Samson 6111 Service manual

Mounting and
Operating Instructions
EB 6111 EN
Edition June 2016
Electropneumatic Converters
Type6111 i/p Converter
Type 6111 in standard version
Type 6111 mounted on a supply air
manifold
Type 6111 in eld enclosure

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

2 EB 6111 EN

EB 6111 EN 3
Contents
1 General safety instructions.............................................................................4
2 Description....................................................................................................5
2.1 Application ...................................................................................................5
2.2 Principle of operation .....................................................................................5
2.3 Versions ........................................................................................................6
3 Installation....................................................................................................9
3.1 Mounting position..........................................................................................9
3.2 Electrical connection.......................................................................................9
3.2.1 Mounting and installation in hazardous areas..................................................9
3.3 Pneumatic connection...................................................................................10
4 Operation...................................................................................................10
4.1 Checking zero and span...............................................................................10
4.1.1 Zero............................................................................................................11
4.1.2 Span...........................................................................................................11
4.2 Zero adjustment for versions with an input signal of 0 to 20mA ......................11
5 Maintenance ...............................................................................................12
6 Servicing explosion-protected devices ..........................................................12
7 Supply air manifold for rail-mounting unit....................................................13
7.1 Mounting the supply air manifold..................................................................13
7.2 Preparing the supply air manifold..................................................................13
7.2.1 Connectors..................................................................................................13
7.2.2 Fittings for pneumatic output signals ..............................................................15
7.2.3 Connecting supply air manifolds ...................................................................15
7.3 Mounting the Type6111 Converter on the manifold .......................................15
8 Troubleshooting...........................................................................................16
9 Technical data .............................................................................................17
10 Dimensions .................................................................................................19
11 Accessories .................................................................................................21
12 Article code.................................................................................................23
13 PTB certication...........................................................................................25

4 EB 6111 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 comply with the requirements of the Directive 2014/30/EU. De-
vices with a CE marking have a declaration of conformity, which includes
information about the applied conformity assessment procedure. This decla-
ration 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 6111 EN 5
Description
2 Description
2.1 Application
The device is used to convert a direct current
input signal into a pneumatic output signal
for measuring and control tasks.
It is particularly suitable as an intermediate
element between electric measuring devices
and pneumatic controllers or between elec-
tric control devices and pneumatic control
valves.
The input is a load-independent direct cur-
rent of 4 to 20mA or 0 or 20mA.
The output is a pneumatic signal of 0.2 to
1bar or other signal ranges up to max.
8bar.
2.2 Principle of operation
See Fig.1 on page7.
The devices consist 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 pK, which is produced on the
apper (6) by the air jet leaving the nozzle
(7). The supply air (9) ows to the bottom
chamber of the volume booster (8) and a
certain amount of air determined by the dia-
phragm position ows past the sleeve (8.5)
and leaves through the output (OUTPUT 36).
The output signal pAis used also to supply
the nozzle (7). The offset spring (8.2) ensures
that the output signal is at least 100mbar
even at an input signal of 0mA. 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 pKupstream of
the restriction (8.4) increase until it corre-
sponds with the input current.
The increasing backpressure pushes the dia-
phragm (8.3) and the plug sleeve (8.5)
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 backpressure pK drops, the dia-
phragm moves upwards, releasing the plug
sleeve. The output pressure pA can escape
through the sleeve until the forces are equal
again.
Volume booster
See Fig.1 on page7.
Booster I (top
diagram)
II (bottom
diagram)
Output signal 0.1bar or
higher
0.0bar or
higher
i/p converter
module
Type6109
or
Type6112
Type6112
only
Note:
A relatively stable supply air network
is required for the version with volume
booster II.


6 EB 6111 EN
Description
Sample applications
−Booster I
It can be used in all applications allowing a
zero point of min. 0.1bar. Jumps in the sup-
ply air network can be compensated for,
without affecting the output signal.
For example, to control pneumatic control
valves.
−Booster II
It can be used in applications requiring a ze-
ro point of 0bar. For example, to control
pneumatic cylinders or rollers used in the pa-
per industry.
2.3 Versions
See section 12 on page23.

EB 6111 EN 7
Description
1.1
1
2
3
4
i
5
OUTPUT 36
8.4
8
8.2
8.3
8.5
SUPPLY 9
pA
SPAN
+–
7
6
pK
ZERO
Version with volume booster I
Version with volume booster II
Fig.1: Functional diagram
6
7
8
8.3
8.6
8.5
1
2
3
4
i
SUPPLY 8
OUTPUT 36
pA
ZERO SPAN
+ –
pK
1Balance beam
1.1 Mechanical zero point ad-
juster (0 to 20mA version
only)
2Plunger coil
3 Permanent magnet
4 Zero point and span adjust-
ers (not in 0 to 20mA ver-
sion)
5Slide switch for switch-off
electronics (not in 0 to
20mA version)
6 Flapper
7 Nozzle
8Volume booster
8.2 Offset spring
8.3 Diaphragm
8.4 Restriction
8.5 Plug sleeve (venting)
8.6 Fixed restriction
9 Springs
pAOutput pressure
pKBackpressure (cascade
pressure)
Supply air
Type6109/6112
i/p Module
Type6112
i/p
Module

8 EB 6111 EN
Description
Fig.2: Switch-off electronics
Slide switch for switch-off
electronics
Vent
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 vent-
ed to approximately 100mbar. This guaran-
tees, for example, the tight shut-off function
of a valve. This function requires a charac-
teristic which passes through the zero point,
for example, at an output signal of 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
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

EB 6111 EN 9
Installation
3 Installation
3.1 Mounting position
Rail-mounting unit
Snap the device onto the top-hat rail (see
Rail-mounting unit on page 19).
Optionally, mount it to a wall using the two
Ø 5.5mm holes.
The devices can also be mounted to a supply
air manifold using the corresponding acces-
sories (see section 11).
Field unit
Mount it using the bracket (1400-7432). See
Field unit on page 20.
3.2 Electrical connection
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 pre-
vention regulations of the employers’ liability
insurance.
Adhere to the terminal assignment specied
in the certicate. Switching the assignment of
the electrical terminals may cause the explo-
sion protection to become ineffective.
ÎConnect the wires for the input signal to
the (+) and (–) terminals. The terminals
are designed for wires with 0.2 to
2.5mm² (see section 9). No additional
voltage supply is required.
Fig.3: Terminal connection·Input signal
3.2.1 Mounting and installa-
tion in hazardous areas
The following regulations apply:
EN60079-14 (VDE 0165-1) Electrical Ap-
paratus for Explosive Gas Atmospheres and
EN50281-1-2 (VDE0165-2) Electrical Ap-
paratus for Use in the Presence of Combusti-
ble Dust.
The maximum permissible values specied in
the EC type examination certicates apply
when interconnecting intrinsically safe elec-
trical equipment (Ui or U0, lior I0, Pior P0, Ci
or C0and Lior L0).
WARNING!
Incorrect electrical connection will
render the explosion protection un-
safe.
Adhere to the terminal assignment
specied in the certicate.
0/4 to 20mA
ZERO + _SPAN
+_

10 EB 6111 EN
Operation
3.3 Pneumatic connection
Rail-mounting unit
The standard connections for supply air
(SUPPLY 9) and output (OUTPUT 36) are de-
signed as hose connections suitable for hose
with 4mm inside diameter and 6mm out-
side diameter (see Rail-mounting unit on
page 19).
The hose connection are also available with
1
/
8
NPT, G
1
/
8
or M5 female thread.
Field unit
See Field unit on page 20. The pneumatic
connections (supply air and output) are de-
signed as a bore with ¼-18NPT thread.
Supply air (see section 9)
−Min. + 0.4bar above the upper signal
pressure range value
−Max. 10 bar
Optional for rail-mounting unit:
−Supply over manifold (see section 7).
4 Operation
See Fig.5 on page19.
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. The specied range is xed and can
only be changed by approx. 10% using the
potentiometers.
If the device does not work properly for any
reason, check the zero and span.
The ZERO and SPAN potentiometers are ac-
cessible through the holes in the front cover
after opening the clear plastic cover (see
Fig.1 and section 10).
Note:
The zero point of devices with
booster I cannot be adjusted lower
than 0.1bar.
Do not adjust the characteristic in de-
vices with boosterII at all as the setting
is much more complicated than in the
version with boosterI.
