Samson 6000 Series Service manual

Translation of original instructions
EB 6126 EN
Edition October 2016
System 6000 · Electropneumatic Converters
Type6126 i/p Converter
Type6126 u/p Converter
Type6126 i/p Converter with pressure gauge and mounting bracket

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
at www.samson.de > Service & Support > Downloads > Documentation.
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 6126 EN
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
Damage to health relating to REACH Regulation.
If a SAMSON device contains a substance which is listed as being a substance of very high
concern on the candidate list of the REACH Regulation, this circumstance is indicated on the
SAMSON delivery note.
Information on safe use of the part affected uhttp://www.samson.de/reach-en.html
WARNING
!

Contents
EB 6126 EN 3
1 General safety instructions.............................................................................4
2 Description....................................................................................................5
2.1 Application ...................................................................................................5
2.2 Principle of operation .....................................................................................5
3 Installation....................................................................................................8
3.1 Mounting ......................................................................................................8
4 Connections ..................................................................................................9
4.1 Electrical connection .......................................................................................9
4.2 Pneumatic connection ...................................................................................10
5 Operation...................................................................................................11
6 Maintenance ...............................................................................................12
7 Troubleshooting...........................................................................................13
8 Dimensions .................................................................................................14
9 Technical data.............................................................................................15
10 Ordering data.............................................................................................17
10.1 Accessories .................................................................................................18

4 EB 6126 EN
General safety instructions
1 General safety instructions
−The device must be mounted, started up, or serviced by fully trained and qualied per-
sonnel only; the accepted industry codes and practices are to be observed. Make sure
employees or third persons are not exposed to any danger.
−All safety instructions and warnings given in these mounting and operating instructions,
particularly those concerning installation, start-up, and maintenance, must be strictly ob-
served.
−According to these mounting and operating instructions, trained personnel refers to indi-
viduals who are able to judge the work they are assigned to and recognize possible dan-
gers due to their specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.
−Devices with a CE marking fulll the requirements of the Directive 2004/30/EU. Devices
with a CE marking have an EC declaration of conformity, which includes information
about the applied conformity assessment procedure. This declaration of conformity can
be provided on request.
−To ensure appropriate use, only use the device in applications where the operating pres-
sure and temperatures do not exceed the specications used for sizing the device at the
ordering stage.
−The manufacturer does not assume any responsibility for damage caused by external
forces or any other external factors.
−Proper transport, storage, installation, operation, and maintenance are assumed.

EB 6126 EN 5
Description
2.2 Principle of operation
The device consists of an i/p converter module and a downstream volume booster.
When operated, the supplied direct current i ows through the plunger coil (2) located in the
eld of a permanent magnet (3). At the balance beam (1), the force of the plunger coil,
which is in proportion to the current, is balanced against the force of the dynamic backpres-
sure. The backpressure is produced on the apper plate (6) by the air jet leaving the nozzle
(7).
The supply air (SUPPLY 8) ows to the bottom chamber of the volume booster (8). A certain
amount of air determined by the diaphragm position ows past the sleeve (9) and leaves
through the output (OUTPUT 36).
2 Description
2.1 Application
The devices are used to convert a direct cur-
rent input signal into a pneumatic output sig-
nal for measuring and control tasks. They
are particularly suitable as intermediate ele-
ment between electric measuring devices
and pneumatic controllers or between elec-
tric control devices and pneumatic control
valves.
The input is a load-dependent direct current
from 0/4 to 20mA or a DC voltage signal
from 0/2 to 10V with an auxiliary power of
24V DC. The output is, for example, a
pneumatic signal of 0.2 to 1bar (3 to
15psi) or 0.4 to 2 bar (6 to 30psi) or spe-
cial ranges up to 5bar (75psi).

6 EB 6126 EN
Description
6
7
8
10
8.2
9
1
2
3
4
i
5
pA
pK
ZERO SPAN
SUPPLY 8
EXHAUST
OUTPUT 36
GAUGE (36)
Fig. 1: Functional diagram
1 Balance beam
2 Plunger coil
3Permanent magnet
4Zero point and span adjusters (not in
version without electronics)
5Switch-off electronics: slide switch (only
with 4 to 20mA version with electronics)
6 Flapper
7 Nozzle
8Volume booster
8.2 Fixed restriction
9Sleeve
10 Diaphragm
Type6109/Type6112
i/p Module
As the input current and the forces acting on
the plunger coil increase, the apper (6)
moves closer to the nozzle (7). This causes
the backpressure and the cascade pressure
pK upstream of the restriction (8.2) to in-
crease until the cascade pressure corre-
sponds with the input current.
The increasing cascade pressure pushes the
diaphragm (10) and the plug sleeve (9)
downwards. As a result, the supply air caus-
es the output pressure pA to increase until a
new state of equilibrium is reached in the di-
aphragm chambers.
When the cascade pressure drops, the dia-
phragm moves upward, releasing the plug
sleeve and thus allowing the output pressure
pA to escape through the venting (EXHAUST)
until the forces are equal again.

EB 6126 EN 7
Description
Switch-off electronics (see Fig. 2)
Devices with an input range from 4 to
20mA have a slide switch which activates
the switch-off electronics. This function allows
the input signal to be set to 0mA when the
signal falls below the switching point of
4.08± tolerance. This causes the pneumatic
output to be vented to approximately
100mbar. This guarantees, for example, the
tight shut-off function of a valve.
This function requires a characteristic which
passes through the zero point, for example,
for the version with 4 to 20mA/0.2 to
1bar.
If the characteristic line does not pass
through zero, for example, for an allocated
output signal from 0.8 to 2.7bar, then the
pneumatic output is vented to a remaining
pressure of approx. 0.3bar when the
switch-off electronics are activated.
Fig. 2: Switch-off electronics and remaining
pressure
4812 16 20 m
A
0.2
0.4
0.6
0.8
1.0 bar
Output 0.2 to 1bar
Remaining pressure approx. 0.1bar
Output 0.8 to 2.7bar
Remaining pressure approx. 0.3bar
4 8 12 16 20 m
A
1
2
3
bar
2.7
0.3
0.8

8 EB 6126 EN
Installation
3 Installation
3.1 Mounting
The converter can be mounted to a wall, a
pipe or directly to a control valve as illustrat-
ed in the dimension diagrams on
page14.
The device is delivered with a stainless steel
bracket for wall mounting.
The following mounting accessories are re-
quired depending on the type of mounting to
be used:
−Pipe mounting, order no. 1400-6216
−Attachment to a valve with cast yoke,
order no. 1400-6217
−Attachment to a valve with rod-type
yoke, order no. 1400-6218
Mounting position
The converter is to be installed horizontally,
with the pressure gauge (or screw plug) fac-
ing upward.
If a different mounting position is used for
the 4 to 20mA version with switch-off elec-
tronics, the zero point must be readjusted as
described in section4.
With degree of protection IP54, the connec-
tion for the vent plug must always be in-
stalled facing downward to the oor.

EB 6126 EN 9
Connections
4 Connections
4.1 Electrical connection
Risk of electric shock and/or the formation
of an explosive atmosphere.
For electrical installation, observe the rele-
vant electrotechnical regulations and the ac-
cident prevention regulations that apply in
the country of use.
In Germany, these are the VDE regulations
and the accident prevention regulations of
the employers’ liability insurance.
A male angle connector conforming to
DINEN175301-803 A is used for electrical
connection.
1. Unscrew the fastening screw (1) of the
plug connector and pull the plug insert
(3) out of the plug base at the case.
2. Pull the fastening screw out of the plug
connector and remove the rubber seal
(5).
DANGER
!
2
6
13
4
5
1
4
2
3
1 (+)
0/4 to 20 mA
0/2 to 10 V
24 V DC
Only for 0/2 to 10 V
3 (+) 2 (–)
3
1
Fig. 3: Terminal assignment at the plug connector
1 Fastening screw
2 Plug connector case
3Plug insert
4Recess
5Rubber seal
6 Cable gland

10 EB 6126 EN
Connections
3. Place a screwdriver at the recess (4) and
lever the plug insert (3) out of the plug
connector case.
4. Run the wires for the input signal through
the cable gland of the plug connector
case to the terminals of the insert marked
1 (+) and 2 (–). Secure them with screws.
– For u/p converters (devices with [V]
input), additionally run the wire for the
auxiliary power 24V DC (+) to terminal
3.
– i/p converters (devices with [mA] in-
put) do not require a supply voltage.
5. Push the insert into the plug connector
case, making sure that the cable gland
points in the correct direction after the
plug connector case has been reassem-
bled (the plug connector case can be
mounted in all four directions, turned at
90° angles around the insert).
6. Plug the plug connector onto the device
and screw tight the screw (1).
4.2 Pneumatic connection
The pneumatic connections for supply air
(SUPPLY 8) and output (OUTPUT36) are de-
signed as threaded ports with G¼ or
¼–18NPT thread.
Customary ttings for metal tubing or plastic
hoses can be used.
Risk of property damage due to water en-
tering the device when a pipe is used to ex-
tend the vent pipe.
Make sure that no water can enter at the end
of an extension pipe (minimum cross-section
of 28mm² = 6mm inside diameter) connect-
ed to either vent elbow piece or directly to
the G or NPT connection.
Note
NOTICE
!

EB 6126 EN 11
Operation
Span:
6. Set the input signal to 20mA using a
suitable ammeter. The output signal at
the test pressure gauge should indicate
the upper range value of 1.0bar. If an-
other value is indicated, readjust the
span accordingly with the SPAN adjuster.
7. Change the input signal abruptly from
the upper range value (20mA) to 0mA
(or gently tap the device) and check
whether the output signal assumes the
upper range value, e.g. 1.0bar. As the
adjustment of zero and span inuence
each other, recheck both values and cor-
rect them, if necessary.
8. Reactivate the switch-off electronics in the
4 to 20mA version at the switch (5), if
required.
Voltage signal as input:
For u/p converters (devices with [V] input)
proceed in the same way as already de-
scribed.
The pneumatic output signal, e.g. 0.2 to
1bar is assigned to the signal range 0 or 2
to 10V with the ZERO and SPAN adjusters
(see nameplate).
Converters with voltage input do not have
the switch-off electronic function.
Note
5 Operation
See Fig. 1 on page 6.
The device converts the input signal propor-
tionally into the output signal.
The signal ranges are specied on the name-
plate.
In case of a mounting position that is not
horizontal or when the pressure gauge/
screw plug does not face upwards, zero and
span can be corrected by approx. 10% us-
ing the electronics. To do this, proceed as
follows:
Example:
The output signal 0.2 to 1bar is to be as-
signed to an input signal of 4 to 20mA.
1. Unscrew the enclosure cover to access
the ZERO and SPAN adjusters on the cir-
cuit board.
Zero:
2. Connect a pressure gauge (minimum ac-
curacy class 1) to the converter output.
3. Set the supply air to at least 0.4bar
above the upper output signal range val-
ue and apply it to the device.
4. Deactivate the switch-off electronics in
the 4 to 20mA version at the switch (5).
5. Set the input signal to the lower range
value (4mA) using a suitable ammeter.
The output signal at the test pressure
gauge should indicate a lower range val-
ue of 0.2bar.
If this is not the case, readjust the zero point
accordingly with the ZERO adjuster.

12 EB 6126 EN
Maintenance
6 Maintenance
No specic maintenance measures need to
be carried out.
To guarantee trouble-free operation of the
converter, make sure that the supply air is al-
ways clean (see section9 on page15 for
air quality).
Therefore, check the air lter and trap in-
stalled in the upstream air reducing station
regularly.
The pneumatic connections have lters with
plastic rims (order no. 0550-0213) which
can be removed for cleaning or replacement.
4 to 20mA version
0/2 to 10V version
Slide switch for
switch-off electronics
SPAN
ZERO
SPAN
ZERO
OFF
ON
Fig. 4: Adjusters with enclosure

EB 6126 EN 13
Troubleshooting
7 Troubleshooting
Problem Possible reasons Corrective action to be
taken Comments
No output
signal despite
changing the
input signal
Supply air not connected
Check supply air
connection. See
section4.2.
Incorrect terminal assign-
ment
Connect + and – termi-
nals correctly. See sec-
tion4.1.
NOTICE
i/p converters do not need
any extra voltage. Do not
connect 24V.
u/p converters (device with
[V] input) require a 24V DC
voltage supply (see
section4.1).
Incorrect input signal Connect correct signal.
Read nameplate:
0 to 20mA or 4 to 20mA, 0
to 10V or 2 to 10V.
e/p converter
constantly vents
off air loudly.
Connections for supply air
and output at the e/p
converter mixed up.
Check pneumatic
connections. See
section4.2.
e/p converter
does not reach
100% output
e.g. 20mA
input: output
only 70%
instead of
100%.
Supply pressure too low.
Supply air must be
0.4bar greater than the
max. output signal (sup-
ply air 0.4bar).
Read nameplate: output 0.2 to
1bar → Supply air at least
1.4bar, max. 6bar.
Input signal faulty
Check whether the input
signal at the terminals
reaches 100% (100% is
e.g. 20mA in standard
version and 12mA for
split-range operation)
NOTICE The i/p converters
have a load of:
– max. 6V
Check specication
concerning permissible load
at the source of the input
signal.

14 EB 6126 EN
Dimensions
8 Dimensions
Fig. 5: Dimensions with different types of mounting·All dimensions in mm
100
120
136
Ø7
50
113
188.5
158.5
SUPPLY
40
95
74.5
127
40
178.5
74.5
77
74.5
8
75.5
74.5
126
2”
pipe
OUTPUT
EXHAUST (vent plug)
Pressure gauges
(accessories)
Pipe mounting
Attachment to a valve with cast yoke,
order no.: 1400-6217
Attachment to a valve with
rod-type yoke, order no.:
1400-6218
Wall and pipe mounting,
order no. 1400-6216
Wall mounting with bracket, order no.: 1400-7432 (included in scope of delivery)
Attachment to the control valve with accessories, order no. 1400-6217
Electrical connection
Mounting bracket
(on the device)
EXHAUST (venting)
IP65

EB 6126 EN 15
Technical data
9 Technical data
Type No explosion
protection
Type6126-0
Input
0/4 to 20mA
0/2 to 10V (30kΩ input resistance) with 24VDC power supply
Load impedance ≤6V (corresponding to 300Ω at 20mA)
Output
0.2 to 1bar (3 to 15psi) with Type6109 or Type6112 i/p Module
0.4 to 2bar (6 to 30psi) with Type6112 i/p Module
(special ranges up to max. 5bar (75psi) with Type6112 i/p Module)
Air output
capacity1)
2.0m³/h at an output of 0.6bar (0.2 to 1.0bar) · 2.5m³/h at an output of 1.2bar
(0.4 to 2.0bar)
Supply
air
Pneumatic At least 0.4bar (6psi) above the upper signal pressure range value, max. 5.4bar
(80psi) without supply pressure regulator
Air quality acc.
to ISO8573-1:
2001
Max. particle size and density: Class 4 · Oil content: Class 3 · Pressure dew point:
Class 3 or at least 10 K below the lowest ambient temperature to be expected
Air
consumption2) 0.08mn³/h at 1.4bar (20psi) · 0.1mn³/h at 2.4bar (35psi)
24VDC (with
voltage-to-pres-
sure converter)
10 to 28VDC · 9 to 25mA (max. 30mA) for 0/2 to 10V input
Characteristic Characteristic: Output linear to input
Hysteresis ≤0.3% of upper range value
Deviation from
terminal-based
conformity
≤1% of upper range value
Effect in % of the
upper range
value
Supply air: 0.1%/0.1bar2)
Alternating load, supply air failure, interruption of the input current: <0.3%
Ambient temperature: lower measuring range value <0.03%/K, span <0.03%/K
Dynamic response (measured according to IEC60770-1)
Limiting
frequency 5.3Hz
Phase shift –130°
Variable position Max. 3.5% depending on attachment: ±1% when horizontal (Type6109)
Max. 1% depending on attachment: ±0.3% when horizontal (Type6112)

16 EB 6126 EN
Technical data
Technical data (continued)
Ambient conditions, degree of protection, compliance, and weight
Ambient temperature –25 to +70°C
Degree of protection IP54/IP65
Compliance
Weight Approx. 0.6kg
Materials
Housing Die-cast aluminum, chromated and plastic coated/glass-ber-reinforced polyamide
Other parts Corrosion-resistant material
1) Measured with 2m hose with 4mm inside diameter and 6mm outside diameter
2) Measured with average output pressure

EB 6126 EN 17
Ordering data
10 Ordering data
Article code Type6126- ... ... ... ... ... ... ... ... ... ... ... ... ...
Explosion
protection
Without 0
Pneumatic
connection
¼ -18NPT 1
ISO-228/1 - G¼ 2
i/p converter
module
Type61091) 1 0 0
Type6112 2
Input
4 to 20 mA 1
0 to 20mA, without switch-off electronics2) 2 2
4 to 20mA, without switch-off electronics2) 3
0 to 10V, 24VDC power supply5) 4
2 to 10V, 24VDC power supply 5
Output
0.2 to 1.0bar 0 1
3 to 15psi 0 2
0.4 to 2.0bar 2 0 4
6 to 30psi 2 0 5
Special
ranges3) 4)
Initial value 0.1 to 0.4bar; span 0.75 to 1.00bar 2 1 1
Initial value 0.1 to 0.4bar; span 1.00 to 1.35bar 2 1 2
Initial value 0.1 to 0.4bar; span 1.35 to 1.81bar 2 1 3
Initial value 0.1 to 0.8bar; span 1.81 to 2.44bar 2 1 4
Initial value 0.1 to 0.8bar; span 2.44 to 3.28bar 2 1 5
Initial value 0.1 to 0.8bar; span 3.28 to 4.42bar 2 1 6
Initial value 0.1 to 1.2bar; span 4.42 to 5.94bar 2 1 7
Direction of
action
Increasing/increasing 0
Increasing/decreasing 1
Degree of
protection
IP54 0
IP65 1
Output
pressure
gauge
Without 0
Pressure gauge in bar 1
Pressure gauge 0 to 0.6MPa/0 to 6kg/cm² 2
Temperature
range Tmin ≥ –25°C 0
Special
version
Without 0 0 0
Type6109 i/p Module, 4 to 20mA, without switch-off electronics, 0.2 to 1.0bar
output 008
Raised zero (up to max. 1.5bar) 30 0
Raised zero (up to max. 3.0bar) 30 1

18 EB 6126 EN
Ordering data
1) Only with 0.2 to 1bar (3 to 15psi) output
2) Without switch-off electronics and without adjuster for zero point and span correction. Not possible with Type6109
i/p module, adjusted to 3 to 15psi
3) Raised zero up to 3bar (45psi) possible as special version
4) Specify setting range, e.g. set to 0.1 to 4bar; output pressure max. 5bar, supply air 5.4bar
5) 0 to 5V input possible as special version.
10.1 Accessories
Mounting material for Order no.
−Bracket for wall mounting, stainless steel (1.4301) 1400-7432 (included
in scope of delivery)
−Wall and pipe mounting (2" pipes) 1400-6216
−Mounting on cast yoke according to NAMUR1) 1400-6217
−Mounting on rod-type yoke according to NAMUR1) 1400-6218
__
1) Only mounting part without assembly and without any possibly required screw tting. Order together with
mounting unit (M6116).
Pressure gauge retrot
−Pressure gauge: 0 to 1.2bar pressure range 0080-0185
−Pressure gauge: 0 to 6bar pressure range 0080-0186
−Pressure gauge: 0 to 10bar pressure range 8520-0032
−Pressure gauge: pressure range 0 to 0.6MPa/0 to 6kg/cm² 0800-0204
−For all pressure gauges: screw tting 0250-1090
−Male screw tting G¼ on hose with 4mm inside diameter and
6mm outside diameter, brass
8582-1452
−Male screw tting ¼NPT on hose, 4mm inside diameter and
6mm outside diameter, brass
8582-1523
−T-union for hose with 4mm inside diameter and 6mm outside
diameter, brass
8582-1480

EB 6126 EN 19

2018-06-27 · English
SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[email protected] · www.samson.de
EB 6126 EN