Samson TROVIS 5724-3 Service manual

Mounting and

Operating Instructions

EB 5724 EN

Firmware version 2.20

Edition August 2016

Translation of original instructions

Electric Actuators with Process Controllers

TROVIS5724-3 (without fail-safe action)

TROVIS5725-3 (with fail-safe action)

for domestic hot water heating

2 EB 5724 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 5724 EN 3

1 Safety instructions and measures ...................................................................5

1.1 Notes on possible severe personal injury .........................................................8

1.2 Notes on possible personal injury ...................................................................9

1.3 Notes on possible property damage................................................................9

2 Markings on the device ...............................................................................10

2.1 Actuator nameplate......................................................................................10

2.2 Valve nameplate ..........................................................................................10

3 Design and principle of operation ................................................................11

3.1 Fail-safe positions ........................................................................................12

3.2 Operating controls .......................................................................................12

3.3 Accessories .....................................................................................................

3.4 Technical data .............................................................................................15

3.5 Dimensions in mm........................................................................................17

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.................................................................................21

5.1 Mounting the actuator onto the valve.............................................................21

5.1.1 Force-locking attachment ..............................................................................21

5.1.2 Form-t attachment ......................................................................................22

5.2 Installing the control valve into the pipeline ....................................................22

5.3 Electrical connections ...................................................................................22

5.4 Conguring the electric actuator....................................................................24

5.5 Quick check ................................................................................................24

6 Operation...................................................................................................27

6.1 Manually changing the stem position.............................................................27

4 EB 5724 EN

Contents

7 Servicing.....................................................................................................29

7.1 Preparation for return shipment.....................................................................29

8 Malfunctions ...............................................................................................30

8.1 Emergency action ........................................................................................30

9 Decommissioning and disassembly ..............................................................30

9.1 Decommissioning.........................................................................................30

9.2 Removing the actuator from the valve ............................................................31

9.2.1 Force-locking attachment ..............................................................................31

9.2.2 Form-t attachment ......................................................................................31

9.3 Disposal......................................................................................................31

10 Appendix....................................................................................................31

10.1 After-sales service........................................................................................31

10.2 Conguration and parameter list...................................................................32

10.3 Parameter list...............................................................................................33

10.4 Customer setting ..........................................................................................34

10.5 EU declaration of conformity.........................................................................35

Firmware revisions

2.11

(old)

2.13 (new)

Additional setting option 'Circulation pump (heating) reversed' in Function of switching

output (F16). See section10.2 and uKH 5724.

2.13

(old)

2.20 (new)

New pump protection function (F17). See section10.2 and uKH 5724.

EB 5724 EN 5

Safety instructions and measures

1 Safety instructions and measures

The TROVIS5724-3 and TROVIS5725-3 Electric Actuators with Process Controllers are a

combination of an electric actuator and an integrated digital controller. They are designed

for operating a mounted globe valve. In combination with the valve, the actuator is used to

control the ow of liquids in the pipeline. The electric actuators with process controllers are

suitable for DHW heating applications.

The actuator is designed to operate under exactly dened conditions (e.g. thrust, travel).

Therefore, operators must ensure that the actuator is only used in applications that meet the

specications used for sizing the actuator at the ordering stage. In case operators intend to

use the actuator in other applications or conditions than specied, SAMSON must be con-

tacted.

SAMSON does not assume any liability for damage resulting from the failure to use the de-

vice for its intended purpose or for damage caused by external forces or any other external

factors.

ÎRefer to the technical data for limits and elds of application as well as possible uses. See

section3.4.

Reasonably foreseeable misuse

The actuator is not suitable for the following applications:

−Use outside the limits dened during sizing and in the technical data

Furthermore, the following activities do not comply with the intended use:

−Use of non-original spare parts

−Performing service and repair work not described in these instructions

Qualications of operating personnel

The actuator must be mounted, started up, serviced, and repaired by fully trained and quali-

ed personnel only; the accepted industry codes and practices are to be observed. Accord-

ing to these mounting and operating instructions, trained personnel refers to individuals who

are able to judge the work they are assigned to and recognize possible hazards due to their

specialized training, their knowledge and experience as well as their knowledge of the appli-

cable standards.

6 EB 5724 EN

Safety instructions and measures

Personal protective equipment

No personal protective equipment is required for the direct handling of the electric actuator

with process controller. Work on the valve on which the electric actuator is mounted may be

necessary when mounting or removing the actuator from the valve.

ÎObserve the requirements for personal protective equipment specied in the valve docu-

mentation.

ÎCheck with the plant operator for details on further protective equipment.

Revisions and other modications

Revisions, conversions or other modications to the product are not authorized by SAMSON.

They are performed at the user's own risk and may lead to safety hazards, for example. Fur-

thermore, the product may no longer meet the requirements for its intended use.

Safety features

The following safety features exist:

−Upon power supply failure, the TROVIS5725-3 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 actuator 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 maintenance.

Responsibilities of the operator

The operator is responsible for proper operation and compliance with the safety regulations.

Operators are obliged to provide these mounting and operating instructions 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.

EB 5724 EN 7

Safety instructions and measures

Referenced standards and regulations

The electric actuators with process controllers 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 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:

−Conguration Manual for TROVIS5724-3 and TROVIS5725-3 Electric Actuators with

Process Controllers uKH5724

−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5867 for Type3222N 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

uEB3018 for Type42-36E Pressure-independent Control Valve (PICV) with electric ac-

tuator

8 EB 5724 EN

Safety instructions and measures

1.1 Notes on possible severe personal injury

DANGER

Risk of electric shock.

ÎBefore connecting wiring, performing any work on the device or opening the de-

vice, disconnect the power supply and protect it against unintentional reconnection.

ÎOnly use power interruption devices that are protected against unintentional recon-

nection of the power supply.

ÎDo not remove any covers to perform adjustment work on live parts.

ÎDo not open the back housing cover.

The electric actuators with process controllers are protected against spray water

(IP54).

ÎAvoid jets of water.

The switching output L' might be live after the supply voltage has been connected.

ÎDo not touch the switching output L'.

ÎWhen the switching output is not used, deactivate it in function F16 ('Passive' set-

ting).

Risk of bursting in pressure equipment.

Control valves and pipelines are pressure equipment. Improper opening can lead to

valve components bursting.

ÎBefore starting any work on the control valve, depressurize all plant sections con-

cerned as well as the valve.

ÎDrain the process medium from all the plant sections concerned and from the valve.

ÎWear recommended personal protective equipment. See associated valve docu-

mentation.

EB 5724 EN 9

Safety instructions and measures

1.2 Notes on possible personal injury

WARNING

Crush hazard arising from moving parts.

The form-t version of the electric actuator with process controller contains moving

parts (actuator and plug stems), which can injure hands or ngers if inserted into the

actuator.

ÎDo not insert hands or nger 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.

1.3 Notes on possible property damage

NOTICE

Risk of actuator damage due to the power supply exceeding the permissible toler-

ances.

The electric actuators are designed for use according to regulations for low-voltage in-

stallations.

ÎObserve the permissible tolerances of the power supply.

Risk of actuator damage due to excessively high tightening torques.

The connection of the electric actuator must be tightened with certain torques. Excessive-

ly tightened torques lead to parts wearing out quicker.

ÎObserve the specied tightening torques.

Malfunction due to a conguration that does not meet the requirements of the appli-

cation.

The electric actuator with process controller is congured for the specic application by

setting conguration items and parameters.

ÎPerform the conguration for the specic application during start-up and after a re-

set to default settings.

10 EB 5724 EN

Markings on the device

2 Markings on the device

2.1 Actuator nameplate

Var.-ID

Serial no.

SAMSON

Controller with

Model

0062

10 11

Electric Actuator

Firmware - Version:

1 Type designation

2 Year of manufacture

3Conguration ID

4Model designation (TROVIS5725-3 only)

5 Serial number

6DIN registration number (TROVIS5725-3

only)

7 Thrust

8 Rated travel

9 Transit time for rated travel

10 Power supply

11 Power line frequency

12 Power consumption

13 Fail-safe action (TROVIS5725-3 only)

Actuator

stem re-

tracts

Actuator

stem extends

14 Firmware version

15 Inputs

16 Outputs

2.2 Valve nameplate

See associated valve documentation.

Risk of damage to the screw heads on the front cover due to the use of the wrong

tool.

The actuator housing cover is fastened using TORX PLUS® screws, size 10IP.

ÎTo loosen and tighten the screws, only use the following screwdrivers:

−TORX®T10

−TORX PLUS®10IP

−Flat-blade screwdriver with 0.8mm blade thickness and 4.0mm blade width

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