Mounting and Operating Instructions EB 8359-2 EN
Contents
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9. be switched under normal operating conditions Caution The terminal assignment specified in the cer tificate must be adhered to Reversing the assignment of the electrical terminals may cause the explosion protection to become in effective Do not tamper with enameled screws inside or on the housing Note on the selection of cables and wires To install intrinsically safe circuits observe section 12 of the standard EN 60079 14 2003 VDE 0165 Part 1 To run multi core cables or lines with more than one intrinsi cally safe circuit section 12 2 2 7 of this standard applies An additional cable gland can be installed when connecting the device over two sepa rate cables Cable entries left unused must be sealed with blanking plugs Devices used at ambient temperatures down to 40 must have metal cable entries 411 12 B Input Control signal 4 0 to 20 mA Fig 6 Electrical connection The wiring for the input signal is led using cable glands to the terminals 11 and 12 The ground connection can be con nected inside or outside of the positioner case The following accessories are available Cable gland M 20 x 1 5 Black Order no 1400 6985 Blue Order no 1400 6986 Adapter M 20 1 5 to V2 NPT Aluminum powder coated Order no 0310 2149 3 2 Pneumatic connections The pneumatic connections are designed as tapped holes with 1 4 or ISO 2228 1 14
10. F Upper range value of the actuator pstmax F In the absence of such specifications pro ceed as follows Required supply pressure Upper bench range value 1 bar The positioner output pressure is led to the top or bottom diaphragm case of the actua tor as shown in Figs 7 to 10 8359 2 11 Operation 4 Operation 4 1 Combining positioner and ac tuator The arrangement of the actuator input sig nal operating direction and mounting loca tion is schematically represented in Figs 7 to 10 Each subsequent change such as reversal of the control loop s operating direction or field reversing the actuator version from direct Actuator stem extends to reverse Actuator stem retracts or vice versa also involves changing the mounting location of the positioner 4 1 1 Determining reversing the operating direction Figs 7 to 11 When the input signal reference variable w increases the signal pressure pst can either be increasing direct operating direction lt lt or decreasing reverse operating direction lt gt The same applies to a decreasing input sig nal the output pressure either decreases di rect operating direction lt lt or increases re verse operating direction lt gt Symbols are located on the flapper 10 2 which identify the respective operating di rections direct lt lt or reverse lt gt 12 EB 8359 2 EN Depending on the flapper position the ad just
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13. speed of response by pressing the range spring 6 as far as it will go 2 Set the input signal to approximately 50 of its range Then turn the zero adjustment screw 4 until the valve is at approximately 50 valve travel Operation On setting the Xp restriction observe the re lationship with the supply air pressure as in dicated in Fig 14 The preset value of Xp should read approximately 3 3 Check the plug stem s tendency to oscil lation by pressing the range spring 6 briefly as far as it will go Xp should be set to a value as small as possible however without causing no ticeable overshoot Note Always determine the X setting prior to ad justing the starting point Subsequent modifi cation displaces the zero point The zero can also be shifted by altering the adjusted supply air pressure If necessary check the zero adjustment un der operating conditions of the plant and re adjust if need be 180 270 Qf 90 0 Xp Zul Supply Alim bar 1 4 bar 5 44 3 2 1 0 0 90 180 270 360 X Fig 14 Setting the X restriction 8359 2 15 Operation 4 3 2 Setting actuator version Stem extends Note To ensure that the total closing force of the actuator can be effective in the control valve the diaphragm chamber must be completely vented at the lower range value of the refer the valve
14. thread The conventional male connec tions for metal and copper pipes or plastic hoses can be used Note The supply air must be dry and free of any oil and dust Always observe the mainte nance instructions applicable to the con nected pressure reducing stations Blow out air lines thoroughly before connecting them 3 2 1 Pressure gauges We recommend attaching pressure gauges for the supply air and signal pressure in or der to monitor the positioner The parts are listed as accessories in the table on page 19 Connections 3 2 2Supply pressure The required supply pressure is determined by the bench range and the operating direc tion fail safe action of the actuator The bench range is written on the nameplate as spring range or signal pressure range de pending on the type of actuator FA actua tor stem extends or FE actuator stem re tracts or a symbol indicates the operating direction Actuator stem extends FA Fail safe position Valve CLOSED for globe and angle valves Required supply pressure Upper bench range value 0 2 bor minimum 1 4 bar Actuator stem retracts FE Fail safe position Valve OPEN for globe and angle valves The required supply pressure for a tight closing valve is roughly estimated from the maximum signal pressure pstmax d YpYDp b aya Pol d Seat diameter cm Ap Differential pressure at the valve bar Actuator diaphragm area 2
15. Electropneumatic Positioner Type 4763 Fig 1 Type 4763 Mounting and Operating Instructions EB 8359 2 EN Edition September 2004 Contents Contents 2 2 1 2 2 2 3 3 3 1 3 2 32 1 3 2 2 4 4 1 4 1 4 2 4 3 4 3 1 1 4 3 2 4 3 3 4 4 5 6 7 8 2 8359 2 EN Design and principle of operation 6 Attachment 8 Attachment to valves with cast yokes 2 8 Attachment to valves with rod type yokes 9 Cover of the positioner case 2222 ee 9 Connedions 5 5 54214512 eae X y Pops eas 10 Electrical connections 10 Pneumatic connections 11 Pressure gauges 2 11 Supply pressure 22 oo on 11 Operations sos ccie x 404406 wa na OE PH ee Ses 12 Combining positioner and 12 Determining reversing the operating direction 12 Starting point and input signal reference 14 Setting the positioner atthe valve 15 Setting the air delivery volume restriction Q and proportional band Xp 15 Setting actuator version Stem extends 16 Setting actuator version Stem retracts 16 Exchanging the range spring 17 Conversion from electropneumatic to pneumatic positioner 18 Servicing explosion protec
16. G threaded connection Order number 1400 6724 for NPT threaded connection Order number 1400 6725 Required conversion kit for model index 03 or higher for G threaded connection Order number 1400 6795 for NPT threaded connection Order number 1400 6796 1 Undo mounting screws and lift the i p converter unit together with the printed circuit board out of the positioner case 2 Remove screw gland 1 Plug on hose 5 and screw the connecting nipple 4 of the conversion kit tightly on the case 3 Insert sealing element 7 into connecting plate 6 and screw tight in the case A Push the free end of the hose onto the connecting plate 6 1 Screw gland 2 Printed circuit board 3 i p module Fig 15 Converting the positioner Connecting nipple Hose Connecting plate Sealing element 18 EB 8359 2 EN Servicing explosion protected devices 6 Servicing explosion protected devices If a part of the positioner on which the ex plosion protection is based needs to be ser viced the positioner must not be put back into operation until an expert has inspected the device according to explosion protection requirements has issued a certificate stating this or given the device a mark of confor mity Inspection by an expert is not required if the manufacturer performs a routine
17. If the upper range value is in correct the pin 2 must be moved as fol lows in order to correct the signal Move pin to End of lever to increase travel Pivot to reduce travel Whenever you correct the input signal re adjust zero afterwards Subsequently ence variable operating direction lt lt and at the upper range value operating direc tion lt gt Therefore set input signal to a slightly in creased starting point of 4 5 mA when the operating direction is direct lt lt and to a slightly lowered starting point of 19 5 mA when the operating direction is reverse lt gt This applies in particular to controllers and control systems whose output signal is lim ited to a range of 4 to 20 mA Starting point zero e g 4 5 mA 1 Turn the zero adjustment screw 4 until the plug stem just begins to move from the resting position observe plug stem with travel indicator 2 Reduce the input signal on the ammeter and increase again slowly Check whether the plug stem starts moving at a starting point of 4 5 mA and if neces sary correct Upper range value span e g 20 mA 3 After the starting point has been ad check the upper range value Repeat until the two values match 4 3 3 Setting actuator version Stem retracts Note For actuator version Actuator stem re tracts the diaphragm chamber must be loaded with a pressure that is capable of tightly closing the con
18. Model index 02 or lower PG 13 5 Model index 03 or higher M 20 x 1 5 Tapped hole G Input for case with G threaded connection Output or 38 26 NPT Supply for case with 9 NPT threaded connection 20 8359 2 EN POP 5917 0294 91182 OOL Psepung eupsttupe upsietiskua WJolsuasepung oupsiuqse upsirexrefug ay jo paosddo eur embau joys ojnpoups 5 noy ald paur OBS pun eaniouBis nous sorore uoy 4 aq uonpununxg 53 SEL Buy ug 1229 48 2002 61 zinipssuorso dx3 ajparssBunjerzyiuaz 91211 1x33 DZ 9 eut yous uswd nbe jo y 21 pun Biomypsunnug eu 6444 POP ESLY 9 LLgE G OOL sejipsepung ijoisunsepung SypstuiupoL upsimnts yd ijoisuosopung eupsiuqso uosiexiefug eur jo Joud our joys ojnpoups soBupuo paonpoadea oq 81091109
19. check on the device prior to putting it back into oper ation The passing of the routine check must be documented by attaching a mark of con formity to the device 7 Accessories and mounting parts Explosion protected components may only be replaced by original checked compo nents from the manufacturer Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future must com ply with the safety demands placed on re paired devices Prior to operation they must be tested according to the specifications stip ulated for Repairing explosion protected devices Accessories Mounting parts Order number Range spring 1 1190 0736 Range spring 2 1190 0737 Range spring 3 1190 0738 Lever 1690 6469 Lever extension 1400 6716 Pressure gauge attachment 1400 6950 Pressure gauge attachment free of copper 1400 6951 Mounting kit for valves with cast yoke acc to NAMUR 1400 5745 Mounting kit for valves with rod type yokes acc to NAMUR 1400 5745 for rod diameters 18 to 35 mm and 1400 5342 Spare parts assortment with seals and diaphragms 1400 6792 Conversion kit to upgrade to degree of protection IP 65 1790 7408 refer to Samsomatic print Z 900 7 for more details 8359 2EN 19 Dimensions in mm 8 Dimensions in mm Useable lever length 40 to 127 mm with 40 to 200 mm lever extension Pneum connection ISO 228 1 G V4 Cable gland
20. ed operating direction is marked with the corresponding symbol If the operating di rection of the required function does not match the symbol or if the operating direc tion is to be changed proceed as follows 1 Remove both screws of the cover plate and lift off the nozzle block 10 along with the cover plate 2 Reinstall the nozzle block turned 180 to gether with the cover plate and screw tight Make sure that the nozzle block and flapper are correctly located above or below the feeler pin 9 1 as shown in Fig 11 If the operating direction is to be changed after the initially determined arrangement of positioner and actuator note that the positioner must be mounted in a different lo cation and the nozzle block must be turned Always consider the location of the lever 1 and the plate 20 lever on top of plate or reversed plate on top of lever as shown in Figs 7 to 10 Operation Actuator Stem extends FA Pst 1 Pst wo 9 20 2 e ko 9 3 20 1 B Lever 1 on top of plate 20 Plate 20 on top of lever 1 Fig 7 Operating direction lt lt Left attachment Fig 8 Operating direction lt gt Right attachment Actuator Stem retracts FE Pst Fig 9 O
21. has been installed 3 Screw tight the support and clamping plate 151 28 27 26 20 21 2 21 24 23 Fig 5 Attachment to valves with rod type yokes EB8359 2EN 9 Connections 3 Connections 3 1 Electrical connections For electrical installation you are re quired to observe the relevant electrotechnical regulations and the accident prevention regulations that apply in the country of use In Ger many these are the VDE regulations and the accident prevention regula tions of the employers liability insur ance association The following standards apply for in stallation in hazardous areas EN 60079 14 2003 VDE 0165 Part 1 Electrical apparatus for ex plosive gas atmospheres and EN 50281 1 2 1999 VDE 0165 Part 2 Electrical apparatus for use in the presence of combustible dust For the interconnection of intrinsically safe electrical equipment the permissi ble maximum values specified in the EC type examination certificate apply U or Ug I or lo Por C or Co and Lo Note for Zone 2 and Zone 22 equip ment For EEx nA equipment non sparking apparatus the standard EN 50021 1999 specifies that connecting inter rupting or switching circuits while en ergized is only allowed during instal lation maintenance or repair work 10 EB 8359 2 EN For EEx nL equipment energy limited apparatus the standard EN 50021 1999 allows this type of equipment to
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23. on the Internet at http www samson de 8359 2 3 Versions Positioner Type 0 Explosion protection Without 0 Il 2 EEx ia IIC 16 acc to ATEX 1 Ex ia CSA FM 3 II 3 G EEx nA II T acc to ATEX 8 Range spring 2 2 3 3 Pneumatic connections 14 V4 NPT 3 Electrical connections 20 x 1 5 blue M 20 x 1 5 black 2 Harting connector 5 Reference variable 4 20 mA 11 O to 20 mA 22 1105 mA 253 8359 2 EN Technical data Controlled variable travel 7 5 to 60 mm with 90 mm lever extension Reference variable Split range O to 50 or 50 to 100 Reference variable span up to 50 mm travel 4 bis 20 mA Ex Internal resistance Ri at 20 C approx 250 0 7 4 bis 20 mA not Ex Internal resistance Ri at 20 C approx 200 Q 7 0 to 20 mA The data specified in the Certificate of Conformity must be taken into consideration for devices with type of protection EEx II C Range spring See table on page 14 for selection Supply air 1 4 to 6 bar 20 to 90 psi Air quality as per ISO 8573 1 Max particle size and density Class 4 Oil contents Class 3 Pressure dew point Class 3 Signal pressure p output Max 0 to 60 bar 0 to 90 psi Characteristic Linear characteristic Deviation from terminal based conformity lt 1 5 96 Hysteresis 0 5 Sensitivity 0 1 26 Operating di
24. perating direction lt lt Right attachment Range spring Cover plate EN NEED Nozzle block I Feeler pin Marking Flapper Operating direction increasing increasing direct lt lt direction increasing decreasing reverse lt gt feeler pin on top of flapper flapper on top of feeler pin Fig 11 Position of nozzle block cover plate removed 8359 2EN 13 Operation 4 2 Starting point and input sig nal reference variable The attached lever and the installed range spring of the positioner are assigned to the values of rated valve travel mm and the in put signal reference variable as in the table below In standard operation the reference vari able span is 100 16 mA A smaller span of for example 50 8 mA is only required for split range operation Fig 13 The span can be changed by exchanging the range spring section 4 4 On making adjustments to the positioner the travel must be adapted to the input signal and vice versa With a 4 to 20 mA input signal for exam ple the valve must also move through the entire range 0 to 100 The starting point 100 Open Travel Closed 0 4 20mA Reference variable _ Input signal Fig 12 Standard operation 100 Open Travel Valve 1 20mA 4 12 e Dead band Fig 13 Split range operation two valves ope
25. rating in opposing directions Rated travel mm Min max travel Reference variable input signal Range spring mm Standard travels for SAMSON valves with lever 40 to 127 mm long 100 15 7 5 15 50 9 2 100 2 30 14 to 32 50 3 60 30 to 70 100 3 Additional travel ranges with lever and lever extension 40 to 200 mm long 100 20 7 5 to 26 50 2 100 2 40 14 to 50 50 3 gt 60 30 to 90 100 3 14 8359 2 EN then is 4 mA and the upper range value 20 mA In split range operation the controller output signal used to control two control valves is divided in such a way that these valves move through their entire travel with half of the input signal range e g first valve set to A to 12 mA second valve set to 12 to 20 mA To prevent the two from overlap ping a dead band of 0 5 mA as in Fig 13 must be taken into account The starting point zero is adjusted using the zero adjustment screw 4 the reference variable span and hence the upper range value using the pin 2 4 3 Setting the positioner at the valve Connect an ammeter to the control signal input at the terminals 11 and 12 Connect the supply air to the supply input supply 9 4 3 1 Setting the air delivery vol ume restriction Q and pro portional band X 1 Close the volume restriction 14 as far as the required speed of response al lows You can check the
26. rection Reversible Proportional band Xp at 110325 with spring 1 and 2 1 4 bar supply oir 1 5 with spring 3 Air consumption in steady state 1 With 1 4 bar supply air 0 19 m 3 h With 6 bar supply air 0 5 m 3 h Air delivery At Ap 1 4 bar 3 0 m 3 h At Ap 6 bar 8 5 m 3 h Transit time with Type 3271 Actuator stem extends 240 cm lt 1 8 s 350 lt 2 55 700 lt 105 Permissible ambient temperature 20 to 70 C 35 to 70 C for devices with metal cable entry 45 to 70 C special version Version with oxygen as operating medium up to max 60 C Specifications in Certificate of Conformity additionally apply for Ex devices Influences Temperature 0 03 1 K Supply air lt 0 3 0 1 bar Vibration lt 2 between 10 to 150 Hz and 4 g Effect when turned by 180 lt 3 5 Degree of protection IP 54 special version IP 65 Weight Approx 1 2 kg Materials Case Die cast aluminum chromated and plastic coated External parts Stainless steel 8359 2 EN 5 Design and principle of operation 1 Design and principle of opera tion The electropneumatic positioner is used for the correlation between the valve stem posi tion controlled variable x and the input sig nal reference variable w received from the controller In this case the input signal ac cepted from the control device is compared to the travel valve
27. st yokes 1 Fasten the plate 20 to the stem connec tor clamps 22 of the valve using the screws 21 2 Unscrew the positioner cover and secure the device to the valve yoke using the mounting screw 15 Make sure that the pin 2 is led inside the wire strap and therefore clamped against the plate 20 Legends for Figs 4 and 5 1 Lever 2 Pin 21 Nut 15 Mounting screw 20 Plate 21 Screw 22 Stem connector 23 Plug stem 24 Travel indicator 26 Clamping plate 27 Valve pillars 15 1 20 2 2 21 28 Support 22 23 Fig 4 Attachment to valves with cast yokes NAMUR rib 8 EB8359 2 EN Attachment 2 2 Attachment to valves with 4 Mount the positioner to the support using rod okes the mounting screw 15 Make sure that od the pin 2 is led inside the wire strap 1 Screw the plate 20 off centered to the and therefore clamped against the plate travel indicator 24 of the plug stem 23 20 using the screws 21 2 Place both the support 28 and the clamping plate 26 on the pillar 27 and lightly fasten Move the support until both the center of the plate 20 and the support 28 are aligned at half the valve travel 2 3 Cover of the positioner case After attaching the positioner make sure that the vent plug on the cover of the positioner case points downwards after the valve
28. stem position of the con trol valve and a pneumatic signal pressure output variable y is delivered The positioner consists of an i p converter unit 21 and the pneumatic section includ ing the lever 1 shaft 1 1 and range spring 6 plus the control system compos ing nozzle flapper and booster The input signal e g 4 to 20 mA is directly fed to the i p converter unit and converted to a pro portional air pressure signal pe Any change of the input current signal causes a propor tional change of the air pressure pe sent to the pneumatic control system The air pressure pe in turn produces a force which acts on the surface of the mea suring diaphragm 8 and is compared to the force of the range spring 6 The motion of the diaphragm 8 is transferred to the flapper 10 2 via 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 down stream of the nozzle The signal pressure pst which is released causes the plug stem to as sume a position based on the input signal The adjustable volume restriction Q 14 and Xp gain restriction 13 are used to opti mize the control loop The range spring 6 which can be exchanged is assigned to both the rated valve travel and the nominal voltage of the input signal
29. ted devices 2222222020 19 Accessories and mounting parts 19 Dimensions in mm 2000000002 bee 20 Test certificates ERA EKG Behe ee CER eH 21 Safety instructions Assembly start up and operation of the device may only be performed by trained and experienced personnel familiar with this 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 possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the relevant stan dards Explosion protected versions of this device may only be operated by person nel who have undergone special training or instructions or who are autho rized to work on explosion protected devices in hazardous areas Any hazards which could be caused by the process medium the signal pressure and moving parts of the control valve are to be prevented by means of the appropriate measures If inadmissible motions or forces are produced in the actuator as a result of the level of the supply air pressure this must be restricted by means of a suitable pressure reducing station Proper shipping and appropriate storage are assumed Note The device with a CE marking fulfils the requirements of the Directives 94 9 EC ATEX and 89 336 EEC EMC The declaration of conformity can be viewed and downloaded
30. the travel indicator at the valve If the upper range value is incorrect the pin 2 must be moved to correct the sig nal Adjust 20 mA and turn the zero adjust ment screw 4 until the required signal pressure is indicated on the pressure gauge By way of substitution for a pressure gauge set 19 5 mA as the starting point Operation 4 4 Exchanging the range spring If the range is to be altered or changed to split range operation replace the range spring as shown in Fig 3 as follows 1 Remove screw 7 range spring Pull out hexagon socket screw 5 and the lever together with shaft Exchange range spring Slide lever with shaft through sleeve 3 positioner case and bracket 6 1 Secure range spring with the screw 7 4 Move bracket and shaft until the screw 5 sits on the flattened part of the shaft Tighten screw 5 Allow for a play from 0 05 to 0 15 mm between the lever 1 and the sleeve 3 as well as between the range spring 6 and the positioner case 8359 2 17 Conversion from electropneumatic to pneumatic positioner 5 Conversion from electropneu matic to pneumatic positioner The appropriate conversion kit allows the electropneumatic positioner to be converted into a Type 4765 Pneumatic Positioner Note EB 8359 1 EN then applies for the con verted Type 4765 Pneumatic Positioner Required conversion kit for model index 02 or lower for
31. trol valve even with prevailing upstream pressure in the plant This concerns an upper range value of the input signal corresponding to 20 mA direct operating direction or a lower range value corresponding to 4 mA reverse oper ating direction lt gt The required signal pressure is indicated on the adhesive label on the positioner or is roughly estimated as in section 3 2 2 on page 11 Starting point zero e g 20 mA 1 Adjust the input signal to a starting point justed increase the input signal The plug stem must be motionless at an upper range value of exactly 20 mA and there fore already moved through 100 of its travel range watch the travel indicator at 16 EB 8359 2 EN of 20 mA on the ammeter Turn the zero adjustment screw 4 until the control valve just begins to move from the initial position Increase the input signal and slowly re duce to a starting point of 20 mA again Check if the valve begins to move at ex actly 20 mA Correct deviation using the zero adjust ment screw 4 turning it counterclock wise moves the control valve earlier from its final position and clockwise later Upper range value span e g 4 mA 3 After adjusting the starting point adjust the input signal to an upper range value of 4 mA using the ammeter With an up per range value of exactly 4 mA the plug stem must be motionless and there fore already moved through 100 of its travel range watch
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