Samson 6000 Series Service manual

Mounting and
Operating Instructions
EB 6116 EN
Translation of original instructions
Edition October 2016
System 6000
Electropneumatic Converter for
DC Signals
Type6116 i/p Converter
Type6116 i/p Converter

2 EB 6116 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
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

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
indicated on the SAMSON delivery note.
Information on safe use of the part affected,
see uhttp://www.samson.de/reach-en.html.

Contents
EB 6116 EN 3
1 General safety instructions.............................................................................4
2 Description....................................................................................................5
2.1 Application ...................................................................................................5
2.2 Versions ........................................................................................................5
2.3 Principle of operation .....................................................................................7
3 Installation....................................................................................................8
3.1 Mounting position ..........................................................................................8
3.2 Mounting ......................................................................................................8
3.3 Electrical connection .......................................................................................9
3.4 Pneumatic connection ...................................................................................10
4 Operation...................................................................................................10
4.1 Checking zero and span ...............................................................................10
5 Maintenance ...............................................................................................12
5.1 Cleaning the restriction .................................................................................12
6 Servicing explosion-protected devices ..........................................................12
7 Positioner attachment ..................................................................................13
7.1 Principle of operation ...................................................................................13
7.2 Installation ...................................................................................................14
7.2.1 Mounting position of the converter ................................................................14
7.3 Electrical connection .....................................................................................14
7.4 Pneumatic connection ...................................................................................14
7.5 Operation ...................................................................................................15
8 Troubleshooting...........................................................................................19
9 Technical data .............................................................................................20
10 Article code.................................................................................................22
10.1 Accessories .................................................................................................24
11 Dimensions .................................................................................................25

4 EB 6116 EN
General safety instructions
1 General safety instructions
−The device must be mounted, started up or serviced by fully trained and
qualied personnel 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 mainte-
nance, must be strictly 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 dangers due to their specialized training, their
knowledge and experience as well as their knowledge of the applicable
standards.
−The devices with a CE marking comply with the requirements of the Europe-
an Pressure Equipment Directive 2014/30/EU. Devices with a CE marking
have a declaration of conformity, which includes information about the ap-
plied conformity assessment procedure. This declaration of conformity can
be provided on request.
−To ensure appropriate use, only use the device in applications where the op-
erating pressure 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.
−Any hazards that could be caused in the valve by the process medium, op-
erating pressure or by moving parts are to be prevented by taking appropri-
ate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

EB 6116 EN 5
Description
Further versions
−Type6116-x2xxxxxxxxx2… :
−Temperatures down to –45°C
−Type6116-0… :
−AS-interface connection with
Type6150 Slave
−Voltage input (e.g. 0 to 10V) with
Type6151 u/i Module
−Electropneumatic converter without
booster or switch-off electronics:
Converters can be combined with
SAMSON Type3760, Type3766-000
(model index .02 and higher) and
Type4765 Pneumatic Positioners. See
section7 on page13.
−Type 6116-xx060111000xxxx for
attachment to p/p positioners
(½NPT connection)
−Type 6116-xx060112000xxxx for
attachment to p/p positioners
(M20x1.5 connection)
Fig.1: Sample application
2 Description
2.1 Application
The devices (proportional valves) are used to
convert a direct current input signal into a
pneumatic output signal for measuring and
control tasks. They are particularly suitable
as an intermediate element between electric
measuring devices and pneumatic controllers
or between electric control devices and
pneumatic control valves.
The input is a load-independent direct cur-
rent (e.g. 4 to 20mA) and the output is a
pneumatic signal, for example, 0.2 to 1bar
(3 to 15psi) or signal ranges up to 8bar
(116psi).
2.2 Versions
Versions for safe areas:
−Type6116-0 ...
Versions for hazardous areas:
−Type6116-1... Ex i according to ATEX
and GOST
−Type6116-2... Ex d according to ATEX,
IEC and GOST
−Type6116-3... Explosion-proof acc. to
CSA and FM standards
−Type6116-4... Intrinsically safe accord-
ing to CSA and FM standards
−Type6116-5... Explosion Proof/Austra-
lia/IEC/Korea
−Type6116-6... Intrinsically Safe/Austra-
lia/IEC
−Type6116-7… Ex d according to JIS
standard/Japan
TROVIS6493
Type3241-1
Type6116
Supply air
p
e

6 EB 6116 EN
General safety instructions
Fig.2: Functional drawing
1 Balance beam
2Plunger 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
7Nozzle
8Volume booster
8.2 Fixed restriction
9Sleeve
10 Diaphragm
6
7
8
10
8.2
9
1
2
3
4
i
5
p
A
pK
ZERO SPAN
SUPPLY 8
EXHAUST
OUTPUT 36
GAUGE (36)
Type6109/Type6112
i/p Module
−Type6116-xx06011x000xxxx (for positioner attachment) 1)
Input: 4 to 20mA, other signals on request, internal resistance approx. 200Ω at 20°C
Output: 0.2 to 1bar for positioner
Other data same as standard version (see section9 on page20)
1) With Type6109 i/p Converter Module only

EB 6116 EN 7
General safety instructions
2.3 Principle of operation
See Fig.2 on page 6.
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) and
a certain amount of air determined by the
diaphragm position ows past the sleeve (9)
and leaves through the output (OUTPUT 36).
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 upwards, 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)
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.
4812 16 20 m
A
0.2
0.4
0.6
0.8
1.0
bar
4 8 12 16 20 m
A
1
2
3
bar
2.7
0.3
0.8
Fig.3: Switch-off electronics and remaining
pressure
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

8 EB 6116 EN
Installation
3 Installation
3.1 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, the zero point must be readjusted as
described in section4.1 on page10.
With degree of protection IP54, the vent
plug must always be installed facing down-
ward to the oor.
3.2 Mounting
The converter can be mounted to a wall, a
pipe or directly to a control valve (Fig.4).
The following accessories are required:
Order no. 1400-6216
−For wall and pipe mounting
Order no. 1400-6217
−For attachment to valve with cast yoke
Order no. 1400-6218
−For attachment to valve with rod-type
yoke
See section10.1 on page24 for further
mounting parts.
Fig.4: Mounting
2Plate
3 Rail
4 M6x16 screw
5M6x25 screw
6 Spring washer B6
7A6.4 washer
8M8 nut
9A8.4 washer
10 M8x25 screw
11 Clamp
13 Wall or pipe bracket
765
8913 12
67
4
10
89
11
5632
Wall and pipe
mounting
Top view
Top view
Valve with cast yoke/rod-
type yoke mounting
Side view
Rod-type yoke
bracket
Yoke
bracket
Clamp for
attachment to
2” pipe

EB 6116 EN 9
Installation
3.3 Electrical connection
DANGER!
Risk of electric shock and/or the for-
mation of an explosive atmosphere.
For electrical installation, observe the
relevant electrotechnical regulations
and the accident prevention regula-
tions that apply in the country of use.
In Germany, these are the VDE regulations
and the accident prevention regulations of
the employers’ liability insurance.
DANGER!
Adhere to the terminal assignment.
Switching the assignment of the elec-
trical terminals may cause the explo-
sion protection to become ineffective.
Do not loosen enameled screws in or
on the enclosure.
The following regulations apply to installa-
tion in hazardous areas: EN60079-14
(VDE0165, Part1) and DINEN50281-1-2
(VDE0165, Part2).
The maximum permissible values specied in
the EC type examination certicates apply
when interconnecting intrinsically safe elec-
trical equipment (Ui or U0, li or I0, Pi or P0, Ci
or C0 and Li or L0).
WARNING!
Leakage to the terminal space leads
to the degree of protection not being
met.
Only operate the device with sealed
cable entries and locked cover.
11 12
+–
Fig.5: Electrical connection
1. Unscrew the enclosure cover and connect
the wires for the input signal to the termi-
nals 11 (+) and 12 (–) using suitable ca-
ble glands or connectors.
No additional voltage supply is required.
Connect Exd versions with an approved
metal cable entry (certicate of conformi-
ty) or a seal box pipe.
Approved versions (certicate of confor-
mity) are equipped with permanently
sealed cable entries.
2. Secure grounding conductor at the
ground terminal located either inside or
outside the enclosure.
3. Check the O-ring for damage and re-
place it, if necessary.
4 to 20 mA input
Green/yellow
grounding conductor

10 EB 6116 EN
Operation
through and clean all air pipes and hoses
thoroughly before connecting them.
NOTICE
Risk of property damage due to wa-
ter entering the device when a pipe is
used to extend the vent pipe.
Make sure that no water can enter at
the end of an extension pipe (mini-
mum cross-section of 28mm² =
6mm inside diameter) connected to
either vent elbow piece or directly to
the G or NPT connection.
4 Operation
See Fig.2 on page 6.
4.1 Checking zero and span
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:
1. Unscrew the enclosure cover to access
the ZERO and SPAN potentiometers (4)
on the circuit board.
2. Connect a pressure gauge (minimum ac-
curacy class 1) to the converter output.
4. Screw on the cover as far as it will go.
Unscrew the cover until the rst possible
safety position (notch) is reached.
5. Unscrew the llister head screw to lock
the cover.
NOTICE
Loss of Exd protection due to dam-
age to the cover's thread and/or the
connecting thread. The enclosure
cover must be rmly closed during
operation.
3.4 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 (see section11 on
page25).
Customary ttings for metal tubing or plastic
hoses can be used.
Supply air (see section9 on page20).
−Min. + 0.4bar above the upper signal
pressure range
−Max. 10bar·Type6116-2: max. 6bar
(see EC type examination certicate in
Appendix)
Note:
The supply air must be dry and free
of oil and dust (see section9 on
page20).
Read the maintenance instructions for up-
stream pressure reducing stations. Blow
