Samson 4763 Service-Handbuch
Electropneumatic Positioner
Type 4763
Fig. 1 · Type 4763
Mounting and
Operating Instructions
EB 8359-2 EN
Edition September 2010
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 housing . . . . . . . . . . . . . . . . . . . . . 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 Converting an electropneumatic into a pneumatic positioner . . . . . . 18
6 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 19
7 Maintenance, calibration and work on equipment . . . . . . . . . . . 19
8 Accessories and mounting parts . . . . . . . . . . . . . . . . . . . . 20
9 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2EB 8359-2 EN
Contents
EB 8359-2 EN 3
Safety instructions
General safety instructions
4
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
refers to 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 applicable standards.
4
Explosion-protected versions of this positioner are to be operated only by
personnel who have undergone special training or instructions or who are
authorized to work on explosion-protected devices in hazardous areas. Refer
to section 6.
4
Any hazards that could be caused by the process medium, the operating
pressure, the signal pressure or by moving parts of the control valve are to be
prevented by means of the appropriate measures.
4
If inadmissible motions or forces are produced in the pneumatic actuator as a
result of the supply pressure, the supply pressure must be restricted by means
of a suitable supply pressure reducing station.
4
Proper shipping and appropriate storage are assumed.
4
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 is available on request.
4EB 8359-2 EN
Versions
Electropneumatic Positioner Type 4763- x1x00x 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 (ATEX) 8 2/7
Range spring
Range spring 1, travel = 15 mm 1
Range spring 2, travel = 30 mm,
split-range 15 mm 2
Range 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) 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
None 000
For oxygen as the operating medium 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
Type 4736 Positioner
Travel range 7.5 to 60 mm, with 90 mm lever extension
Reference variable
Split-range 0 to 50 %
and 50 to 100 %
Reference variable span
(up to 50 mm travel)
4 to 20 mA (Ex) Internal resistance Riat 20 °C approx. 250 W±
7 %
4 to 20 mA (not Ex) Internal resistance Riat 20 °C approx. 200 W±
7 %
0 to 20 mA Internal resistance Riat 20 °C approx. 200 W±
7 %
1 to 5 mA Internal resistance Riat 20 °C approx. 880 W±
7 %
Range spring See table on page 14
Supply air Supply air 1.4 to 6 bar (20 to 90 psi)
Air quality acc.
to ISO 8573-1
(2001)
Maximum particle size and density: Class 4 · Oil content: Class 3
Pressure dew point: Class 3 or at least 10 K below the ambient temperature to
be expected
Output signal pressure pst Max. 0 to 6 bar (0 to 90 psi)
Characteristic Linear · Deviation from terminal-based conformity: £1.5 %
Hysteresis < 0.5 %
Sensitivity < 0.1 %
Operating direction Reversible
Proportional band Xp
(at 1.4 bar supply air)
1 to 3 % with spring 1 or 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 capacity At Dp 1.4 bar: 3.0 mn³/h At Dp 6 bar: 8.5 mn³/h
Transit time for Type 3271
“Stem extends” 240 cm²: £1.8 s · 350 cm²: £2.5 s · 700 cm²: £10 s
Permissible ambient
temperature
–20 to 70 °C;
With metal cable gland: –35 to 70 °C
Special version: –45 to 80 °C
The limits specified in the EC Type Examination Certificate additionally apply
for explosion-protected devices.
Version with oxygen as operating medium up to max. 60 °C
Influences Temperature < 0.03 %/1 K
Supply air < 0.3 %/0.1 bar
Vibration: < 2 % between 10 and 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 Housing: 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 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.
6EB 8359-2 EN
Design and principle of operation
4
21 14 13 10.2 7
1
15
8
5 6.1 6 3
Fig. 2 · Positioner with cover removed
EB 8359-2 EN 7
Design and principle of operation
p
st
Output
36
p
e
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
1 2 2.1 20
Fig. 3 · Functional diagram
Legend 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 Xp restriction
14 Volume restriction Q
15 Hole 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 20).
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). The O-ring in-
cluded in the mounting kit is not required
for this device. Make sure that the pin (2)
is routed inside the wire strap and there-
fore 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)
Legend 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 rods
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 rod (27) and
lightly fasten. Move the support until both
the center of the plate (20) and the sup-
port (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
housing
After attaching the positioner, make sure
that the vent plug on the cover of the
positioner housing 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
DANGER!
Risk of electric shock and/or the
formation of an explosive atmo-
sphere!
–
For electrical installation, observe the rel-
evant electrotechnical regulations and
the accident prevention regulations that
apply in the country of use.
–
The following regulations apply to
mounting and installation in hazardous
areas: EN 60079-14: 2008 Explosive
atmospheres – Part 14: Electrical instal-
lations design, selection and erection (or
VDE 0165 Part 1).
NOTICE
–
Adhere to the terminal assignment!
Switching the assignment of the electrical
terminals may cause the explosion pro-
tection to become ineffective!
–
Do not loosen enameled screws in or on
the housing.
–
The maximum permissible values speci-
fied in the national EC type examination
certificates apply when interconnecting
intrinsically safe electrical equipment (U
i
or U
o
; I
i
or I
o
; P
i
or P
o
; C
i
or C
o
, and L
i
or
L
o
).
Selecting cables and wires:
Observe Clause 12 of EN 60079-14: 2008
when installing intrinsically safe circuits. The
Subclause 12.2.2.7 applies when running
multi-core cables containing more than one
intrinsically safe circuit.
In particular, the radial thickness of the con-
ductor insulation for common insulation ma-
terials, such as polyethylene, must have a
minimum radial thickness of 0.2 mm.
The diameter of an individual wire in a
fine-stranded conductor must not be smaller
than 0.1 mm. Protect the conductor ends
against splicing, e.g. by using wire-end fer-
rules.
When two separate cables are used for con-
nection, an additional cable gland can be
installed.
Seal cable entries left unused with plugs.
Devices used at ambient temperatures be-
low –20 °C must be fitted with metal cable
glands.
Equipment for use in zone 2/zone 22
In equipment operated with type of protec-
tion Ex nA II (non-sparking equipment) ac-
cording to EN 60097-15: 2003, circuits
may be connected, interrupted or switched
while energized only during installation,
maintenance or repair.
The wiring for the input signal is led using
cable glands to the terminals 11 (+) and 12
(–). The ground connection can be
connected inside or outside of the positioner
housing.
10 EB 8359-2 EN
Connections
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