Samson 6000 Series Service manual

Translation of original instructions
EB 6126 EN
Edition April 2020
System 6000 · Electropneumatic Converters
Type6126 i/p Converter
Type6126 u/p Converter

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. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
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
([e-mail]).
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.samsongroup.com > Service & Support > Downloads >
Documentation.
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
EB 6126 EN

Contents
EB 6126 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible personal injury ................................................................1-3
1.2 Notes on possible property damage .............................................................1-4
2 Marking on the device................................................................................2-1
2.1 Nameplate .................................................................................................2-1
2.2 Article code ................................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Technical data ............................................................................................3-3
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Remove the packaging from the converter. ....................................................4-1
4.3 Transporting the converter ...........................................................................4-1
4.4 Storing the converter ...................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions ..................................................................................5-1
5.2 Preparation for installation ...........................................................................5-1
5.3 Mounting the converter ................................................................................5-2
5.4 Mounting accessories ..................................................................................5-4
6 Connections ...............................................................................................6-1
6.1 Establishing pneumatic connections ..............................................................6-1
6.2 Establishing electrical connections ................................................................6-1
7 Start-up .....................................................................................................7-1
7.1 Tuning zero and span ..................................................................................7-1
8 Operation..................................................................................................8-1
9 Malfunctions ..............................................................................................9-1
9.1 Troubleshooting ..........................................................................................9-1
9.2 Emergency action .......................................................................................9-2
10 Servicing..................................................................................................10-1
10.1 Periodic testing .........................................................................................10-1
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
13 Repairs ....................................................................................................13-1
13.1 Returning devices to SAMSON ..................................................................13-1

Contents
EB 6126 EN
14 Disposal...................................................................................................14-1
15 Certicates...............................................................................................15-1
16 Annex......................................................................................................16-1
16.1 After-sales service .....................................................................................16-1

EB 6126 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type6126 Electropneumatic Converter is used to convert a direct current input signal in-
to a pneumatic output signal for measuring and control tasks. The electropneumatic converter
is particularly suitable as an intermediate element between electric measuring devices and
pneumatic controllers or between electric control devices and pneumatic control valves.
The input of the electropneumatic converter is a load-dependent direct current from 0 or 4
to 20mA or a DC voltage signal from 0 or 2 to 10V with a 24V DC supply. 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
special ranges up to 5bar (75psi).
The device is designed to operate under exactly dened conditions (e.g. input signal, pres-
sure). Therefore, operators must ensure that the device is only used in operating conditions
that meet the specications used for sizing the device at the ordering stage. In case operators
intend to use the device 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 and nameplate for limits and elds of application as well as
possible uses.
Reasonably foreseeable misuse
The device is not suitable for use outside the limits dened by the technical data. Further-
more, 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 device must be mounted, started up, serviced and repaired by fully trained and qualied
personnel only; the accepted industry codes and practices must 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.

1-2 EB 6126 EN
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the plant and the process medium being
used (e.g. uGESTIS (CLP) hazardous substances database).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the
material safety data sheet.
ÎCheck with the plant operator for details on further protective equipment.
Revisionsandothermodications
Revisions, conversions or other modications of 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.
Warning against residual hazards
To avoid personal injury or property damage, operators and operating personnel must
prevent hazards that could be caused in the device by the process medium and operating
pressure by taking appropriate precautions. Operators and operating personnel must
observe all hazard statements, warning and caution notes in these mounting and operating
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 as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third parties are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

EB 6126 EN 1-3
Safety instructions and measures
Referenced standards and regulations
The electropneumatic converters comply with the requirements of the Directives 2014/30/EU
and 2011/65/EU. Converters with a CE marking have a declaration of conformity, which
includes information about the applied conformity assessment procedure. This declaration of
conformity is included in the 'Certicates' section.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions of the downstream pneumatic controller
−Mounting and operating instructions of the downstream pneumatic control valve (valve,
actuator and valve accessories)
−Mounting and operating instructions of the upstream electric measuring equipment
1.1 Notes on possible personal injury
WARNING
!
Damage to health relating to the 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 indi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected: go to uwww.samsongroup.com >
About SAMSON > Material Compliance > REACH.
Risk of personal injury through incorrect operation, use or installation as a result of
information on the device being illegible.
Over time, markings, labels and nameplates on the device may become covered with
dirt or become illegible in some other way. As a result, hazards may go unnoticed and
the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.

1-4 EB 6126 EN
Safety instructions and measures
1.2 Notes on possible property damage
NOTICE
!
Risk of personal injury due to exhaust air being vented.
While in operation, the converter vents exhaust air over the vent plug.
ÎLocate the vent plug on the opposite side to the work position of operating person-
nel.
A zero shift, malfunction or device damage may occur due to vibration, shocks or
jolting.
Vibration, shocks or jolts can cause a zero shift and impair correct functioning. In
extreme cases, they may damage the device.
ÎProtect the device against external inuences (e.g. vibrations, impact, jolts or
shocks).
Damage to the converter and downstream devices due to failure to meet air quality
requirements.
An insufcient air quality may lead to the output signal not being proportional to the
input signal.
ÎOnly use supply air that is dry and free of oil and dust.
ÎComply with air quality requirements for the converter and downstream device
(pneumatic controller or pneumatic control valve).
ÎBlow through all air pipes and hoses thoroughly before connecting them.

EB 6126 EN 2-1
Marking on the device
2 Marking on the device
2.1 Nameplate
The nameplate is lasered on the enclosure of the converter.
SAMS0N 6126
i/p - Converter
Input
0utput
Supply
Model
Var.-ID
Serial no.
Made in Germany
pin assignment
Input
+11 –12
1 2
SAMS0N 6126
u/p - Converter
Input
0utput
Supply
Model
Var.-ID
Serial no.
Made in Germany
pin assignment
Input
+11 –12
1 2
L L
+3 –2
Supply
1 Input signal
2 Output (pneumatic standardized signal)
3 Supply pressure
4 Type number
5Conguration ID
6 Serial number
7Conformity

2-2 EB 6126 EN
Marking on the device
2.2 Article code
Type6126- xxxxxxxxxxxxx
Explosion
protection
Without 0
Pneumatic
connection
¼ -18NPT 1
ISO-228/1 - G ¼ 2
i/p converter
module
Type6109 1) 1 0 0
Type6112 2
Input
4 to 20 mA 1
0 to 20mA, without switch-off electronics 2) 5) 2 2
4 to 20mA, without switch-off electronics 2) 5) 3
0 to 10V, 24VDC supply 4
2 to 10V, 24VDC 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
ranges 3) 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
With pressure gauge in bar 1
With pressure gauge 0 to 0.6MPa/0 to 6kg/cm² 2
Temperature
range
Tmin ≥ –25°C 0

EB 6126 EN 2-3
Marking on the device
Type6126- xxxxxxxxxxxxx
Special
version
Without 000
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) 300
Raised zero (up to max. 3.0bar) 301
1) Only with 0.2 to 1bar (3 to 15psi) output
2) Without switch-off electronics and without potentiometer 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) 4 to 20mA, without switch-off electronics: no longer available since 2020

2-4 EB 6126 EN

EB 6126 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The device consists of an i/p converter mod-
ule 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
backpressure. 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 bot-
tom chamber of the volume booster (8). A
certain amount of air determined by the dia-
phragm position ows past the sleeve (9)
and leaves through the output (OUTPUT 36).
6
7
8
10
8.2
9
1
2
3
4
i
5
pA
pK
ZERO SPAN
SUPPLY 8
EXHAUST
OUTPUT 36
GAUGE (36)
Type6109/
Type6112 i/p
Module
1 Balance beam
2 Plunger coil
3 Permanent magnet
4 Zero 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 plate
7Nozzle
8 Volume booster
8.2 Fixed restriction
9Sleeve
10 Diaphragm
Fig.3-1: Functional diagram

3-2 EB 6126 EN
Design and principle of operation
As the input current and the forces acting on
the plunger coil increase, the apper plate
(6) moves closer to the nozzle (7). This caus-
es the backpressure and the cascade pres-
sure pK upstream of the restriction (8.2) to in-
crease until the cascade pressure corre-
sponds with the input current. The cascade
pressure increases until it corresponds 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.
Switch-off electronics (see Fig.3-2)
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mA± tolerance. This causes the pneu-
matic 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.
Output 0.2 to 1bar
Remaining pressure approx.
0.1bar
4812 16 20
m
A
0,2
0,4
0,6
0,8
1,0 bar
4 8 12 16 20 mA
1
2
3
bar
2,7
0,3
0,8
Output 0.8 to 2.7bar
Remaining pressure approx.
0.3bar
Fig.3-2: Switch-off electronics and remaining
pressure

EB 6126 EN 3-3
Design and principle of operation
3.1 Technical data
Type No explosion protection Type6126-0
Input 0/4 to 20mA or 0/2 to 10V (30kΩ input resistance) with
24VDC power supply;
load impedance ≤ 6V (corresponds to 300Ω at 20mA)
Output 0.2 to 1bar (3 to 15psi) with Type6109/6112 i/p Module or
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 capacity 1) 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 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 consumption 2) 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-pressure 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 nal value
Deviation from terminal-
based conformity ≤1% of nal value
Effect in % of the upper
range value
Supply: 0.1%/0.1bar 2)
Alternating load, supply air failure, interruption of the input
current: <0.3%
Ambient temperature: lower range value <0.03%/K,
measuring 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 how the device is attached: ±1% in
horizontal position (Type6109)
Max. 1% depending on how the device is attached: ±0.3% in
horizontal position (Type6112)

3-4 EB 6126 EN
Design and principle of operation
Ambient conditions, degree of protection, compliance and weight
Ambient temperature –25 to +70°C
Degree of protection IP54/IP65
Conformity ·
Weight Approx. 0.6kg
Materials
Enclosure 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 3-5
Design and principle of operation
Dimensional drawings
Wall mounting with bracket, order no.: 1400-7432 (included in scope of delivery)
100
120
136
Ø7
Ø40
70
70
50
75,5
74,5 126
1
3
4
2
113
188,5
158,5
40 95
74,5
127
178,5
74,5
77
74,5
8
OUTPUT
EXHAUST
SUPPLY
1 EXHAUST (vent plug)
2 Electrical connection
(angle connector)
3 Pressure gauge
4 Mounting bracket
Mounting on control valves Wall and pipe mounting
100
120
136
Ø7
Ø40
70
70
50
75,5
74,5 126
1
3
4
2
113
188,5
158,5
40 95
74,5
127
178,5
74,5
77
74,5
8
OUTPUT
EXHAUST
SUPPLY
Attachment to a valve with
cast yoke
Attachment to a valve with rod-type
yoke
Vent plug
Electrical
connection
Wall
mounting
Clamp for attachment
to 2“ pipe

3-6 EB 6126 EN

EB 6126 EN 4-1
Shipment and on-site transport
4 Shipment and on-site trans-
port
The work described in this section is only to
be performed by personnel qualied for the
assignment accordingly.
4.1 Accepting the delivered
goods
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Check that
the specications on the nameplate and
on the converter itself match the speci-
cations in the delivery note. See the
'Markings on the device' section for
nameplate details.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.2 Remove the packaging
from the converter.
Observe the following sequence:
ÎDo not remove the packaging until im-
mediately before installation.
ÎDispose and recycle the packaging in
accordance with the local regulations.
4.3 Transporting the converter
Transport instructions
−Protect the converter against external in-
uences (e.g. impact).
−Protect the converter against moisture
and dirt.
−Observe transport temperature
depending on the permissible ambient
temperature (see the 'Design and
principle of operation' section).
4.4 Storing the converter
Risk of device damage due to improper
storage.
ÎObserve the storage instructions.
ÎAvoid long storage times.
ÎContact SAMSON in case of different
storage conditions.
We recommend regularly checking the con-
verter and the prevailing storage conditions
during long storage periods.
Storage instructions
−Protect the converter against external in-
uences (e.g. impact).
−Protect the converter against moisture
and dirt. Store it at a relative humidity of
less than 75%. In damp spaces, prevent
condensation. If necessary, use a drying
agent or heating.
NOTICE
!
Note

4-2 EB 6126 EN
Shipment and on-site transport
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe transport temperature
depending on the permissible ambient
temperature (see the 'Design and
principle of operation' section).
−Do not place any objects on the convert-
er.