System 6000

Electropneumatic Converters (proportional valves)

Electronic Controllers

Signal Converters

Edition February 2009

Information Sheet T 6000 EN

Proportional valves

2 T 6000 EN

e/p Converters

Type 6111 6116 6126 6127

Body style Rail-mounting unit 5) Field unit 7) Industrial unit 19" rack-mounting unit, 7 HP 6)

Explosion protection EEx iaATEX

EEx ia, EEx d,ATEX, FM, CSA,

Australian standard 1)– –

Degree of protection IP 20 IP 54, IP 65, NEMA 4 IP 54, IP 65 IP 00

Fieldbus AS-Interface 4) –

Input 0 to 20 mA • • •

4 to 20 mA • • • •

0 to 10 V • 3) •

2 to 10 V • 3) •

Output 0.2 to 1 bar • • • •

0.4 to 2 bar • • • •

Special ranges Up to 5 bar •

Up to 8 bar • • 2)

Supply air 0.4 bar above upper signal pressure range, maximum 10 bar Max. 2.4 bar

Electrical connection Phoenix terminal orangle connector

DIN EN 175301-803 A

M20 x 1.5½-14 NPT

Angle connectorDIN EN 175301-803 A

Electropneumaticconnection strip Form F

Pneumatic connection M10 x 1, G 18;

18 NPT ¼ NPT; G ¼ ¼ NPT; G ¼ Electropneumatic

connection strip Form F

For further informationsee Data Sheet T 6111 EN T 6116 EN T 6126 EN T 6127 EN

1) Others on request2) Not for EEx d devices3) With Type 6151 u/i Module4) With Type 6150 AS-Interface Module5) Also available as field unit with stainless steel enclosure6) Also available with two channels7) Special version for operation with natural gas on request

3 T 6000 EN

Example of an application

1 Transducer2 Pneumatic converter3 p/i converter4 Controller5 Two-wire network

1 2 3 4

Type 6132

1 2 3 4

524V

Type 6134mA

mA

p/e Converters

Type 6132 6134

Body style Rail-mounting unit Rail-mounting unit Field unit

Explosion protection – – EEx ia 1), EEx d 1)

p/i converter unit 1 1 or 2 1

Degree of protection IP 20 IP 20 IP 54, IP 65

Input 0.2 to 1 bar • • •

Output 0 to 20 mA •

4 to 20 mA • • •

0 to 5 V •

1 to 5 V •

0 to 10 V •

2 to 10 V •

Power supply 230 V AC, 115 V AC,24 V AC, 24 V DC 24 V DC

Electrical connection Four-wire Two-wire

Terminals for0.5 to 2.5 mm² wires

Terminals for0.5 to 2.5 mm² wires

M20 x 1.5; ½ NPT;Terminals for

0.5 to 2.5 mm² wires

Pneumatic connection Hose connection 4 x 1 Hose connection 4 x 1 ¼ NPT; G ¼

For further informationsee Data Sheet T 6132 EN T 6134 EN

1) Applied for

Converter modules

4 T 6000 EN

Input

Auxiliarypower

Control levelProfibus DP, PLC, PC, etc.

Field levelProfibus PA, CAN, Interbus,DeviceNet, FIP, etc.

ASI field levelSAMSON SlaveType 6150

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

MASTER

GATEWAY

Type 6150 6151

Designation AS-Interface module u/i module

Input AS-Interface •

0 to 10 V •

2 to 10 V •

Output 0 to 20 mA •

4 to 20 mA • •

Auxiliary power Over ASi line 16 to 30 V DC

Electrical connection Angle connector acc. to DIN EN 175301-803 A, M20 x 1.5 (adapter connector)

Compatibility withSAMSON devices

Positioners 3730, 3760, 3761, 3767, 4763

V2001 valve 3372-IP

i/p converter 6111, 6116, 6126

Max. load at the output: 300 ΩR =

U VmA

H −1020

e.g. 700 Ω with auxiliary power UH = 24 V

For further information, see Data Sheet T 6150 EN T 6151 EN

Output

AS Interface

AS Interface

Electronic Controllers

5 T 6000 EN

Controllers TROVIS 6412 6442 6493 6495 6497

Style Panel-mounting unit • • • •

Rack-mounting unit (14 HP) •

Front frame W x H (mm) 72 x 144 70.5 x 128.5 48 x 96 96 x 96 96 x 96

Degree of protection (front) IP 54 IP 54 IP 65 IP 65 IP 54

Display LCD LCD LCD Graphics LED

Keys 8 8 6 9 6

Functions Control loops 1 1 1 2 1

P, PI, PD, PID control modes • • • • •

Fixed set point and follow-up control • • • • •

Ratio control • • •

Cascade control • • •

Limitation control • • •

Linking of input variables • • • •

Input Quantity 3 to 4 2) 3 to 4 2) 2 4 2

4 to 20 mA, 0 to 20 mA • • • • •

0 to 10 V, 2 to 10 V • • • • •

Pt 100 resistance thermometers • • • • •

Pt 1000 resistance thermometers • •

Thermocouples •

Potentiometers • • • • •

Transmitter supply • • • • •

Binary inputs 3 3 1 4 1

Output Continuous 1 to 3 1) 1 to 3 1) 1 3 2 3)

4 to 20 mA, 0 to 20 mA • • • • •

0 to 10 V, 2 to 10 V • • • •

Relays 2 to 6 1) 2 to 6 1) 2 4 2 to 4 1)

Transistor outputs 1 1 1 3

On/off, three-step signals 1 1 1 2 1

Limit values 2 2 2 4 2 to 4 1)

Interface

Configuration Infrared • •

RS-232 • • • 1)

USB • 1)

Memory pen • 1) • 1) • 1)

TROVIS-VIEW software • 1) • 1)

TROVIS 6482 software • 1) • 1)

Communication RS-485 Modbus RTU • 1) • 1) • 4) • 1)

Operating voltage 85 to 264 V AC •

90 to 250 V AC •

230 V AC • • •

120 V AC • • •

24 V AC • • • •

24 V AC/DC • • •

For further information, see Data Sheet T 6412 T 6412 T 6493 T 6495 T 6497

1) Optional2) Quantity depends on input board3) 1 control output and 1 output for issuing the controlled variable4) In preparation

Controlling a valveValves equipped with small pneumatic actuators can be control-led directly by an e/p converter. The e/p converter receives theelectric signal from a controller or a PLC.The e/p converter can also control a pneumatic positioner.

Field or industrial units can be mounted directly to a valve(attachment to rod-type yoke or according to NAMUR).

Pressure controlThe p/e converter measures the pressure in the pipeline andconverts it to an electric signal. The controller uses the electricsignal to calculate the control signal which is passed on by thepositioner to finally close or open the pneumatic control valve.

e

pType 6134

Type 3241-1

Application examples

6 T 6000 EN

Type 3241-1

Air

Type 6116

TROVIS 6493

p

e

TROVIS 6493

Controlling a positioning cylinder in the paper and printingindustryThe electric signal coming from a controller or a PLC isconverted to a pneumatic signal (p) by the e/p converter. Thepressure signal is used to position a cylinder which, in turn,moves a roller that keeps the paper under a certain tension.

p

Air

e

Type 6111

Booster controlBoosters are used to amplify the flow rate of compressed air. Tocontrol boosters, you can use, apart from handwheels, alsoe/p converters which receive an electric signal from a controlleror a PLC.

7 T 6000 EN

Air p

e

Type 6111

Filling of liquids in the beverage industry and breweriesThe e/p converter converts an electric signal to a pneumaticsignal. The pneumatic signal controls cylinders which insertfilling tubes more or less deep, depending on the liquid level,into bottles, filling them with beverages or detergents. e

p

AirType 6126

To the PLC

Applying adhesive or glueGlue or adhesive is to be applied on different bases.Depending on the speed of the conveyor belt, varying quantitiesmust be applied. The e/p converter receives an electric signal,which changes with the belt speed, and converts it to a pressuresignal. The pressure causes the ball of a dispenser to adapt theoutlet to the required amount of glue or adhesive. This ensuresuniform application.

Type 6126

e

p

Air

.

8 T 6000 EN

TROVIS 6493TROVIS 6497TROVIS 6412

Temperature controlThe SAMSON TROVIS 6412, 6493 and 6497 Controllersallow the realization of simple temperature control systems, e.g.flow temperature control in heating installations. The flowtemperature is measured with a Pt 100 sensor and transmittedto the controller. The latter controls a pneumatic control valve byissuing an analog 4 to 20 mA signal via an i/p positioner.

PD

PD

F

F

TROVIS 6412Mixing of two liquidsTROVIS 6412 can be used for ratio control when two liquids aremixed. The controller obtains signals from two differentialpressure transmitters and root-extracts the signals. Thecontroller then uses the signals to calculate an output signal forthe control valve which must reach the required mixing ratio.

PD

TROVIS 6493TROVIS 6412

F

Flow controlTROVIS 6412 and 6493 provide a convenient flow control.When using the root-extracting function of these controllers, theflow rate can be easily calculated from the differential pressuresignal issued by the differential pressure transmitter. The analogoutput signal of the controller activates the positioner and with itthe pneumatic valve.

9 T 6000 EN

M

TROVIS 64122 TROVIS 64972 TROVIS 6493

x

WE yx

Temperature cascade controlThe boiler is heated by a heat exchanger. To minimize thedelays of the controlled system, cascade control with a masterand a slave controller is implemented. TROVIS 6412 isparticularly suited to solve this task since it is capable of beingthe master and the slave controller at the same time. It is alsopossible to use two TROVIS 6497 or two TROVIS 6493controllers. The master controller measures the actual boilertemperature and forwards its manipulated variable asreference variable WE to the slave controller. The slavecontroller controls the flow temperature in the heat exchangerloop. The control valve is activated using a three-step signal.

TROVIS 6412

xWE

y yAA

Limiting controlTROVIS 6412 is also a good choice when performing limitingcontrol with minimum selection, as shown in the exampleopposite. The color is to be heated to a certain predeterminedtemperature, however, the shell temperature of the reactiontank must not exceed the temperature of the paint by apredetermined value. The reaction tank is heated or cooleddown using two heat exchangers.The main controller controls the temperature of the paint. Thelimiting controller controls the temperature difference betweenthe tank shell temperature and the paint temperature. The painttemperature is applied to the analog output AA, fed back to thecontroller input as disturbance variable and subtracted from theshell temperature. The minimum selection function feeds thesmaller control signal of both control loops to the split-rangeunit, thus activating both control valves.

Temperature control with function generationThe SAMSON controllers TROVIS 6412 and 6493 also allowthe realization of a temperature control with functiongeneration, e.g. an outdoor temperature-controlled flowtemperature control. The outdoor temperature is measured withan Pt 100 sensor and passed on to the controller which utilizesfunction generation to directly convert the outdoor temperatureto a set point for the flow temperature. The controller activatesthe electric control valve using a three-step signal.

Explosion protection

Some of the SAMSON e/p Converters are suitable for use inhazardous areas as they are frequently found in the chemicaland petrochemical industry.

Important factors of the explosion protection relevant for suchapplications are listed in the following. For details, please referto the standards indicated.

10 T 6000 EN

Zone classificationHazardous areas are grouped into zones to indicate the danger of explosion. Each zone prescribes particular measures which ensureexplosion protection.

Zone Meaning Example

0 Dangerous, potentially explosive atmospheres occurpermanently or for a long time. Inside of reaction tanks containing flammable gases.

1 Dangerous, potentially explosive atmospheres occursometimes.

In the proximity of Zone 0, immediate area around stuffingboxes that are not sufficiently sealed.

2 Dangerous, potentially explosive atmospheres occurseldom and for a short time (< 2 h). Areas surrounding the Zones 0 and 1.

Type of protectionThe type of protection describes the measures to be taken to prevent electrical appliances from igniting explosive atmospheres.

Type of protection Basic principle Standard, regulation

d Flameproof enclosureParts which can ignite an explosive atmosphere are placed inan enclosure which can withstand the pressure caused by anexplosion inside the housing and prevents the transmission ofthe explosion to the surrounding explosive atmosphere.

Flameproof enclosures are suitable for Zones 0, 1 and 2.

DIN EN 60079-1

i Intrinsic safety

An electrical device is intrinsically safe when all circuits areintrinsically safe. A circuit is intrinsically safe when it does notproduce sparks or thermal effects whose energy suffices toignite an explosive atmosphere.

DIN EN 50020VDE 0170/0171 Part 7

Category ia Devices of this category are suitable for Zones 0, 1 and 2.Zone 0 must be certified separately.

Category ib Devices of this category are suitable for Zones 1 and 2.

Temperature classesThe temperature classes group electrical appliances according to their max. permissible surface temperature. It must be smaller thanthe ignition temperature of the explosive material.

Temperatureclass Maximum permissible surface temperature of the appliance Ignition temperature of the flammable material

T1 450 °C > 450 °C

T2 300 °C > 300 ≤ 450 °C

T3 200 °C > 200 ≤ 300 °C

T4 135 °C > 135 ≤ 200 °C

T5 100 °C > 100 ≤ 135 °C

T6 85 °C > 85 ≤ 100 °C

l

w

U

R L

C

11 T 6000 EN

Safety barriersaccording to DIN EN 60079-0 and DIN EN 50020 Section 8Safety barriers are passive networks which separateintrinsically safe and not intrinsically safe circuits withoutisolating them electrically. The output circuits of the safetybarriers meet the requirements of the intrinsic safety “ia” and“ib”.Safety barriers are always installed outside the hazardousarea.

3

4

Ex

/PA

1

2

UN

/PA

Circuit diagram of a safety barrier

Code numberFirst code number Second code number

Protection againstaccidental contact

Protection against foreignparticles Protection against water

0 None None None

1 Protection against contactwith the back of the hand

Protection againstpenetration of foreignparticles > 50 mm

Protection against water drops

2 Protection against contactwith the finger

Protection againstpenetration of foreignparticles > 12.5 mm

Protection against water drops when the device istilted by up to 15° from the vertical position

3 Protection against contactwith tools

Protection againstpenetration of foreignparticles > 2.5 mm

Protection against spray water hitting the device, atan angle of 60° from the vertical position

4 Protection against contactwith a wire

Protection againstpenetration of foreignparticles > 1.0 mm

Protection against spray water from all directions

5 Protection against contactwith a wire

Protection against dustbuilt-up which couldimpair the functioning ofthe device

Protection against a water jet from all directions

6 Protection against contactwith a wire Dust-tight Protection against a strong water jet from all

directions

7 – – Protection against water when immersed understandardized time and pressure conditions

8 – –Protection against water when permanently immersedunder conditions which are agreed upon by themanufacturer and the customer.

IP Degree of protection

The IP code characterizes an electrical appliance’s protectionagainst accidental contact and foreign particles as well as itsprotection against water. The code consists of two code num-bers whose meanings are listed in the Table below.

IP code IP 6 5

First code number (0 to 6)Prot. ag. contact and foreign particles

Second code number (0 bis 8)Protection against water

T 6000 EN 2009

-02

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de