Samson 4763 Mounting And Operating Instructions
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Samson 4763 Mounting And Operating Instructions

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

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Summary of Contents for Samson 4763

  • Page 1 Type 4763 Electropneumatic Positioner Type 4763 Electropneumatic Positioner Mounting and Operating Instructions EB 8359-2 EN Edition April 2014...
  • Page 2 Definition of signal words DANGER! NOTICE Hazardous situations which, if not Property damage message or mal- avoided, will result in death or seri- function ous injury Note:  WARNING! Additional information Hazardous situations which, if not avoided, could result in death or seri- Tip: ous injury Recommended action...

  • Page 3: Table Of Contents

    Contents General safety instructions ................5 Article code ....................6 Technical data ....................7 3.1 Explosion protection certificates ...............9 Design and principle of operation ..............10 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 Connections ....................14 6.1 Electrical connections ...................14 6.2 Pneumatic connections..................15 6.3 Pressure gauge ....................15 6.4 Supply pressure ...................16 Operation ....................17...

  • Page 5: General Safety Instructions

    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 fulfill the requirements of the Directives 2014/34/EU and 2014/30/EU.

  • Page 6: Article Code

    Article code 2 Article code Electropneumatic positioners Type 4763- x 1 x 0 0 x x x x 0 x 0 x x 0 Explosion protection Without Ex II 2 G Ex ia IIC T6 Gb according to ATEX CSA/FM intrinsically safe/non incendive Ex II 3 G Ex nA II T6 Gc/Ex ic IIC T6 Gc for Zone 2 acc. to ATEX 8 Spring Spring 1, travel = 15 mm Spring 2, travel = 30 mm, split range 15 mm Spring 3, travel = 60 mm, split range 30 mm Pneumatic connections ISO 228/1 G ¼...

  • Page 7: Technical Data

    Technical data 3 Technical data Controlled variable (travel range) 7.5 to 60 mm, with lever extension: 7.5 to 90 mm Reference variable 4 to 20 mA (Ex), = 250 Ω 4 to 20 mA (without explosion protection), = 200 Ω Split-range 0 to 50 % or 0 to 20 mA, = 200 Ω 50 to 100 % 1 to 5 mA, = 880 Ω reference variable span (up to 50 mm travel) 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 p (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 1 to 3.0 % with spring 1 supply air) 1 to 2.0 % with spring 2...
  • Page 8 Technical data Influences 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 The data listed in the certificate of conformity applies to the version with type of protection Ex ia IIC. = Coil resistance (at approx. 20 °C) ± 7 % tolerance Observe the limits in the certificate of conformity for explosion-protected versions. With special version suitable for oxygen up to maximum +60 °C EB 8359-2 EN...

  • Page 9: Explosion Protection Certificates

    Technical data 3.1 Explosion protection certificates Type Certification Type of protection Number RU C DE.08.00697 4763-1 Date 15.12.2014 1Ex ia IIC T6/T5/T4 Gb X Valid until 2019-12-14 Number PTB 02 ATEX 2078 Datum 2002-07-19 4763-1 II 2G Ex ia IIC T6 Gb EC type examination certificate Number 1607873 Ex ia IIC T6; Class I, Zone 0; ® 4763-3 Class I,II, Div.1, Groups A,B,C,D,E,F,G; Date 2005-09-16 Class I,II, Div.2, Groups A,B,C,D,E,F,G; Number 3020228 Class I,Zone 0 AEx ia IIC Class I,II,III; Div.1, Groups A,B,C,D,E,F,G...

  • Page 10: Design And Principle Of Operation

    Design and principle of operation 4 Design and principle of oper- The adjustable volume restriction Q (14) and Xp (gain) restriction (13) are used to opti- ation mize the control loop of the positioner. The electropneumatic positioner is used to The range spring (6), which can be ex- assign the valve position (controlled variable) changed, is assigned to both the rated valve to the input signal (reference variable). The travel and the span of the reference variable. positioner compares the control signal of a Legend for Fig. 1 and Fig. 2 control system to the travel of the control Lever for valve travel valve and issues a signal pressure (output Shaft variable) for the pneumatic actuator. The positioner consists of an electropneumat- Sleeve ic converter unit (21) and a pneumatic unit Zero point adjustment equipped with a lever (1), shaft (1,1) and Fastening screw range spring as well as the pneumatic con- Range spring trol system with nozzle, flapper plate and Bracket booster. The DC control signal, e.g. 4 to...
  • Page 11 Design and principle of operation 5 6.1 13 10.2 7 Fig. 1: Positioner with cover removed Travel 10.2 10.1 Output 10.2 10.1 Supply Arrangement of nozzle/flapper plate for reverse <> operating direction Fig. 2: Functional diagram EB 8359-2 EN...

  • Page 12: Attachment

    Attachment 5 Attachment 2. Place both the support (28) and the clamping plate (26) on the rod (27) and To attach the positioner to valves with cast lightly fasten. Move the support until both yokes according to IEC 60534-6 (NAMUR the center of the plate (20) and the sup- rib), mounting parts (order no. 1400-5745) port (28) are aligned when the valve is are used. For valves with rod-type yokes, the at half of the valve travel. mounting kit (order no. 1400-5745) and ad- 3. Fasten tight the support and the clamp- ditionally the mounting kit (order no. 1400- ing plate. 5342) are necessary (see also accessories in 4. Mount the positioner to the support using section 11 on page 28). the fastening screw (15). Make sure that Since the positioner can be attached on ei- the pin (2) is inserted through the wire ther side of the valve, the physical location strap and, as a result, clamped against (left or right attachment) should be deter- the plate (20). mined before actual attachment. Î See Fig. 6 to Fig. 9 on page 17. 5.3 Housing cover 5.1 Attachment to valve with After attaching the positioner, make sure that the vent plug of the housing cover faces cast yoke...
  • Page 13 Attachment 22 23 Fig. 3: Attachment to valves with cast yokes (NAMUR rib) 20 2.1 Fig. 4: Attachment to valves with rod-type yokes EB 8359-2 EN...

  • Page 14: Connections

    Connections 6 Connections Selecting cables and wires: Observe clause 12 of EN 60079-14: 2008 (VDE 0165, Part 1) for installation of the in- 6.1 Electrical connections trinsically safe circuits. Clause 12.2.2.7 ap- plies when running multi-core cables and DANGER! wires with more than one intrinsically safe For electrical installation, observe the circuit. relevant electrotechnical regulations The radial thickness of the insulation of a and the accident prevention regula- conductor for common insulating materials tions that apply in the country of use. (e.g. polyethylene) must not be smaller than In Germany, these are the VDE regu- 0.2 mm. The diameter of an individual wire...

  • Page 15: Pneumatic Connections

    Connections 6.2 Pneumatic connections Equipment for use in zone 2/zone 22: In equipment operated according to type of The pneumatic connections are optionally protection Ex nA II (non-sparking equipment) designed as a bore with ¼ NPT or according to EN 60079-15: 2003, circuits ISO 288/1-G ¼ thread. Customary fittings may be connected, interrupted or switched for metal or copper tubing or plastic hoses while energized only during installation, can be used. maintenance or repair. Guide the wires for the reference variable NOTICE over the cable gland to the terminals 11 (+) Risk of malfunction due to failure to and 12 (–) located in the housing. comply with required air quality. − Only use supply air that is dry and The ground connection can be connected in- free of oil and dust.

  • Page 16: Supply Pressure

    Connections 6.4 Supply pressure If there are no specifications, calculate as follows: The required supply air pressure depends on Required supply pressure = Upper bench the bench range and the actuator's operating range value + 1 bar direction (fail-safe action). The bench range is written on the nameplate The positioner output pressure is routed to either as the spring range or signal pressure the top or bottom diaphragm case of the ac- range. The operating direction is marked FA tuator as shown in Fig. 6 to Fig. 9. 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 pst is roughly estimated as fol-...

  • Page 17: Operation

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

  • Page 18: Determining And Changing The Operating Direction

    Operation 7.1.1 Determining and versed "plate on top of lever" is correct (Fig. 6 to Fig. 9). changing the operating direction For an increasing input signal (reference variable), the signal pressure p 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 flapper plate, the operating direction is indicated by symbols (direct <<, reverse <>). Depending on the position of the flap- 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 flapper 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.
  • Page 19 Operation Operating direction increasing/increasing Operating direction increasing/decreasing (direct <<) (reverse <>) feeler pin on top of flapper plate flapper plate on top of feeler pin Range spring Cover plate Nozzle block Feeler pin Marking Flapper Fig. 10: Position of nozzle block, cover plate removed 100% 100% Open Open Travel Travel Closed Closed Valve 2 Valve 1 20mA 20mA Reference variable Dead band Input signal Fig. 11: Normal operation Fig. 12: Split-range operation, two valves operating in opposing directions EB 8359-2 EN...

  • Page 20: Starting Point And Reference Variable

    Operation 7.2 Starting point and refer- 7.3 Adjustment after mounting ence variable the positioner on the valve Î Connect an ammeter to the control signal The attached lever and the installed range input at the terminals 11 (+) and 12 (–). spring of the positioner are assigned to the values of rated valve travel and the reference Î Connect the supply air to the supply in- variable as in Table 1. put (supply 9). In normal operation, the reference variable 7.3.1 Setting the air delivery span is 100 % = 16 mA. A smaller span of, (volume restriction Q) and for example, 50 % = 8 mA is only required for split-range operation (Fig. 12). proportional band Xp The span can be changed by exchanging the 1.
  • Page 21 Zul. Supply Alim. 5. Set Xp as described in section 7.3.1. Fig. 13: Setting the Xp restriction Table 1: Range springs Rated travel [mm] Min./max. travel [mm] Reference variable (input signal) Range spring Standard travels for SAMSON valves with lever l (40 to 127 mm in length) 100 % 7.5 to 15 50 % 100 % 14 to 32 50 % 30 to 70 100 %...

  • Page 22: Setting For Actuator With Fail-Safe Action "Stem Extends

    Operation 7.3.2 Setting for actuator with After correcting the input signal, re-ad- just zero. Then check the upper range fail-safe action “stem ex- value again. tends” Repeat the correction procedure until both To ensure that the total closing force of the values are correct. actuator acts on the valve, proceed as fol- 7.3.3 Setting for actuator with lows: fail-safe action “stem re- Î With direct operating direction <<: ad- just starting point to 4.5 mA (slightly tracts” raised). When using an actuator with "actuator stem Î With reverse operating direction <>: ad- retracts" fail-safe action, the diaphragm just starting point to 19.5 mA (slightly chamber must be pressurized with a signal lowered). pressure that is high enough to tightly close Starting point (zero) e.g.

  • Page 23: Exchanging The Range Spring

    Operation 7.4 Exchanging the range wise causes the plug stem to move from its end position earlier; turning it clock- spring wise causes it to move from its end posi- tion later. If the range is to be altered or changed to split-range operation, replace the range Upper range value (span) e.g. 4 mA spring as shown in Fig. 1 on page 11 as 3. Once the starting point has been set, in- follows: crease the input signal to 4 mA at the 1. Unscrew screw (7) on the range spring. ammeter. Undo hexagon socket screw (5) and pull At exactly 4 mA, the plug stem must out the lever together with shaft. stand still, having moved through 100 % 2. Exchange range spring. Slide lever with travel (watch the travel indicator at the shaft through sleeve (3), positioner hous- valve). ing and bracket (6.1). 4. If the upper range value is incorrect, 3. Secure range spring with the screw (7). move the pin (2) to correct it. Readjust 20 mA and turn the zero adjustment 4.

  • Page 24: Converting The Electropneumatic Into A Pneumatic Positioner

    Connecting nipple The electropneumatic positioner can be con- Hose verted into a Type 4765 Pneumatic Position- Connecting plate er with a conversion kit. Sealing element Note:  The version suitable for oxygen of the Type 4763 Pneumatic Positioner can- not be converted to form a Type 4765 Electropneumatic Position- Î Required conversion kits: see Table 2 1. Unscrew fastening screws and lift the i/p converter together with the printed circuit board out of the positioner housing. 2. Unthread cable gland (1). Plug on hose (5) and screw the connecting nipple (4) of the conversion kit tightly on the hous- ing.
  • Page 25 Converting the electropneumatic into a pneumatic positioner Fig. 14: Converting the positioner Table 2: Conversion kits Required conversion kit up to device index .02. For connection with G thread Order no. 1400-6724 For connection with NPT thread Order no. 1400-6725 Required conversion kit for device index .03 and higher. For connection with G thread Order no. 1400-6795 For connection with NPT thread Order no. 1400-6796 EB 8359-2 EN...

  • Page 26: Servicing Explosion-Protected Devices

    Servicing explosion-protected devices 9 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 qualified inspector has assessed it accord- ing to explosion protection requirements, has issued an inspection certificate or given the de- vice a mark of conformity. Inspection by a qualified 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 by original, routine-tested components provid- ed by the manufacturer. Devices that have already been used outside hazardous areas and are intended for future use inside hazardous areas must comply with the safety requirements placed on serviced devices.

  • Page 27: Maintenance, Calibration And Work On Equipment

    Maintenance, calibration and work on equipment 10 Maintenance, calibration and work on equipment Interconnection with intrinsically safe circuits to check or calibrate the equipment inside or outside hazardous areas is to be performed only with intrinsically safe current/voltage cali- brators and measuring instruments to rule out any damage to components relevant to explo- sion protection. Observe the maximum permissible values specified in the certificates for intrinsically safe cir- cuits. EB 8359-2 EN...

  • Page 28: Accessories And Mounting Parts

    Accessories and mounting parts 11 Accessories and mounting parts Accessories – Mounting parts Order no. Range spring 1 1190-0736 Range spring 2 1190-0737 Range spring 3 1190-0738 Lever I 1690-6469 Lever extension 1400-6716 Pressure gauge attachment 1400-6950 Pressure gauge attachment (copper-free) 1400-6951 Mounting unit for valves with cast yoke according to NAMUR 1400-5745 Valves with rod-type yoke according to NAMUR for 18 to 35 mm rod 1400-5745 and 1400-5342 diameter Assortment of spare parts including gaskets and diaphragms 1400-6792 Assortment of spare parts including gasket, diaphragms and pneu- 1402-0040 matic parts (for positioners with device index .02 and higher) Upgrade to degree of protection IP 65: Venting over check valve 1790-7408 Accessories for electrical connections...

  • Page 29: Dimensions In Mm

    Dimensions in mm 12 Dimensions in mm 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: M20 x 1.5 connection for housing with G thread NPT connection for housing with NPT thread EB 8359-2 EN...
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  • Page 40 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 EB 8359-2 EN samson@samson.de · www.samson.de...

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