
Standard mm/s 0.2 0.2 0.2
Fast mm/s 0.36 0.36 0.36
Transit time for rated
travel
(depending on the
stroking speed)
Slow s 45 89 111
Standard s31 61 76
Fast s 17 33 41
Thrust Extends N 700 700 700
Retracts N – – 700
Attachment Force-locking • • –
Form-t – – •
Handwheel Yes
Power supply
24VDC (–10%, + 20%), 24V, 50 and 60Hz •••
85 to 264 V, 50 and 60Hz •••
Input signal 0 to 10 V, Ri = 20 kΩ · 0 to 20 mA, Ri = 50 Ω
Output signal 0 to 10 V, RB = 1 kΩ
Power consumption 6)
24VDC (–10%, +20%) W 5
24V, 50 and 60Hz VA 5
85 to 264 V, 50 and 60 Hz 4) VA 8
Permissible temperatures7)
Ambient 0 to 50°C
Storage –20 to +70°C

EB 5824-2 EN 17
Design and principle of operation
Safety
Degree of protection IP54 5)
Class of protection II (according to EN61140)
Overvoltage category II (according to EN60664)
Degree of contamination 2 (according to EN60664)
Noise immunity According to EN61000-6-2
Noise emission According to EN61000-6-3
Vibration According to EN60068-2-6 and EN60068-2-27
Compliance ·
Additionalelectricalequipment(notsuitableforretrotting)
Twolimitcontacts 4), max. 230 V, 1A •
Materials
Housing, housing cover Plastic (PPO with glass ber reinforcement)
Coupling nut, M32x1.5 Brass
Weight kg (approx.) 0.75
1) Actuators with 6mm travel can also be used for valves with 7.5mm travel.
2) Adjustable (default settings in bold print)
3) With a fast stroking speed and 24VDC power supply, make sure the voltage does not fall below the specied
value.
4) Actuators for 85 to 264V power supply cannot be tted with limit contacts.
5) The degree of protection IP54 can only be achieved up to device index .03 when the actuator is installed in the
upright position. See last two gures of the conguration ID written on the nameplate, e.g. Var.-ID xxxxxxx.xx, for
the device index.
6) With standard speed level
7) The permissible medium temperature depends on the valve on which the electric actuator is mounted. The limits in
the valve documentation apply.

18 EB 5824-2 EN
Design and principle of operation
3.6 Technicaldata·Type5825
Type 5825
-10 -20 -30 -15 -25 -35
Fail-safe action With
Direction of action Extends Retracts
Rated travel mm 61) 12 15 6 1) 12 15
Stroking speed 2), 3) Slow mm/s 0.13 0.13 0.13 0.13 0.13 0.13
Standard mm/s 0.2 0.2 0.2 0.2 0.2 0.2
Fast mm/s 0.36 0.36 0.36 0.36 0.36 0.36
Transit time for rated
travel
(depending on the
stroking speed)
Slow s 45 89 111 45 89 111
Standard s31 61 76 31 61 76
Fast s 17 33 41 17 33 41
Transit time for fail-safe action s 4 67467
Thrust Extends N500 500 280 500 500 280
Retracts N – – 280 – – 280
Nominal thrust of safety spring N 500 500 280 –4) –4) 280
Attachment Force-locking • • – • • –
Form-t – – • – – •
Handwheel Possible 5)
Power supply
24VDC (–10%, + 20%), 24V, 50 and 60Hz ••••••
85 to 264 V, 50 and 60Hz ••••••
Input signal 0 to 10 V, Ri = 20 kΩ · 0 to 20 mA, Ri = 50 Ω
Output signal 0 to 10 V, RB = 1 kΩ
Power consumption 8)
24VDC (–10%, +20%) W 8
24V, 50 and 60Hz VA 8
85 to 264 V, 50 and 60Hz 6) VA 10
Permissible temperatures9)
Ambient 0 to 50°C
Storage –20 to +70°C

EB 5824-2 EN 19
Design and principle of operation
Safety
Degree of protection IP54 7)
Class of protection II (according to EN61140)
Overvoltage category II (according to EN60664)
Degree of contamination 2 (according to EN60664)
Noise immunity According to EN61000-6-2
Noise emission According to EN61000-6-3
Vibration According to EN60068-2-6 and EN60068-2-27
Compliance ·
Additionalelectricalequipment(notsuitableforretrotting)
Twolimitcontacts 6), max. 230 V, 1A •
Materials
Housing, housing cover Plastic (PPO with glass ber reinforcement)
Coupling nut, M32x1.5 Brass
Weight kg (approx.) 1.00
1) Actuators with 6mm travel can also be used for valves with 7.5mm travel.
2) Adjustable (default settings in bold print)
3) With a fast stroking speed and 24VDC power supply, make sure the voltage does not fall below the specied
value.
4) Safety spring pulls actuator stem to retracted end position; valve operated by valve spring.
5) Manual override using 4mm Allen key (after removing the cover); actuator always returns to fail-safe position after
release.
6) Actuators for 85 to 264V power supply cannot be tted with limit contacts.
7) The degree of protection IP54 can only be achieved up to device index .03 when the actuator is installed in the
upright position. See last two gures of the conguration ID written on the nameplate, e.g. Var.-ID xxxxxxx.xx, for
the device index.
8) With standard speed level
9) The permissible medium temperature depends on the valve on which the electric actuator is mounted. The limits in
the valve documentation apply.

20 EB 5824-2 EN
Design and principle of operation
3.7 Accessories
Accessories for version with digital positioner (see Fig.16 on page61) Order number
Hardware package consisting of: 1400-9998
−Memory pen-64
−Connecting cable
−Modular adapter
Memory pen-64 1400-9753
Connecting cable 1400-7699
Modular adapter 1400-7698
USB 1.1 serial adapter 8812-2001
Formountingonform-tvalveswithoutreturnspring 1) Order number
Yoke for V2001 Valves 1400-7414
Adapter for other valve types 1400-7415
1) With Types5824-30/-33 and Types5825-30/-33/-35 Actuators