Samson 4763 Service manual

Mounting and
Operating Instructions
EB 8359-2 EN
Edition April 2014
Type 4763 Electropneumatic Positioner
Type 4763 Electropneumatic Positioner

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 8359-2 EN

Contents
EB 8359-2 EN 3
1 General safety instructions.............................................................................5
2 Article code...................................................................................................6
3 Technical data...............................................................................................7
3.1 Explosionprotectioncerticates.......................................................................9
4 Design and principle of operation ................................................................10
5 Attachment .................................................................................................12
5.1 Attachmenttovalvewithcastyoke ................................................................12
5.2 Attachmenttovalvewithrod-typeyoke..........................................................12
5.3 Housingcover .............................................................................................12
6 Connections ................................................................................................14
6.1 Electricalconnections ...................................................................................14
6.2 Pneumaticconnections..................................................................................15
6.3 Pressuregauge ............................................................................................15
6.4 Supplypressure ...........................................................................................16
7 Operation...................................................................................................17
7.1 Assignmentofthepositionerandtheactuator ................................................17
7.1.1 Determiningandchangingtheoperatingdirection .........................................18
7.2 Startingpointandreferencevariable.............................................................20
7.3 Adjustmentaftermountingthepositioneronthevalve.....................................20
7.3.1 Settingtheairdelivery(volumerestrictionQ)andproportionalbandXp ..........20
7.3.2 Settingforactuatorwithfail-safeaction“stemextends”...................................22
7.3.3 Settingforactuatorwithfail-safeaction“stemretracts” ...................................22
7.4 Exchangingtherangespring ........................................................................23
8 Converting the electropneumatic into a pneumatic positioner ........................24
9 Servicing explosion-protected devices ..........................................................26
10 Maintenance, calibration and work on equipment ........................................27
11 Accessories and mounting parts...................................................................28
12 Dimensions in mm.......................................................................................29

EB 8359-2 EN 5
General safety instructions
1 General safety instructions
Foryourownsafety,followtheseinstructionsconcerningthemounting,startupandopera-
tionofthepositioner:
−Thepositioneristobemounted,starteduporoperatedonlybytrainedandexperienced
personnelfamiliarwiththeproduct.
Accordingtothesemountingandoperatinginstructions,trainedpersonnelisreferredto
asindividualswhoareabletojudgetheworktheyareassignedtoandrecognizepossi-
bledangersduetotheirspecializedtraining,theirknowledgeandexperienceaswellas
theirknowledgeoftheapplicablestandards.
−Explosion-protectedversionsofthispositioneraretobeoperatedonlybypersonnelwho
hasundergonespecialtrainingorinstructionsorwhoisauthorizedtoworkonexplo-
sion-protecteddevicesinhazardousareas.
−Anyhazardsthatcouldbecausedinthevalvebytheprocessmedium,thesignalpres-
sureorbymovingpartsaretobepreventedbytakingappropriateprecautions.
−Ifinadmissiblemotionsorforcesareproducedinthepneumaticactuatorasaresultof
thesupplypressurelevel,itmustberestrictedusingasuitablesupplypressurereducing
station.
−Propershippingandstorageareassumed.
Note:
Devices with a CE marking fulll the requirements of the Directives 2014/34/EU and
2014/30/EU.
The Declaration of Conformity is available on request.


6 EB 8359-2 EN
Article code
2 Article code
Electropneumatic positioners Type 4763- x 1x0 0 xxxx0x0x x 0
Explosion protection
Without 0 2/7
ExII2GExiaIICT6GbaccordingtoATEX 1
CSA/FMintrinsicallysafe/nonincendive 3
ExII3GExnAIIT6Gc/ExicIICT6GcforZone2acc.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)
M20x1.5blue(plastic) 1
M20x1.5black(plastic) 2
M20x1.5(nickel-platedbrass) 7 2
i/pconverters
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 000
Foroxygen1) 0/1 0 1 6
GOSTcerticate 8 2 0 1 0
1) Specialversionsuitableforoxygenuptomaximum+60°C
(accordingtoAIRLIQUIDEtestreportno.2014/R171a1)

EB 8359-2 EN 7
Technical data
3 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21
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characteristicaccordingto
terminalpointmethod:≤1.5%
Hysteresis <0.5%
Sensitivity <0.1%
Operatingdirection 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
Perm.ambienttemperature3),4) 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)

8 EB 8359-2 EN
Technical data
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
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.
4) Withspecialversionsuitableforoxygenuptomaximum+60°C

EB 8359-2 EN 9
Technical data
3.1 Explosion protection certicates
Type Certication Type of protection
4763-1
Number RUCDE.08.00697
1ExiaIICT6/T5/T4GbXDate 15.12.2014
Validuntil 2019-12-14
4763-1
Number PTB02ATEX2078
II2GExiaIICT6Gb
Datum 2002-07-19
ECtypeexamination
certicate
4763-3 ®
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
4763-3
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 2005-02-28
4763-7 JIS
Number TC14411
ExiaIICT6Date 2015-02-09
Validuntil 2018-03-01
4763-8
Number RUCDE.08.00697
2ExnAIICT6/T5/T4GcXDate 2014-12-15
Validuntil 2019-12-14
4763-8
Number PTB03ATEX2183X
II3GExnAicIICT6Gc
Date 2003-09-30
Statementof
conformity

10 EB 8359-2 EN
Design and principle of operation
4 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
pefedtothepneumaticcontrolsystem.
Theairpressurepeproduces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)
releasespressure.Anychangeofeitherthe
airpressurepeor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
1Leverforvalvetravel
1.1 Shaft
2Pin
2.1 Nut
3Sleeve
4Zeropointadjustment
5Fasteningscrew
6Rangespring
6.1 Bracket
7Fasteningscrew
8Measuringdiaphragm
9Diaphragm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 11
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

12 EB 8359-2 EN
Attachment
5 Attachment
Toattachthepositionertovalveswithcast
yokesaccordingtoIEC60534-6(NAMUR
rib),mountingparts(orderno.1400-5745)
areused.Forvalveswithrod-typeyokes,the
mountingkit(orderno.1400-5745)andad-
ditionallythemountingkit(orderno.1400-
5342)arenecessary(seealsoaccessoriesin
section11onpage28).
Sincethepositionercanbeattachedonei-
thersideofthevalve,thephysicallocation
(leftorrightattachment)shouldbedeter-
minedbeforeactualattachment.
ÎSeeFig.6toFig.9onpage17.
5.1 Attachment to valve with
cast yoke
1. Fastentheplate(20)tothestemconnec-
tor(22)ofthevalveusingthescrews
(21).
2. Unscrewthepositionercover,andsecure
thepositionertothevalveyokeusingthe
fasteningscrew(15).TheO-ringinclud-
edinthemountingkitisnotrequiredfor
thispositioner.Makesurethatthepin(2)
isinsertedthroughthewirestrapand,as
aresult,clampedagainsttheplate(20).
5.2 Attachment to valve with
rod-type yoke
1. Fastentheplate(20),off-centered,tothe
travelindicator(24)oftheplugstem(23)
usingthescrews(21).
2. Placeboththesupport(28)andthe
clampingplate(26)ontherod(27)and
lightlyfasten.Movethesupportuntilboth
thecenteroftheplate(20)andthesup-
port(28)arealignedwhenthevalveis
athalfofthevalvetravel.
3. Fastentightthesupportandtheclamp-
ingplate.
4. Mountthepositionertothesupportusing
thefasteningscrew(15).Makesurethat
thepin(2)isinsertedthroughthewire
strapand,asaresult,clampedagainst
theplate(20).
5.3 Housing cover
Afterattachingthepositioner,makesurethat
theventplugofthehousingcoverfaces
downwardwhenthevalveisinstalled.
Legend for Fig.3 and Fig.4:
1Lever
2Pin
2.1 Nut
15 Fasteningscrew
20 Plate
21 Screw
22 Stemconnector
23 Plugstem
24 Travelindicator
26 Clampingplate
27 Rod(pillar)
28 Support

EB 8359-2 EN 13
Attachment
15 1202 2.1 21 22 23
Fig.3: Attachment to valves with cast yokes (NAMUR rib)
15 128272620 2.1 2212423
Fig.4: Attachment to valves with rod-type yokes

14 EB 8359-2 EN
Connections
6 Connections
6.1 Electrical connections
DANGER!
For electrical installation, observe the
relevant electrotechnical regulations
and the accident prevention regula-
tions that apply in the country of use.
In Germany, these are the VDE regu-
lations and the accident prevention
regulations of the employers’ liability
insurance.
The following regulations apply to in-
stallation in hazardous areas:
EN60079-14:2008 (VDE 0165,
Part1) Explosive Atmospheres–
Electrical Installations Design, Selec-
tion and Erection.
NOTICE
Adhere to the terminal assignment!
Switching the assignment of the elec-
trical terminals may cause the explo-
sion protection to become ineffective.
Do not loosen enameled screws in or
on the housing. The maximum per-
missible values specied in the EC
type examination certicates apply
when interconnecting intrinsically
safe electrical equipment (Ui or Uo, li
or Io, Pior Po, Cior Coand Lior Lo).
Selecting cables and wires:
Observeclause12ofEN60079-14:2008
(VDE0165,Part1)forinstallationofthein-
trinsicallysafecircuits.Clause12.2.2.7ap-
plieswhenrunningmulti-corecablesand
wireswithmorethanoneintrinsicallysafe
circuit.
Theradialthicknessoftheinsulationofa
conductorforcommoninsulatingmaterials
(e.g.polyethylene)mustnotbesmallerthan
0.2mm.Thediameterofanindividualwire
inane-strandedconductormustnotbe
smallerthan0.1mm.
Protecttheconductorendsagainstsplicing,
e.g.byusingwire-endferrules.
Whentwoseparatecablesorwiresareused
forconnection,anadditionalcablegland
canbeinstalled.Sealcableentriesleftun-
usedwithplugs.Fitequipmentusedinambi-
enttemperaturesbelow–20°Cwithmetal
cableglands.

EB 8359-2 EN 15
Connections
Equipment for use in zone2/zone22:
Inequipmentoperatedaccordingtotypeof
protectionExnAII(non-sparkingequipment)
accordingtoEN60079-15:2003,circuits
maybeconnected,interruptedorswitched
whileenergizedonlyduringinstallation,
maintenanceorrepair.
Guidethewiresforthereferencevariable
overthecableglandtotheterminals11(+)
and12(–)locatedinthehousing.
Thegroundconnectioncanbeconnectedin-
sideoroutsideofthepositionerhousing.
Accessories for electrical connections
ÎSeesection11onpage28
Input
controlsignal
0/4to20mA
Fig.5: Electrical connection
6.2 Pneumatic connections
Thepneumaticconnectionsareoptionally
designedasaborewith¼NPTor
ISO288/1-G¼thread.Customaryttings
formetalorcoppertubingorplastichoses
canbeused.
NOTICE
Risk of malfunction due to failure to
comply with required air quality.
−Only use supply air that is dry and
free of oil and dust.
−Read the maintenance instructions
for upstream pressure reducing sta-
tions.
−Blow through all air pipes and hos-
es thoroughly before connecting
them.
6.3 Pressure gauge
Tomonitorthepositioner,werecommendin-
stallingpressuregaugesforthesupplyair
andsignalpressure.Therequiredpartsare
listedasaccessoriesinsection11on
page28.

16 EB 8359-2 EN
Connections
6.4 Supply pressure
Therequiredsupplyairpressuredependson
thebenchrangeandtheactuator'soperating
direction(fail-safeaction).
Thebenchrangeiswrittenonthenameplate
eitherasthespringrangeorsignalpressure
range.TheoperatingdirectionismarkedFA
or FE,orbyasymbol.
Actuator stem extends (FA)
Fail-close
(forglobeandanglevalves)
Requiredsupplypressure=Upperbench
rangevalue+0.2bar,
minimum1.4bar
Actuator stem retracts (FE)
Fail-open
(forglobeandanglevalves)
Fortight-closingvalves,themaximumsignal
pressure pstmaxisroughlyestimatedasfol-
lows:
pstmax = F+ d²·π·∆p [bar]
4·A
d = Seatdiameter[cm]
∆p = Differentialpressureacrossthevalve
[bar]
A= Actuatordiaphragmarea[cm²]
F= Upperbenchrangevalue[bar]
If there are no specications, calculate as
follows:
Requiredsupplypressure=Upperbench
rangevalue+1bar
Thepositioneroutputpressureisroutedto
thetoporbottomdiaphragmcaseoftheac-
tuatorasshowninFig.6toFig.9.

EB 8359-2 EN 17
Operation
7 Operation
7.1 Assignment of the posi-
tioner and the actuator
Arrangementoftheactuator,themounting
positionofthepositioner,thereferencevari-
ableandtheoperatingdirection:
ÎSeeFig.6toFig.9
Whenanysubsequentchangesaremade,
e.g.reversingtheoperatingdirectionofthe
positionercontrollooporchangingtheactu-
atorfail-safeactionfrom“actuatorstemex-
tends”to“actuatorstemretracts”orvicever-
sa,thepositioner'smountingpositionmust
bechangedaccordingly.
Actuator stem extends (FA)
1
20
pst
w
1
20
pst
w
Lever(1)ontopofplate(20) Plate(20)ontopoflever(1)
Fig.6: Operating direction << Left attachment Fig.7: Operating direction <> Right
attachment
Actuator stem retracts (FE)
p
st
w
p
st
w
Fig.8: Operating direction << Right
attachment
Fig.9: Operating direction <> Left attachment

18 EB 8359-2 EN
Operation
7.1.1 Determining and
changing the operating
direction
Foranincreasinginputsignal(reference
variable),thesignalpressurepstcaneither
beincreasing(directaction<<)ordecreas-
ing(reverseaction<>).
Similarly,asthereferencevariabledecreas-
es,thesignalpressurecaneitherdecrease
(directaction<<)orincrease(reverseaction
<>).
Ontheapperplate,theoperatingdirection
isindicatedbysymbols(direct<<,reverse
<>).Dependingonthepositionoftheap-
perplate,theadjustedoperatingdirection
andtheassociatedsymbolbecomevisible.
Iftherequiredoperatingdirectiondoesnot
correspondtothevisiblesymbol,orifthe
operatingdirectionistobechanged,pro-
ceedasfollows:
1. Unscrewbothscrewsonthecoverplate,
andliftoffthenozzleblockalongwith
thecoverplate.
2. Reinstallthenozzleblockturned180°to-
getherwiththecoverplate,andrefasten.
Makesurethatthenozzleblockandapper
platearecorrectlylocatedaboveorbelow
thefeelerpinasshowninFig.10.
Iftheoperatingdirectionistobechanged
aftertheinitiallydeterminedarrangementof
positionerandactuator,notethattheposi-
tionermustbemountedinadifferentloca-
tionandthenozzleblockmustbeturned.
Makesurethelocationofthelever(1)and
theplate(20),"leverontopofplate"orre-
versed"plateontopoflever"iscorrect
(Fig.6toFig.9).

EB 8359-2 EN 19
Operation
Operatingdirectionincreasing/increasing
(direct<<)
feelerpinontopofapperplate
Operatingdirectionincreasing/decreasing
(reverse<>)
apperplateontopoffeelerpin
Rangespring
Feeler pin
Coverplate
Nozzleblock
Marking Flapper
Fig.10: Position of nozzle block, cover plate removed
100%
0% 4 20mA
Referencevariable
Inputsignal
Open
Travel
Closed
100%
0% 412 20mA
Deadband
Valve2 Valve1
Open
Travel
Closed
Fig.11: Normal operation Fig.12: Split-range operation, two valves operating in
opposing directions

20 EB 8359-2 EN
Operation
7.2 Starting point and refer-
ence variable
Theattachedleverandtheinstalledrange
springofthepositionerareassignedtothe
valuesofratedvalvetravelandthereference
variableasinTable1.
Innormaloperation,thereferencevariable
spanis100%=16mA.Asmallerspanof,
forexample,50%=8mAisonlyrequired
forsplit-rangeoperation(Fig.12).
Thespancanbechangedbyexchangingthe
rangespring(section7.4).Onmakingad-
justmentstothepositioner,thetravelmustbe
adaptedtothereferencevariableandvice
versa.
Withareferencevariable,forexample,4to
20mA,thevalvemustmovethroughitsen-
tiretravelrangefrom0to100%.Thestart-
ingpointthenis4mAandtheupperrange
value20mA.
Insplit-rangeoperation,thecontrolleroutput
signalisusedtocontroltwocontrolvalves,
dividingitsuchthatthevalvesmovethrough
theirentiretravelrangeathalftheinputsig-
nalrangeeach(e.g.rstvalvesetto4to
12mA,secondvalvesetto12to20mA).To
avoidoverlapping,allowforadeadbandof
±0.5mAasshowninFig.12.
Thestartingpoint(zero)isadjustedatthe
screw(4);thereferencevariablespan,i.e.
theupperrangevalue,isadjustedatthepin
(2).
7.3 Adjustment after mounting
the positioner on the valve
ÎConnectanammetertothecontrolsignal
inputattheterminals11(+)and12(–).
ÎConnectthesupplyairtothesupplyin-
put(supply9).
7.3.1 Setting the air delivery
(volume restriction Q) and
proportional band Xp
1. Closethevolumerestriction(14)asfar
astherequiredpositioningspeedper-
mits.
Checkthepositioningspeedbypushing
therangespring(6)asfaritwillgo.
2. Adjustthereferencevariableattheinput
toapprox.50%ofitsrange.Then,turn
thezeroadjustmentscrew(4)untilthe
valveisatapproximately50%valve
travel.
OnsettingtheXprestriction,observethere-
lationshipwiththesupplyairpressureasin-
dicatedinFig.13.ThepresetvalueofXp
shouldbeapproximately3%.
3. Checktheplugstem'stendencytooscil-
latebypressingtherangespring(6)
brieyasfarasitwillgo.
TheXpvalueistobeadjustedtobeas
smallaspossible,withoutconsiderable
overshootingoccurring.
Additional points that apply concerning ad-
justment:
ÎAlwaysadjusttheXprestrictionbefore
settingthestartingpoint.