Samson 611 Service manual

Translation of original instructions
EB 6116 EN
Edition August 2018
Type6116 Electropneumatic Converter for Direct Current Signals

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 6116 EN

Contents
EB 6116 EN
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................8
2 Markings on the device .................................................................................9
2.1 Nameplate....................................................................................................9
2.2 Article code.................................................................................................10
3 Design and principle of operation ................................................................12
3.1 Versions......................................................................................................14
3.2 Technical data .............................................................................................16
3.3 Accessories .................................................................................................23
4 Measures for preparation............................................................................25
4.1 Unpacking ..................................................................................................25
4.2 Transporting and lifting ................................................................................25
4.3 Storage.......................................................................................................25
4.4 Preparation for installation............................................................................25
5 Mounting and start-up.................................................................................26
5.1 Mounting orientation....................................................................................26
5.2 Installing i/p converters................................................................................26
5.3 Electrical connection.....................................................................................26
5.4 Pneumatic connection...................................................................................28
5.5 Mounting the i/p converter to positioners.......................................................28
5.5.1 Principle of operation...................................................................................29
5.5.2 Accessories .................................................................................................29
5.5.3 Mounting position of the converter ................................................................29
5.5.4 Electrical connection.....................................................................................30
5.5.5 Pneumatic connection...................................................................................30
5.5.6 Operation ...................................................................................................30
6 Operation...................................................................................................34
6.1 Checking zero and span...............................................................................34
6.1.1 Checking zero .............................................................................................34
6.1.2 Checking span.............................................................................................36
6.2 Zeroadjustment(versionswith0to20mAinputsignal)..................................36

Contents
EB 6116 EN
7 Maintenance ...............................................................................................37
7.1 Cleaning the restrictor ..................................................................................37
7.2 Cleaning pneumatic connections ...................................................................37
7.3 Servicing explosion-protected devices............................................................38
8 Malfunctions ...............................................................................................39
9 Decommissioning and removal ....................................................................41
9.1 Removing the i/p converters .........................................................................41
9.2 Disposal......................................................................................................41
10 Annex.........................................................................................................41
10.1 After-sales service........................................................................................41
10.2 Certicates ..................................................................................................41

EB 6116 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType6116i/pConverterisusedtoconvertadirectcurrentinputsignalintoapneumatic
output signal for measuring and control tasks. The i/p converter is particularly suitable as an
intermediate element between electric measuring devices and pneumatic controllers or be-
tween electric control devices and pneumatic control valves.
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duringsizingandby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device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. 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 spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

6 EB 6116 EN
Safety instructions and measures
Personal protective equipment
SAMSONWe 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 ma-
terial 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 pre-
vent hazards that could be caused in the device by the process medium and operating pres-
sure by taking appropriate precautions. They 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 persons 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.
Referenced standards and regulations
Devices with a CE marking have an EU declaration of conformity, which includes information
about the applied conformity assessment procedure. The EU declaration of conformity is in-
cludedintheannexoftheseinstructions(seesection10.2).

EB 6116 EN 7
Safety instructions and measures
For electrical installation, observe the relevant electrotechnical regulations and the accident
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.
For installation in hazardous areas, observe the relevant standards that apply in the country
ofuse.StandardapplicableinGermany:EN60079-14(VDE0165,Part1)Explosive
Atmospheres–ElectricalInstallationsDesign,SelectionandErection.
ThemaximumpermissiblevaluesspeciedintheECtypeexaminationcerticatesapply
when interconnecting intrinsically safe electrical equipment (Uior U0, lior I0, Pior P0, Cior C0
andLiorL0).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Safety Manual uSH6116foruseinsafety-instrumentedsystems
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to the ignition of an explosive atmosphere.
Incorrect installation, operation or maintenance of the i/p converter in potentially explo-
sive atmospheres may lead to ignition of the atmosphere and cause death.
ÎThefollowingregulationsapplytoinstallationinhazardousareas:EN60079-14
(VDE0165,Part1).
ÎInstallation, operation or maintenance of the i/p converter must only performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.
Loss of Exd protection due to opening the enclosure cover or damage to the cover's
thread and/or the connecting thread.
ÎTheenclosurecovermustbermlyclosedduringoperation.
ÎPut the i/p converter out of operation when its cover thread or connecting thread is
damaged. Replace it with a new device.

8 EB 6116 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
The i/p converter poses no hazard with possible personal injury.
ÎCheck with the plant operator for details on possible personal injury which could
be caused by the plant and ambient conditions (e.g. process medium, tempera-
ture).
1.3 Notes on possible property damage
NOTICE
!
A zero shift may occur due to shocks.
Shocks can cause a zero shift which impairs the correct functioning.
ÎProtectthedeviceagainstexternalinuences(e.g.impact,shocks).
ÎCheckzero,ifnecessary(seesection6).
Risk of malfunction due to failure to comply with required air quality.
Aninsufcientairqualitymayleadtotheoutputsignalnotbeingproportionaltothe
input signal.
ÎMakesurethattheairqualitycomplieswiththerequirements(seesection3.2).
ÎChecktheairlterandseparatorinstalledintheupstreamairreducingstationreg-
ularly.

EB 6116 EN 9
Markings on the device
2 Markings on the device
2.1 Nameplate
Input
Output
Supply
SAMSON 6116
i/p Converter
Model 6116 -
Var.-ID
Serial no.
SAMSON AG D-60314 Frankfurt
See technical data for ambient temperature
Made in Germany
4
3
2
5
6
7
1 Explosion protection
specications
2 Input signal (electric)
3 Output signal (pneumatic)
4 Supply pressure
5 Model no.
6CongurationID
7 Serial number
SAMSON 6116-…
i/p Converter
Model 6116 -
Var.-ID Serial no.
SAMSON AG D-60314 Frankfurt Made in Germany
0044
Input
Output
Supply
* See technical data and
explosion-protection certificate for
permissible ambient temperature
and maximum values.
1
2
3
4
5
67
Fig.1: Nameplate examples for Type6116 i/p Converter
The Type6109 and Type6112 i/p Modules have their own nameplate which differs from the
nameplate on the i/p converter.
Location of the nameplate
Thenameplateisafxedwithgroovedpinstothesideofthei/pconverter.
Nameplate
Fig.2: Location of the nameplate
Note

10 EB 6116 EN
Markings on the device
2.2 Article code
Order no. Type6116- xxxxx x xxxxxxxx x
Explosion
protection Without 0
ATEX1)2) II2GExiaIICT6Gb 1
1/2
ATEX3) II2GExdIICT6;II2GExdIICT6/T5/T4Gb 2
CSA5)12) ClassI,GroupsB,C,D;ClassII,GroupsE,F,G;
Class III; Type 4 Enclosure
3
0 1…5 1/2 0…3
FM5)12) ClassI,II,III;Div.1,GroupsB,C,D,E,F,G;
ClassI,Div.2,GroupsB,C,D;
ClassII,Div.2,GroupsF,G;ClassIII;
Type 4X Enclosure
1 0/3
CSA1) Ex ia IIC T6; Class I, Zone 0:
ClassI,Div.1,GroupsA,B,C,D;
ClassII,Div.1,GroupsE,F,G;ClassIII;
ClassI,Div.2,GroupsA,B,C,D;
ClassII,Div.2,GroupsE,F,G;ClassIII;
Type 4 Enclosure
4
3
FM1) IS,ClassI,II,III;Div.1,GroupsA–G;
Class I, Zone 0, AEx ia IIC;
NI,ClassI,Div.2,GroupsA,B,C,D;
Type 4X Enclosure
IECEx4)6) Ex d IIC T6/T4 5
0 1/2 1 0/2
IECEx1) Ex ia IIC T6; Ex nA IIC T6 62 2
JIS4) Ex d IIC T6 7 0 1/2
i/p converter
module Type6109 4) 1
0 1 0 1 1
Type6112 2
Input 4 to 20 mA 0 1
4to12mA 1) 11)
2 0 3
12to20mA,withoutswitch-offelectronics 1) 7) 11)
2 04
0to20mA,withoutswitch-offelectronics 7)
2 0 5
4to20mA,withoutswitch-offelectronics 7) for positioner
attachment 0 6
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 8) 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
Initialvalue0.1to1.2bar;span5.94to8.00bar
2 1 8