Samson 4763 Service manual

Translation of original instructions
EB 8359-2 EN
Edition January 2022
Type4763 Electropneumatic Positioner

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 8359-2 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. 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]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 8359-2 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-3
1.2 Notes on possible personal injury ................................................................1-3
1.3 Notes on possible property damage.............................................................1-4
1.4 Special instructions concerning explosion protection ......................................1-5
2 Markings 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
3.2 Summary of explosion protection approvals..................................................3-4
3.3 Dimensions in mm.......................................................................................3-5
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the positioner.................................................4-1
4.3 Transporting the positioner...........................................................................4-1
4.4 Storing the positioner ..................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-2
5.2.1 Determining the operating direction of the positioner control loop...................5-2
5.2.2 Determining on which side of the valve the positioner is to be mounted ...........5-2
5.3 Positioner attachment ..................................................................................5-4
5.3.1 Attachment to valve with cast yoke ...............................................................5-4
5.3.2 Attachment to valve with rod-type yoke.........................................................5-4
5.4 Pneumatic connection..................................................................................5-4
5.4.1 Pressure gauges..........................................................................................5-6
5.4.2 Supply pressure ..........................................................................................5-6
5.5 Selecting the range spring ...........................................................................5-6
5.6 Adjusting the positioner...............................................................................5-9
5.6.1 Air output capacity and proportional band XP........................................................................... 5-9
5.6.2 Zero and span..........................................................................................5-10
5.7 Electrical connection..................................................................................5-11
5.8 Accessories and mounting parts.................................................................5-13
6 Start-up .....................................................................................................6-1
7 Operation..................................................................................................7-1

Contents
EB 8359-2 EN
8 Malfunction................................................................................................9-1
8.1 Troubleshooting ..........................................................................................9-1
8.2 Emergency action .......................................................................................9-1
9 Servicing....................................................................................................9-1
9.1 Changing the operating direction of the positioner control loop ......................9-2
9.2 Converting the electropneumatic into a pneumatic positioner..........................9-2
9.3 Periodic inspection and testing of the positioner.............................................9-2
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
12 Repairs ....................................................................................................12-1
12.1 Servicing explosion-protected devices.........................................................12-1
12.2 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Accessories ..............................................................................................15-1
15.2 After-sales service.....................................................................................15-2

EB 8359-2 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type4763 Positioner is mounted on pneumatic control valves and used to as-
sign the valve position to the control signal. The device is designed to operate under exactly
dened conditions (e.g. operating pressure, temperature). Therefore, operators must ensure
that the positioner is only used in applications where the operating conditions correspond to
the technical data. In case operators intend to use the positioner in applications or conditions
other than those 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 for limits and elds of application as well as possible uses.
Reasonably foreseeable misuse
The Type4763 Positioner is not suitable for the following applications:
− 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 maintenance activities not described in these instructions
Qualications of operating personnel
The positioner must be mounted, started up and serviced by fully trained and qualied per-
sonnel 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 stan-
dards.
Explosion-protected versions of this device must be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

1-2 EB 8359-2 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the positioner. Work
on the control valve may be necessary when mounting or removing the device.
ÎObserve the requirements for personal protective equipment specied in the valve docu-
mentation.
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
The positioner has direct inuence on the control valve. To avoid personal injury or property
damage, plant operators and operating personnel must prevent hazards that could be
caused in the control valve by the process medium, the operating pressure, the signal pres-
sure or by moving parts by taking appropriate precautions. Plant 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.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure, it must be restricted using a suitable supply pressure reducing station.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions to the operating per-
sonnel and to instruct them in proper operation. Furthermore, operators must ensure that op-
erating personnel or third parties are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specied hazard statements, warning and caution notes. Furthermore, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
Referenced standards, directives and regulations
Devices with a CE marking fulll the following requirements of the Directives:

EB 8359-2 EN 1-3
Safety instructions and measures
−Type4763-0: 2014/30/EU, 2011/65/EU
−Type4763-1/-8: 2014/30/EU, 2014/34/EU, 2011/65/EU
Devices with an EAC marking fulll the requirements of the Regulation TRCU020/2011.
See the 'Certicates' section for the declarations of conformity and EAC certicates.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−The mounting and operating instructions of the components on which the positioner is
mounted (valve, actuator, valve accessories etc.).
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 positioner in potentially explosive
atmospheres may lead to ignition of the atmosphere and ultimately to death.
ÎThe following regulations apply to installation in hazardous areas: EN60079-14
(VDE0165, Part1).
ÎInstallation, operation or maintenance of the positioner must only be performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.
ÎRead the special instructions concerning explosion protection (see section1.4).
1.2 Notes on possible personal injury
WARNING
!
Risk of injury by possible movement of the actuator stem after connecting the signal
pressure.
ÎDo not touch or block the actuator stem.

1-4 EB 8359-2 EN
Safety instructions and measures
Incorrect electrical connection will render the explosion protection unsafe.
ÎAdhere to the terminal assignment.
ÎDo not undo the enameled screws in or on the housing.
Intrinsic safety rendered ineffective in intrinsically safe devices.
Every time the positioner is operated, even not within the plant (e.g. during maintenance,
calibration and work on equipment), it must be ensured that the conditions for intrinsical-
ly safe circuits are observed.
ÎOnly connect intrinsically safe devices intended for use in intrinsically safe circuits to
certied intrinsically safe input-connected units.
ÎDo not place intrinsically safe devices back into operation that were connected to in-
trinsically safe input-connected units without certication.
ÎDo not exceed the maximum permissible electric values specied in the EC type ex-
amination certicates when interconnecting intrinsically safe electrical equipment (Ui
or U0, lior I0, Pior P0, Cior C0and Lior L0).
1.3 Notes on possible property damage
NOTICE
!
An incorrect electric signal will damage the positioner.
A current source must be used to power the positioner.
ÎOnly use a current source and never a voltage source.
Incorrect assignment of the terminals will damage the positioner and will lead to mal-
function.
For the positioner to function properly, the prescribed terminal assignment must be ob-
served.
ÎConnect the electrical wiring to the positioner according to the prescribed terminal
assignment.
Risk of malfunction due to failure to comply with air quality requirements.
ÎOnly use supply air that is dry and free of oil and dust.
ÎRead the maintenance instructions for upstream pressure reducing stations.
ÎBlow through all air pipes and hoses thoroughly before connecting them.

EB 8359-2 EN 1-5
Safety instructions and measures
1.4 Special instructions concerning explosion protection
Equipment for use in zone2/zone22
ÎIn equipment operated according to type of protection ExnA II (non-sparking equip-
ment) according to EN60079-15: 2003, circuits may be connected, interrupted or
switched while energized only during installation, maintenance or repair.
ÎGuide wires for the set point through the cable gland to the terminals 11 (+) and 12
(–) located on the housing.
ÎConnect the ground connection inside or outside of the housing.
Servicing explosion-protected devices
ÎObserve the following for servicing equipment in a section relevant for explosion pro-
tection:
– The equipment must not be put back into operation until a qualied inspector has
assessed the equipment according to explosion protection requirements, has is-
sued an inspection certicate or given the device a mark of conformity. Inspection
by a qualied inspector is not required if the manufacturer performed a routine
test on the device before putting it back into operation. Document the passing of
the routine test by attaching a mark of conformity to the device.
– Replace explosion-protected components only with original, routine-tested compo-
nents by the manufacturer.
– Devices that have already been operated outside hazardous areas and are in-
tended for future use inside hazardous areas must comply with the safety require-
ments placed on serviced devices. Before being operated inside hazardous areas,
test the devices according to the specications for servicing explosion-protected
devices.
Maintenance, calibration and work on equipment
ÎOnly use intrinsically safe current/voltage calibrators and measuring instruments for
interconnection with intrinsically safe circuits to check or calibrate the equipment in-
side or outside hazardous areas.
ÎObserve the maximum permissible values specied in the certicates for intrinsically
safe circuits.

1-6 EB 8359-2 EN

EB 8359-2 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
i/p Positioner single-acting
4763
See technical data for
ambient temperature
Made in Germany
SAMSON AG D-60314 Frankfurt
Date
Var.-ID
Model
Serial no.
Input
Supply
2
1
3 4
5
6
7
8
Input
i/p Positioner single-acting
4763
Supply max.
Made in Germany
SAMSON AG D-60314 Frankfurt
Model
* See technical data and
explosion-protection certificate for
permissible ambient temperature
and maximum values for connection
to certified intrinsically safe circuits.
Mat. S/N
SAM HV
Date
7
2 1
5
4
6
9
3 10 11
8
1 Supply pressure
2 Signal range
3Conguration ID/material number
4 Serial number
5 Model number
6 Approvals (CE, EAC, UKCA etc.)
7 Data Matrix code
(electronic nameplate)
8 Date of manufacture
9 Explosion protection marking
10 Code for NAMUR Recommendation
NE 53 (internal specication)
11 Hardware version

2-2 EB 8359-2 EN
Markings on the device
2.2 Article code
Electropneumatic Positioner Type4763- x 1x0 0 x x x x 0x0x x 0
Explosion protection
Without 0 2/7
ATEX: II 2G Ex ia IIC T6 Gb 1
CCC Ex: Ex ia IIC T4 ~ T6 Gb
EAC: 1Ex ia IIC T6/T5/T4 Gb X
CSA: Ex ia IIC T6; Class I, Zone 0
Class I, II, Div. 1, Groups A, B, C, D, E, F, G
Class I, II, Div. 2, Groups A, B, C, D, E, F, G
3
FM: Class I, Zone 0 AExia IIC
Class I, II, III, Div. 1, Groups A, B, C, D, E, F, G
Class I, Div. 2, Groups A, B, C, D;
Class II, Div. 2 Groups F, G; Class III
ATEX: II 3G Ex nA ic IIC T6 Gc 8 2/7
Spring
Spring 1, travel = 15 mm 1
Spring 2, travel = 30 mm, split range 15 mm 2
Spring 3, travel = 60 mm, split range 30 mm 3
Pneumatic connections
ISO228/1G¼ 1
¼-18NPT 3
Electrical connection (cable gland)
M20x1.5 blue (plastic) 1
M20x1.5 black (plastic) 2
M20x1.5 (nickel-plated brass) 7 2
i/p converters
Type6109 1
Type6112 2
Set point
4 to 20 mA 0
0 to 20 mA 2 2
1 to 5 mA 2 3

EB 8359-2 EN 2-3
Markings on the device
Electropneumatic Positioner Type4763- x 1x0 0 x x x x 0x0x x 0
Temperature range
Standard 0
Low temperature down to –45 °C 2 2
Special version
Without 0 0 0
EAC explosion protection certication 1010
The following devices are marked with the article code as listed on page2-3:
− Type4763, device index up to .03
−Type4763, device index .04 (some already with the currently used article code)
Type4763 up to device index .04 x 0xxxxxxxx0
Explosion protection
Without 0
II 2 GExia IIC T6 according to ATEX 1
Exia according to FM/CSA 3
Ex according to JIS 7
II 3 GEx nA II T6 according to ATEX 8
Lever
Lever 1 (40 to 127mm long) 1
Spring
Spring 1, travel = 15 mm 1
Spring 2, travel = 30 mm, split range 15 mm 2
Spring 3, travel = 60 mm, split range 30 mm 3
Special version
Without 0 0
Japan 0 2 0 4 0
Japan 7 2 0 4 0
Note

2-4 EB 8359-2 EN
Markings on the device
Type4763 up to device index .04 x 0xxxxxxxx0
Pneumatic connections
ISO228/1G¼ 1
¼-18NPT 3
ISO-7/1-Rc¼ 4
Electrical connection (cable gland)
ISO228/1G½ 0
M20x1.5 blue (plastic) 1
M20x1.5 black (plastic) 2
Harting connector HAN 7D 5
M20x1.5 blue (metal) 6
M20x1.5 (metal) 7
i/p converter
Type6109 1
Type6112 2
Set point
4 to 20mA 1 1
4 to 20mA 2 1
0 to 20mA 2 2
1 to 5 mA 2 3

EB 8359-2 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The electropneumatic positioner is used to
assign the valve position (controlled variable)
to the input signal (set point). The positioner
compares the control signal of a control sys-
tem to the travel of the control valve and is-
sues a signal pressure (output variable) for
the pneumatic actuator.
The positioner consists of an electropneumat-
ic converter unit (21) and a pneumatic unit
equipped with a lever (1), shaft (1,1) and
range spring as well as the pneumatic con-
trol system with nozzle, apper plate and
booster. The DC control signal, e.g. 4 to
20mA, issued by the controller, is transmit-
ted to the electropneumatic converter unit
(i/p converter) where it is converted into a
proportional pressure signal pe.
Any change of the input current signal caus-
es a proportional change of the air pressure
pefed to the pneumatic control system.
The air pressure peproduces a force which
acts on the surface of the measuring dia-
phragm (8) and is compared to the force of
the range spring (6).
The motion of the measuring diaphragm (8)
is transferred to the apper plate (10.2) over
the feeler pin (9.1) and the nozzle (10.1) re-
leases pressure. Any change of either the air
pressure peor the valve stem position causes
the pressure to change in the booster (12)
connected downstream of the nozzle. The
signal pressure pst which is released causes
the plug stem to assume a position based on
the set point.
The adjustable volume restriction Q (14) and
Xp (gain) restriction (13) are used to opti-
mize the control loop of the positioner.
The range spring (6), which can be ex-
changed, is assigned to both the rated valve
travel and the span of the set point.
Legend for Fig.3-1 and Fig.3-2
1 Lever for valve travel
1.1 Shaft
2Pin
2.1 Nut
3 Sleeve
4 Zero point adjustment
5 Fastening screw
6 Range spring
6.1 Bracket
7 Fastening screw
8 Measuring diaphragm
9 Diaphragm plate
9.1 Feeler pin
10 Nozzle block
10.1 Nozzle
10.2 Flapper plate
11 Cover plate
12 Booster
13 Xp restriction
14 Volume restriction Q
15 Hole for fastening screw
20 Plate
21 i/p converter

3-2 EB 8359-2 EN
Design and principle of operation
4
21 14 13 10.2 7
1
15
8
5 6.1 63
Fig.3-1: Positioner with cover removed
pst
Output
38
pe
Suppl
y
9
21
1.1
4
5
6
8
9
9.1
10.2
10
10.1 6
8
9
9.1
10.2
10.1
10
11
iip
12
14
13
122.120
Travel
Arrangement of nozzle/apper plate for in-
creasing/decreasing <> operating direction
Fig.3-2: Functional diagram

EB 8359-2 EN 3-3
Design and principle of operation
3.1 Technical data
Controlled variable (travel range) 7.5 to 60mm, with lever extension: 7.5 to 90mm
Set point1)
Split-range 0 to 50% or 50 to
100% set point span (up to
50mm travel)
4 to 20mA (Ex), Ri = 250Ω 2)
4 to 20mA (without explosion protection), Ri = 200Ω 2)
0 to 20mA, Ri = 200Ω 2)
1 to 5mA, Ri = 880Ω 2)
Range spring See the 'Installation' section for selection.
Supply Supply air: 1.4 to 6 bar (20 to 90 psi)
Air quality acc. to ISO8573-1: max. particle size and density:
Class 4
Oil content: Class 3 · Pressure dew point: Class 3
Signal pressure pst (output) Max. 0 to 6.0bar (0 to 90psi)
Characteristic Linear characteristic
Deviation from terminal-based conformity ≤1.5%
Hysteresis <0.5%
Sensitivity <0.1%
Direction of action Reversible
Proportional band Xp (at 1.4bar
supply air)
1 to 3.0% with spring 1
1 to 2.0% with spring 2
1 to 1.5% with spring 3
Air consumption in steady state
(Xp = 1%)
With 1.4bar supply air: 0.19 mn³/h
With 6bar supply air: 0.5 mn³/h
Air output At Δp 1.4bar: 3.0 mn³/h · At Δp 6bar: 8.5 mn³/h
Transit time with Type3271
Actuator, “stem extends”
175cm²: ≤1.8s
350cm²: ≤2.5s
750cm²: ≤10.0s
Permissible ambient
temperature3)
With Type6109 i/p Converter:
–20 to +70°C
–35 to +70°C (metal cable gland)
With Type6112 i/p Converter:
–20 to +80°C
–40 to +80°C (metal cable gland)
–45 to +80°C (special version)
Inuences Temperature: <0.03%/1K
Supply air: <0.3%/0.1bar
Vibrations: <2% between 10 up to 150Hz and 4g
Variable position when turned by 180°: <3.5%

3-4 EB 8359-2 EN
Design and principle of operation
Degree of protection IP54 · Venting over check valve (1790-7408): IP65
Conformity ·
Electromagnetic compatibility Complying with EN61000-6-2, EN61000-6-3 and EN61326-1
Weight Approx. 1.2kg
Materials Enclosure Die-cast aluminum, chromated and plastic coated
External parts Stainless steel
1) The data listed in the certicate of conformity applies to the version with type of protection Ex ia IIC.
2) Ri = Coil resistance (at approx. 20°C) ± 7% tolerance
3) Observe the limits in the certicate of conformity for explosion-protected versions.
3.2 Summary of explosion protection approvals
Type Certication Type of protection/comments
4763-1
ATEX Number PTB 02 ATEX 2078 II 2G Ex ia IIC T6 Gb
Date 2002-07-19
CCC Ex
Number 2021322307003870
Ex ia IIC T4 ~ T6 GbDate 2021-04-05
Valid until 2026-04-04
EAC
Number RU C-DE.HA65.B.00510/20
1Ex ia IIC T6/T5/T4 Gb XDate 2020-03-18
Valid until 2025-03-18
4763-3
CSA
Number 1607873 Ex ia IIC T6; Class I, Zone 0
Class I, II, Div. 1, Groups A, B, C, D, E,
F, G
Class I, II, Div. 2, Groups A, B, C, D, E,
F, G
Date 2005-09-16
FM
Number 3020228 Class I, Zone 0 AExia IIC
Class I, II, III, Div. 1, Groups A, B, C, D,
E, F, G
Class I, Div. 2, Groups A, B, C, D;
Class II, Div. 2 Groups F, G; Class III
Date 2015-10-12
4763-8 ATEX Number PTB 03 ATEX 2183 X II 3G Ex nA ic IIC T6 Gc
Date 2003-09-30

EB 8359-2 EN 3-5
Design and principle of operation
3.3 Dimensions in mm
157
49,5
15
2,5
38
Useable lever length I:
40 to 127mm
(with lever extension 40
to 200mm)
Pneumatic connections:
ISO-228/1-G¼
Cable gland:
Device index .02 and
lower: Pg 13.5
Device index .03 and
higher: M20x1.5
G
1
/
8
connection
for housing with G
thread
or
1
/
8
NPT connection
for housing with NPT
thread

3-6 EB 8359-2 EN