Samson 4763 Service manual

Translation of original instructions
EB 8359-2 EN
Edition April 2020
Type4763 Electropneumatic Positioner

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
([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
2 EB 8359-2 EN

Contents
EB 8359-2 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................10
2.1 Article code.................................................................................................10
3 Design and principle of operation ................................................................14
3.1 Accessories and mounting parts....................................................................16
3.2 Technical data .............................................................................................17
3.3 Summary of explosion protection approvals...................................................19
3.4 Dimensions in mm........................................................................................20
4 Measures for preparation............................................................................21
4.1 Unpacking ..................................................................................................21
4.2 Transporting ................................................................................................21
4.3 Storage.......................................................................................................21
5 Mounting and start-up.................................................................................22
5.1 Attachment to valve with cast yoke ................................................................22
5.2 Attachment to valve with rod-type yoke..........................................................22
5.3 Housing cover .............................................................................................22
5.4 Pneumatic connections..................................................................................24
5.4.1 Pressure gauges...........................................................................................24
5.4.2 Supply pressure ...........................................................................................24
5.5 Electrical connections ...................................................................................25
6 Operating the positioner..............................................................................27
6.1 Assignment of the positioner and the actuator ................................................27
6.1.1 Determining and changing the operating direction .........................................28
6.2 Starting point and reference variable.............................................................30
6.3 Adjustment after mounting the positioner on the valve.....................................30
6.3.1 Setting the air delivery (volume restriction Q) and proportional band Xp..........30
6.3.2 Setting for actuator with fail-safe action “stem extends”...................................32
6.3.3 Setting for actuator version “stem retracts” .....................................................32

Contents
4 EB 8359-2 EN
6.4 Exchanging the range spring........................................................................33
7 Converting the electropneumatic into a pneumatic positioner ........................34
8 Servicing.....................................................................................................36
8.1 Preparation for return shipment.....................................................................36
9 Decommissioning and removal ....................................................................37
9.1 Decommissioning.........................................................................................37
9.2 Removing the positioner ...............................................................................37
9.3 Disposal......................................................................................................37
10 Annex.........................................................................................................38
10.1 After-sales service........................................................................................38

EB 8359-2 EN 5
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
assign 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 other
applications or conditions than specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the
device 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 specied by SAMSON
Qualications of operating personnel
The positioner must be mounted, started up and serviced 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
specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.
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.

6 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.
Furthermore, 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
pressure or by moving parts 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.
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
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions to the operating
personnel and to instruct them in proper operation. Furthermore, the operator must ensure
that operating personnel or third persons 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.

EB 8359-2 EN 7
Safety instructions and measures
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
according to explosion protection requirements, has issued an inspection certicate, or given
the device a mark of conformity. Inspection by a qualied inspector is not required if the
manufacturer performs 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 components by the
manufacturer.
Devices that have already been operated outside hazardous areas and are intended for
future use inside hazardous areas must comply with the safety requirements 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 in-
terconnection with intrinsically safe circuits to check or calibrate the equipment inside or
outside hazardous areas.
ÎObserve the maximum permissible values specied in the certicates for intrinsically safe
circuits.
Referenced standards and regulations
Devices with a CE marking fulll the requirements of the Directives 2014/34/EU and
2014/30/EU. The declaration of conformity is included at the end of these instructions.
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.).

8 EB 8359-2 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to the formation 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. Switching
the assignment of the electrical terminals may cause the explosion protection to become
ineffective.
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 performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.
ÎAdhere to the terminal assignment. Do not undo the enameled screws in or on the
enclosure.
ÎThe maximum permissible values specied in the EC type examination certicates
apply when interconnecting intrinsically safe electrical equipment (Uior Uo, lior Io, Pi
or Po, Cior Coand Lior Lo).

EB 8359-2 EN 9
Safety instructions and measures
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.
1.3 Notes on possible property damage
NOTICE
!
An incorrect electric signal will damage the positioner.
A current source must be used to provide the electrical power for 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
malfunction.
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 required air quality.
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.

10 EB 8359-2 EN
Markings on the device
2 Markings on the device
2.1 Article code
Electropneumatic Positioner Type4763- x 1x0 0 xxxx0x0x x 0
Explosion protection
Without 0 2/7
II 2G Ex ia IIC T6 Gb according to ATEX 1
CSA/FM intrinsically safe/non incendive 3
II 3G Ex nA ic IIC T6 Gc according to ATEX 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 converter
Type6109 1
Type6112 2
Reference variable
4 to 20 mA 0
0 to 20 mA 2 2
1 to 5 mA 2 3
Temperature range
Standard 0
Low temperature down to –45 °C 2 2
Special version
Without 0 0 0
EAC certicate 1 0 1 0

EB 8359-2 EN 11
Markings on the device
The following devices are marked with the article code as listed below:
− Type4763, device index up to .03
− Type4763, device index .04 (some devices are marked with the new 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
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
Note

12 EB 8359-2 EN
Markings on the device
Type4763 up to device index .04 x 0xxxxxxxx0
i/p converters
Type6109 1
Type6112 2
Reference variable
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 13

14 EB 8359-2 EN
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 (reference variable). The
positioner compares the control signal of a
control system to the travel of the control
valve and issues 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 reference variable.
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 reference variable.
Legend for Fig.1 and Fig.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

EB 8359-2 EN 15
Design and principle of operation
4
21 14 13 10.2 7
1
15
8
5 6.1 63
Fig.1: Positioner with cover removed
pst
Output
38
pe
Supply
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
ii
p
12
14
13
122.1 20
Travel
Arrangement of nozzle/apper plate
for reverse <> operating direction
Fig.2: Functional diagram

16 EB 8359-2 EN
Design and principle of operation
3.1 Accessories and mounting parts
Accessories – Mounting parts Ordering number
Range spring 1
Range spring 2
Range spring 3
Lever I
Lever extension
Pressure gauge attachment
Pressure gauge attachment (copper-free)
1190-0736
1190-0737
1190-0738
1690-6469
1400-6716
1402-0938
1402-0939
Mounting kit for valves with cast yoke according to NAMUR
Valves with rod-type yoke according to NAMUR for 18 to 35mm rod
diameter
1400-5745
1400-5745 and 1400-5342
Assortment of spare parts including gaskets and diaphragms 1400-6792
Assortment of spare parts including gasket, diaphragms and
pneumatic parts (for positioners with device index .02 and higher) 1402-0040
Upgrade to degree of protection IP65:
Venting over check valve 1790-7408
Accessories for electrical connections Ordering number
Black cable gland M20x1.5
Blue cable gland M20x1.5 1400-6985 1400-6986
Adapter M20x1.5 to ½ NPT, powder-coated aluminum: 0310-2149

EB 8359-2 EN 17
Design and principle of operation
3.2 Technical data
Controlled variable (travel range) 7.5 to 60mm, with lever extension: 7.5 to 90mm
Reference variable 1)
Split-range 0 to 50% or
50 to 100%
reference variable 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 Table 1 on page31
Supply air 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” 240cm² ≤ 1.8s 350cm² ≤ 2.5s
700cm² ≤ 10.0s
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.

18 EB 8359-2 EN
Design and principle of operation
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%
Degree of protection IP54 · Venting over check valve (1790-7408): IP65
Compliance ·
Electromagnetic compatibility Complying with EN61000-6-2, EN61000-6-3 and EN61326-1
Weight Approx. 1.2kg
Materials
Housing Die-cast aluminum, chromated and plastic coated
External parts Stainless steel

EB 8359-2 EN 19
Design and principle of operation
3.3 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
EAC
Number RU C-DE.HA65.B.00510/20
1Ex ia IIC T6/T5/T4 Gb X
Date 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

20 EB 8359-2 EN
Design and principle of operation
3.4 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