Samson 4763 Manuel de service

Electropneumatic Positioner

Type 4763

Fig. 1 · Type 4763

Mounting and

Operating Instructions

EB 8359-2 EN

Edition April 2008

Contents

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 6

2 Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Attachment to valves with cast yokes. . . . . . . . . . . . . . . . . . . 8

2.2 Attachment to valves with rod-type yokes . . . . . . . . . . . . . . . . 9

2.3 Cover of the positioner case. . . . . . . . . . . . . . . . . . . . . . . 9

3 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.1 Pressure gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Combining positioner and actuator . . . . . . . . . . . . . . . . . . 12

4.1.1 Determining/reversing the operating direction . . . . . . . . . . . . . 12

4.2 Starting point and input signal (reference variable) . . . . . . . . . . . 14

4.3 Setting the positioner at the valve . . . . . . . . . . . . . . . . . . . 15

4.3.1 Setting the air delivery (volume restriction Q) and proportional band XP.15

4.3.2 Setting actuator version “Stem extends” . . . . . . . . . . . . . . . . 16

4.3.3 Setting actuator version “Stem retracts”. . . . . . . . . . . . . . . . . 16

4.4 Exchanging the range spring . . . . . . . . . . . . . . . . . . . . . 17

5 Conversion from electropneumatic to pneumatic positioner. . . . . . . 18

6 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 19

7 Accessories and mounting parts . . . . . . . . . . . . . . . . . . . . 19

8 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2EB 8359-2 EN

Contents

EB 8359-2 EN 3

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 on the

Internet at http://www.samson.de.

4EB 8359-2 EN

Versions

Electropneumatic Positioner Type 4763- x 1x00x x xx0x0xx0

Explosion protection

Without 0 2/7

II 2 G EEx ia IIC T6 acc. to ATEX 1

CSA/FM intrinsically safe/non incendive 3

II 3 G EEx nA II T6 for Zone 2 acc. to ATEX 8 2/7

Range 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 connection

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) 72

i/p module

Type 6109 1

Type 6112 2

Reference variable

4 … 20 mA 0

0 … 20 mA 22

1 … 5 mA 23

Temperature range

Standard 0

Low temperature down to –45 °C 22

Special version

Without 000

For oxygen 0/1 0 1 6

II 3 D IP 54 T 80 °C (with manufacturer’s

declaration) 8 2/7 0 1 8

EB 8359-2 EN 5

Technical data

Controlled variable (travel) 7.5 to 60 mm, with 90 mm lever extension

Reference variable

Split-range 0 to 50 %

or 50 to 100 %

Reference variable span

(up to 50 mm travel)

4 to 20 mA Ex Internal resistance Riat 20 °C approx. 250 Ω±7%

4 to 20 mA not Ex Internal resistance Riat 20 °C approx. 200 Ω±7%

0 to 20 mA Internal resistance Riat 20 °C approx. 200 Ω±7%

1 to 5 mA Internal resistance Riat 20 °C approx. 880 Ω±7%

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 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 %

Operating direction Reversible

Proportional band XPat

1.4 bar supply air 1 to 3 % with spring 1 and 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 delivery 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 s

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: < 0.3 %/0.1 bar

Vibration: < 2 % between 10 to 150 Hz and 4 g

Effect when turned by 180°: < 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

1 Design and principle of

operation

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 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 pesent 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 peor 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

optimize 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.

6EB 8359-2 EN

Design and principle of operation

21 14 13 10.2 7

5 6.1 6 3

Fig. 2 · Positioner with cover removed

EB 8359-2 EN 7

Design and principle of operation

pst

Output

Supply

1.1

9.1

10.2

10.1 6

9.1

10.2

10.1

iip

1 2 2.1 20

Fig. 3 · Functional diagram

Legends for Figs. 2 and 3

1 Lever for valve travel

1.1 Shaft

2 Pin

2.1 Nut

3 Sleeve

4 Zero adjustment screw

5 Mounting screw

6 Range spring

6.1 Bracket

7 Mounting screw

8 Measuring diaphragm

9 Diaphragm plate

9.1 Feeler pin

10 Nozzle block

10.1 Nozzle

10.2 Flapper

11 Cover plate

12 Booster

13 XPrestriction

14 Volume restriction Q

15 Borehole for mounting screw

20 Plate

21 i/p converter unit

Arrangement of nozzle/flapper for

reverse <> operating direction

Travel

2 Attachment

To attach the positioner to valves with cast

yokes, mounting parts (order no.

1400-5745) are used. For valves with

rod-type yokes (pillars), the mounting kit (or-

der no. 1400-5745) and additionally the

mounting kit (order no. 1400-5342) are

necessary (see also accessories table on

page 19).

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 (see corre-

sponding Figs. 7 to 10 in section 4.1).

2.1 Attachment to valves with

cast 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).

8EB 8359-2 EN

Attachment

15 1 20 2 2.1 21 22 23

Fig. 4 · Attachment to valves with cast yokes (NAMUR rib)

Legends for Figs. 4 and 5:

1 Lever

2 Pin

2.1 Nut

15 Mounting screw

20 Plate

21 Screw

22 Stem connector

23 Plug stem

24 Travel indicator

26 Clamping plate

27 Valve pillars

28 Support

2.2 Attachment to valves with

rod-type yokes

1. Screw 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 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.

3. Screw tight the support and clamping

plate.

4. Mount the positioner to the support using

the mounting screw (15). Make sure that

the pin (2) is led inside the wire strap

and therefore clamped against the plate

(20).

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 has been installed.

EB 8359-2 EN 9

Attachment

151282726202.12 212423

Fig. 5 · Attachment to valves with rod-type yokes

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 permis-

sible maximum values specified in the

EC type examination certificate apply

(Uior U0; Iior I0; Pior P0; Cior C0,

and Lior L0).

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.

For EEx nL equipment (energy-limited

apparatus), the standard EN 50021:

1999 allows this type of equipment to

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 °C

must have metal cable entries.

10 EB 8359-2 EN

Connections

Fig. 6 · Electrical connection

Input

Control signal

4 (0) to 20 mA

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