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
!