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.


EB 6111 EN 11
Operation
4.1.1 Zero
1. Connect a pressure gauge (minimum ac-
curacy class 1) to the converter output.
2. Set the supply air to 0.4bar above the
upper output signal range value and ap-
ply it to the device.
3. Deactivate the switch-off electronics at
the slide switch (5) (push the switch ac-
cessible through the oblong hole at the
bottom of the converter away the ACTIVE
arrow).
4. Set the input signal to the lower range
value using a suitable ammeter (e.g. set
it to 4mA for 4 to 20mA range = 0.2 to
1bar).
The output signal of the pressure gauge
should now indicate 0.2bar.
If this is not the case, readjust the zero
point accordingly with the ZERO potenti-
ometer.
4.1.2 Span
1. Set the input signal to 20mA (upper
range value) using a suitable ammeter.
For example, the output signal at the
pressure gauge should now indicate
1.0bar for a 4 to 20mA range=0.2 to
1.0bar.
2. If this is not the case, readjust the span
accordingly with the SPAN potentiome-
ter.
3. Change the input signal abruptly from
20 to 0mA and check whether the out-
put signal assumes the upper range val-
ue of 1.0bar.
As the adjustment of zero and span inu-
ence each other, recheck both values and
correct them, if necessary.
4.2 Zero adjustment for ver-
sions with an input signal
of 0 to 20mA
These versions do not have potentiometers to
adjust zero or span nor switch-off electron-
ics. The zero point can only be adjusted me-
chanically at the zero screw (1.1).
To proceed, remove the front cover and in-
sert a screwdriver through the hole in the
cover of the Type6112 i/p Module (see
Fig.1 and section 10).

12 EB 6111 EN
Maintenance
5 Maintenance
No specic maintenance measures need to
be carried out. To guarantee trouble-free op-
eration of the converter, make sure that the
supply air is always clean (see section 9 for
air quality).
Therefore, check the air lter and separator
installed in the upstream air reducing station
regularly.
6 Servicing explosion-protected
devices
If a part of the device on which the explosion
protection is based needs to be serviced, the
device must not be put back into operation
until a qualied inspector has assessed it ac-
cording to explosion protection require-
ments, has issued an inspection certicate or
given the device a mark of conformity.
Inspection by a qualied inspector is not re-
quired if SAMSON performs a routine test
on the device before putting it back into op-
eration. Document the passing of the routine
test by attaching a mark of conformity to the
device.
Replace explosion-protected components on-
ly with original, routine-tested components
from the manufacturer.
Devices that have already been used outside
hazardous areas and are intended for future
use inside hazardous areas must comply
with the safety requirements placed on ser-
viced devices. Before being operated inside
hazardous areas, test the devices according
to the specications for servicing explo-
sion-protected devices.

EB 6111 EN 13
Supply air manifold for rail-mounting unit
7 Supply air manifold for
rail-mounting unit
See Fig.4 on page14.
Supply air manifolds and the corresponding
accessories are listed in section 11.
The manifold (Fig.4) is available as an ac-
cessory and provides a common air supply
for several Type6111 i/p Converters.
The manifold can be made to be as long as
required by combining two or more connect-
ing rails of the manifolds for 3, 4, 5 and 6
converters. Individual connecting rails are
connected by a coupling (5, order no. 1400-
7294) with seals (4).
Optionally, the manifold can be tted with a
shut-off valve, pressure gauge as well as
hose connections (screw or push-on connec-
tions) for the output signals.
7.1 Mounting the supply air
manifold
To x the manifold to a wall or to a panel in
a control cabinet, drill holes for M5 screws
in the groove of the connecting rail.
Make sure you keep 18mm distance be-
tween the holes and the left and right edge
of the rail to allow you to mount the i/p con-
verters properly.
7.2 Preparing the supply air
manifold
7.2.1 Connectors
Mount connectors (3 and 4) at the ends of
the manifold rail and secure them in place
with the grub screws (6).
Supply air
Connect the supply air either over the con-
nector (3) or over a hose screw connection
or push-on connection (10a or 10b).
Firmly screw the hose screw connection
(10a) or push-on connection (10b) with its
seal (10.1) into one of the two connectors
(3). If the accessories include a shut-off valve
(11), mount it between the connector and
supply air port screw tting.
End connection
Screw screw plug (2) into the connector us-
ing sealing tape.
If a pressure gauge (1) is tted, seal it in
place of the screw plug.
Insert seals (4) on both connectors and push
them on the left or right side into the con-
necting rail.
Align connectors and secure them in place
with the grub screws (6).

14 EB 6111 EN
Supply air manifold for rail-mounting unit
Fig.4: Exchanging the connecting plate in the converter (top) · Assembling the supply air manifold
(below)
15
16
18
15
11 11.1
10.1 34
68
9
7a
7.1
7b
6
1
12
544
43
2
10b
10a
16
12
1) M3x6 screw with seal
15 Connecting plate (hose
connection)
16
1) Connecting plate
(supply air manifold)
with 3x10mm screws
1 Pressure gauge
2Screw plugs
3
1) Connector G¼
4
1) Seals
5 Coupling
6
1) M4x6 grub screw
7Connection for output signal
a: Hose screw connection
b: Hose push-on connection
7.1 Washer
8
1) Cap screw M4x16
9
1) O-ring 3x2.7mm
10 Connection for supply air
(G¼)
a: Hose screw connection
b: Hose push-on connection
10.1 Seal
11 Shut-off valve
11.1 Seal
Height of supply air manifold:
75mm
Holes for mounting
1) Included in the scope of delivery of the basic version

EB 6111 EN 15
Supply air manifold for rail-mounting unit
7.2.2 Fittings for pneumatic
output signals
Attach the output signal connection (7a or
7b) to the holes on the bottom of the con-
necting rail (G
1
/
8
thread).
Fasten the hose screw connection (7a) to-
gether with a washer (7.1).
The hose push-on connection (7b) has an in-
tegrated seal and is fastened without the
washer (7.1).
7.2.3 Connecting supply air
manifolds
A coupling (5) with seals (4) is used to con-
nect the individual connecting rails together:
ÎPlace seals (4) on the outer grooves of
the coupling (5).
ÎPress the coupling into the manifold hole
and push on the connecting rail as far as
it will go.
ÎScrew in grub screws (6) to fasten the
parts together.
7.3 Mounting the Type6111
Converter on the manifold
ÎAttach fastening screws for Type6111:
Insert cap screws (8) from below into the
holes in the connecting rail and push on
O-rings (9) from the top to prevent the
screws from falling out.
ÎUnscrew the original connecting plate
(15) from the bottom of the converter
and replace it with the black connecting
plate (16) using the two 3x10mm screws
included in the accessories (Fig.4, top).
ÎSlightly tilt the converter upwards and
place it on the manifold already mounted
(7.1). Press the converter down and se-
cure it with the fastening screw (8).
Note:
If fewer Type 6111 Converters are
mounted on the manifold than it is in-
tended for, seal any unused holes in
the supply air duct with the M3x6 cap
screws (12) and seals included in the
accessories.
Qty.
Type
6111
Combination with
coupling
Manifold rail 1)
length [mm]
Height: 75mm
Units per manifold
rail
3 4 5 6
3 1 – – – 108
4–1– – 144
5– – 1–180
6–––1 216
7 1 1 – – 252
8–2– – 288
9–1 1 –324
10 – – 2–360
11 – – 1 1 369
12 –––2 432
13 1 –2–468
14 –1 2 –504
15 – – 3–540
1) Plus length of accessories


16 EB 6111 EN
Troubleshooting
8 Troubleshooting
Problem Possible reasons Corrective action to be
taken Comments
No output signal de-
spite changing the
input signal
Supply air not connect-
ed
Check supply air connec-
tion. See section 3.3.
Incorrect terminal as-
signment
Connect + and – termi-
nals correctly. See sec-
tion 3.2.
NOTICE
i/p converter does not need
any extra voltage!
Do not connect 24 V DC!
Incorrect input signal Connect correct signal. Read nameplate:
0 to 20mA or 4 to 20mA.
i/p converter con-
stantly vents off air
loudly
Connections for supply
air and output at the
i/p converter mixed up
Check pneumatic con-
nections. See section
3.3.
i/p converter does
not reach 100%
output e.g. 20mA
input: Output only
70% instead of
100%
Supply pressure too
low.
Supply air must be
0.4bar higher than the
max. output signal (sup-
ply air = 0.4bar)
Read nameplate:
Output 0.2 to 1bar →Sup-
ply air at least 1.4bar
Input signal faulty
Check whether the input
signal at the terminals
reaches 100% (100% is
e.g. 20mA in standard
version and 12mA for
split-range operation)
NOTICE
i/p converter has a load of:
– max. 6V (standard version)
– max. 7V (Ex ia version)
Check specication concern-
ing permissible load at the
source of the input signal.

EB 6111 EN 17
Technical data
9 Technical data
Type6111 Rail-mounting unit Field unit
Explosion protection II 2 GExia IIC T6 II 3 GEx nA IIC T6
Input 4 to 20mA (0 to 20mA on request), for split-range: 4 to 12mA or 12 to
20mA, other signals on request
Load
Standard
Explosion-protected version
without switch-off electronics
≤ 6V (corresponding to 300Ω at 20mA)
7V (corresponding to 350Ω at 20mA)
≤ 4V (corresponding to 200Ω at 20mA)
Out-
put
with Type6112 i/p Module
0.2 to 1bar (3 to 15psi) (standard range)
0.4 to 2bar (6 to 30psi) (standard range)
Special ranges adjustable at the factory to meet customer specications
Module A
Module B
Module C
Module D
Module E
Module F
Module G
Module H
Initial value
2)
0.1 to 0.4bar
0.1 to 0.4bar
0.1 to 0.4bar
0.1 to 0.8bar
0.1 to 0.8bar
0.1 to 0.8bar
0.1 to 1.2bar
0.1 to 1.2bar
Span ∆p
0.75 to 1.0bar
1.0 to 1.35bar
1.35 to 1.81bar
1.81 to 2.44bar
2.44 to 3.28bar
3.28 to 4.42bar
4.42 to 5.94bar
5.94 to 8.0bar
1)
Max. air output capacity
3)
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)
8.5m³/h at an output of 5.0bar (0.1 to 8.0bar)
Supply air At least 0.4bar above the upper signal pressure range value, max. 10bar
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
Power consumption 0.08mn³/h at 1.4bar · 0.1 mn³/h at 2.4bar · Max. 0.26mn³/h at 10bar
Characteristic Characteristic: Output linear to input
Hysteresis ≤0.3% of nal value
Deviation from terminal-based
conformity
≤1% of upper range value (for upper range values up to 5bar); more
exact values on request
≤1.5% of upper range value (for upper range values above 5bar)
Effect in % of the upper range
value
Supply air: <0.1%/0.1bar
Alternating load, supply air failure, interruption of the input current: <0.3%
Ambient temperature: lower range value <0.03%/K, span <0.03%/K
Dynamic response At an output of of 0.2 to 1bar
Limiting frequency 5.3Hz
Phase shift –130°
Variable position Max. 3.5% depending on mounting position: e.g. ± 1% when mounted
horizontally
1) Initial value raised up to 3.0bar (special version)
2) The max. possible output pressure is 8 bar.
3) Measured with 2m hose with 4mm inside diameter.

18 EB 6111 EN
Technical data
Technical data (continued)
Ambient conditions, degree of protection, weight
Storage temperature –40 to 70°C
Ambient temperature –20 to 70°C
Degree of protection IP 20 IP65
Weight, approx. 0.35kg 1.9kg
Materials
Housing Glass-ber-reinforced polyamide Stainless steel 1.4581

EB 6111 EN 19
Dimensions
10 Dimensions
−Rail-mounting unit
Fig.5: Rail-mounting unit·Dimensions in mm
Plastic cover
Label
Electric terminals
Top-hat rails
Ø 5.5mm holes for wall
mounting
Pneumatic connections for hose with 4mm
inside diameter and 6mm outside diameter
Adjuster
Zero Span
Connecting plate
113
35 20
1283
118
SUPPLY
9
OUTPUT
36
ZERO + _SPAN
113
32.5
12.5
1283
8010
Version with connecting plate G
1
/
8
or
1
/
8
NPT thread

20 EB 6111 EN
Dimensions
−Field unit
Fig.6: Field unit·Dimensions in mm
Holes for attaching the
bracket
Bracket 1400-7432
76136
NPT 1/4 R 1/4 M20x1.5
M6x1
Cover
Enclosure
126
120
Ø 9
Ø 30
69.5