Samson Type 5824 Service manual

Mounting and
Operating Instructions
EB 5824-1 EN
Translation of original instructions
Edition January 2015
Electric Actuators
Type 5824 without fail-safe action
Type 5825 with fail-safe action
Three-step version

2 EB 5824-1 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 5824-1 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 Cover screws ...............................................................................................13
3.2 Additional equipment...................................................................................13
3.3 Technical data · Type5824...........................................................................14
3.4 Technical data · Type5825...........................................................................16
3.5 Accessories .................................................................................................17
3.6 Dimensions in mm........................................................................................18
4 Measures for preparation............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................20
4.2.2 Lifting..........................................................................................................20
4.3 Storage.......................................................................................................20
4.4 Aligning the travel indication scale................................................................21
5 Mounting and start-up.................................................................................22
5.1 Mounting the actuator onto the valve.............................................................22
5.1.1 Type5824: force-locking attachment .............................................................22
5.1.2 Type5824: form-t attachment .....................................................................22
5.1.3 Type5825: force-locking attachment .............................................................22
5.1.4 Type5825: form-t attachment .....................................................................24
5.2 Installing the control valve into the pipeline ....................................................24
5.3 Electrical connections ...................................................................................25
5.3.1 Connecting the power supply........................................................................25
6 Additional functions ....................................................................................27
6.1 Limit contacts...............................................................................................27
6.2 Resistance transmitters..................................................................................27

4 EB 5824-1 EN
Contents
7 Operation...................................................................................................28
7.1 Handwheel..................................................................................................28
8 Servicing.....................................................................................................29
8.1 Preparation for return shipment.....................................................................29
9 Malfunctions ...............................................................................................30
9.1 Emergency action ........................................................................................30
10 Decommissioning and disassembly ..............................................................31
10.1 Decommissioning.........................................................................................31
10.2 Removing the actuator from the valve ............................................................31
10.2.1 Force-locking attachment ..............................................................................31
10.2.2 Form-t attachment ......................................................................................31
10.3 Disposal......................................................................................................31
11 Annex.........................................................................................................32
11.1 After-sales service........................................................................................32

EB 5824-1 EN 5

6 EB 5824-1 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 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 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3.3 and section3.4.
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.
According to these mounting and operating instructions, trained personnel refers to
individuals who are able to judge the work they are assigned to and recognize possible
hazards due to their specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.
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.

EB 5824-1 EN 7
Safety instructions and measures
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.
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.

8 EB 5824-1 EN
Safety instructions and measures
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 5824-1 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 5824-1 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 due to incorrect connection of the voltage.
The electric actuator has terminals to retract the stem (eL terminal) and to extend the
stem (aL terminal).
ÎDo not apply a voltage to eL and aL at the same time.
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 5824-1 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
13
F:
7
s:
8
9
10
f:
11
P:
12
6
14
15
1 Type designation
2 Year of manufacture
3Conguration ID
4 Model designation (Type5825 only)
5Serial number
6DIN registration number (Type 5825 only)
7 Thrust
8Rated travel
9 Stroking speed
10 Power supply
11 Power line frequency
12 Power consumption
13 Fail-safe action (Type5825 only)
Extends Retracts
14 Resistance transmitters
15 Limit contact

12 EB 5824-1 EN
Design and principle of operation
3 Design and principle of oper-
ation
The actuator contains a reversible synchro-
nous motor and a maintenance-free gear.
The motor is switched off by torque-depen-
dent limit contacts or in case of overload.
The force of the motor is transmitted to the
actuator stem (3) via gear and crank disk.
When the actuator stem extends, the actua-
tor 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).
Actuator and valve are connected by the
coupling nut (4).
Type 5824 without fail-safe action
This 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 actuator contains a spring mechanism
(8) and an electromagnet. The actuator is
moved by the force of the spring to the fail-
safe position when the electromagnet (termi-
nals L and N) is de-energized. The direction
of action depends on the actuator version
and cannot be reversed.
The Type 5825 Actuator is available with
fail-safe action "actuator stem extends" or
"actuator stem retracts".
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
1 Housing
1.1 Front cover
1.2 Cable entry
2Handwheel (Type 5824 only)
2.1 Actuating shaft
3 Actuator stem with actuator
piston
4Coupling 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), force-locking attachment

EB 5824-1 EN 13
Design and principle of operation
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.
Version with faster motor
The Types5824-13/-23/-33 and
Types5825-13/-23 have a more powerful
motor in a housing at the back of the actua-
tor.
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.
3.1 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
3.2 Additional equipment
−The resistance transmitter is linked to the
gear and produces a resistance signal
between approx. 0 and 1000Ω (use-
able range 0 to 800Ω ) proportional to
the valve travel. The resistance transmit-
ter is not suitable for retrotting.
−On request, the actuator 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 5824-1 EN
Design and principle of operation
3.3 Technical data · Type5824
Type 5824
-10 -13 -20 -23 -30 -33
Fail-safe action Without
Rated travel mm 6 1) 61) 12 12 15 15
Stroking speed Standard: 0.17mm/s •–•–•–
Actuator with faster motor:
0.33mm/s –•–•–•
Transit time for rated travel s 35 1) 18 1) 70 36 90 45
Thrust Extends N 700 700 700 700 700 700
Retracts N – – – – 700 700
Attach-
ment
Force-locking • • • • – –
Form-t – – – – • •
Handwheel Yes
Power supply
24V, 50Hz •–•–•–
230V, 50Hz/60Hz 2) ••••••
Power consumption Approx. VA 363636
Permissible temperatures4)
Ambient 0 to 50°C
Storage –20 to +70°C
Safety
Degree of protection IP54 3)
Class of protection II (according to EN61140)
Overvoltage category II (according to EN60664)
Degree of contamination 2 (according to EN60664)
Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326
Vibration According to EN60068-2-6 and EN60068-2-27
Compliance ·

EB 5824-1 EN 15
Design and principle of operation
Additional electrical equipment (not suitable for retrotting)
Two limit contacts, max. 230 V, 1A ••••••
One resistance transmitter, 0 to 1000Ω ±15%
(90% of final value at rated travel); max. 1mA,
5V
•–•–••
Materials
Housing, housing cover Plastic (PPO with glass ber reinforcement)
Coupling nut, M32x1.5 Brass
Weight kg (approx.) 0.75 1.00 0.75 1.00 0.75 0.75
1) Actuators with 6mm travel can also be used for valves with 7.5mm travel (45s transit time, 22.5s for actuator
with faster motor).
2) Special version
3) 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.
4) The permissible medium temperature depends on the valve on which the electric actuator is mounted. The limits in
the valve documentation apply.

16 EB 5824-1 EN
Design and principle of operation
3.4 Technical data · Type5825
Type 5825
-10 -13 -20 -23 -30 -33 -15 -25 -35
Fail-safe action With
Direction of action Extends Retracts
Rated travel mm 6 1) 61) 12 12 15 15 61) 12 15
Stroking speed Standard:
0.17mm/s •–•–•–•••
Actuator with
faster motor:
0.33mm/s
–•–•–•–––
Transit time for rated travel s 35 1) 18 1) 70 36 90 45 35 1) 70 90
Transit time for fail-safe
action s44667746 7
Thrust Extends N500 500 500 500 280 280 500 500 280
Retracts N – – – – 280 280 – – 280
Thrust in the event of fail-
safe action N500 500 500 500 280 280 – 3) – 3) 280
Attach-
ment
Force-locking • • • • – – • • –
Form-t – – – – • • – – •
Handwheel Possible 2)
Power supply
24V, 50Hz •–•–•–•••
230V, 50Hz/60Hz 4) •••••••••
Power consumption Approx.
VA 484848444
Permissible temperatures6)
Ambient 0 to 50°C
Storage –20 to +70°C
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)

EB 5824-1 EN 17
Design and principle of operation
Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326
Vibration According to EN60068-2-6 and EN60068-2-27
Compliance ·
Additional electrical equipment (not suitable for retrotting)
Two limit contacts, max. 230 V,
1A •••••••••
One resistance transmitter, 0 to
1000Ω ±15%
(90% of final value at rated travel);
max. 1mA, 5V
• – • – • • • • •
Materials
Housing, housing cover Plastic (PPO with glass ber reinforcement)
Coupling nut, M32x1.5 Brass
Weight kg (approx.) 1.00 1.25 1.00 1.25 1.00 1.25 1.00 1.00 1.00
1) Actuators with 6mm travel can also be used for valves with 7.5mm travel (45s transit time, 22.5s for actuator
with faster motor).
2) Manual override using 4mm Allen key (after removing the cover); actuator always returns to fail-safe position after
release
3) Safety spring pulls actuator stem to retracted end position; valve operated by valve spring.
4) Special version
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) The permissible medium temperature depends on the valve on which the electric actuator is mounted. The limits in
the valve documentation apply.
3.5 Accessories
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

18 EB 5824-1 EN
Design and principle of operation
3.6 Dimensions in mm
Type5824-10 and Types 5825-10/-15/-25
146
82
113
48 44
103
Types 5824-13/-23/-33 and Types 5825-13/-23 (version with faster motor)
12
18
Ø 70
51
(33)
136
146
48 44
103
82
113

EB 5824-1 EN 19
Design and principle of operation
Type 5824-30 and Types5825-30/-33/-35
203
50
136
Ø10
46.5
6
15mm travel
Actuator with yoke (1400-7414)
15mm
travel
Actuator without yoke

20 EB 5824-1 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
(refer 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 electric actuator damage due to im-
proper 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.
Note
NOTICE
!
Note