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1 sipart ps2 manual a5e00074630--06 sipart ps2 6DR50XX 6dr51xx 6dr52xx 6dr53xx edition 10/2006 manual electropneumatic positioner for linear and part-turn actuators
2 sipart ps2 manual a5e00074630--06 copyright e siemens ag 2006 all rights reserved the reproduction, transmission or use of this docu- ment or its contents is not permitted without ex- press written authority. offenders will be liable for damages. all rights, including rights created by pa- tent grant or registration of a utility model or design, are reserved. siemens ag bereich automatisierungs-- und antriebstechnik gesch?ftsgebiet prozessinstrumentierung-- und analytik d--76181 karlsruhe disclaimer of liability we have checked the contents of this manual for agreement with the hardware and software descri- bed. since deviations cannot be precluded entirely, we cannot guarantee full agreement. however, the data in this manual are reviewed regularly and any necessary corrections included in subsequent edi- tions. suggestions for improvement are welcomed. e siemens ag 2006 technical data subject to change. trademarks simatic, sipart, sirec, sitrans are registered trademarks of siemens ag. third parties using for their own purposes any other names in this document which refer to trade- marks might infringe upon the rights of the trademark owners.
sipart ps2 manual a5e00074630--06 3 contents 0 information for the operator 5 ............................................. 0.1 general information 5 ........................................... 0.2 classification of safety related notices 6 ......................... 0.3 qualified personnel 7 ........................................... 0.4 use as intended 9 .............................................. 0.5 technical documentation 9 ...................................... 0.6 warranty information 9 .......................................... 0.7 delivery notes 10 ............................................... 0.8 standards and regulations 10 .................................... 1 introduction 11 ............................................................ 1.1 general information about the positioner 11 ......................... 2 design and method of operation 15 ........................................ 2.1 overview 15 .................................................... 2.2 design name plate 17 ............................................ 2.3 instrument components 17 ....................................... 2.3.1 motherboard 18 ................................................. 2.3.2 electrical connections 18 ......................................... 2.3.3 pneumatic connections 19 ....................................... 2.3.4 mounting kit 22 ................................................. 2.3.5 purge air switching (not in the explosion proof version) 22 ............ 2.3.6 restrictors 22 ................................................... 2.4 method of operation 23 .......................................... 2.5 hart-function 26 ............................................... 2.6 state as supplied 26 ............................................. 2.7 installation of options modules 27 ................................. 2.7.1 installation of options modules in normal and intrinsically safe versions 27 ................................................ 2.7.2 installation of options modules in explosion proof version 29 .......... 2.7.3 iy-module 31 ................................................... 2.7.4 alarm module 32 ................................................ 2.7.5 sia module 33 .................................................. 2.7.6 mechanical limit switch module 35 ................................. 2.7.7 emc filter module 38 ............................................ 2.7.8 accessories 39 ................................................. 3 preparing for operation 41 ................................................. 3.1 instrument identification (type key) 41 .............................. 3.2 dimensional drawings 41 ......................................... 3.3 assembly 43 .................................................... 3.3.1 instructions for using positioners in a wet environment 44 ............. 3.3.2 instructions for using positioners which are exposed to strong accelerations or vibrations 46 ..................................... 3.3.3 mounting kit ?linear actuator? 6dr4004-8v and 6dr4004-8l 49 ....... 3.3.4 assembly procedure (see figure 3-7, page 51) 50 ....................
sipart ps2 manual a5e00074630--06 4 3.3.5 mounting kit ?part-turn actuator? 6dr4004-8d 52 .................... 3.3.6 assembly procedure (see figure 3-8 and figure 3-9) 53 ............... 3.4 electrical connection 57 .......................................... 3.4.1 connection in non-intrinsically safe and explosion proof version 59 ..... 3.4.2 connection in intrinsically safe version 62 ........................... 3.4.3 connection in type of protection ?n? version 68 ...................... 3.5 pneumatic connection 71 ........................................ 3.6 commissioning 72 ............................................... 3.6.1 preparations for linear actuators 73 ................................ 3.6.2 automatic initialization of linear actuator 74 ......................... 3.6.3 manual initialization of linear actuator 76 ............................ 3.6.4 preparations for part-turn actuator 79 .............................. 3.6.5 automatic initialization of part-turn actuator 79 ...................... 3.6.6 manual initialization of part-turn actuators 81 ........................ 3.6.7 automatic initialization (structograms) 82 ........................... 3.7 copying initialization data (positioner exchange) 87 .................. 4 operation 89 .............................................................. 4.1 display 89 ...................................................... 4.2 input keys 89 ................................................... 4.3 operating modes 92 ............................................. 4.4 parameters 95 .................................................. 4.5 diagnostics 122 .................................................. 4.5.1 diagnostic display 122 ............................................ 4.5.2 meaning of the diagnostic values 123 ............................... 4.5.3 online diagnostics 131 ............................................ 4.5.4 fault correction 136 .............................................. 4.6 meaning of the other display text 139 ............................... 4.7 optimizing the controller data 143 .................................. 5 service and maintenance 145 ................................................ 6 technical data 147 ......................................................... 7 scope of delivery 153 ....................................................... 7.1 scope of delivery of standard controller 154 .......................... 7.2 scope of delivery of options 154 .................................... 7.3 scope of delivery of accessories 155 ................................ 7.4 list of spare parts 156 ............................................ 8 index 158 .................................................................. 9 appendix 160 .............................................................. 9.1 literature and catalogs 160 ........................................
information for the operator 5 sipart ps2 manual a5e00074631--06 information for the operator dear customer, please read this manual before starting work! it contains important information and data which, when observed, ensure full availability of the equipment and save service costs. this simplifies handling of this control instrument considerably and provides accurate measuring results. you have purchased an instrument which can be installed in various configurations: s sipart ps2 without ex-protection in a metal- or plastic housing. s sipart ps2 with eex ia/ib-protection in a metal- or plastic hous- ing. s sipart ps2 eex d in a pressurized explosion proof housing this manual takes each of these possibilities into consideration. any differences between the devices are indicated specially. scope of delivery, see chapter 7, page 153. 0.1 general information the product described in this manual left the factory in a perfectly safe and tested condition. to maintain this condition and to achieve perfect and reliable operation of this product, it must only be used in the way described by the manufacturer. successful and safe operation of this equipment is dependent on proper handling, installation, operation and maintenance. 0
information for the operator sipart ps2 manual a5e00074631--06 6 this manual contains the information required for use as intended of the product it describes. it is addressed to technically qualified person- nel specially trained or having relevant knowledge of instrumentation and control technology, hereafter called automation technology. familiarity with and proper technical observance of the safety notes and warnings contained in this manual are essential for safe installation and commissioning and for safety in operation and maintenance of the product described. only qualified personnel as defined in chapter 0.3 has the necessary specialist knowledge to interpret the general safety notes and warnings given in this document in specific cases and to take the necessary action. the documentation supplied with the instrument is listed in chapter 0.5. this manual is not a permanent part of the scope of supply. for reasons of clarity, it does not contain every detail about every version of the product described and cannot take every eventuality in installation, op- eration, maintenance and use in systems into a ccount. if you require further information or if problems occur that have not been dealt with in sufficient detail in this document, please request the required informa- tion from your local siemens office or the office responsible for you. functionality, commissioning and operation are described in this manual. please pay special attention to the warning and note texts. these are separated from the remaining text by horizontal lines and specially marked with symbols (see chapter 0.2). 0.2 classification of safety related notices this manual contains notices which you should observe to ensure your own personal safety, as well as to protect the product and connected equipment. these notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger: ! danger indicates an immenently hazardous situation which, if not avoided, will result in death or serious inury. ! warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
information for the operator 7 sipart ps2 manual a5e00074631--06 ! caution used with the safety alert symbol indicates a potentially hazardous si- tuation which, if not avoided, may result in minor or moderate injury. caution used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. notice indicates a potential situation which, if not avoided, may result in an undesirable result or state. . note highlights important information on the product, using the product, or part of the documentation that is of particular importance and that will be of benefit to the user. 0.3 qualified personnel the result of unqualified intervention in the instrument or nonobser- vance of the warnings given in this manual or on product labels can be severe personal injury and/or serious material damage. therefore only properly qualified personnel must make changes and settings in the instrument. for the purpose of the safety information in this manual and on the product labels, qualified personnel are those who s in the case of ex-proof equipment, are trained, instructed or authorized to perform work on electrical circuits of equipment subject to explosion hazard. s if they are configuration personnel, are familiar with the safety concepts of automation technology s if they are operating personnel, have been instructed in the handling of automation equipment and know the content of this manual relating to operation s if they are commissioning and/or service personnel, are trained to repair such automation equipment and authorized to energize, de-energize, clear ground and tag circuits and equipment according to safety engineering standards. s and instructed additionally in first aid
information for the operator sipart ps2 manual a5e00074631--06 8 ! warning the instrument must only be installed and commissioned by qualified personnel. the device may be used solely for the purposes described in this manual. the instrument is designed for connection to functional and safety extra low voltage. electrical safety depends only on the power supply equipment. pneumatic actuators exert considerable positioning forces. the safety precautions of the actuator used must therefore be scrupulously observed during installation and commissioning in order to prevent injuries. we explicitly draw your attention to the necessity of observing safety regulations regarding operation in zones subject to explosion hazard, if applicable. the specifications of the examination certificate valid in your country must be observed. laws and regulations valid in your country must be observed for the electrical installation in explosions hazardous areas. in germany these are for example: -- working reliability regulations -- regulations for installing electrical equipment in hazardous areas, din en 60079-14 (in the past vde 0165, t1). it should be checked whether the available power supply, insofar as this is required, is compliant with the power supply specified on the rating plate and specified in the examination certificate valid in your country. take care to avoid electrostatic discharges within the hazardous area, such as can arise if a dry cloth is used to clean the positioner in the plastic housing. devices with the protection type ?flameproof enclosure? may only be opened when the power is off. ! warning devices with the protection type ?intrinsically safe? lose their certifica- tion as soon as they are operated with circuits that do not conform to the specifications laid down in the examination certificate valid in your country. the successful and safe operation of this equipment is dependent upon its proper handling, installation, operation and maintenance.
information for the operator 9 sipart ps2 manual a5e00074631--06 ! warning the device may not be operated while the leaflets are in the housing. 0.4 use as intended use as intended for the purpose of this manual means that this product must only be used for the applications described in the technical de- scription (see also chapter 3 of this manual). the product described in this manual has been developed, manufac- tured, tested and documented observing the relevant safety standards. if the handling rules and safety information for configuration, installa- tion, use as intended and maintenance are observed, there is normally no danger with regard to material damage or for the health of person- nel. extra low voltages that are connected must be fed in by safe isola- tion. 0.5 technical documentation the operating instructions are a constituent part of the enclosed cd ?sipartp ps2 positioners? (order number a5e00214567) and is available on the internet at: www.siemens.com/sipartps2 click on ?more info? and --> ?instructions and manuals?. on the enclosed cd, you will find an extract of the catalog fi 01 ?field devices for process automation? with the current order data. the entire fi 01 catalog is also available at the above web address. 0.6 warranty information we should like to point out that the content of this manual is not part of and does not modify a previous or current agreement, undertaking or legal relationship. siemens is bound solely by the contract of sale, which also contains the complete and exclusive warranty. the con- tractual warranty conditions are neither extended nor restricted by this document.
information for the operator sipart ps2 manual a5e00074631--06 10 0.7 delivery notes the scope of delivery is listed on the dispatch papers accompanying the delivery in accordance with the valid contract of sale. when you open the packaging please observe the information on the packaging. check that the delivery is complete and undamaged. if possible, compare the order number on the rating plates with the or- dering data. for the scope of delivery please see chapter 7, page 153. 0.8 standards and regulations as far as possible, the harmonized european standards were used to specify and manufacture this equipment. if harmonized european stan- dards have not been applied, the standards and regulations of the fed- eral republic of germany apply (see also the technical data in chap- ter 6, page 147). if this product is used outside the area of applicability of these stan- dards and regulations, please observe the standards and regulations in force in the country where the product is operated.
introduction 11 sipart ps2 manual a5e00074631--06 introduction 1.1 general information about the positioner the positioner is used to adjust and control pneumatic actuators. the controller operates electropneumatically with compressed air as an energy supply. for example, the positioner can be used to control valves as follows: s with linear actuator (figure 1-1, page 13) or s with part-turn actuator vdi/vde 3845 (figure 1-2, page 13) different mounting types are available for linear actuators: s namur or iec 534 s integrated mounting to arca s integrated mounting to samson (non-explosion-proof version) this means the positioner can be installed and operated on all common actuator systems. the positioner is available for the following actuators: s double-acting and s single-acting for following applications: s potentially explosive or s not potentially explosive applications. the electronics with display, position feedback and valve block are inte- grated in the housing. the housing is available in three versions: s plastic housing for single and double-acting actuators s metal housing for single-acting actuators s explosion proof housing for single and double-acting actuators purpose versions housing 1
introduction 12 sipart ps2 manual a5e00074631--06 the device is designed with ip66/nema4x degree of protection. the intrinsically safe version can be used in hazardous areas in zone 1 or zone 2. the explosion proof version can be used in hazardous areas in zone 1 or zone 2. the version with the type of protection ?n? can be used in hazardous areas of zone 2. the sipart ps2 positioners in the variations 6dr501*, 6dr511*, 6dr521* and 6dr531* (i.e. with 0/4 up to 20 ma control signal in the single-acting design) are also suitable for positioning on fittings with pneumatic actuators, which satisfy the special requirements for safety devices up to sil 2 to iec 61508/ iec 61511-1. for this, the sil safety instructions (see ?sipart ps2 sil safety manual? a5e00442120) must be followed. the positioner can be expanded with various options modules (chap- ter 2.7, page 27). the following modules are available in all: s iy -module: two-wire current output 4 to 20 ma for position feedback s alarm module: 3 digital outputs and 1 digital input s sia module: one digital output for fault messages, two digital out- puts for limit value alarms s manometer block: 2 or 3 manometers for single and double-acting positioners s connection block (namur) for safety valve block s mounting kits for linear and part-turn actuator for decentralized installation of the positioner and position sensor: s external position detection system s non-contacting position sensor (ncs) only environmentally friendly materials have been used in the construc- tion of the positioner. the technical manual is printed on chlorine-free bleached paper. degree of protection explosion protection sil applications options accessories environmental protection
introduction 13 sipart ps2 manual a5e00074631--06 1 2 3 4 1 actuator 2 positioner, single-acting in metal housing 3 lantern 4 manometer block, single-acting 5valve 5 figure 1-1 positioner mounted on linear actuator (single-acting) 1 2 3 1 positioner double-acting in plastic housing 2 part-turn actuator 3 manometer block, double-acting figure 1-2 positioner mounted on part-turn actuator (double-acting)
introduction 14 sipart ps2 manual a5e00074631--06 1 2 3 4 1 actuator 2 positioner, single-acting in explosion proof housing 3 lantern 4 manometer block, single-acting figure 1-3 explosion proof version of the positioner mounted on linear actuator (single -acting ) 1 2 3 1 positioner double-acting in explosion proof housing 2 part-turn actuator 3 manometer block, double-acting figure 1-4 explosion proof version of the positioner mounted on part-turn actuator (double- acting ) table 1-1
design and functional principle 15 sipart ps2 manual a5e00074631--06 design and method of operation the following chapter describes the mechanical and electrical design, the instrument components and method of operation of the positioner. 2.1 overview the electropneumatic pos itioner forms a contro l system in connection with an actuator. the current position of the actuator is detected by a servo potentiometer and fed back as actual value x. the setpoint and actual value are output simultaneously on the display. the setpoint w is formed by a current fed to the positioner which at the same time serves to supply the positioner in two-wire operation. in 3/4-wire operation the supply comes from a 24 v voltage input. the positioner operates as a predictive five-point switch by the output variable ? y of which the integrated actuating valves are controlled with pulse length modulation. these actuating signals cause fluctuations in pressure in the actuator chamber(s) and thus adjustment of the actuator until the control error is zero. operation (manual) and configuration (structuring, initialization and parameterization) is effected by three keys and a display with the hous- ing cover removed. the standard controller has one digital input (di1). this can be config- ured individually and can be used for blocking the operating modes for example. with the i y -option module, the current actuator position can be output as a two wire signal i y =4to20ma. in addition the actuator can be monitored for two programmable limit values which respond on exceeding or dropping below the stroke or angle of rotation. the limit value alarms are output by the alarm option module which can monitor and report the function of the positioner and the actuator addi- tionally through a fault message output. the value of the control differ- ence dependent on the travel time is monitored in automatic mode. the fault signal is always set when the control error cannot be leveled after a certain time because for example the valve is blocked or the mains pressure is insufficient. the three digital outputs are implemented as semiconductor outputs and are error self-reporting, i.e. the outputs re- introduction 2
design and functional principle 16 sipart ps2 manual a5e00074631--06 spond even when the power supply fails or the electronics are defec- tive. the actuator can also be blocked or driven to its final positions depend- ing on the configuration for example by an external event via a digital input (di2) on the alarm module. if you require electrically independent limit value messages from the standard controller, you will have to use the sia module with the slot initiators instead of the alarm module. communication with the controller is possible via the optional hart interface. to be able to use the positioner with a variety of different part-turn and linear actuators, it has a friction clutch and switchable gearing. the switchable gearing allows you to adjust the positioner for small and large lifts. you can switch using the yellow switch (8, fig. 2-11, page 28) between 33 _ (as delivered) and 90 _ . the friction clutch (8, fig. 2-11, page 28) allows you to set the working range, particularly for linear actuators, after installation. you thus do not have to ensure symmetrical mounting during the installation. as it is not allowed to open the housing of an explosion-proof version in a potentially explosive atmosphere, the shaft has an externally fitted, additional friction clutch (8, fig. 2-12, page 31). notice for the explosion-proof version: only adjust the outer friction clutch (8, fig. 2-12, page 31). the internal friction clutch (8, fig. 2-11 page 28) is fixed and, for the explosion- proof version, must not be adjusted.
design and functional principle 17 sipart ps2 manual a5e00074631--06 2.2 name plate design (7) (1) (3) (2) (5) (6) (4) (8) (1) order number (5) serial number (2) manufacturer (6) place of manufacture (3) product name (7) protection class (4) technical data (8) observe manual figure 2-1 design name plate, example with protection class eex ia/ib 2.3 instrument components o 90 o 33 3 14 90 33 4 2 1 15 5 6 6.1 6.2 7 8 9 10 11 12 13 4...20 ma 0/4...20 ma 3/4 w 2w di1 1 input: supply air 7 silencer 2 output: actuating pressure y1 8 transmission ratio selector 3 display 9 adjusting wheel for frichtion clutch 4 output: actuating pressure y2 *) 10 terminals options modules 5 operating keys 12 dummy plug 6 restrictor 13 screw-type cable gland 6.1 restrictor y1 14 terminal plate on cover 6.2 restrictor y2 *) 15 purging air switch *) in double-acting actuators figure 2-2 view of the positioner in normal version (cover open)
design and functional principle 18 sipart ps2 manual a5e00074631--06 8 9 6.2 6.1 10 3 7 -- -- + + 1 10 138 238 9 212 1 4 5 1 input: supply air 7 transmission ratio selector 2 output: actuating pressure y1 (only possible with positioner open) 3 display 8 adjusting wheel for friction clutch 4 output: actuating pressure y2 *) 9 terminals standard controller 5 operating keys 10 terminals options modules 6.1 restrictor y1 12 safety catch 6.2 restrictor y2 *) *) in double-acting actuators figure 2-3 view of the explosion proof version of the positioner 2.3.1 motherboard the motherboard contains all the electronic elements such as the cpu, memory, a/d converter. it also contains the display and the operating keys. in addition, the terminal strips for connecting the options modules are also on the motherboard. 2.3.2 electrical connections the terminals of the standard controller, the i y - and alarm-option mod- ule are arranged at the left-hand front edges and offset against each other in staircase form. a module cover protects the modules from being pulled out and pre- vents incorrect installation.
design and functional principle 19 sipart ps2 manual a5e00074631--06 2.3.3 pneumatic connections the pneumatic connections are on the right hand side of the positioner (figure 2-4 and figure 2-5). 1 2 3 4 5 1 actuating pressure y1 in single- and double-acting actuators 2 feedback shaft 3 supply air p z 4 actuating pressure y2 in double-acting actuators 5 exhaust air output e with silencer on the bottom of the instrument figure 2-4 pneumatic connection in normal version 1 2 3 4 5 6 7 1 restrictor y2 *) 5 actuating pressure y1 2 restrictor y1 6 exhaust air output e 3 actuating pressure y2 *) 7 housing ventilation (2x) 4 supply air pz *) in double-acting actuators figure 2-5 pneumatic connection in explosion proof version in addition, there are pneumatic connections on the back of the posi- tioner for integrated installation in single-acting linear actuators. s actuating pressure y1 s exhaust air output e (not in explosion proof version) in the ex-factory state, these connections are sealed by screws (see figure 3-1, page 41, figure 3-3, page 42 and figure 3-4, page 43).
design and functional principle 20 sipart ps2 manual a5e00074631--06 the exhaust air output e can be provided for supplying dry instrument air to the tapping chamber and spring chamber to prevent corrosion. figure 2-6, page 21 shows the pneumatic connection variants for the different actuator types, the positioning action and the safety position after power failure.
design and functional principle 21 sipart ps2 manual a5e00074631--06 up down up down up down up down safety position after power failure electrical pneumatic down down up up down up y1 y1 y2 y1 y1 y2 y1 y1 y2 y1 y1 y2 open closed closed closed open open closed open last position (before power failure) actuator type positioning pressure connection in part-turn actuators the direction of rotation counterclockwise looking onto the actuating shaft of the valve is usually defined as ?open?. open closed up down open closed open closed open closed last position (before power failure) figure 2-6 pneumatic connection positioning
design and functional principle 22 sipart ps2 manual a5e00074631--06 2.3.4 mounting kit the positioner can be mounted on almost all actuators with the ap- propriate mounting kit. 2.3.5 purge air switching (not in the explosion proof version) the purge air switch is accessible above the pneumatic terminal strip with the housing open (figure 2-7). in the in position the inside of the housing is purged with very small amounts of clean, dry instrument air. in the out position the purge air is fed directly to the outside air. figure 2-7 purge air switch on the valve block, view of the positioner onto pneumatic connection side with cover open 2.3.6 restrictors in order to achieve travel times of > 1.5 s in small actuators, the air rate can be reduced with the restrictors y1 and y2 (figure 2-8, in explosion proof version, see figure 2-5, page 19). by turning to the right the air rate is reduced up to shutting off. to set the restrictors it is advisable to close them and then open them slowly (see initialization run3). in the case of double-acting valves make sure that both chokes are set approximately equal. y1 y2 hexagon socket 2.5 mm figure 2-8 restrictors
design and functional principle 23 sipart ps2 manual a5e00074631--06 2.4 method of operation the electropneumatic positioner sipart ps2 forms a control circuit with the pneumatic actuator in which the actual value x is the position of the actuator bar in linear actuators or the position of the actuator shaft in part-turn actuators and the command variable w is the actuating current of a controller or a manual control station of 4 to 20 ma. the stroke or part-turn movement of the actuator is transferred by the appropriate mounting accessories, the feedback shaft and a play-free switchable gearwheel to a high quality conductive plastic potentiometer and to the analog input of the microcontroller. the current position can also be preset for the positioner via an external sensor. the detection of the stroke or rotation andle is performed by a non-contacting posi- tion sensor ( n on c ontacting position s ensor) directly at the actuator. this may correct the angle error of the stroke tap, compares the potemtiometer voltage as actual value x with the setpoint w fed in at the terminals 3 and 7 and calculates the manipulated variable increments ? y. depending on the size and direction of the control error (x-w) the piezo-controlled supply air or exhaust air valve is opened. the volume of the actuator integrates the positioning increments to actuating pressure y open which moves the actuator bar or actuator shaft approximately proportionally. these positioning increments change the actuating pressure until the control error becomes zero. the pneumatic actuators are available in single and double-acting versions. only one pressure chamber is aerated or deaerated in the single-acting version. the resulting pressure operates against a spring. in the double-acting version, two pressure chambers are counteractive. in this case the one volume is deaerated when the other volume is aerated. see the block diagram figure 2-10, page 25. the control algorithm is an adaptive predictive five-point switch (see figure 2-9, page 24). the valves are controlled with continuous contact at large control errors (fast step zone). at medium control errors the valve is controlled by pulse length modulated pulses (short step zone). no actuating pulses are output in the small control error zone (adaptive dead zone). the dead zone adaptation and the continuous adaptation of the minimum pulse lengths in automatic operation cause the best possible control accuracy to be achieved at the lowest switching fre- quency. the start parameters are determined during the initialization phase and stored in a non-volatile memory. these are basically the real travel with the mechanical limit stops, the travel times, the size of the dead zone etc. in addition the number of fault messages, changes in direction and the number of strokes are determined and stored every 15 minutes during operation. these parameters can be read out and documented by the communication programs such as pdm and ams. conclusions as to the wear on the fitting can be drawn (diagnostic function) especially by comparing the old value with the currently determined values.
design and functional principle 24 sipart ps2 manual a5e00074631--06 figure 2-10, page 25 shows the block diagrams for single- and double- acting actuators with the linear actuator as an example. . note the exhaust air valve is always open when there is no current. figure 2-9 method of operation five-point switch
design and functional principle 25 sipart ps2 manual a5e00074631--06 a d a d 1 3 v i w+ i w- w y 0 x 0 + _ w x +u a1 a2 6 2 _ y + y u u i 5 4 3 zuluft p z abluft p 2 p 1 abluft 8 9 p 2 p 1 p 1 _ + p 2 p 1 a1 a2 7 ii hart be1 micro- controller be2 +24 v +5 v exhaust air exhaust air supply air stroke stroke 1 motherboard with microcontroller and input circuit 2 control panel with lc-display and momentary action switch 3 piezo-valve unit, always built-in 4 valve unit with double-acting positioner always built-in 5 iy-module for positioner sipart ps2 6 alarm module for three alarm outputs and one digital input 7 sia-module (slot initiator-alarm-module) 8 spring-loaded pneumatic actuator (single-acting) 9 spring-loaded pneumatic actuator (double-acting) figure 2-10 block diagram of the electro-pneumatic positioner, functional diagram . note alarm module (6) and sia module (7) can only be used alternatively.
design and functional principle 26 sipart ps2 manual a5e00074631--06 2.5 hart-function the positioner is also available with built-in hart-functions. the hart protocol allows you to communicate with your instrument with a hand- held communicator r , pc or programming unit. this enables you to configure your instrument comfortably, save configurations, call diag- nostic data, display online measured values and much more. commu- nication takes place as frequency modulation over the existing signal lines for the command variable from 4 to 20 ma. the spart ps2 is integrated in the following parameterization tools: s handheld communicator r s pdm (process device manager) s ams (asset management system) s cornerstone (without diagnostic values/-functions) . note operation on the positioner has priority over the settings via the hart interface. communication is aborted by a power failure at the positioner. 2.6 state as supplied there are no mechanical mounting accessories on the controller in the state as supplied. these must be ordered and installed according to the ?operating instructions? depending on the application. the respective connections for single or double-acting versions are prepared at the factory as ordered. the pneumatic connections on the rear are sealed. function
design and functional principle 27 sipart ps2 manual a5e00074631--06 2.7 installation of options modules 2.7.1 installation of options modules in normal and intrinsically safe versions the following option modules are available for the positioner in the standard and the intrinsically safe version: -- l y -module -- alarm module -- sia-module -- mechanical limit switch module -- emc filter module the installation of the options modules is described below: the option modules are secured by a assembly covering ((1), see figure 2-11, page 28) and mechanically fixed. . note to install the option modules the housing of the positioner needs to be opened. as soon as the positioner is opened, the ip66 degree of protection is not guaranteed. to open the positioner, the four screws of the housing cover must be loosened with a phillips screwdriver. disconnect or isolate the power supply cables. remove the module cover (1). to do this, the two screws (1.1) must be removed with a screwdriver. . note to prevent premature wearing of the fixture by the self-tapping screws (1.1), the following method of mounting the module cover (1) has proven effective. 1. turn the screws counterclockwise until you feel them snap into the thread 2. tighten both screws carefully in clockwise direction installation open positioner
design and functional principle 28 sipart ps2 manual a5e00074631--06 5 6 1 1.1 10 2.1 7.1 8 9 3 4 2 1.1 7 2.1 7.2 7.3 11 12 1 module cover 7 sia-module and mechanical limit switch module 1.1 fixing screws 7.1 special screw 2 motherboard 7.2 actuating disc for a1 (terminals 41 and 42) 2.1 fixing screws 7.3 actuating disc for a2 (terminals 51 and 52) 3i y -module with ribbon cable (6) 8 adjusting wheel for friction clutch 4 alarm module with ribbon cable (5) 9 transmission ratio selector 5 ribbon cable for alarm module 10 insulating cover 6 ribbon cable for iy-module 11 pneumatic block 12 actuating disc bearings figure 2-11 installation of options modules
design and functional principle 29 sipart ps2 manual a5e00074631--06 2.7.2 installation of options modules in explosion proof version the following option modules are available for the positioner in the ex- plosion-proof version: -- iy -module -- alarm module the options modules are protected and mechanically fixed by a module cover ((1), see figure 2-12, page 31). . note the housing must be opened to install the options modules. the degree of protection ip66/nema4x is not guaranteed as long as the positioner is open. ! warning in areas in which the atmosphere may be potentially explosive, the explosion-proof positioner may only be supplied with electrical auxiliary power when the housing is closed and when built-in, approved elec- tronics are used. the feed-though openings for the electronic connections must be sealed with eex-d certi fied cable glands or eex-d certified plugs or an ignition lock must be mounted at a maximum distance of 46 cm (18 inches) when using t he ?conduit ?-system. see figure 2-12, page 31. disconnect or isolate the power supply cables first. to open the positioner, the safety catch (12) must be opened and the screw-on cover unscrewed. after loosening the four fixing screws (13.1) the complete rack (13) can be removed. the actuator may have to be turned so that the clutch can be easily disengaged. remove the module cover (1). to do this, the two screws (1.1) must be removed with a screwdriver. installation open the positioner
design and functional principle 30 sipart ps2 manual a5e00074631--06 . note to prevent premature wearing of the fixture by the self-tapping screw (1.1) next to the display, the following method of mounting the module cover (1) has proven effective. 1. turn the screws counterclockwise until you feel them snap into the thread. 2. tighten both screws carefully in clockwise direction.
design and functional principle 31 sipart ps2 manual a5e00074631--06 10 1.1 11 3 4 2 1 1.1 7 13.1 56 13 12 8 13.1 1 module cover 7 transmission ratio selector 1.1 fixing screws 8 adjusting wheel for friction clutch 2 pa module 10 housing 3i y module with ribbon cable 11 screw-on cover 4 alarm module with ribbon cable 12 safety catch 5 ribbon cable for alarm module 13 rack 6 ribbon cable for i y module 13.1 fixing screws figure 2-12 installation of the options modules in the explosion proof version 2.7.3 iy-module with the i y option module, the current actuator position can be output as a two wire signal i y = 4 to 20 ma ? potentially isolated from the standard controller. the dynamic control of the i y module makes it also error self-reporting. function
design and functional principle 32 sipart ps2 manual a5e00074631--06 insert the i y module (3) in the lower slot of the rack up to the stop and use the 6-pin flat ribbon cable (6) provided to connect it to the motherboard (see figure 2-11, page 28). 2.7.4 alarm module the alarm module contains s 3 digital outputs and s 1 digital input the digital outputs serve to output fault messages and alarms. the configuration is described in chapter 4.4, page 95, with the para- meters 44 to 54. by an external signal applied at digital input (di2) the actuator can be blocked or driven to its limit positions for example depending on the configuration. the configuration is described in chapter 4.4, page 95, with the parameters 43. the alarm module is available in two versions: s explosion protected for connecting to switching amplifier en 60947-5-6 s non-explosion protected for connection to voltage sources with a maximum 35 v the semiconductor outputs of the alarm module report an alarm (signal state low) by switching off with high resistance. they are conductive in the high state (without al arm). the dynamic cont rol makes them error self-reporting. the outputs are potentially isolated from the basic circuit and each other. the digital input is double. s one potential isolated for voltage level s one not potential isolated for floating contacts these two inputs are designed as logic or links. insert the alarm unit (4) below the motherboard in the rack up to the stop and use the 8-pin flat ribbon cable (5) to connect it to the mother- board (see figure 2-11, page 28). installation function installation
design and functional principle 33 sipart ps2 manual a5e00074631--06 2.7.5 sia module the sia module contains: s one binary output s two binary outputs a collected fault message (see alarme module) is output via the binary output. the floating digital output is implemented as a self error report- ing semiconductor output. the two binary outputs are used to report two mechanically adjustable limit values (l1, l2) via slot initiators. these two outputs are electrically independent of the rest of the electronics. (slot initiator alarm module) proceed as follows for installation (figure 2-11, page 28):: 1. remove all the electrical connections from the motherboard (2). 2. loosen the two fixing screws (2.1) of the motherboard. 3. snap out the motherboard by carefully bending the four holders. 4. insert the sia module (7) from above until it reaches the upper circuit board rail of the rack. 5. push the sia module into the circuit board rail of the rack approx. 3 mm towards the right. 6. screw the special screw (7.1) through the sia module into the axle of the positioner (torque: 2 nm) : caution the pin pressed into the actuating disc bearing (12) must be adjusted to just before touching with the special screw. the actuating disc bea- ring and the special screw must then be turned simultaneously so that the pins slot into the special screw. 7. place the insulating cover (10) over the sia module underneath the surface of the motherboard at the container wall on one side. the recesses in the insulating cover must slot into the correspond- ing lugs on the container wall. place the insulating cover on the sia module by carefully bending the container walls. 8. snap the motherboard into the four holders and screw it tight again with the two fixing screws (2.1). function installation
design and functional principle 34 sipart ps2 manual a5e00074631--06 9. make all the electrical connections between the motherboard and the options with the ribbon cables provided and between the mo- therboard and potentiometers with the potentiometer cable. 10. fix the enclosed module cover instead of the standard version with the two screws (1.1). 11. select the plates which already exist on the standard version of the module cover from the set of plates enclosed. stick the selected plates according to the standard version to the mounted module cover. in the case of the version which doesn?t feature explosion protection, stick the warning sign onto the side of the ground plate opposite the name plate. 12. make the electrical connections. setting the two limit values: . note connect a suitable display instrument such as the initiator-tester type 2/ex made by peperl+fuchs to the terminals 41 and 42 or termi- nals 51 and 52 of the sia module to be able to see the switching state of the slot initiators. 1. drive the actuator to the first desired mechanical position. 2. adjust the top actuating disc (7.2) by hand until the output signal on terminals 41 and 42 changes. 3. drive the actuator to the second desired mechanical position. 4. adjust the bottom actuating disc (7.3) by hand until the output sig- nal on terminals 51 and 52 changes. . note if you turn the actuating disc beyond the switching point up to the next switching point, you can set a high-low or a low-high change. to avoid the actuating discs being accidentally adjusted during opera- ting, they are relatively sluggish. the following remedy might be of help if you are having trouble with the adjustment: open and close the ac- tuator several times while holding the actuating discs. this temporarily reduces the friction. this allows an easier and finer adjustment.
design and functional principle 35 sipart ps2 manual a5e00074631--06 2.7.6 mechanical limit switch module the mechanical limit switch module contains the following: s a binary output for the output of a group error message) s two switches for signaling two limit values that can be set mechani- cally. these two switches are electrically independent from the rest of the electronic system. the installation has to be carried as follows (figure 2-11, page 28): ! warning when the mechanical limit switch module is run with ac > 16 v or dc > 35 v (low voltage), the housing must be protected against mechanical actions of > 1 joule, since otherwise the proper functioning of the ip66 protectiv e system is not guaranteed. ! danger when the module is supplied with low voltage, you must observe the basic safety rules before beginning work on the device, such as: 1. deenergizing the module by disconnecting it via the disconnecting device located directly upstream from the module 2. securing it against being turned on again 3. ensuring that the module is disconnected from the voltage supply caution the following maximal values only refer to the clamps 41 and 42 as well as the clamps 51 and 52. maximal voltage (not ex) ac 250 v or dc 24 v maximal current (not ex) ac/dc 4 a maximal voltage (ex) dc 30 v maximal current (ex) dc 100 ma when you supply one circuit breaker with extra-low voltage (ac <16 v or dc 35 < v) and the other with low voltage, you ensure that the ca- ble insulation is doubled. when operating the switch with low voltage, you must position the low voltage circuits so that they are separated from the extra-low voltage circuits. installation
design and functional principle 36 sipart ps2 manual a5e00074631--06 follow the instructions below for installation: 1. remove all electrical connections on the motherboard (2). 2. loosen carefully both fixing screws (2.1) for the motherboard. 3. insert the limit switch module (7) from above until it reaches the upper printed circuit board rail of the container. 4. insert the mechanical limit switch module (7) from above until it reaches the upper circuit board rail of the rack. 5. push the mechanical limit switch module (7) into the circuit board rail of the rack approx. 3 mm towards the right. 6. screw the special screw (7.1) through the mechanical limit switch module into the axle of the positioner (torque: 2 nm) . caution the pin pressed into the actuating disc bearing (12) must be adju- sted just before it touches the special screw. in order that the pin slot into the special screw, you must then turn the actuating disc bearing and the special screw simultaneously 7. place the insulating cover (10) over the mechanical limit switch module underneath the surface of the motherboard onto the con- tainer on the wall. the recesses in the insulating cover must slot into the corresponding lugs on the container wall. place the insulat- ing cover on the mechanical limit switch module by carefully bend- ing the container walls. 8. snap the motherboard board into the four holders and screw it tight again with the two fixing screws (2.1). 9. make sure all electrical connections between the motherboard and the options using the ribbon cables provided and between the mo- therboard and potentiometer using the potentiometer cable. 10. fix the enclosed module cover (1) instead of the standard version using the two screws (1.1). . note to prevent premature wearing of the fixture by the self-tapping screws (1.1), the following method of mounting the module cover (1) has pro- ven effective: s turn the screws counterclockwise until you feel them snap into the thread. s tighten both screws carefully in a clockwise direction.
design and functional principle 37 sipart ps2 manual a5e00074631--06 . note before connecting up the limit contact module, ensure that: s only qualified personnel connect and set the limit contact module. s all cables are de-energized. s the cables are stripped so that the insulation is flush with the termi- nal when plugging in the wires. s the ends of stranded wires have sleeves. s the connection cables are insulated according to the permitted cur- rent load. s the permissible working temperature of the cables exceeds the maximal ambient temperature by >25 _ c. s the ex-version is only allowed to be operated in intrinsically safe circuits with approved switching amplifiers. connection 1. loosen the screw (1) on the cover (2). 2. push the cover (2) till it reaches the front stop. 3. screw each cable tight in the appropriate terminal. 4. push the cover (2) till it stops at the motherboard. 5. tighten the screw (1) of the cover (2). 6. fix the cables of each switch in pairs on the mounting eye using the cable binders provided (3). figure 2-13 cable connection
design and functional principle 38 sipart ps2 manual a5e00074631--06 setting the two limit values: 1. drive the actuator to the first desired mechanical position. 2. adjust the top actuating disc (7.2) by hand until the output signal on terminals 41 and 42 changes. 3. drive the actuator to the second desired mechanical position. 4. adjust the bottom actuating disc (7.3) by hand until the output sig- nal on terminals 51 and 52 changes. . note to avoid the actuating discs (7.2/7.3) being accidentally adjusted du- ring operation, they are relatively sluggish. the following remedy might be of help if you are having trouble with the adjustment: open and close the actuator several times while holding the actuating discs. this temporarily reduces the friction. this allows an easier and finer adjust- ment. 2.7.7 emc filter module the positioner can also be driven by an external position sensor (po- tentiometer or ncs) (see page 46 ?3.3.2 instructions for using position- ers which are exposed to strong accelerations or vibrations?). an emc filter module, order number c73451-a430-d23, is required for this.
design and functional principle 39 sipart ps2 manual a5e00074631--06 2.7.8 accessories y1 pz pz y1 y2 figure 2-14 manometer block (left for single-acting, right for double-acting actuators) the manometer block for single-acting actuator contains two mano- meters which are screwed to the lateral pneumatic connection of the positioner with o-rings. the values for the input pressure (supply air pz) and output pressure (actuating pressure y1) are displayed. the manometer block for double-acting actuators contains three manometers which are screwed to the lateral pneumatic connection of the positioner with o-rings. the values for the input pressure (supply air pz) and output pressure (actuating pressure y1 and y2) are displayed. manometer block
design and functional principle 40 sipart ps2 manual a5e00074631--06 table 2-1 scopetuator?
preparing for operation 41 sipart ps2 manual a5e00074631--06 preparing for operation this chapter describes all the preparations necessary for operating the positioner. 3.1 instrument identification (type key) the order number of the positioner is printed on the rating plate and on the packaging. compare this with the order number in chapter 7.1, page 154. installation of any modules required is described in chapter 2.7, page 27 of this technical manual. 3.2 dimensional drawings 11,2 23 50x4xm6 all air connections g 1/4 or 1/4? npt 9 deep m8, 9 deep 182 58 72 29,5 29,5 37 29 95 65 80 m20 x 1.5 or npt-adapter 88,5 8 15 96,6 13,5 h9 1 14,5 7 38,5 y1 e 60 33 y1 pz y2 2 7 48 figure 3-1 dimensional drawing version plastic housing 6dr5xx0 3
preparing for operation 42 sipart ps2 manual a5e00074631--06 90 79.5 20.5 3x g1/4or 1/4? npt 9.5 9 50 14 12 25 29.5 58.75 82 thread depth 5.5 m4 5 5 10 2xm6 5.3 9.5 3.5 figure 3-2 dimensional drawing terminal strip for plastic housing 11.2 23 58 50x4xm6 m8, 9 deep 88.5 8 all air connections g 1/4 or 1/4? npt 9 deep 182 34.5 27.5 84 59 29.5 29 15 96.5 13.5 65 h9 1 14.5 7 38.5 y1 e 6.5 12 29,5 14 7 2 y1 pz m20 x 1.5 or npt-adapter figure 3-3 dimensional drawing version metal housing 6dr5xx1
preparing for operation 43 sipart ps2 manual a5e00074631--06 m8, 14 deep (4x) 23 129.5 ? 8h9 3.5 235,3 60 m6, 11 deep (4x) all air connections g 1/ 4 or 1 / 4 ?npt 7.5 25.7 14,3 1) m6, 8 deep (2x) m20, m25 or 1/ 2 ?npt (2x) 87.2 65 43 7.75 50 ? ? 136.5 34 25 4.5 10.25 19,25 33.5 33.5 7 12 e 82,5 158.5 1) connection 238/y2 only in double action version figure 3-4 dimensional drawing for positioner with metal housing in explosion proof version 6dr5xx5 3.3 assembly ! warning to avoid injury or mechanical damage to the positioner/mounting kit, the following order must be observed for assembly: 1. mechanical fitting of positioner this chapter 2. connection of electric power supply see chapter 3.4, p. 57 3. connection of pneumatic power supply see chapter 3.5, p. 71 4. put into operation see chapter 3.6, p. 72 please also observe the warning on page 58! general
preparing for operation 44 sipart ps2 manual a5e00074631--06 . note the positioner will be equipped at the factory and delivered complete with the necessary options at the customer?s request. options modules may only be retrofitted by our service technicians. the positioner must be assembled ? especially in a moist environment ? in such a way as to rule out freezing of the positioner axle at low ambient temperature. the operating keys must be covered to prevent liquid getting in. ! warning in the combination of components it must be ensured that only positioners and options modules are combined which are approved for the respective area of application. this applies especially for safe operation of the positioner in areas in which the atmosphere is poten- tially explosive (zone 1 and 2). the instrument categories (2 and 3) of the instrument itself and those of its options must be observed. in addition, you must always make sure that no water gets into an open housing or screw-type gland. this may be the case for example when the positioner cannot be finally assembled and connected immediately. it generally applies that the positioner may only be operated with dry compressed air. therefore use the normal water traps. an additional drying unit may even be necessary in extreme cases. this is particu- larly important when operating the positioner at low ambient tempera- tures. please set the purge air switch (on the valve block above the pneumatic terminals) additionally to the ?out? position. use a sufficiently rugged console (e.g. plate thickness > 4 mm with reinforcements) for part-turn actuators and the mounting kit ?linear actuator? or integrated connection for linear actuators. 3.3.1 instructions for using positioners in a wet environment this information gives you important instructions for the assembly and operation of the positioner in a wet environment (frequent, heavy rain and/or prolonged tropical condensation) in which the ip66 degree of protection is no longer sufficient and especially when there is a danger that water may freeze. to prevent water getting into the instrument in normal operation (e.g. through the exhaust air openings) or the display being poorly legible, please avoid the unfavorable installation positions illustrated in figure 3-5.
preparing for operation 45 sipart ps2 manual a5e00074631--06 figure 3-5 favorable and unfavorable installation positions if conditions oblige you to operate the positioner in a unfavorable installation position, you can take additional precautionary measures to prevent penetration by water. . note never clean the positioner with a high pressure water jet because the ip66 degree of protection is inadequate protection for this. the necessary additional measures to prevent penetration by water depend on the installation position chosen and you may additionally require: s screw-type gland with sealing ring (e.g. festo: ck ?1 / 4?pk?6) s plastic hose approx. 20 to 30 cm (e.g. festo pun- 8x1,25 sw) s cable straps (number and length depends on local conditions) procedure s connect the pipes in such a way that rain water which runs along the pipes can drip off before it reaches the terminal strip of the posi- tioner. s check the electrical connections for perfect firm contact. s check the seal in the housing cover for damage and contamination. clean and replace if necessary. s mount the positioner if possible so that the sinter bronze silencer faces downwards on the underside of the housing (vertical installa- tion position). if this is not possible, the silencer should be replaced by a suitable screw-type gland with a plastic hose.
preparing for operation 46 sipart ps2 manual a5e00074631--06 assembly of the screw-type gland with plastic hose s unscrew the sinter bronze silencer from the exhaust air opening on the underside of the housing. s screw the screw-type gland mentioned above into the exhaust air opening. s mount the above mentioned plastic hose on the screw-type gland and check the good fit. s fix the plastic hose with a cable strap to the fitting so that the open- ing faces downwards. s make sure that the hose has no kinks and the exhaust air can flow out unhindered. 3.3.2 instructions for using positioners which are exposed to strong accelerations or vibrations notice for explosion-proof versions: only adjust the outer friction clutch (8, fig. 2-12, page 31). the internal friction clutch (8, fig. 2-11, page 28) is fixed and, for the explosion- proof version, must not be adjusted. the electro-pneumatic positioner sipart ps2 has a friction clutch and switchable gearing and can thus be used universally for part-turn and linear actuators. this means that, for part-turn actuators you don?t have to worry about the zero point and for linear actuators, you don?t have to worry about symmetrical mounting, as you can adjust the working range after installation, with the help of the friction clutch. the switchable gearing allows you to also adjust the positioner for small or large lifts. occasionally it can happen, that in the rough environment of process systems (e.g. due to incorrectly fitted valves or if ?steam pulses? occur) that the shaft to monitor the position of the sipart ps2 positioner is exposed to extreme acceleration, which far exceeds its specified load limits, and which could result in an unwanted shift in the friction clutch or in the gears in the position monitoring jumping briefly out. for cases like this, as standard, the sipart ps2 positioner is fitted with a locking device for the friction clutch and you can also lock the setting of the transmission ratio selector. this means that an unwanted change to the position monitoring due to the above mentioned effects can be reliably prevented. both of these locking options are labeled via additional tags inside the device (see figure 3-6, page 47). note that these locks are only re- quired if extreme acceleration or strong vibration might be present within your process.
preparing for operation 47 sipart ps2 manual a5e00074631--06 procedure after you have installed the positioner and put it fully into operation, you can set the torque for the friction clutch as follows: s on the module cover, insert an ordinary 4 mm wide screwdriver into a slot on the yellow wheel. s now use the screwdriver to move the yellow wheel to the left, until you can feel that it clicks in. this increases the torque of the friction clutch. s you can recognize a locked friction clutch by an approx. 1 mm wide gap between the yellow and black wheels. s if you have to set the zero pint e.g. after exchanging the actuator, first reduce the torque by turning the yellow wheel to the right until you hit the stop. after setting the zero point, you can refix the friction clutch as described above. starting from the neutral setting (as delivered), you can lock the trans- mission ratio selector as follows: s adjust the yellow wheel underneath the terminals with an ordinary 4 mm wide screwdriver to correspond to the setting that you would like (33 _ or 90 _ ), turning to the left or right, until you can feel that it clicks in. s please note that you can only adjust the transmission ratio selector after releasing the fixing. for this reason you first have to put the yellow ring into the neutral position, if you have to adjust the transmission ratio selector e.g. after exchanging the actuator). 33 90 (1) (3) (2) (4) 33 _ 90 _ (1) transmission ratio selector interlock (2) open (3) friction clutch (4) close figure 3-6 locking and fixing mechanisms
preparing for operation 48 sipart ps2 manual a5e00074631--06 applications in which the measures described above are inadequate are also conceivable. this applies for instance with continuous and heavy vibration, increased or too low ambient temperatures and in the case of nuclear radiation. the separate attachment of position displacement sensor and controller unit can help here. a universal component is available which is suitable both for linear and part-turn actuators. you require the following: s the external position detection system (order no. c73451-a430-d78). this consists of a sipart-ps2-housing with integrated friction clutch, built-in potentiometer and various dummy plugs and seals. s or a non-contacting position sensor (e.g. 6dr4004-6n). s the controller unit, any positioner version. s the emc filter module, this is is a set together with cable clips and m-20 screw-type cable gland and has the order number c73451-a430-d23. the emc filter module must be installed in the positioner. the installation instructions enclosed with the emc filter module explain how to assemble the components. s a 3-wire cable for connecting the components. this emc filter module should always be used for the controller unit when any actuator-mounted potentiometer (resistance 10 k ? )isto be used instead of the position detection system c 73451-a430- d78. ! warning the explosion-proof version may not be run together with the external position detection system. external position displacement sensor
preparing for operation 49 sipart ps2 manual a5e00074631--06 3.3.3 mounting kit ?linear actua tor? 6dr4004-8v and 6dr4004-8l the scope of delivery of the mounting kit ?linear actuator iec 534 (3 mm to 35 mm)? are contained (ser . no. see figure 3-7, page 51): ser. no. pieces designation note 1 1 namur mounting kit bracket iec 534 standardized connection for mounting console with ledge, column or plane surface 2 1 pick-up bracket guides the roller with carrier pin and turns lever arm 3 2 clamping assembly mounting of pick-up bracket on actuator spindle 4 1 carrier pin assembly with roll (5) on lever (6) 5 1 roll assembly with driver pin (4) on lever (6) 6 1 lever namur forstrokerange3mmto35mm for stroke ranges> 35 mm to 130 mm (special deli- very), lever 6dr4004-8l is required additionally 7 2 u bolt only for actuators with columns 8 4 hexagon head screw m8 x 20 din 933-a2 9 2 hexagon head screw m8 x 16 din 933-a2 10 6 lock washer a8 -- din 127-a2 11 6 flat washer b 8,4 -- din 125-a2 12 2 flat washer b 6,4 -- din 125-a2 13 1 spring vd--115e 0.70 x 11.3 x 32.7 x 3.5 14 1 spring washer a6 -- din 137a-a2 15 1 lock washer 3.2 -- din 6799-a2 16 3 spring washer a6 -- din 127-a2 17 3 socket cap screw m6 x 25 din 7984-a2 18 1 hexagon nut m6 -- din 934-a4 19 1 square nut m6 -- din 557-a4 21 4 hexagon nut m8 -- din 934-a4 table 3-1 scope of delivery of the mounting kit ?linear actuator?
preparing for operation 50 sipart ps2 manual a5e00074631--06 3.3.4 assembly procedure (see figure 3-7, page 51) 1. mount clamping assembly (3) with hexagon socket cap screws (17) and lock washer (16) on the actuator spindle. 2. insert the pick-up bracket (2) into the recesses of the clamping assembly. set the necessary length and tighten the screws so that the pick-up bracket can still be shifted. 3. insert the pin (4) in the lever (6) and assemble with nut (18), spring washer (14) and washer (12). 4. the value of the stroke range specified on the actuator or if this does not exist as a scaling value, the next greatest scaling value is set. the center of the pin must be in line with the scaling value. the same value can be set later under parameter 3.yway in commissioning to display the way in mm after initialization. 5. assemble the hexagon socket cap screw (17), spring washer (16), washer (12) and square nut (19) on the lever. 6. push the premounted lever onto the positioner axis up to the stop and fix with the hexagon socket cap screw (17). 7. fit the mounting bracket (1) with two hexagon head screws (9), lock washer (10) and flat washer (11) on the rear of the positioner. 8. selection of the row of holes depends on the width of the actuator yoke. the pin (4) should engage in the pick-up bracket (2) as close as possible to the spindle but may not touch the clamping assembly. 9. hold the positioner with the mounting bracket on the actuator so that the pin (4) is guided within the pick-up bracket (2). 10. tighten the pick-up bracket. 11. position the mounting parts according to the type of actuator. -- actuator with ledge: hexagon head screw (8), flat washer (11) and lock washer (10). -- actuator with plane surface: four hexagon head screws (8), flat washer (11) and lock washer (10). -- actuator with columns: two u bolts (7), four hexagon nuts (21) with flat washer (11) and lock washer (10). 12. secure positioner onto the yoke using the previously positioned mounting parts. . note set the height of the positioner so that the horizontal lever position is reached as close to the stroke center as possible. you can use the lever scale as orientation. it must be guaranteed that the horizontal lever position is passed through within the stroke range.
preparing for operation 51 sipart ps2 manual a5e00074631--06 1) 2 17 16 3 3) 9 10 11 9 10 11 1 3) 9 10 11 9 10 11 1 explosion-proof version: without explosion-proof version: 17 16 12 19 4 6 12 14 18 figure 3-7 assembly procedure (linear actuator)
preparing for operation 52 sipart ps2 manual a5e00074631--06 4) 8 1 10 11 7 21 11 10 11 as required mounting on yoke with columns mounting on yoke with plane surface 8 10 mounting on yoke with ledge figure 3-7 assembly procedure (linear actuator) continued 3.3.5 mounting kit ?part-turn actuator? 6dr4004-8d the scope of delivery of the mounting kit ?part-turn actuator? contains (ser. no. see figures 3-8 and 3-9): ser. no. pieces designation note 2 1 coupling wheel mounting on position feedback shaft of the sipart ps2 3 1 carrier mounting on end of actuator shaft 4 1 multiple plate indication of actuator position, comprising 4.1 and 4.2 4.1 8 scales different divisions 4.2 1 pointer mark reference point for scale 14 4 hexagon head screw din 933 -- m6 x 12 15 4 lock washer s6 16 1 fillister head screw din84--m6x12 17 1 washer din125?6.4 18 1 hexagon socket head screw premounted with coupling wheel 19 1 allen key for item 18 table 3-2 scope of delivery of the mounting kit ?part-turn actuator?
preparing for operation 53 sipart ps2 manual a5e00074631--06 3.3.6 assembly procedure (see figure 3-8 and figure 3-9) 1. attach vdi/vde 3845 mounting console ((9), actuator-specific, scope of delivery actuator manufacturer) onto rear of positioner and secure using hexagon head screws (14) and lock washers (15). 2. adhere pointer (4.2) onto mounting console in the center of the centering hole. 3. push the coupling wheel (2) onto positioner axis, pull back by about 1 mm and tighten the hexagon socket head screw (18) with the allen key provided. 4. place the carrier (3) onto the end of the actuator and secure using fillister head screw (16) and washer (17). 5. carefully place positioner with mounting console onto the actuator such that the pin of the coupling wheel engages in the actuator. 6. align the positioner/mounting console assembly in the center of the actuator and screw tight. (screws not included in delivery; they are part of the actuator mounting console!) 7. following startup as described in chapter 3.6, page 72: drive the actuator to the end position and adhere scale (4.1) on the coupling wheel (2) according to direction of rotation and part-turn actuator. the scale is self--adhesive!
preparing for operation 54 sipart ps2 manual a5e00074631--06 0% 20 40 60 80 100% 1) 2) 3) 4) 5) 18 2 3 16 17 2 4.1 2 3 9 14 15 figure 3-8 assembly procedure (part-turn actuator)
preparing for operation 55 sipart ps2 manual a5e00074631--06 0% 20 40 60 80 100% 1) 2) 3) 5) 18 2 3 16 17 2 4.1 9 14 15 4) 2 3 figure 3-9 assembly procedure for explosion proof version (part-turn actuator)
preparing for operation 56 sipart ps2 manual a5e00074631--06 positioner part-turn actuator 3 16, 17 10 4.1 9 a 25 2 14, 15 15 b cut a -- b 4.2 14, 15 g1/4 2 coupling wheel 10 feedback shaft 3 carrier 14 hexagon head screw m6 x 12 4 multiple plate 15 lock washer s6 4.1 scale 16 fillister head screw m6 x 12 4.2 pointer mark 17 washer 9 vdi/vde 3845-mounting bracket 18 hexagon socket head screw figure 3-10 mounted positioner for part-turn actuator
preparing for operation 57 sipart ps2 manual a5e00074631--06 m6 4 35 schwenkantrieb befestigungsebene stellungsregler f05-lkr.- 50 +0,1 fastening level positioner part-turn actuator figure 3-11 attachment of part-turn actuator, mounting console (scope of delivery actuator manufacturer), dimensions 3.4 electrical connection . note any necessary options modules must be installed before electrical connection (see chapter 2.7, page 27). n.b.: the transmission ratio selector can only be set when the positioner is open. therefore check this setting before closing the controller. ! warning the specifications of the examination certificate valid in your country must be observed. electrical connection in hazardous areas the national directives and laws which apply in your country for haz- ardous areas, must be followed for electrical installations. in germany these are, for example: -- working reliability regulations -- regulations for installing electrical equipment in hazardous areas, din en 60079-14 (in the past vde 0165, t1). -- the ec type examination certificates
preparing for operation 58 sipart ps2 manual a5e00074631--06 ! warning if the intrinsically safe version is operated with a higher operating vol- tage by mistake, the positioner must no longer be used for intrinsically safe application. the explosion-proof positioner may only be supplied with electrical power in areas in which the atmosphere may be potentially explosive when the housing is closed. where power supply is required, we recommend checking the power supply to ensure that it corresponds with that on the name plate and with the test certification valid for your country. the feed-though openings in the explosion-proof version for the electronic connections must be seal ed with eex-d cer tified cable glands or eex-d certified plugs or an ignition lock must be mounted at a maximum distance of 46 cm (18 inches) when using the ?conduit?- system. the plastic housing is metal lined to increase the electromagnetic compatibility (emc) against high frequency radiation. this screen is connected electrically to the threaded bushes shown in figure 3-12, page 58. please bear in mind that this protection can only be effective if you con- nect at least one of these bushes with grounded fittings by electrically conductive (blank) mounting parts. shield figure 3-12 base plate
preparing for operation 59 sipart ps2 manual a5e00074631--06 . note use standard m20 x 1.5 cable gland nuts to ensure leakage (ip-protec- tion of the housing) and for the necessary tensile strength use only cables with a cable diameter 8 mm, or for smaller diameters use a suitable sealing insert. for the npt version, the positioner will be delivered with an adapter. make sure that when fitting a part into the adapter, that the maximum permissible torque of 10 nm is not exceeded. note for use in zone 2: non-sparking equipment for zone 2 may not be connected or discon- nected under power in normal operation. however, during installation or repair work the positioner may be con- nected or disconnected even under power (see also certificate for zone 2). note for use in two-wire systems: never connect the current input (terminal 6 and 7) to a voltage source as this could destroy the positioner. always use a current source with a maximum output current of 20 ma. to maintain the power supply, the input current must be 3.6 ma. 3.4.1 connection in non-intrinsically safe and explosion proof version + j 4to20ma positioner digital input 1 6 7 8 9 10 only for: 6dr51x0-xnxxx 6dr5111-xnxxx 6dr51x5-xexxx hart communicator a e 6dr50x0-xnxxx 6dr5011-xnxxx 6dr51x0-xnxxx 6dr5111-xnxxx 6dr50x5-xexxx 6dr51x5-xexxx figure 3-13 two-wire connection
preparing for operation 60 sipart ps2 manual a5e00074631--06 + 4to20ma 6dr53x0-xnxxx 6dr52x5-xexxx 6dr53x5-xexxx positioner 2 3 4 5 6 7 8 9 10 a e j hart communicator only for: 6dr52x5-xexxx digital input 1 figure 3-14 two-wire connection + 0/4to20ma 6dr53x0-nxxx 6dr52x5-exxx 6dr53x5-exxx positioner 2 3 4 5 digital input 1 6 7 8 9 10 a e *) *) only for three-wire connection + 18 to 30 v u *) hart communicator only for: 6dr52x5-xexxx j figure 3-15 three-/four-wire connection
preparing for operation 61 sipart ps2 manual a5e00074631--06 u h 61 62 61 62 j e + + 35 v iy module: 6dr4004-8j figure 3-16 i y- module 6dr4004-8j, not ex digital inputs and outputs + 11 12 +13 v +4,5 v 1 digital input 2 21 22 + +3 v 31 32 41 42 51 52 alarm module 6dr4004-8a 1k 1k 1k 35 v + 35 v + 35 v 30 v fault message limit value a1 limit value a2 figure 3-17 alarm module 6dr4004-8a, not ex current output
preparing for operation 62 sipart ps2 manual a5e00074631--06 31 32 41 42 51 52 sia module 6dr4004-8g + + + 1k21 10k <35 v 8.2 v 8.2 v fault message limit value a1 limit value a2 switching amplifier according to en 60947-5-6 figure 3-18 sia module 6dr4004-8g, not ex mechnical limit switch module 31 32 41 42 51 52 limit switch module 6dr4004-8k + + + 1k21 10k <35 v dc 24 v = ? ? max. ac 250 v ac/dc 4 a dc 24 v max. ac 250 v ac/dc 4 a fault message limit value a1 limit value a2 figure 3-19 mechanical limit switch module 6dr4004-8k, not ex 3.4.2 connection in intrinsically safe version . note only certified intrinsically safe circuits may be connected as power supply, control and signal circuits. sia module
preparing for operation 63 sipart ps2 manual a5e00074631--06 standard controller + j 4to20ma 6dr5010-xexxx 6dr5020-xexxx 6dr5011-xexxx 6 7 8 9 10 a e eex non-hazardous area intrinsically safe power source hazardous area zone 1 or zone 2 positioner digital input 1 figure 3-20 two-wire connection, eex i + 6dr5210-xexxx 6dr5220-xexxx 6dr5211-xexxx 2 3 4 5 6 7 8 9 10 a e 4to20ma eex j hazardous area zone 1 or zone 2 non-hazardous area intrinsically safe power source positioner digital input 1 hart communicator figure 3-21 two-wire connection, eex i
preparing for operation 64 sipart ps2 manual a5e00074631--06 + 18 to 30 v 6dr5210-xexxx 6dr5220-xexxx 6dr5211-xexxx 2 3 4 5 6 7 8 9 10 a e u *) only for three-wire connection j 4to20ma eex eex + *) *) hart communicator hazardous area zone 1 or zone 2 non-hazardous area intrinsically safe power source positioner digital input 1 figure 3-22 three-/four-wire connection, eex i
preparing for operation 65 sipart ps2 manual a5e00074631--06 l+ iy m m instrument 1 6dr5210-xexxx 6dr5220-xexxx 6dr5211-xexxx 6dr5210-xexxx 6dr5220-xexxx 6dr5211-xexxx i eex u eex # # +18to30v +0/4 to 20 ma power supply intrinsically safe feed sources instrument 2 positioner positioner setting range 1 setting range 2 digital input 1 digital input 1 hazardous area zone 1 or zone 2 non-hazardous area total setting range iy figure 3-23 series circuit of two positioners, e.g. split range (separate power supply), eex i split-range
preparing for operation 66 sipart ps2 manual a5e00074631--06 u h 61 62 61 62 j e i y module 6dr4004-6j + + j eex u + 30 v non-hazardous area intrinsically safe power source hazardous area zone 1 or zone 2 figure 3-24 i y -module 6dr4004-6j, eex i digital inputs and outputs alarm module 6dr4004-6a + 11 12 1 21 22 + 31 32 41 42 51 52 eex eex eex eex + + + 2k1 2k1 2k1 10k 10k 10k 3v 8.2 v 8.2 v 8.2 v 25.2 v hazardous area zone 1 or zone 2 non-hazardous area digital input 2 fault message limit value a1 limit value a2 intrinsically safe switching amplifier to din en 60947-5-6 figure 3-25 alarm module 6dr4004-6a, eex i current output
preparing for operation 67 sipart ps2 manual a5e00074631--06 sia module 6dr4004-6g eex eex eex 31 32 41 42 51 52 2k1 10k + + + 8.2 v 8.2 v 8.2 v hazardous area zone 1 or zone 2 non-hazardous area fault message limit value a1 limit value a2 intrinsically safe switching ampli- fier to din en 60947-5-6 figure 3-26 sia module 6dr4004-6g, eex i mechnical limit switch module 31 32 41 42 51 52 mechanical limit switch module 6dr4004-6k + + + 2k1 10k max. dc 8,2 v u max dc 30 v = i max 100 ma u max dc 30 v i max 100 ma = eex hazardous area zone 1 or zone 2 non-hazardous area intrinsically safe switching ampli- fier to din en 60947-5-6 fault message limit value a1 limit value a2 figure 3-27 mechnical limit switch module 6dr4004-8k, eex i sia module
preparing for operation 68 sipart ps2 manual a5e00074631--06 3.4.3 connection in type of protection ?n? version standard controller + j 4to20ma 6dr5010-xgxxx 6dr5020-xgxxx 6dr5011-xgxxx 6 7 8 9 10 a e hazardous area zone 2 non-hazardous area positioner digital input 1 figure 3-28 two-wire connection, eex n + 4to20ma 6dr5210-xgxxx 6dr5220-xgxxx 6dr5211-xgxxx 2 3 4 5 6 7 8 9 10 a e j hart communicator hazardous area zone 2 non-hazardous area positioner digital input 1 figure 3-29 two-wire connection, eex n
preparing for operation 69 sipart ps2 manual a5e00074631--06 + 0/4to20ma 6dr5210-gxxx 6dr5220-gxxx 6dr5211-gxxx 2 3 4 5 6 7 8 9 10 a e *) *) only for three-wire connection + 18 to 30 v u *) har communicator j hazardous area zone 2 non-hazardous area positioner digital input 1 figure 3-30 three-/four-wire connection, eex n u h 61 62 61 62 i e i y module 6dr4004-6j + + + 30 v non-hazardous area hazardous area zone 1 or zone 2 figure 3-31 i y -module 6dr4004-6j, eex n current output
preparing for operation 70 sipart ps2 manual a5e00074631--06 digital inputs and outputs + 11 12 1 21 22 + +3 v 31 32 41 42 51 52 alarm module 6dr4004-6a + + 2k1 10k 2k1 10k 2k1 10k 8.2 v 8.2 v 8.2 v hazardous area zone 2 non-hazardous area digital input 2 fault message limit value a1 limit value a2 figure 3-32 alarm module 6dr4004-6a, eex n sia module 6dr4004-6g 31 32 41 42 51 52 2k1 10k + + + 8.2 v 8.2 v 8.2 v hazardous area zone 2 non-hazardous area fault message limit value a1 limit value a2 figure 3-33 sia module 6dr4004-6g, eex n sia module
preparing for operation 71 sipart ps2 manual a5e00074631--06 3.5 pneumatic connection ! warning for reasons of safety, the pneumatic power may only be supplied after assembly when the positioner is switched to operating level p manual operation with electrical signal applied (as-delivered state, see figure 4-4, page 92). . note note the air quality! oil-free industrial air, solid content < 30 m, pressure dew point 20 k below the lowest ambient temperature (chapter 7 ?techni- cal data?, page 153). s connect a manometer block for supply air and actuating pressure if necessary. s connection by female thread g 1/4 din 45141 or 1/4? npt: p z supply air 1.4 to 7 bar y1 actuating pressure 1 for single- and double-acting actuators y2 actuating pressure 2 for double-acting actuators e exhaust air outlet (remove silencer if necessary) see figure 2-4 and 2-5, page 19. s safety position when the electric power supply fails: single-acting: y1 deaerated double-acting: y1 max. actuating pressure (supply air pressure) y2 deaerated s connect actuating pressure y1 or y2 (only in double-acting actua- tors) according to the desired safety position. s connect supply air to p z . . note in order for spring-loaded pneumatic actuators to be able to reliably exploit the maximum possible travel, the supply pressure must be sufficiently greater than the maximum required final pressure of the actuator. after installing the device, check the pneumatic connections of the entire assembly for leakage. any leakage would cause not only continuous consumption of compressed air but also would cause the positioner to continually endeavor to compensate for the variance in position, leading in time to premature wear of the whole control mechanism.
preparing for operation 72 sipart ps2 manual a5e00074631--06 3.6 commissioning once the positioner has been fitted to a pneumatic actuator, it must be provided with electrical and pneumatic auxiliary power. then you can then adapt the position controller to the respective actua- tor by parameterizing and initializing it. mode? operating mode (which can also if necessary be attained by ?prst?) -- ?noini? will flash. if the positioner has not been initialized it will be in the ?p manual mode? operating mode (which can also if necessary be attained by ?prst?) -- ?noini? will flash. this initialization can be effected in three different ways: s automatic initialization initialization takes place automatically. hereby the positioner deter- mines the direction of action, the stem travel and the angle of rota- tion, the travel times of the actuator one after the other and adapts the control parameters to the dynamic behavior of the actuator. s manual initialization the stem travel or angle of rotation of the actuator can be set manually, the other parameters are determined as in automatic init- ialization. this function is useful in actuators with soft limit stops. s copying initialization data (positioner exchange) in the devices with hart function the initialization data of a posi- tioner can be read out and copied to another positioner. this en- ables a defective device to be changed without having to interrupt an ongoing process by initialization. only a few parameters need to be set in the positioner prior to initializa- tion. the others are defaulted so that they do not normally need to be adjusted. you will have no problems with commissioning if you observe the following points. the possible operating modes and parameters, together with the adjustment capabilities and their effects are described in chapter 4, page 89 ?operation?. . note n.b.: the operating pressure should be at least one bar greater than is necessary for closing/opening the valve during initialization. however, the operating pressure may not be higher than the maximum permis- sible operating pressure of the actuator. n.b.: the transmission ratio selector can only be set when the positioner is open. therefore check this setting before closing the housing.
preparing for operation 73 sipart ps2 manual a5e00074631--06 3.6.1 preparations for linear actuators 1. assemble the positioner with the appropriate mounting kit (see chapter 3.3.3, page 39). . note particularly important is the position of the transmission ratio selec- tor (8, figure 2-2, page 17) in the positioner: stroke lever position of the transmission ratio selector 5to20mm short 33 (i.e. down) 25 to 35 mm short 90 (i.e. up) 40 to 130 mm long 90 (i.e. up) 2. push the carrier pin (4, figure 3-7 (page 51) 2) onto the lever (6, figure 3-7, 2) to the scale position corresponding to the rated stroke or next highest position and screw the carrier pin tight with the nut (18, figure 3-7, 2). 3. connect the actuator and the positioner with the pneumatic lines and supply pneumatic power to the positioner (figure 2-4 and 2-5, page 19). 4. connect a suitable current or voltage source (see figure 3-13, page 59 and figure 3-20, page 63). 5. the positioner is now in the operating mode ? p-manual opera- tion ? the current potentiometer voltage (p) is displayed in percent in the top line of the display, e.g.: ? p12.3 ?, and ? noini ? flashes in the bottom line: 6. check the free running of the mechanics in the whole actuating range by moving the actuator with the keys and and driving to the respective end position. . note you can move the actuator quickly by pressing the other direction key additionally whilst keeping the direction key selected first pressed. 7. now move the actuator to the horizontal position of the lever. a value between p48.0 and p52.0 should be visible in the display. if this is not the case, adjust the friction clutch (8, figure 2-11, page 28 or in frameproof enclosure 8, figure 2-12, page 31) until ? p50.0 ? is displayed with a horizontal lever. the more accurately you hit this value, the more exactly the positioner can determine the path.
preparing for operation 74 sipart ps2 manual a5e00074631--06 notice for the explosion-proof version: only adjust the outer friction clutch (8, fig. 2-12, page 31). the internal friction clutch (8, fig. 2-11 page 28) is fixed and, for the explosion- proof version, must not be adjusted. 3.6.2 automatic initialization of linear actuator if you can move the actuator correctly, leave it standing in a central position and start automatic initialization: 1. press the operation mode key for longer than 5 s. this brings you to the configuration mode. display: 2. switch to the second parameter by pressing the operation mode key briefly. display: or . note it is vital that this value corresponds to the setting of the transmission ratio selector (8, figure 2-2, page 17) (33 or 90 ). 3. switch on to the following display with the operation mode key : you only need to set this parameter if you want to have the total stroke in mm displayed at the end of the initialization phase. to do this, select the same value in the display to which you have set the carrier pin to the scale on the lever. 4. switch on to the following display with the operation mode key :
preparing for operation 75 sipart ps2 manual a5e00074631--06 5. start initialization by pressing the key for longer than 5 s. display: during the initialization phase ? run1 ?to? run5 ? appear one after another in the bottom display (see also structograms figure 3-35, page 83 to figure 3-38, page 86). . note the initialization process may last up to 15 minutes depending on the actuator. the initialization is complete when the following display appears: the following display appears after pressing the operation mode key briefly: to e x i t t h e configuration mode, press the operation mode key for longer than 5 s. the software version is displayed after about 5 s. the instrument is in manual operation after releasing the operation mode key. . note you can abort an ongoing initialization at any time by pressing the operation mode key. your previous settings are retained. all the para- meters are reset to the factory setting only after performing a ?preset?.
preparing for operation 76 sipart ps2 manual a5e00074631--06 3.6.3 manual initialization of linear actuator the positioner can be initialized with this function without the actuator being driven hard against the limit stop. the start and end positions of the travel are set manually. the other initialization steps (optimization of the control parameters) run automatically as in automatic initializa- tion. 1. make preparations as described in chapter 3.6.1, page 73 for linear actuator. in particular, make sure by manually driving the whole travel that the displayed potentiometer setting moves in the permis- sible range between p5.0 and p95.0. press the operation mode key for longer than 5 s. this brings you to the configuration mode. display: 3. switch to the second parameter by pressing the operation key briefly. one of the following displays appears: or . note it is vital that this value corresponds to the setting of the transmission ratio selector (33 _ or 90 ). 4. switch on to the following display with the operation mode key: you only need to set this parameter if you want to have the total stroke in mm displayed at the end of the initialization phase. to do this, select the same value in the display to which you have set the carrier pin to the scale on the lever or the next highest position in intermediate positions. manual initializa- tion procedure in linear actuator
preparing for operation 77 sipart ps2 manual a5e00074631--06 5. switch on to the following display by pressing the operation mode key twice: 6. start initialization by pressing the increment key for longer than5s. display: 7. after 5 s the display changes to: (the display of the potentiometer setting is shown here and below as an example only). now move the actuator to the position which you want to define as the first of the two end positions with the increment and decre- ment key. then press the operation mode key . this accepts the current position as end position 1 and switches on to the next position. . note if the message ?range? appears in the bottom line, the selected end position is outside the permissible measuring range. there are several ways to correct the error: s adjust the friction clutch until ?ok? appears and press the operation mode key again or s move to another end position with the increment and decrement key or s abort initialization by pressing the operation mode key. you then have to change to p manual operation and correct the travel and the posi- tion detection according to step 1.
preparing for operation 78 sipart ps2 manual a5e00074631--06 8. if step 7 was successful, the following display appears: now move the actuator to the position which you want to define as the second end position with the increment and decre- ment key. then press the operation mode key . this enters the current position as end position 2. . note if the message ?range? appears in the bottom line, the selected end position is outside the permissible measuring range. there are several ways to correct the error: s move to another end position with the increment and decrement key or s abort initialization by pressing the operation mode key. you then have to change to p manual operation and correct the travel and the posi- tion detection according to step 1. . note if the message ?set middl? appears, the lever arm must be driven to horizontal position using the increment and decrement key and then the operation mode key pressed. this sets the reference point of the sine correction in linear actuators. 9. the rest of the initialization now runs automatically. ?run1? to ?run5? appear one after another in the bottom line of the display. the following display appears on successful completion of initiali- zation: the first line additionally contains the determined stroke in millimeters if the set lever length was specified with parameter 3 yway. 5 initm appears in the bottom line again after pressing the operation mode key briefly. this brings you back to the configuration operating mode. to exit the configuration mode, press the operation mode key for longer than 5 seconds. the software version is displayed after about 5 seconds. the instrument is in manual operation after releasing the operation mode key.
preparing for operation 79 sipart ps2 manual a5e00074631--06 3.6.4 preparations for part-turn actuator . note very important: switch the transmission ratio selector in the positioner (8, figure 2-2, page 17) to position 90 (normal angle for part-turn actuator). 1. mount the positioner with the appropriate mounting kit (see chapter 3.3.5, page 52). 2. connect the actuator and the positioner with the pneumatic lines and supply pneumatic power to the positioner (figure 2-4 and 2-5, page 19). 3. connect a suitable current or voltage source (see figure 3-13, page 59 and figure 3-20, page 63). 4. the positioner is now in the operating mode ? p-manual operation ? the current potentiometer voltage (p) is displayed in % in the top line of the display, e.g.: ? p12.3 ?, and ? noini ? flashes in the bottom line: 5. check the free running of the mechanics in the whole actuating range by moving the actuator with the keys and and driving to the respective end position. . note you can move the actuator quickly by pressing the other direction key additionally whilst keeping the direction key selected first pressed. 3.6.5 automatic initializ ation of part-turn actuator if you can move the actuator correctly through the actuating range, leave it standing in a central position and start automatic initialization: 1. press the operation mode key for longer than 5 s. this brings you to the configuration operating mode. display
preparing for operation 80 sipart ps2 manual a5e00074631--06 2. set the parameter with the -key to ?turn? display: 3. switch to the second parameter by pressing the operation mode key briefly. this has set automatically to 90 . display: 4. switch on to the following display with the operation mode key : 5. start initialization by pressing the key for longer than 5 s. display: during the initialization phase ? run1 ?to? run5 ? appear one after another in the bottom display (see also structograms in figure 3-35, page 83 to figure 3-38, page 86). . note the initialization process may last up to 15 minutes depending on the actuator. the initialization is complete when the following display appears: the top value indicates the total angle of rotation of the actuator (example 93.5 ). the following display appears after pressing the operation mode key briefly:
preparing for operation 81 sipart ps2 manual a5e00074631--06 to e x i t t h e configuration mode, press the operation mode key for longer than 5 s. the software version is displayed after about 5 s. the instrument is in manual operation after releasing the operation mode key. . note you can abort an ongoing initialization at any time by pressing the ope- ration mode key. your previous settings are retained. all the parame- ters are set to the factory setting only after performing a ?preset?. 3.6.6 manual initialization of part-turn actuators the positioner can be initialized with this function without the actuator being driven hard against the limit stop. the start and end positions of the travel are set manually. the other initialization steps (optimization of the control parameters) run automatically as in automatic initializa- tion. 1. make preparations as described in chapter 3.6.4, page 79 for part-turn actuators. in particular, make sure by manually driving the whole travel that the displayed potentiometer setting moves in the permissible range between p5.0 and p95.0. 2. press the operation mode key for longer than 5 s. this brings you to the configuration mode. display: 3. set the parameter yfct to ?turn? with the decrement key. display: 4. switch to the second parameter by pressing the operation mode key briefly. display: manual initializa- tion procedure in part-turn actuators
preparing for operation 82 sipart ps2 manual a5e00074631--06 . note make sure that the transmission ratio selector is in position 90 ! 5. switch on to the following display by pressing the operation mode key twice: the following steps are identical with the steps 6) to 9) for initiali- zation of linear actuators. after successful initialization the determined part-turn range ap- pears in the top display. ?5.initm? appears in the bottom line again after pressing the op- eration mode key briefly. this brings you back to the configu- ration mode. to exit the configuration mode, press the operation mode key for longer than 5 seconds. the software version is displayed after about 5 seconds. the instrument is in manual operation after re- leasing the operation mode key. 3.6.7 automatic initialization (structograms) open closed up down part-turn actuator linear actuator figure 3-34 direction of action of the actuators the initialization procedure should be taken from the following structo- gram (figure 3-35 to figure 3-38). the terms open/closed and up/down in the structogram refer to the direction of action of the actuators as illustrated in figure 3-34.
preparing for operation 83 sipart ps2 manual a5e00074631--06 configure piezo valve 1 opens piezo valve 2 opens dy > 4 % ? dy > 4 % ? t>60s? t>60s? no no no no yes yes yes yes move the actuator into the travel range 1 2 run 1 manual intervention continue with: with: >5s start: press figure 3-35 automatic initialization, part 1
preparing for operation 84 sipart ps2 manual a5e00074631--06 2 3 1 no no no yes yes yes continue with: continue with: continue with: turn slip clutch until 0 appears in the bottom line of the display check mechanics manual intervention actuator moves into open position tolerance band 4% > dw >10%? hard stop up < 97 % ? span up-dw > 25 % ? run 2 actuator into closed position moves figure 3-36 automatic initialization part 2 (in part-turn actuators)
preparing for operation 85 sipart ps2 manual a5e00074631--06 2 3 1 1 continue with: continue with: no no no no no yes yes yes yes yes continue with: continue with: correct height adjustment or turn friction clutch until 0 appears in the bottom line of the display set the next lowest travel value on the lever and check the setting of the transmission ratio selector set the next highest travel value on the lever and check the setting of the transmission ratio selector has friction clutch moved? been actuator into closed position moves was the vertical position (to stem) of the lever driven through ? set lever vertical to stem with: arm run 2 actuator moves into open position continue with: manual intervention tolerance band 4>d>20%? hard stop up < 97 % ? span up-dw > 25 % ? figure 3-37 automatic initialization part 2 (in linear actuators)
preparing for operation 86 sipart ps2 manual a5e00074631--06 3 determine travel times within 5s? within 5s? no no yes yes continue with: continue with: continue with: or or set restrictor(s) to change the travel times actuator comes to standstill display travel times optimizing of transient behavior and determining of prediction horizon determine minimum positioning increments if setting of travel times is desired if leakage test of actuator is desired display of leakage in % / min display of travel times in s display of stroke in mm or angle of rotation in degrees, is also the identification for complete initialization run 3 run 4 run 5 after 1 minute flashes alternating flashes alternating configure manual intervention figure 3-38 automatic initialization, part 3
preparing for operation 87 sipart ps2 manual a5e00074631--06 3.7 copying initialization data (positioner exchange) with this function you have the possibility of starting up a positioner without running the initialization routine. this allows for example a posi- tioner to be changed on a r unning syst em in which aut omatic or manual initialization cannot be performed without disturbing the process. notice initialization (automatic or manual) should be performed as soon as possible afterwards because only then can the positioner be optimally adapted to the mechanical and dynamic properties of the actuator. data are transmitted from the positioner to be replaced to the replacement instrument via the hart ? - communication interface. the following steps must be performed to exchange a positioner: 1. read in and save instrument parameters and initialization data (determined in initialization) of the instrument to be replaced with pdm ( p rocess d evice m anager). this step is unnecessary if the instrument has been parameterized with pdm and the data have already been stored. 2. fix the actuator in its momentary position (mechanical or pneumatic). 3. read and note the current position actual value of the positioner to be changed. if the electronics are defective, determine the current position by measuring on the actuator or valve. 4. disassemble the positioner. mount the lever arm of the positioner on the replacement instrument. mount the replacement instrument on the fitting. move the transmission ratio selector to the same position as the defective instrument. copy the instrument data and initialization data from the pdm or handheld. 5. if the displayed actual value does not match the noted value of the defective positioner, set the correct value with the friction clutch. 6. the positioner is now ready to operate. the accuracy and dynamic behavior may be restricted in relation to correct initialization. the position of the hard stops and the rela- ted maintenance data may show deviations in particular. therefore initialization must be performed at the earliest opportunity.
preparing for operation 88 sipart ps2 manual a5e00074631--06
operation 89 sipart ps2 manual a5e00074631--06 operation the following chapter describes the operation of the positioner. 4.1 display the lc display has two lines whereby the lines have different segmentation. the elements of the top line consist of 7, those of the bottom line of 14 segments. the contents of the display depend on the selected operating mode (see chapter 4.3, page 92) . note if the positioner is operated in ranges with temperatures below --10 c the liquid crystal display becomes sluggish and the display refresh rate is reduced considerably. figure 4-1 shows you the various display options. the meaning of fur- ther display capabilities is detailed in chapter 4.3 page 139. 4.2 input keys the positioner is operated by three keys (figure 4-2, page 91) the function of which depends on the selected operating mode. in the explosion proof version of the positioner the input keys are underneath a key cover which can be lifted up after loosening the cover screw. . note the input keys of the explosion proof version must be covered to prevent liquid getting in. the ip66/nema4x degree of protection is not guaranteed when the housing is open or the key cover is open. the housing cover must be removed to operate the keys in the normal and intrinsically safe versions of the positioners. 4
operation 90 sipart ps2 manual a5e00074631--06 figure 4-1 meaning of the various display options . note the degree of protection ip 66/nema4x is not guaranteed as long as the positioner is open.
operation 91 sipart ps2 manual a5e00074631--06 1 23 4 1 display 2 operation mode key 3 decrement key 4 increment key figure 4-2 display and input keys of the positioner explanations of the input keys. s the operation mode key (manual key) serves to switch over the op- erating mode and pass on parameters. . note by pressing and holding the operation mode key and additionally pressing the decrement key, you can select the parameters in reverse order. s the decrement key serves to select parameter values in config- uration and to move the actuator in manual operation. s the increment key serves to select parameter values in config- uration and to move the actuator in manual operation. the current firmware state is displayed when you exit the configuration menu. figure 4-3 firmware version, example: 4.00.00 firmware version
operation 92 sipart ps2 manual a5e00074631--06 4.3 operating modes the positioner can be operated in five operating modes. 1. p-manual mode (ex-factory state) 2. configuration and initialization 3. manual mode (man) 4. automatic (aut) 5. diagnostic display figure 4-4 gives you an overview of the possible operating modes and the change between them. figure 4-4 change between the operating modes
operation 93 sipart ps2 manual a5e00074631--06 the display of the positioner shows you the current potentiometer setting in the top line and ?noinit? flashes in the second line. you can move the actuator with the decrement and increment key . in order to adapt the positioner to your actuator, you have to change to the configuration menu. see also chapter 3.6, page 72 ?commissioning?. output of alarms and position feedback is possible after successful init- ialization. to go to the configuration menu, press the operation mode key for at least 5 seconds. in the configuration menu you can adapt the positioner individually to your actuator and start initialization. only a few parameters need to be set in the positioner prior to initialization. the others are defaulted so that they do not normally need to be adjusted. you can block the configuration menu against manipulation by an appropriately parameterized and activated digital input. which parameters you need to set and all other parameters are explained in chapter 4.4, page 95 parameters. the configuration mode can be reported by outputting a parameterizable fault message, a position feedback or output of limit values a1 and a2 is not possible. . note if the electric power supply fails during configuration, the positioner switches back to the first parameter after recovering the power supply, values which have already been parameterized are retained. when doing this, please note that the new value will only be saved when leaving the configuration menu or when another parameter is selected. without a power failure you re-enter the configuration menu at the point you exited it when you call the configuration menu again. p-manual mode (ex-factory state) configuration and initialization
operation 94 sipart ps2 manual a5e00074631--06 at the same time at the same time at the same time at the same time to figure 4-5 overview: configuration in this operating mode you can move the actuator with the decrement ( ) and increment keys ( ) and the current position is held regard- less of the setpoint current and any leakages. . note you can move the actuator quickly by pressing the other direction key additionally whilst keeping the direction key selected first pressed. the manual mode can be reported by outputting a parameterizable fault message, a position feedback or output of limit values a1 and a2 is only possible in automatic mode. . note the positioner switches over to automatic mode automatically after an electrical power failure. the automatic mode is the normal mode. in this mode the positioner compares the setpoint current with the current position and moves the actuator until the control deviation reaches the parameterizable dead zone. error messages are output if this is not possible for various reasons. in this operating mode you can have the current operating data (such as number of strokes, number of changes in direction, number of faults messages, etc.) displayed (see table 4-1, page 123). from the automatic or manual mode you go to the diagnostic display by simultaneously pressing all three keys for at least two seconds. manual mode (man) automatic (aut) diagnostic display
operation 95 sipart ps2 manual a5e00074631--06 see chapter 4.5, page 122 for further information. . note the respective operating mode (man or aut) of the positioner is retai- ned when you switch to the diagnostic display, i.e. in automatic opera- tion the specified setpoint is still used for controlling and in manual operation the position last reached is retained. 4.4 parameters all the parameters of the positioner are listed in this chapter. figure 4-6 shows an overview of the parameters. the parameter name is shown once in plain text and once as it ap- pears in the display. the function of the parameter is described briefly in the ?function? column. in addition, the possible parameter values, the physical unit and the factory setting of the parameters are shown.
operation 96 sipart ps2 manual a5e00074631--06 figure 4-6 parameter table of the positioner
operation 97 sipart ps2 manual a5e00074631--06 the following configuration block diagram shows the effects of the pa- rameters. figure 4-7 configuration block diagram
operation 98 sipart ps2 manual a5e00074631--06 normally adjustment of the first three following parameters is com- pletely sufficient to enable a positioner to be operated by an actuator. if you wish to become familiar with all details of the positioner, try out incrementally the effects of the remaining parameters by selective trials. . note in particular if the positioner has previously been operated using a different actuator, it must always be reinitialized in order to restore the factory settings. only in this way can the positioner matching process start from known conditions. the parameter ?55.prst? is provided for this purpose. this is also recommended if multiple parameters have been changed in a single session, the effects cannot be assessed and unintended consequences may result. positioning actuator type this is to match the positioner with the respective actuator and where necessary to the position sensor being used. the following adjustment capabilities are provided: s yfct = turn this adjustment is necessary for the part-turn actuator. if ?turn? is selected, the following parameter ?2. yagl? is automati- cally set to 90 _ and cannot be changed. s yfct = way (factory setting) this is necessary for a linear actuator. this allows the positioner to compensate for the non-linearity that arises due to the conversion of the linear movement of the linear actuator into the part-turn move- ment of the feedback shaft. for this the positioner is factory set so that it shows between ?p 49.0 and p 51.0? when the arm on the feedback shaft is vertical to the linear actuator spindle. s yfct = lway this must be adjusted, if an external linear potentiometer is to be connected to a linear actuator. tip : use this adjustment also for part-turn actuators with reverse direction of control action. s yfct = ncst use this when an ncs is fitted to a part-turn actuator. s yfct = -ncst this must be set when an ncs is used with a part-turn actuator with reverse direction of control action. s yfct = ncsl this must be set when an ncs is used with a linear actuator. 1.yfct
operation 99 sipart ps2 manual a5e00074631--06 s yfct = ncsll this must be adjusted if an ncs is to be connected to a linear ac- tuator with the position converted by an arm into a part--turn move- ment. . note after ?lway, ncst, --ncst or ncsl? have been adjusted, the parameter ?3. yway? will not be displayed. rated angle of rotation of the feedback shaft in part-turn actuators, an angle of 90 is preset automatically by 1.yfct = turn (see above). in linear actuators (1.yfct = way) a value of 33 or 90 can be selected depending on the stroke range: s 33 for strokes 20 mm s 90 for strokes > 20 mm when using the lever up to 35 mm, both angles of rotation (33 and 90 ) are possible. the long lever (> 35 mm stroke) is only designed for an angle of rotation setting of 90 . it is not part of the mounting kit set 6dr4004-8v but must be ordered separately under order number 6dr4004-8l. . note the setting of the transmission ratio selector on the positioner (see figure 2-2, page 17 and figure 2-3, page 18) must correspond to the angle value selected under ?2.yagl?. lever arm transmission selection of the lever arm range: serves to display the real stroke after initialization. the use of this parameter is optional. you only need to set this parameter if you want to have the way in mm displayed at the end of the initialization. if the parameter value ?off? is selected here, the real stroke is not displayed after initialization. . note the specification ?yway? must match the mechanical lever arm trans- mission. the carrier must be set to the value of the actuator stroke, if this is not scaled to the next highest scaled value. 2.yagl 3.yway
operation 100 sipart ps2 manual a5e00074631--06 automatic initialization (see chapter 3.6, page 72) by selecting ?strt? and pressing the increment key for at least 5 seconds, automatic initialization is started. the initialization process is displayed by ?run 1? to ?run 5? (see figure 3-35, page 83 to figure 3-38, page 86). manual initialization by selecting ?strt? and pressing the increment key for at least 5 seconds, manual initialization is started. the manual initialization process is described in chapter 3.6.3, page 76 and chapter 3.6.6, page 81. . note if the positioner has already been initialized, for inita and initm it is possible to transfer it to its non-initialized state without changing the remaining parameters by pressing the decrement key for 5 s. current range of the setpoint the selection of the current range depends on the connection type. ?0ma? (0 to 20 ma) is only possible in three-/four-wire connections (see figure 3-23, page 64). setpoint direction (see figure 4-8, page 101) the setting of the setpoint direction serves to reverse the direction of action of the setpoint. it is used mainly for the split range mode and in single-acting actuators with the safety position ?up?. split range start (see figure 4-8) and split range end (see figure 4-8) the parameters ?8.spra? and ?9.spre? in connection with the parameter ?7.sdir? serve to restrict the active setpoint range. in this way split range tasks can be solved with the following characteristics. s rising / falling s falling / rising s falling / falling s rising / rising 4.inita 5.initm 6.scur 7.sdir 8.spra 9.spre
operation 101 sipart ps2 manual a5e00074631--06 positioner 1 positioner 2 100 %-spre 100 %-spra spra spre [0 % to 100 %] y=x 100 % 0% positioner 1 positioner 2 6.sdir = fall 6.sdir = rise j w setting range 1 setting range 2 total setting range 100 % figure 4-8 example: split range-operation with two positioners setpoint ramp up and setpoint ramp down the setpoint ramp is effective in automatic operation and limits the speed of alteration of the active setpoint. when switching over from manual operation to automatic the active setpoint is adjusted to the set- point on the positioner with the setpoint ramp. this bumpless manual/automatic switchover avoids excessive pressure increases on long pipelines. in the position tsup = auto the slower of the two travel times deter- mined during initialization is used for the setpoint ramp. tsdo is then ineffective. setpoint function (see figure 4-9, page 102) non-linear valve characteristics can be linearized with this function and any flow characteristics simulated in linear valve characteristics. 10.tsup 11.tsdo 12.sfct
operation 102 sipart ps2 manual a5e00074631--06 six valve characteristics are stored in the positioner s linear (12.sfct = lin, factory setting) s equal percentage 1 : 25 (12.sfct = 1:25) s equal percentage 1 : 33 (12.sfct = 1:33) s equal percentage 1 : 50 (12.sfct = 1:50) s inverse equal percentage 25 : 1 (12.sfct = n1:25) s inverse equal percentage 33 : 1 (12.sfct = n1:33) s inverse equal percentage 50 : 1 (12.sfct = n1:50) s freely adjustable (12.sfct = free) setpoint turning points a flow parameter can be assigned to the respective setpoint turning value at an interval of 5 %. these points lead to a polygon chain with 20 straight lines which therefore represents a projection of the valve characteristic. w x 10 20 30 40 50 60 70 80 90 100% 10 0 0 20 30 40 50 60 70 80 90 100 % 9sfct=lin modulation range w x 10 20 30 40 50 60 70 80 90 100% 10 0 0 20 30 40 50 60 70 80 90 100 % 210 61419 41217 816 19 51318 311 71520 sl 0 12 sfct = free l imit for tight closing example: 39 ycls = up 41 ycup = 85.0 l imit for tight closing example: 39 ycls = up 41ycup = 75.0 l imit for tight closing example: 39 ycls = do 40ycdo = 10.0 l imit for tight closing example: 39 ycls = do 40 ycdo = 15.0 setpoint turning point example: 18 sl5 = 45.0 modulation range setpoint setpoint figure 4-9 setpoint characteristic, manipulated variable standardization and tight closing function the setpoint vertex values can only be input at 12.sfct=free. you may only enter a strictly monotonous characteristic, and two consecu- tive vertex values must differ by at least 0.2 %. 13.sl0 to 33.sl20
operation 103 sipart ps2 manual a5e00074631--06 dead zone of the controller at deba = auto the dead zone in automatic operation is adapted con- tinuously to the requirements of the control circuit. the dead zone is gradually increased on detecting a control oscillation. the reverse adaptation takes place by a time criterion. in the other discrete settings the fixed value is used for the dead zone. manipulated variable limiting start (see figure 4-9 and 4-10) and manipulated variable limiting end (see figure 4-9 and 4-10) with the parameters ?ya? and ?ye? the mechanical actuating distance (from stop to stop) is limited to the set values. in this way the mechani- cal setting range of the actuator can be limited to the active flow and the integral saturation of the commanding controller avoided. . note ye must always be set to greater than ya. manipulated variable standardization (see figure 4-9 and 4-10) with limiting of the manipulated variable (by ?35.ya? and ?36.ye?) two different scalings are produced for the display and the position feed- back via the current output (mpos or flow). the mpos scaling shows the mechanical position (0 to 100%) be- tween the hard stops of the initialization. this is not affected by the pa- rameters ?35.ya? and ?36.ye?. the parameters ?35.ya? and ?36.ye? are displayed in the mpos-scale. the flow-scale is the standardization (0 to 100%) to the range be- tween ?35.ya? and ?36.ye?. the setpoint w (0 to 100%) is always re- ferred to this range. this gives (also by using valve characteristics) a quasi-flow-proportional display and position feedback iy. to calculate the control difference, the setpoint is also shown in the ap- propriate scale on the display. 34.deba 35.ya 36.ye 37.ynrm
operation 104 sipart ps2 manual a5e00074631--06 example: ynrm = flow with ya = 10 % and ye = 80 % ynrm = mpos or ynrm = flow presetting: ya = 0% and ye = 100% input current (setpoint) x display w display x display w display x display w display mechan. stroke (actual value) mechan. stroke (actual value) mechan. stroke (actual value) 0mm 0mm 0mm 80mm 80mm 80mm 16mm 16mm 16mm 32mm 32mm 32mm 48mm 48mm 48mm 64mm 64mm 64mm 0% 0% 0% 100% 100% 100% 20% 20% 20% 40% 40% 40% 50% 50% 50% 60% 60% 60% 80% 80% 80% ye = 80% ye = 80% ye = 100% ya = 10% ya = 10% ya = 0% example: ynrm = mpos with ya = 10 % and ye = 80 % 4ma 20ma 7.2ma 10.4ma 13.6ma 16.8ma input current (setpoint) input current (setpoint) 4ma 20ma 7.2ma 10.4ma 13.6ma 16.8ma 4ma 20ma 7.2ma 10.4ma 13.6ma 16.8ma figure 4-10 dependence on the stroke of standardization and on ya and ye in the example of an 80 mm linear actuator manipulated variable direction of action the direction of action (rising or falling) of the display and the position feedback (iy) can be set with this. tight closing with manipulated variable (see figure 4-9, page 102) with this function the valve can be driven to the seat with the maximum actuating force of the actuator (continuous contact of the piezo-valves). the tight closing function can be activated on one side or for both limit positions. ycls becomes active when the setpoint is below the value set with parameter ?ycdo? or above that set with parameter ?ycup?. 38.ydir 39.ycls
operation 105 sipart ps2 manual a5e00074631--06 . note if the control function to close tightly is activated, for parameter ?49. lim? the monitoring of the control deviation in each overrun direc- tion (ycdo: < 0 %, ycup: > 100 %) is disabled. this function is par- ticularly useful for valves with a soft seating. for long term monitoring of the end-stop positions, we recommend activating the parameters ?52. zero? and ?53. open?. value for tight closing, bottom and value for tight closing, top . note ?40.ycdo? must always be set to less than ?41.ycup?. the tight closing function has a fixed hysteresis of 1 %. ?40.ycdo? and ?41.ycup? relate to mechanical stops and are independent of the settings of ?7.sdir? and ?38.ydir?. function digital input 1 (see figure 4-6, page 96) and function digital input 2 (see figure 4-6) the parameters ?bin1? and ?bin2? can be set individually depending on the purpose. the direction of action can be adapted to an ncc or an noc. s bin1 or bin2 = on or --on digital messages of the periphery (e.g. pressure or temperature switches) can be read out via the hart interface or lead to re- sponding of the fault message output by or linking with other mes- sages. s bin1 = bloc1 the configuration operating mode is locked to prevent it being ad- justed (e.g. by a wire jumper between terminals 9 and 10). s bin1 = bloc2 if digital input 1 has been activated, manual operation is also locked in addition to the configuration operating mode. s bin1 or bin2 = up or down (contact closes) or --up or --down (con- tact opens). the actuator drives the linear actuator to the upper or lower stop when the digital input is activated with continuous contact. s bin1 or bin2 (contact closes) = stop or --stop (contact opens). 40.ycdo 41.ycup 42.bin1 43.bin2
operation 106 sipart ps2 manual a5e00074631--06 with activated digital input the piezo-valves are blocked and the ac- tuator remains in the last position. leakage messages can then be executed without initialization function. s bin1 oder bin2 = pst oder --pst depending on settings, a partial stroke test can be initiated via binary input 1 or 2 by actuating an opener or closer. s bin1 or bin2 = off (factory setting) no function special function of di1: if the digital input 1 is activated in p manual operation by a jumper between terminals 9 and 10, , when the oper- ating mode key is pressed the firmware version will be displayed. line of the display. if one of the above named functions is selected with the parameters ?bin1? and ?bin2? simultaneously, then ?blocking? has priority over ?up? and ?up? priority over ?down?. alarm function the actuator can report the exceeding (max.) or dropping below (min) of a specified stroke or angle of rotation. the response of the alarms (limit values) is related to the mpos-scaling (see figure 4-10, page 104). the alarms are reported by the alarm module (order no. 6dr4004-6a or -8a). in addition the alarms can be read out through the hart interface (optional). the direction of action of the digital outputs can be adapted from high active to low act ive sequence systems. a2 max min a1 max max min min --m a x --m in --m a x --m a x --m in --m in limit way a1 a2 a1 = 48 a2 = 52 travel = 45 activated travel = 50 travel = 55 activated a1 = 48 a2 = 52 travel = 45 activated travel = 50 activated activated travel = 55 activated a1 = 52 a2 = 48 travel = 45 activated travel = 50 activated activated travel = 55 activated a1 = 52 a2 = 48 travel = 45 activated travel = 50 travel = 55 activated afct = min / max afct = --min / --max afct = min / max alarm module afct = --min / --max 44.afct
operation 107 sipart ps2 manual a5e00074631--06 . note if you have activated the extended diagnostics (parameter 51.xdiag) with on2 or on3, the alarms cannot be output via the alarm unit. however, the message is possible via hart communication at any time. response threshold alarm 1 and response threshold alarm 2 the alarm thresholds are related to the mechanical path (mpos-scale). function of the fault message output the fault message output serves as a group message for following faults: s control error (e.g. by actuator fault, valve fault, compressed air fail- ure) with the parameters ?48. tim? and ?49. lim? s positioner not in automatic mode s digital input activated (see parameter ?42.bin1? and ?43.bin2?) s exceeding of a limit value (e.g. way integral or valve seat, see pa- rameter 50 to 54) it also responds at: s power failure s processor fault the direction of action of the digital outputs can be adapted from high active to low act ive sequence systems. for more information on error messages, see chapter 4.5.3 online- diagnostics, page 131. 45.a1 46.a2 47. fct
operation 108 sipart ps2 manual a5e00074631--06 monitoring time for setting the fault messages the set value(s) is/are for the specification of the time, within which the positioner must have reached a compensated state. the corresponding response threshold is preset with ?49. lim?. if the set time is exceeded, the fault message output is set. . note if the tight closing function is activated, for parameter ?49. lim?, the monitoring of the control deviation in each overrun direction (ycdo: < 0 %, ycup: > 100 %) is deactivated. this function is particularly useful for valves with a soft seat. for the long-term monitoring of the endstop positions, we recommend activating the parameters ?f. zero? and ?g. open?. you can find more information on fault messages in chapter 4.5.3 online diagnostics. response threshold for fault messages a value (%) can be set here for the permissible control deviation for triggering the fault message. if parameters 48 and 49 are set to ?auto? (factory setting), the fault message is set if the short step zone is not reached within a certain time.within5to95%oftheactuatortravel,thistimeis10to90%of 10 times the initialization actuating time. preset establishes the factory setting and resets the initialization. . note after ?preset? the positioner needs to be re-initialized. all previously determined maintenance parameters are deleted. 48. tim 49. lim 50.prst
operation 109 sipart ps2 manual a5e00074631--06 activation of the extended diagnostics the extended diagnostics is deactivated at the factory, parameter 51 is therefore at ?off?. there are three operating modes for activating the extended diagnostics: s on1: the extended diagnostics is activated and the threshold 3 error messages are also output via the fault message output. s on2: the extended diagnostics is activated, the threshold 2 error messages are output via alarm output 2 and the threshold 3 error messages are also output via fault message output. s on3: the extended diagnostics is activated, the threshold 1 error messages are output via alarm output 1, the threshold 2 error messages are output via alarm output 2 and the threshold 3 error messages are also output via the fault message output. . note please note that the menu items of the extended diagnostics from a. pst to p. pavg are only displayed in the display after selecting one of the three on operating modes. with the factory setting, the parameters of menu items a to p are deactivated by default (off). the corresponding parameters are only displayed once you have activated the relevant menu item with ?on?. 51.xdiag
operation 110 sipart ps2 manual a5e00074631--06 partial stroke test this parameter activates the partial stroke test for the cyclic or manual partial stroke test of up/down and modulating valves. the partial stroke test can be triggered via keyboard, a binary input or the hart communication. start position the start position of the partial stroke test is specified here within the range of 0.0 to 100.0%. start tolerance the start tolerance in relation to the start position is specified here in the range of 0.1 to 10.0%. that means, with a start position of e.g. 50% and a start tolerance of 2%, a partial stroke test can only be triggered during operation if the current position is between 48 and 52%. step height input of the step height of the partial stroke test within the range of 0.1 to 100.0%. the factory setting is 10.0%. step direction input of the step direction of the partial stroke test. the following options are available: ?up?, ?do? (down), ?up do? (up and down). if ?up? is selected, the actuator is moved in a controlled manner from its start position to the target position (start position + step height) and then back to the original position in a controlled way once the target position has been reached. the procedure for the ?do? option is the same but in the opposite direction. with ?up do?, the actuator first travels in a controlled manner from its start position to the upper target position (start position + step height), then controlled from the upper to the lower target position (start position -- step height). after reaching the lower target position, it returns to its original position in a controlled manner. te s t i n t e r v a l input of the interval for the cyclic par tial stroke test within the range of one day to 365 days. a. pst a1.stpos a2.sttol a3.step a4.stepd a5.intrv
operation 111 sipart ps2 manual a5e00074631--06 partial stroke test reference step time (pstin = partial stroke test initialization) measurement of the reference step time for the partial stroke test. after the initialization of the device, the calculated (c = calculated) average actuating time of the control valve is displayed in seconds in the form: c ###.#. this time can be used as reference step time, however it is only a rough guide value. that is why it is recommended to measure the reference step time here after the specification of the partial stroke test (parameters a1 to a5) by pressing the greater than button for five seconds. in doing so, ?real? is shown in the display. the device then automatically moves to the set start position, performs the desired step and saves the time required to do this. the time that is measured is the controlled movement from start position to target position. after the succesful measurement, this reference step time is shown in the display in the form: ?###.#? seconds. if a reference step is attempted without previous initialization of the device, ?noini? appears in the display. if the start position cannot be approached or if the jump destination cannot be reached, ?fdini? (failed pst initialization) is displayed. factor 1 input of the factor for the threshold 1 error message. the factor 1 refers to the reference step time. if a specified partial stroke test results e.g. in a reference step time of 1.0 second and factor 1 is used in the factory setting of 1.5, the threshold 1 error message of the partial stroke test is performed for a measuring time of 1.5 seconds. factor 2 input of the factor for the threshold 2 error message. the factor 2 refers to the reference step time. if a specified partial stroke test results e.g. in a reference step time of 1.0 second and factor 2 is used in the factory setting of 3.0, the threshold 2 error message of the partial stroke test is performed for a measuring time of 3.0 seconds. factor 3 input of the factor for the threshold 3 error message. the factor 3 refers to the reference step time. if a specified partial stroke test results e.g. in a reference step time of 1.0 second and factor 3 is used in the factory setting of 5.0, the threshold 3 error message of the partial stroke test is performed for a measuring time of 5.0 seconds. at the same time, if this time threshold is exceeded, the excitation signal of the actuator is cancelled to prevent any sudden breaking free and overshooting of a valve that might be jammed or rusted in place. the partial stroke test is thus stopped immediately, a threshold 3 error is reported and the actuator is moved back to its original position. a6.pstin a7.fact1 a8.fact2 a9.fact3
operation 112 sipart ps2 manual a5e00074631--06 general control valve malfunction this parameter activates the dynamic monitoring of the control valve reaction. to do this, the actual position sequence is compared to the guide value and the expected position sequence, which allows conclusions with regard to the correct operational behavior of the control valve. when the parameter is activated, the submenu for the general control valve malfunctions from b1 to b5 opens. the function can be configured there. time constant of the low-pass filter the time constant of the low-pass filter is determined during the automatic initialization of the device. in the factory setting, parameter b1 therefore indicates ?auto?. if the user is very familiar with the process sequence or desires a certain filter time constant for application-specific reasons, parameter b1 can be set from one second to 400 seconds manually. one second causes no damping, 400 seconds result in a strong damping effect. limit for the general control valve malfunction sets the limit for the deviation from the model behavior. this limit is a reference value for the error message factors. factory setting is 1.0 %. factor 1 input of the factor for the threshold 1 error message. this factor refers to the limit for the general control valve malfunction. factory setting for factor 1 is 5.0. that means, for b2.limit = 1.0% and factor 1 = 5.0, the first error message is triggered at a control deviation of 5.0 % from the model behavior. factor 2 input of the factor for the threshold 2 error message. this factor refers to the limit for the general control valve malfunction. factory setting for factor 2 is 10.0. that means, for b2.limit = 1.0% and factor 2 = 10.0, the second error message is triggered at a control deviation of 10.0 % from the model behavior. factor 3 input of the factor for the threshold 3 error message. this factor refers to the limit for the general control valve malfunction. factory setting for factor 3 is 15.0. that means, for b2.limit = 1.0% and factor 3 = 15.0, the third error message is triggered at a control deviation of 15 % from the model behavior. b. devi b1.tim b2.limit b3.fact1 b4.fact2 b5.fact3
operation 113 sipart ps2 manual a5e00074631--06 pneumatic leakage this parameter is used to activate the function for the detection of a pneumatic leakage. to do so, the changes of position and the internally used controller output are recorded and filtered, depending on the direction. the filter result provides a coefficient that allows the detection of any leakage. note that the detection of a leak can only provided clear results for spring-loaded actuators. limit for the leakage indicator sets the limit for the leakage indicator the leakage indicator is scaled within the range of 0.0 to 100.0. factory setting for the limit is 30.0. in other words, there is leakage below this limit. a leak can be expected if this value is exceeded. to be able to make full use of the sensitivity of the detection process, it is recommended to perform a ramp test with a calibrator after the automatic initialization of the device. the ramp should cover the standard operating range of the valve and correspond in steepness to the approximate dynamic requirements of the application. during the ramp test, parameter 15.onlk of the diagnosics menu provides information on the values shown by the leakage indicator. this allows the limit for the leakage coefficient to be defined above the maximum ramp test value. factor 1 input of the factor for the threshold 1 error message. this factor refers to the limit for the leakage indicator. factory setting for factor 1 is 1.0. that means, for c1.limit = 30.0 and factor 1 = 1.0, the first leakage error message is triggered at a leakage indication of 30.0. factor 2 input of the factor for the threshold 2 error message. this factor refers to the limit for the leakage indicator. factory setting for factor 2 is 1.5. that means, for c1.limit = 30.0 and factor 2 = 1.5, the second leakage error message is triggered at a leakage indication of 45.0. factor 3 input of the factor for the threshold 3 error message. this factor refers to the limit for the leakage indicator. factory setting for factor 3 is 2.0. that means, for c1.limit = 30.0 and factor 3 = 2.0, the third leakage error message is triggered at a leakage indication of 60.0. c. leak c1.limit c2.fact1 c3.fact2 c4.fact3
operation 114 sipart ps2 manual a5e00074631--06 slipstick effect this parameter is used to activate the function for the detection of a slipstick effect. the device tries to detect sudden changes of the valve position that indicate excess slipstick. if the device detects a slipstick, the filtered step is saved as slipstick value. when the valve moves normally again (without detection of a slipstick), the slipstick value is reduced slowly. note that to avoid misinterpretations, for actuators with actuating times below 1 s, the positioner cannot distinguish reliably between a normal movement and a sudden change. limit for the slipstick detection sets the limit for a step caused by a slipstick effect. the limit can be set within the range of 0.0 to 100.0%. factory setting for the limit is 1.0. factor 1 input of the factor for the threshold 1 error message. this factor refers to the limit for the slipstick detection. factory setting for factor 1 is 2.0. that means, for d1.limit = 1.0 and factor 1 = 2.0, the first slipstick error message is triggered when the current slipstick value has reached 2.0. factor 2 input of the factor for the threshold 2 error message. this factor refers to the limit for the slipstick detection. factory setting for factor 2 is 5.0. that means, for d1.limit = 1.0 and factor 2 = 5.0, the second slipstick error message is triggered when the current slipstick value has reached 5.0. factor 3 input of the factor for the threshold 3 error message. this factor refers to the limit for the slipstick detection. factory setting for factor 3 is 10.0. that means, for d1.limit = 1.0 and factor 3 = 10.0, the third slipstick error message is triggered when the current slipstick value has reached 10.0. d. stic d1.limit d2.fact1 d3.fact2 d4.fact3
operation 115 sipart ps2 manual a5e00074631--06 dead zone monitoring this parameter activates the monitoring of the dead zone adaptation. prerequisite for the function is th e setting of param eter ?34.deba? = auto. threshold for the monitoring of the dead zone adaptation. this value (%) can be used for the automatic adaptation of the dead zone. if the dead zone exceeds the set value, the threshold 3 error message is triggered. the three-level error message is not imple- mented for dead zone monitoring. zero point offset this function is for detecting when the lower stop has changed its value compared to the value during initialization by more than the set thresholds. monitoring is only possible if the valve is within the tight closing function. the activation of the ?bottom tight closing function? (parameter ?39.ycls?) is therefore prerequisite. threshold 1 first threshold for monitoring the lower limit stop. if the set absolute value is exceeded during ?bottom tight closing?, this will trigger the threshold 1 error message. threshold 2 second threshold for monitoring the lower limit stop. if the set absolute value is exceeded during ?bottom tight closing?, this will trigger the threshold 2 error message. threshold 3 third threshold for monitoring the lower limit stop. if the set absolute value is exceeded during ?bottom tight closing?, this will trigger the threshold 3 error message. e. deba e1.levl3 f. z e r o f1.levl1 f2.levl2 f3.levl3
operation 116 sipart ps2 manual a5e00074631--06 shifting the upper stop this function is for detecting when the upper stop has changed its value compared to the value during initialization by more than the specified tolerance value. monitoring is only possible if the valve is within the tight closing function. the activation of the ?top tight closing function? (para?meter ?39.ycls?) is therefore prerequisite. threshold 1 first threshold for monitoring the upper limit stop. if the set absolute value is exceeded during ?top tight closing?, this will trigger the thres- hold 1 error message. threshold 2 second threshold for monitoring the upper limit stop. if the set absolute value is exceeded during ?top tight closing?, this will trigger the thres- hold 2 error message. threshold 3 third threshold for monitoring the upper limit stop. if the set absolute value is exceeded during ?top tight closing?, this will trigger the thres- hold 3 error message. . note monitoring of the lower and upper limit stops does not only react to valve faults. a misadjustment of the position feedback is also detected as a malfunction if the threshold values are exceeded. g. open g1.levl1 g2.levl2 g3.levl3
operation 117 sipart ps2 manual a5e00074631--06 monitoring of the lower temperature limit the current temperature in the positioner housing is measured by a sensor on the electronic circuit board. this parameter is for the three-level monitoring of the lower temperature limit. temperature unit the temperature unit can be switched over by pressing the greater than or smaller than button between c and f. another way of switching over is the j1.tunit parameter for monitoring the upper temperature limit. the selected unit applies to all temperature-related parameters. threshold 1 first threshold for monitoring the lower temperature limit. the factory setting is --25.0 c. if the temperature falls below the set value, the threshold 1 error message is triggered. threshold 2 second threshold for monitoring the lower temperature limit. the factory setting is --30.0 c. if the temperature falls below the set value, the threshold 2 error message is triggered. threshold 3 third threshold for monitoring the lower temperature limit. the factory setting is --40.0 c. if the temperature falls below the set value, the threshold 3 error message is triggered. h. tmin h1.tunit h2.levl1 h3.levl2 h4.levl3
operation 118 sipart ps2 manual a5e00074631--06 monitoring of the upper temperature limit the current temperature in the positioner housing is measured by a sensor on the electronic circuit board. this parameter is for the three-level monitoring of the upper temperature limit. temperature unit the temperature unit can be switched over by pressing the greater than or smaller than button between c and f. another way of switching over is the h1.tunit parameter for monitoring the lower temperature limit. the selected unit applies to all temperature-related parameters. threshold 1 first threshold for monitoring the upper temperature limit. the factory setting is 75.0 c. if the temperature exceeds the set value, the thres- hold 1 error message is triggered. threshold 2 second threshold for monitoring the upper temperature limit. the factory setting is 80.0 c. if the temperature exceeds the set value, the threshold 2 error message is triggered. threshold 3 third threshold for monitoring the upper temperature limit. the factory setting is 90.0 c. if the temperature exceeds the set value, the thres- hold 3 error message is triggered. j. tmax j1.tunit j2.levl1 j3.levl2 j4.levl3
operation 119 sipart ps2 manual a5e00074631--06 monitoring of the displacement integral this parameter activates the monitoring of the displacement integral. this function allows the preventive maintenance of the control valve, also see chapter 4.5 ?diagnosics?, page 122. limit for the number of strokes input of the limit for the number of strokes. the parameter can be used depending on the requirement profile of the user. on the one hand, it is possible to enter a maximal number for the strokes and to use factors smaller than one to receive warning messages when a certain fraction of the maximal number is reached. on the other hand, a minimum value can be entered for the strokes. factors greater than one are then used to receive warning messages for certain limits above the minimum value. factory setting for the limit is 1 000 000. factor 1 input of the factor for the threshold 1 error message. this factor refers to the limit for the number of strokes. factory setting for factor 1 is 1.0. that means, for l1.limit = 1 000 000 and factor 1 = 1.0, the first stroke counter error message is triggered after 1 000 000 strokes. factor 2 input of the factor for the threshold 2 error message. this factor refers to the limit for the number of strokes. factory setting for factor 2 is 2.0. that means, for l1.limit = 1 000 000 and factor 2 = 2.0, the second stroke counter error message is triggered after 2 000 000 strokes. factor 3 input of the factor for the threshold 3 error message. this factor refers to the limit for the number of strokes. factory setting for factor 3 is 5.0. that means, for l1.limit = 1 000 000 and factor 3 = 5.0, the third stroke counter error message is triggered after 5 000 000 strokes. l. strk l1.limit l2.fact1 l3.fact2 l4.fact3
operation 120 sipart ps2 manual a5e00074631--06 monitoring of the changes of direction this parameter activates the monitoring of the changes of direction. this function allows the preventive maintenance of the control valve, also see chapter 4.5 ?diagnosics?, page 122. limit for the changes of direction input of the limit for the number of changes of direction. on the one hand, it is possible to enter a maximal number for the changes of direction and to use factors smaller than one to receive warning messages when a certain fraction of the maximal number is reached. on the other hand, a minimum value can be entered for the changes of direction. factors greater than one are then used to receive warning messages for certain limits above the minimum value. factory setting for the limit is 1 000 000. factor 1 input of the factor for the threshold 1 error message. this factor refers to the limit for the number of changes of direction. factory setting for factor 1 is 1.0. that means, for o1.limit = 1 000 000 and fac- tor 1 = 1.0, the first direction change error message is triggered after 1 000 000 strokes. factor 2 input of the factor for the threshold 2 error message. this factor refers to the limit for the number of changes of direction. factory setting for factor 2 is 2.0. that means, for o1.limit = 1 000 000 and fac- tor 2 = 2.0, the second direction change error message is triggered after 2 000 000 strokes. factor 3 input of the factor for the threshold 3 error message. this factor refers to the limit for the number of changes of direction. factory setting for factor 3 is 5.0. that means, for l1.limit = 1 000 000 and fac- tor 3 = 5.0, the third direction change error message is triggered after 5 000 000 strokes. calculation of the position average this parameter is used to activate the function for the calculation of the position average. the function allows the calculation of a reference average for the position sequence within preset intervals and the calculation of comparison average values for the following intervals. if the comparison average values deviate from the reference average, error messages are displayed, depending on the set thresholds. o. dchg o1.limit o2.fact1 o3.fact2 o4.fact3 p. pav g
operation 121 sipart ps2 manual a5e00074631--06 time basis for the formation of the average value sets the intervals for the formation of the average value. the following time intervals are available: 30 minutes 8 hours 5 days 60 days 2.5 years status of the calculation of the position average after activating the function with parameter p. pavg, the initial status of the calculation of the position average is ?idle? (inactive). to start the calculation of the position average, the greater than button is pressed for five seconds. the display text then switches from ?idle? to ?ref? (reference average is calculated) and remains there until the selected time interval has passed. the reference average is then shown on the display. . note the current comparison average is displayed in the diagnosis menu under parameter 19.pavg as soon as the first comparison interval has passed. during the first comparison interval, ?comp? (comparison interval) is displayed there. threshold 1 first threshold for monitoring the reference average. the factory setting is 2.0%. if a comparison average deviates from the reference by more than this value, the threshold 1 error message is triggered. threshold 2 second threshold for monitoring the reference average. the factory setting is 5.0%. if a comparison average deviates from the reference by more than this value, the threshold 2 error message is triggered. threshold 3 third threshold for monitoring the reference average. the factory setting is 10.0%. if a comparison average deviates from the reference by more than this value, the threshold 3 error message is triggered. p1.tbase p2.state p3.levl1 p4.levl2 p5.levl3
operation 122 sipart ps2 manual a5e00074631--06 4.5 diagnosis 4.5.1 diagnostic display to access the diagnostic display in automatic or manual mode, press all three buttons for at least two seconds. this following table gives an overview of the values that can be displayed. the third column contains the term from which the abbreviation is derived, unless it is self-explaining. the structure of the diagnostic display is similar to that in ?configu- ration? mode: the upper line shows the diagnosis value, the lower line shows the number and abbreviation of the displayed value. use the operating mode button to select the next diagnosis value. by pressing and holding the operating mode button and simultaneously pressing the decrement button the diagnosis values can be selected in reverse order. certain values can be set to zero by pressing the increment button for at least 5 seconds. this is noted in the last table column. some diagnosis values can be greater than 99999. in this case, the display switches to exponential indication. example: the value for 1234567 is displayed as 1.23e6. no. abbre- viation meaning values than can be indicated unit reset possible 1 strks number of strokes ( str o k e s ) 0to4.29e9 -- x 2 chdir changes of direction ( ch anges of dir ection) 0to4.29e9 -- x 3 cnt number of fault messages ( c ou nt er) 0to4.29e9 -- x 4 a1cnt number of alarms 1 ( a larm 1c ou nt er) 0to4.29e9 -- x 5 a2cnt number of alarms 2 ( a larm 2c ou nt er) 0to4.29e9 -- x 6 hours operating hours ( hours ) 0to4.29e9 hours 7 way determined actuator travel ( way ) 0to130 mm or _ 8 tup actuating time up (travel t ime up ) 0 to 1000 s 9 tdown actuating time down (travel t ime down ) 0 to 1000 s 10 leak leakage ( leak age) p 0.0 to 100.0 % 11 pst monitoring of the p artial s troke t est off / ###.#, fdini, notst, sdtst, fdtst, notd, strt s for ###.# 12 prpst time since the last p artial s troke t est ###, notst, sdtst, fdtst days 13 nxpst time until the next p artial s troke t est ###, notst, sdtst, fdtst days 14 devi general control valve malfunction off, 0.0 to 100.0 % 15 onlk pneumatic leakage off, 0.0 to 100.0 -- 16 stic slipstick effect off, --100.0 to 100.0 % 17 zero zero point offset off, --100.0 to 100.0 % 18 open shifting the upper stop off, --100.0 to 100.0 % 19 pavg average position value 0.0 to 100.0 % 20 p0 p otentiometer value lower stop ( 0 %) 0.0 to 100.0 %
operation 123 sipart ps2 manual a5e00074631--06 no. reset possible unit values than can be indicated meaning abbre- viation 21 p100 p otentiometer value upper stop ( 100 %) 0.0 to 100.0 % 22 impup pulse length up ( imp ulse length up ) 2to160 ms 23 impdn pulse length down ( imp ulse length d ow n ) 2to160 ms 24 dbup dead zone up ( d ead b and up ) 0.1 to 10.0 % 25 dbdn dead zone down ( d ead b and d ow n ) 0.1 to 10.0 % 26 ssup short step zone up ( s hort s tep zone up ) 0.1 to 100.0 % 27 ssdn short step zone down ( s hort s tep zone d ow n ) 0.1 to 100.0 % 28 temp current temp erature --40 to 85 _ c 29 tmin min imum t emperature (?min/max pointer?) --40 to 85 _ c 30 tmax max imum t emperature (?min/max pointer?) --40 to 85 _ c 31 t1 number of operating hours in t emperature range 1 0to4.29e9 hours 32 t2 number of operating hours in t emperature range 2 0to4.29e9 hours 33 t3 number of operating hours in t emperature range 3 0to4.29e9 hours 34 t4 number of operating hours in t emperature range 4 0to4.29e9 hours 35 t5 number of operating hours in t emperature range 5 0to4.29e9 hours 36 t6 number of operating hours in t emperature range 6 0to4.29e9 hours 37 t7 number of operating hours in t emperature range 7 0to4.29e9 hours 38 t8 number of operating hours in t emperature range 8 0to4.29e9 hours 39 t9 number of operating hours in t emperature range 9 0to4.29e9 hours 40 vent1 number of switching operations pilot val lve 1 0to4.29e9 -- 41 vent2 number of switching operations pilot val lve 2 0to4.29e9 -- 42 store save current values as ?last maintenance? (press increment button for 5s) ( store ) -- -- 43 prup prediction up 1to40 -- 44 prdn prediction down 1to40 -- 45 wt00 number of operating hours in actuating range wt00 0to4.29e9 hours x 46 wt05 number of operating hours in actuating range wt05 0to4.29e9 hours x 47 wt10 number of operating hours in actuating range wt10 0to4.29e9 hours x 48 wt30 number of operating hours in actuating range wt30 0to4.29e9 hours x 49 wt50 number of operating hours in actuating range wt50 0to4.29e9 hours x 50 wt70 number of operating hours in actuating range wt70 0to4.29e9 hours x 51 wt90 number of operating hours in actuating range wt90 0to4.29e9 hours x 52 wt95 number of operating hours in actuating range wt95 0to4.29e9 hours x 53 ma setpoint current 0.0 to 20.0 ma table 4-1 overview of diagnosis values 4.5.2 meaning of the diagnosis values number of strokes during operation, the actuator movements are added up and can be read off here as the number of strokes. unit: 100% strokes, i.e. the path between 0 and 100 % and back. the value is written into a non-volatile memory every 15 minutes. it can be set to zero with the increment button . number of changes of direction 1 strks 2 chdir
operation 124 sipart ps2 manual a5e00074631--06 in the controller, every change of direction coming from the dead zone is noted and added to the number of changes of direction. the value is written into a non-volatile memory every 15 minutes. it can be set to zero with the increment button .
operation 125 sipart ps2 manual a5e00074631--06 number of fault messages in the controller, every malfunction is noted and added to the number of fault messages. the counter can be set to zero with the increment button . number of alarms 1 and number of alarms 2 the reaction of alarms 1 and 2 is counted with these two counters. prerequisite is the activation of the alarms with parameter ?44.afct?. the counters can be set to zero with the increment button . operating hours the operating hours counter is incremented every hour as soon as the positioner is supplied with electrical power. determined actuator travel this value specifies the actuator travel determined during initialization, according to the indication at the end of an initialization phase. prerequisite for linear actuators: specification of the lever arm with parameter ?3.yway?. actuating time up and actuating time down these values indicate the actuating times that were determined during initialization. the unit is seconds. leakage if a leakage measurement was initiated during initialization, the leakage value can be read off here in %/min. 3 cnt 4 a1cnt 5 a2cnt 6 hours 7way 8tup 9tdown 10 leak
operation 126 sipart ps2 manual a5e00074631--06 monitoring of the partial stroke test the measured step time of the last partial stroke test is displayed here. a partial stroke test can be triggered manually by pressing the greater than button, or a partial stroke test that is just being performed can be interrupted. thefollowingstatesareshowninthedisplay: s off the partial stroke test function is deactivated in the configuration menu. s fdini (failed pst initialization) the partial stroke test reference step time measurement failed. s notst (no test) no partial stroke test carried out yet. s ###.# (measured step time in seconds) the last partial stroke test was carried out successfully. s sdtst (stopped test) the last partial stroke test was interrupted. s fdtst (failed test) the last partial stroke test failed. the following status messages appear on pressing the greater than button: s notol (no tolerance) the control valve is outside the tolerance range for starting the partial stroke test. no manual partial stroke test has been started. s strt (start) a manual partial stroke test was started after pressing the button for five seconds. s stop (stop) the currently performed partial stroke test is interrupted. time since the last partial stroke test the time that has passed since the last partial stroke test is displayed here (in days). the following status messages can also appear: s notst (no test) no partial stroke test carried out yet. s sdtst (stopped test) the last partial stroke test was interrupted. s fdtst (failed test) the last partial stroke test failed. 11 pst 12 prpst
operation 127 sipart ps2 manual a5e00074631--06 time until the next partial stroke test the time until the next partial stroke test is displayed here (in days). conditions are that the partial stroke test is deactivated in the configuration menu and a test interval is set. if one of these two conditions is not fulfilled ?off? appears in the display. general control valve malfunction this value provides information on the current dynamically determined deviation from the model behavior. if the basic function is deactivated in the configuration menu ?off? is displayed. pneumatic leakage the current leakage indicator is displayed here. if the leakage detection is deactivated in the configuration menu ?off? is displayed. slipstick effect the filtered step height value cause by slipstick is displayed here in percent. if the function is deactivated in the configuration menu, ?off? is displayed. zero point offset display of the current displacement of the lower limit stop compared to its initialization value. condition for the determination is the activation of the ?bottom tight closing function? (parameter ?39.ycls? in the configuration menu). if the basic function is deactivated in the configuration menu ?off? is displayed. shifting the upper stop display of the current displacement of the upper limit stop compared to its initialization value. condition for the determination is the activation of the ?top tight closing function? (parameter ?39.ycls? in the config- uration menu). if the basic function is deactivated in the configuration menu ?off? is displayed. 13 nxpst 14 devi 15 onlk 16 stic 17 zero 18 open
operation 128 sipart ps2 manual a5e00074631--06 average position value the comparison average calculated last is displayed here. there are also the following status messages: s off the basic function is deactivated in the configuration menu. s idle (inactive) the function has not been started yet. s ref (reference average is calculated) the function was started and the reference interval is currently active. s comp (comparison average is calculated) the function was started and the comparative interval is currently active. potentiometer value lower stop and potentiometer value upper stop these two values indicate the measured values of the position displacement sensor (potentiometer) at the lower or upper limit stop, as determined during the automatic initialization. with manual initializa- tion, the values of the manually approached end positions can be found here. pulse length up and pulse length down during the initialization phase, the smallest pulse lengths are deter- mined, with which a movement of the actuator can be achieved. they are determined separately for the ?up? direction and the ?down? direction and displayed here. these two parameters can be set for special applications (see chap- ter 4.7, page 143). dead zone up and dead zone down the dead zone of the controller in ?up? direction or in ?down? direction is displayed here. the values correspond either to the manually set value of parameter ? 34.deba? or to th e value automatically adapted by the device if ?deba? was set to ?auto?. 19 pavg 20 p0 21 p100 22 impup 23 impdn 24 dbup 25 dbdn
operation 129 sipart ps2 manual a5e00074631--06 short step zone up and short step zone down the short step zone is the range of the controller, in which pulse- shaped excitation signals are output. the pulse length is proportional to the control deviation. if the control deviation is not within the short step zone, then the valves are activated in permanent contact. these two parameters can be set for special applications (see chap- ter 4.7, page 143). current temperature current temperature in the positioner housing. the sensor is on the electronic circuit board. the temperature display can be switched between _ c and _ fby pressing the decrement button. minimum temperature (min/max pointer) and maximum temperature (min/max pointer) the minimum and maximum temperature in the housing interior is determined continuously in the form of a min/max pointer and saved and can only be reset at the factory. number of operating hours in temperature range t1 to t9 the device gives statistical information as to how long and in which temperature ranges it was operated. for this purpose, the measured temperature is averaged for each hour and the counter that is assigned to the relevant temperature range is incremented every hour. this allows conclusions to be made about past operating conditions of the device and the entire control valve. the temperature ranges are divided as follows: t1 t2 t3 t4 t5 t6 t7 t8 t9 temperature range [ _ c] -- 3 0 -- 3 0 <--15 -- 1 5 <0 0 <15 15 <30 30 <45 45 <60 60 <75 75 number of switching operations pilot valve 1 and number of switching operations pilot valve 2 these two counters add up the activation processes of the pilot valves and are for the assessment of the switching dependency. 26 ssup 27 ssdn 28 temp 29 tmin 30 tmax 31 t1 to 39 t9 40 vent1 41 vent2
operation 130 sipart ps2 manual a5e00074631--06 save maintenance data pressing the increment button for at least 5 seconds triggers a memory function. in doing so, the diagnostic data 7 to 18 is saved in a non--volatile memory as the ?data of the last maintenance?. this diagnostic data consists of selected values that, when changed, can provide information on the mechanical wear of the valve. normally, this function is operated via pdm, menu item: device ! save maintenance info. the comparison of the data of the last maintenance to the current data is possible via pdm. prediction up prediction down see chapter 4.7, page 143. number of operating hours in actuating range wt00 to wt95 if the positioner is in automatic mode, statistical information is generated as to how long a valve or a flap was operated in which section of the actuating range. for this purpose, the entire actuating range (0 to 100 %) is divided into 8 sections (actuating ranges). the positioner registers the current position continuously and increments the operating hours counter that is assigned to the relevant section (actuating range) every hour. this allows conclusions to be made about past operating conditions and is in particular for the assessment of the control characteristics of the control loop or of the entire control valve. the actuating range is divided as follows: actuating range wt00 wt05 wt10 wt30 wt50 wt70 wt90 wt95 actuating range section <5% 5% <10% 10 % <30% 30 % <50% 50 % <70% 70 % <90% 90 % <95% 95 % the 8 operating hours counters can be set to zero together by pressing the increment button (for at least 5 seconds). tip: since the actuating ranges are arranged at the end of the diagnosis menu with numbers 45 to 52, press the decrement button several times in addition to the operating mode button. that is how you access diagnosis numbers 45 to 52 quickly. setpoint current you can have the current setpoint displayed here in ma. . note all diagnosis values are updated every 15 minutes in the non-volatile memory so that only the values of the past quarter of an hour are lost if there is a power failure. 42 store 43 prup 44 prdn 45 wt00 to 52 wt95 53 ma
operation 131 sipart ps2 manual a5e00074631--06 4.5.3 online diagnosis while the positioner is in operation, some important values and parameters are monitored on a continuous basis. in ?configuration? mode, you can configure this monitoring in such a way that the fault message output is activated when a certain event occurs, such as e.g. when a limit is exceeded. table 4-2, page 133, shows which events can activate the fault message output and the alarm outputs, how the parameters need to be set for this event to be monitored, when the fault messages disappears again and what the possible causes of the malfunction are. in automatic and manual mode, the display shows what triggered the fault message when the fault message output reacts. the two numbers at the bottom left indicate the relevant error code. if several triggers occur simultaneously, t hey are display in succe ssion cyclically. the device status that also includes all fault messages, can be called using command #48 via hart. the parameters of the extended diagnostics allow error messages to be displayed in one, two or three levels. in addition to the fault message output, alarm outputs 1 and 2 are then used. for this purpose, para- meter 51.xdiag needs to be set according to the following table: settings of 51.xdiag message by off extended diagnostics not activated on1 fault message output for threshold 3 error messages (one-level) on2 fault message output for threshold 3 error messages and alarm output 2 for threshold 2 error messages (two-level) on3 fault message output for threshold 3 error messages and alarm output 2 for threshold 2 error messages and alarm output 1 for threshold 1 error messages (three-level)
operation 132 sipart ps2 manual a5e00074631--06 error code three- level event parameter- setting error message disappears if... possible causes 1 no remaining control deviation always active ... the control deviation has disappeared again. compressed air missing, actuator fault, valve fault (e.g. blockage). 2 no device not in automatic mode 47. fct= na or = nab ... the device is switched to automatic mode. the device is configured or is in manual mode. 3 no binary input be1 or be2 active 47. fct= nab and binary function bin1 or bin2 at ?on? ... the binary input is no longer activated. the contact connected to the binary input became active (e.g. stuffing box monitoring, overpressure, temperature switch). 4 yes limit stroke number exceeded l. strk ? off ... the stroke counter is reset or the thresholds are increased the sum of the distance covered by the actuator exceeds one of the set thresholds. 5 yes direction change limit exceeded o. dchg ? off ... the direction change counter is reset or the thresholds are increased the number of changes of direction exceeds one of the set thresholds. 6 yes lower limit stop limit exceeded f. z e r o ? off 39.ycls = do or up do ... the deviation of the stop disappears or the device was re-initialized. wear of the valve seat, deposit or foreign matter in the valve seat, mechanical misadjustment, friction clutch misadjusted. 7 yes limit of upper limit stop exceeded g. open ? off 39.ycls = up or up do ... the deviation of the stop disappears or the device was re-initialized. wear of the valve seat, deposit or foreign matter in the valve seat, mechanical misadjustment, friction clutch misadjusted. 8 no limit dead zone adaptation exceeded e. deba ? off 34.deba = auto ... the value has fallen below the limit again. increased stuffing box friction, mechanical batches of the position feedback. 9 yes partial stroke test exceeds reference step time a. pst ? off ... a partial stroke test is performed successfully within the reference step time or the function is deactivated. valve jams or is rusted in place, increased friction 10 yes general control valve malfunction b. devi ? off ... the position is back within a narrow corridor between guide value and model, or the function is deactivated. actuator fault, valve fault, valve jams, increased friction, compressed air drop 11 yes pneumatic leakage c. leak ? off ... the leakage falls below the set thresholds, or the function is deactivated. pneumatic leakage
operation 133 sipart ps2 manual a5e00074631--06 error code possible causes error message disappears if... parameter- setting event three- level 12 yes slipstick effect occurs d. stic ? off ... no more slipstick can be detected, or the function is deactivated. increased slipstick, valve no longer moves constantly but judders instead 13 yes temperature short of h. tmin ? off ... the lower tem- perature threshold values are no longer fallen short of. ambient temperature too low 14 yes temperature exceeded j. tmax ? off ... the upper tem- perature thresholds are no longer exceeded. ambient temperature too high 15 yes position average deviates from the reference value p. pavg ? off ... after a comparison interval, a position average is calculated that is within the reference value thresholds or the function is deactivated. in the last comparison interval, the valve trajectory changed so much that a deviating position average was calculated. table 4-2 events that can activate the fault message output explanations for the ?error codes? column: 1 control deviation monitoring in automatic mode, the deviation between the setpoint and actual value is monitored continuously. according to the setting of parameter 48. tim, the monitoring time for setting the fault messages, and 49. lim, the response threshold of the fault message, the fault message is activated if the control deviation remains. as soon as the control deviation falls below the response threshold again, the fault message is cancelled. 2 automatic mode monitoring if parameter ?47. fct?, the fault message output function, is set accordingly, a fault message is generated if the device is not in automatic mode. in this way, e.g. the control system can be warned if the device was switched to manual mode or configuration on location. 3 binary input be1 or be2 active if parameter ?47. fct?, the fault message output function, and parameter ?42.bin1?, the binary input 1 function, are set accordingly, a fault message is generated when the binary input is activated. this can be e.g. a stuffing box monitoring switch, a temperature switch or a limit switch (e.g. for pressure). binary input 2 (for the alarm unit option) can be configured in the same way.
operation 134 sipart ps2 manual a5e00074631--06 4 stroke number monitoring 5 monitoring of the number of changes of direction the two values, number of strokes and number of changes of direction, are compared to the threshold values on a continuous basis. these values result from the parameters ?l1.limit? to ?l4.fact3? and ?o1.limit? to ?o4.fact3?. if they are exceeded, depending on the operating mode of the extended diagnostics, the fault message output reacts, and possibly also the alarm outputs. the two functions can be deactivated by the parameter setting ?off? for ?l. strk? or ?o. dchg?. 6 monitoring of the lower limit stop (valve seat) 7 monitoring of the upper limit stop the monitoring of the lower limit stop is activated if parameter ?f. zero? has a value ? off. this function can be used e.g. to detect valve seat errors. if the limit is exceeded, this can be an indication of deposits or foreign particles on the valve seat. if the limit is fallen short of, wear to the valve seat or reactor body could be the cause. the mechanical misadjustment of the position feedback can also trigger this error message. monitoring takes place every time the valve is in ?bottom tight closing? position. in doing so, the current position is compared to the position that was determined as lower end stop during the initialization phase. the activation of the ?bottom tight closing function? (parameter ?39.ycls?) is therefore prerequisite. example: 3% is set as value. for ?bottom tight closing?, the 0% position is normally established. if a value of >3% or <--3% is determined instead, a fault is reported. the fault message remains activated until either a subsequent monitoring process remains within the tolerance range or a re-initialization is carried out. the deactivation of the monitoring process (?f. zero?=off) also deletes any fault messages. this monitoring function does not provide any useful results if the stops were not determined automatically during initialization but instead the limits were set by hand (manual initializ ation, ?5 .initm?). an appropriate diagnosis was carried out for the upper limit stop. the parameter ?g. open? is used to set this limit. the activation of the ?top tight closing function? (parameter ?39.ycls?) is therefore prerequisite. 8 dead zone adaptation monitoring if, during the automatic adaptation of the dead zone (parameter 34.deba=auto) the dead zone increases disp roportionatel y during operation, this is an indication of a f ault in the syst em (e.g. significantly increased stuffing box friction, play in the position displacement sensor, leakage). therefore a limit can be specified for this value (?e1.levl3?, threshold for dead zone monitoring) that activates the fault message output if it is exceeded.
operation 135 sipart ps2 manual a5e00074631--06 9 partial stroke test exceeds reference step time this error message appears o n the one hand if a manual or cyclic partial stroke test is triggered and the test cannot be started because the valve is not within the start tolerance range. the error message also appears if one of the three thresholds of the partial stroke test that are a result of the reference step time (a6.pstin) times factors (a7.fact1 to a9.fact3) is violated. how serious the error message is, can be seen at the bar graph on the right side of the display. at the same time, the severity of the error message is output via the fault message output or the alarm outputs, according to the operating mode of the extended diagnostics. 10 general control valve malfunction the monitoring of the operational behavior triggers if the actual valve position leaves a narrow corridor between guide value and expected position sequence. in this case, the deviation between expected and actual position sequence is filtered and output and compared to the set thresholds that are the result of the limit (b2.limit) times the factors (b3.fact1 to b5.fact3). 11 pneumatic leakage this error message appears if the leakage indicator exceeds the set thresholds. note that the function can only take effect with its entire sensitivity if a ramp test is performed to set the leakage indicator after initialization (see explanations on c1.limit). 12 slipstick effect too high if the slipstick of the control valve is increased during operation of if an increasing number of slip jumps are detected, the relevant limits can be exceeded, resulting in an error message. 13 temperature fallen short of this error message appears if the lower temperature limit thresholds are fallen short of. 14 temperature exceeded this error message appears if the upper temperature limit thresholds are exceeded. 15 monitoring of the position average if a position average is calculated when a comparison interval passes that deviates from the reference value by more than the set thresholds, this error message triggers.
operation 136 sipart ps2 manual a5e00074631--06 4.5.4 fault correction guide see table in whichoperating mode does the fault occur? ? initialization 5 ? manual mode and automatic mode 6 7 8 9 in which environment and under which basic conditions does the fault occur? ? wet environment (e.g. heavy rain or continuous condensation) 6 ? vibrating (oscillating) control valves 6 9 ? stress due to knocks or shocks (e.g. steam pulses or flaps breaking away) 9 ? damp (wet) compressed air 6 ? dirty compressed air (contaminated with solid particles) 6 7 when does the fault occur? ? constantly (reproducible) 5 6 7 8 ? sporadically (not reproducible) 9 ? usually after a certain operation time 6 7 9
operation 137 sipart ps2 manual a5e00074631--06 fault indication (symptoms) possible cause(s) remedies ? sipart ps2 stops during ?run 1?. ? initialization started from end position and ? reaction time of max. 1 min. not waited for. ? mains pressure not connected or insufficient. ? up to 1 min. delay time required. ? do not start initialization from end position. ? secure the mains pressure. ? sipart ps2 stops during ?run 2?. ? transmission ratio selector and parameter 2 (yagl) as well as actual stroke do not match. ? stroke not correctly set for lever. ? piezo valve(s) do(es) not switch (see table 6). ? check settings: ? see leaflet: figure ?device view (7)? as well as parameters 2 and 3 ? check stroke setting at lever. ? seetable2 ? sipart ps2 stops during ?run 3?. ? actuating time too high. ? open reactor completely and/or set pz pressure (1) to maximum permissible value. ? if necessary, use booster. ? sipart ps2 stops during ?run 5?and does not reach ?finish? (delay time: >5min). ? ?batches? (play) in the positioner -- actuator -- control valve system ? part-turn actuator: check if set screw of the coupling wheel is inserted firmly ? linear actuator: check if lever is connected firmly to positioning shaft. ? eliminate any other play between actuator and control valve. table 5 fault indication (symptoms) possible cause(s) remedies ? for sipart ps2, ?cpu test? flashes in the display (approx. every 2 sec). ? piezo valve(s) do(es) not switch. ? water in the pneumatic block (due to wet compressed air) ? at an early stage, this fault can be eliminated by subsequent operation with dry air (if ne- cessary, in the temperature cabinet at 50 to 70 c). ? in manual or automatic mode, the actuator cannot be moved or only in one direction. ? moisture in the pneumatic block ? otherwise: repair (see chapter 5, page 145) ? piezo valve(s) do(es) not switch (no quiet ?clicking? can be heard when the + or ? buttonispressedin ? screw between shrouding cover and pneumatic block not tightened firmly or cover jammed. ? tighten screw, if necessary eliminate jam. b u t t o n i s p r e s s e d i n manual mode). ? dirt (chips, particles) in the pneumatic block ? repair (see chapter 5, page 145) or new device; integrated fine screen, also replace and clean. ? deposits on contact(s) between electronics board and pneumatic block can develop due to abrasion as a result of continuous high vibration stress. ? clean all contact surfaces with spirit; if necessary, re-bend the pneumatic block springs slightly. table 6
operation 138 sipart ps2 manual a5e00074631--06 fault indication (symptoms) possible cause(s) remedies ? actuator does not move ? compressed air < 1.4 bar ? set supply air pressure to > 1.4 bar. ? piezo valve(s) do(es) not switch (quiet ?clicking? can be heard however when the + or ? button is pressed ? reactor valve(s) closed (screw(s) at the right-hand stop) ? open reactor screw(s) (see leaflet, figure ?device view (6)? by turning it/them anti-clockwise. t h e + o r b u t t o n i s p r e s s e d in manual mode). ? dirt in the pneumatic block ? repair (see chapter 5, page 145) or new device; integrated fine screen, also replace and clean. ? a piezo valve switches continuously in stationary automatic mode (constant setpoint) and in manual mode. ? pneumatic leakage in the positioner ? actuator system start leakage test in ?run 3? (initialization)!!! ? eliminate leakage in the actuator and/or supply line ? if the actuator is intact and the supply line is leak-tight: repair (see chapter 5, page 145) or new device ? dirt in the pneumatic block (see above) ? see above table 7 fault indication (symptoms) possible cause(s) remedies ? both piezo valves switch continuously and alternately in stationary automatic mode (constant ? too much slipstick of stuffing box of control valve or actuator ? reduce slipstick or increase dead zone of sipart ps 2 (deba parameter) until oscillation stops. a u t o m a t i c m o d e ( c o n s t a n t setpoint) and in manual mode, actuator osc illates around a mean value. ? batches (play) in the positioner -- actuator ? control valve system ? part--turn actuator: check if set screw of the coupling wheel is inserted firmly ? linear actuator: check if lever is connected firmly to positioning shaft. ? eliminate any other play between actuator and control valve. ? actuator too fast ? increase actuating times via reactor screws. ? if fast actuating time is required, increase dead zone (deba parameter) until oscillation stops. ? sipart ps 2 does not ?drive? control valve up to the stop (at 20 ma). ? supply pressure too low. ? load of the feeding controller or system output is too low. ? increase supply pressure ? interconnect load converter ? select 3/4 transmitter operation table 8
operation 139 sipart ps2 manual a5e00074631--06 fault indication (symptoms) possible cause(s) remedies ? zero point misadjusts sporadically (> 3 %). ? stress caused by knocks or shocks result in acceleration values that are so high that the friction clutch is misadjusted (e.g. with ?steam pulses? in steam lines) ? eliminate causes of shock stress. ? re-initialize positioner. ? complete device function failure: also no indication in the display ? electrical power supply insufficient ? check electrical power supply. ? in the event of continuous high vibration stress (vibrations): ? screws on the electrical connecting terminals can loosen. ? electrical connecting terminals and/or electronic components can loosen due to vibrations. ? tighten screws and secure them with locking varnish. ? repair (see chapter 5, page 145) ? for prevention purposes: fit sipart ps 2 on shock mounts. table 9 4.6 meaning of the other display text remarks on the tables: nn stands for variable numerical values error symbol / (slash): the text segments to the left and right of the- slash flash alternately messages before the installation phase (initial start-up): upper line lower line meaning/cause measure cpu start x x message after applying the electrical power supply s wait p nnn.n x potentiometer voltage when positioner is not initialized (p manual mode) (actual position value in % of measuring range) s check with the ?+? and ?--? buttons whether the entire actuator travel can be moved along and that ? p------ ?is never displayed s perform initialization p------ x measuring range exceeded, potentiometer is in the inactive zone, switch transmission ratio selector or effective lever arm have not been adapted to the actuator travel s switch transmission ratio selector to 90 degrees for part-turn actuators s adjust effective lever length for linear actuators to measuring range noini x positioner is not initialized s start initialization
operation 140 sipart ps2 manual a5e00074631--06 messages during the installation phase: upper line lower line meaning/cause measure p---- x see above see above run 1 x initialization has been started, part 1 is active (direction of action is being determined) s wait run 2 x initialization, part 2 is active (actuator travel check and determination of the end stops) s wait run 3 x initialization, part 3 is active (determination and display of the actuating times) s wait run 4 x initialization, part 4 is active (determination of the minimum actuator increment length) s wait run 5 x initialization, part 5 is active (optimization of the transient response) s wait until ?finsh? is displayed (initialization completed successfully) s press the operating mode button briefly to acknowledge and exit the configuration level by pressing it continuously yend1 x only for manual initialization first end position can be approached s approach first end position with the ?+?or?--?button s press operating mode button to acknowledge yend2 only for manual initialization second end position can be approached s approach second end position with the ?+? or ?--? button s press operating mode button to acknowledge range x only for manual initialization end position or measuring span are outside the permitted measuring range s press the ?+? and ?--? buttons to approach another end position and acknowledge with the operating mode button, or s adjust the friction clutch until ? ok ?is displayed and acknowledge with the operating mode button or s cancel the initialization by pressing the operating mode button, switch to p manual mode and correct the actuator travel and the position displacement sensor ok only for manual initialization permitted measuring range of the end positions has been reached s acknowledge with the operating mode button, the remaining steps (? run1 ?to? finsh ?) run automatically run 1/ error x error in run 1 no movement e.g. due to insufficient compressed air s make sure there is sufficient compressed air s open reactor(s) s restart initialization d___u x bar graph display of the zero point zero point is outside the tolerance range s usefrictionclutchtosetbetween ? p4.0 ? and ? p9.9 ?(>0<) s continue with the ?+? or ?--? button set middl x x friction clutch has been misadjusted; no ?p 50.0? display if the lever is in horizontal position s with linear actuators, press the ?+? and ?--? buttons to move the lever at right angles to the spindle s press operating mode button briefly to acknowledge (initialization is continued)
operation 141 sipart ps2 manual a5e00074631--06 measure meaning/cause lower line upper line up > x ?up? tolerance range exceeded or inactive zone of the potentiometer passed s increase effective lever length for linear actuators or switch transmission ratio selector to 90 degrees s press operating mode button briefly to acknowledge s restart initialization 90_95 x only possible for part-turn actuators: actuator travel is not within the range of 90 to 95% s use the ?+? and ?--? buttons to move it to the range between 90 and 95% s press operating mode button briefly to acknowledge u--d> x ?up-down? measuring span fallen short of s reduce effective lever length for linear actuators or switch transmission ratio selector to 33 degrees s press operating mode button briefly to acknowledge s restart initialization u nn.n d-->u x x display of actuating time ?up? s wait, or s press the ?--? button to interrupt the initialization process to change the actuating time, or s activate the leakage test with the ?+? button d nn.n u-->d x x display of the actuating time ?down? s wait, or s press the ?--? button to interrupt the initialization process to change the actuating time, or s activate the leakage test with the ?+? button nozzl x actuator stationary (initialization was interrupted with the ?--? button during the indication of the actuating speed) s actuating time can be changed by adjusting the reactor(s) s press the ?--? button to repeat the determination of the actuating speed s continue with the ?+? button test leakg x x leakage test active (?+? button was pressed during the indication of the actuating speed) s wait one minute s continue with the ?+? button nn.n _ omin x x value and unit of the result after the leakage test s eliminate if leakage value is too great s continue with the ?+? button nn.n finsh x x initialization was completed successfully, possibly along with the indication of the actuator travel or angle s press the operating mode button briefly to acknowledge and exit the configuration level by pressing it continuously
operation 142 sipart ps2 manual a5e00074631--06 messages on exiting configuration mode: upper line lower line auto- matic manua l mode p manual mode meaning/cause measure 4.nn.nn ver x x software version s wait error sl nn x x monotony violation of the free characteristic curve at vertice n s correct value messages during operation: upper line lower line auto- matic manua l mode p manual mode meaning/cause measure cpu start x x message after applying the electrical power supply s wait hw / error x hardware error s replace electronics noini x x positioner is not initialized s start initialization nnn.n x x x actual position [in %] with initialized positioner. flashing decimal point indicates com- munication with a class 2 master aut nn x x automatic mode (nn = setpoint) mannn x manual mode (nn = setpoint) s press operating mode buttontoswitchto automatic mode ofl / 127.9 x x x display range was exceeded. possible causes: s friction clutch or s transmission ratio selector were misadjusted or s positioner was fitted on another actuator without re-initialization. s adjust friction clutch in such a way that the indication of the actual value remains between 0.0 and 100.0 on moving the actuator or s switch over the transmission ratio selector or s set to the factory setting (preset) and initialize exstp x x actuator was stopped via binary input ex up x x actuator is moved to the upper stop via binary input exdwn x x actuator is moved to the lower stop via binary input extpst partial stroke test was activated e.g. via binary input inpst cyclic partial stroke test htcnf x x x x hard configuration running
operation 143 sipart ps2 manual a5e00074631--06 4.7 optimizing the controller data the data for the control quality that was automatically determined during initialization is optimized for short compensation with low overshooting. in special cases (e.g. extremely small and therefore particularly fast actuators or for operation with boosters), you might want to modify this data specifically for faster compensation or a greater damping effect. the following six parameters are available for this purpose: this is for defining the smallest pulse lengths with which the actuator is to move for each actuating direction. the optimal value mainly depends on the volume of the actuator. small values result in small actuating increments and frequent activa- tion of the actuator. bear in mind that if the values are too small, there will be no movement. large values are advantageous for large actuator volumes. also bear in mind that large actuating increments for small actuators also result in large movements. the short step zone is the range of the control deviation between the fast step zone and the dead band in which the actuator is activated by pulses. in the case of small control deviations, small values already cause relatively high actuating speeds and can therefore result in over- shooting. large values in particular reduce overshooting in the case of large changes in the nominal value and result in slow actuating speeds near the compensated status. this parameter has the same effect as a damping factor and is used to set the control dynamics. small values cause fast compensation with overshooting. large values cause slow compensation without overshooting. we recommend that you perform an automatic initialization first and only then adapt the parameter determined by the positioner to your own special requirements. tip: to have a fixed reference value, it is helpful if you specify a fixed value for the dead zone (deba parameter) instead of ?auto? for the optimization of your particular controller. you select the parameters above from the diagnosis menu in the accustomed manner and activate the joint adjustment by pressing the increment or decrement button for 5 seconds. if you now adjust the relevant parameter, the new value is activated immediately. you can test the effects of the new values on the controller results immediately. when you quit the diagnosis menu, the parameter adjustment option is deactivated again. 13 pulse length up 14 pulse length down 17 short step zone up 18 short step zone down 34 prediction up 35 prediction down
operation 144 sipart ps2 manual a5e00074631--06
care and maintenance 145 sipart ps2 manual a5e00074631--06 service and maintenance the positioner is largely maintenance-free. the positioners are fitted with filters in the pneumatic connections as protection against coarse particles of dirt. if the pneumatic energy supply contains particles of dirt, the filters may clog and impair the function of the positioner. in this case the filters can be cleaned as follows. positioner in metal housing and explosion proof version 1. switch off the pneumatic power supply and remove the pipes. 2. remove the metal filters carefully from the holes and clean (e.g. with compressed air). 3. insert the filters. 4. re-connect the pipes and supply pneumatic energy. positioner in plastic housing removal 1. switch off the pneumatic power supply and remove the pipes. 2. unscrew the cover 3. remove the three screws from the pneumatic connector strip. 4. remove the filters and o-rings behind the connector strip. 5. clean the filters (e.g. with compressed air). installation 6. first insert the filters in the recesses in the plastic housing and then place the o-rings on the filters. 7. align the pneumatic connector strip on the two lugs and screw tight with the three self--tapping screws. important: make sure that the same thread is used. to do this turn the screws counterclockwise until they snap into the thread audibly. only then should you tighten the screws. 5
care and maintenance 146 sipart ps2 manual a5e00074631--06 8. replace the cover and screw it tight. 9. re-connect the pipes and supply pneumatic energy. ! danger electrostatic charging must be prevented in hazardous areas. these could be caused by example when cleaning the positioner in plastic housing with a dry cloth. faulty equipment should be sent to the repair department with details of the fault and its origin. when ordering replacement equipment, please specify the serial number of the original equipment. you will find the serial number on the name plate. address of the responsible repair location, your contact, lists of spare parts etc. can all be found on the internet, under: www.siemens.com/automation/services&support or www.automation.siemens.com/partner repair/upgrade
technical data 147 sipart ps2 manual a5e00074631--06 technical data general data for basic device 6DR50XX 6dr51xx 6dr52xx 6dr53xx (see following pages) 6
technical data 148 sipart ps2 manual a5e00074631--06 technical specifications sipart ps2 (all versions) general data travel range (linear actuators) 3 ... 130 mm (0.12 ... 5.12 inch) (angle of feedback shaft 16 ... 90) angle of rotation (part-turn actuators) 30 ... 100 installation on linear actuators using attachment set 6dr4004-8v and where necessary with an additional lever arm 6dr4004-8l on actuators accord- ing to iec 534-6 (namur) with ribs, bars or flat face on part-turn actuators using attachment set 6dr4004-8d on actuators with mounting plane according to vdi/vde 3845 and din 3337: the required mounting console has to be provided on the actuator side; shaft with groove and female thread m6 controller five-point switch self-adjusting dead zone - deba = auto self-adjusting or can be set as fixed value - deba = 0.1 ... 10% self-adjusting or can be set as fixed value a/d converter scan time 10 ms resolution 0.05% transmission error 0.2% temperature effect 0.1%/10 k ( 0.1%/18 f) cycle time 20 ma/hart device 20 ms pa device 60 ms ff device 60 ms (min. loop time) binary input be1 (terminals 9/10; electrically connected to the basic device) suitable only for floating contact; max. contact load < 5 ma with 3 v degree of protection 1) ip66 to en 60 529/nema 4x mounting position any; pneumatic connections and exhaust opening not facing up in wet environment ce marking conformity as regards emc direc- tive 89/336 ec in accordance with the following standards emc requirements en 61326/a1 appendix a.1 and namur ne21 august 98 material housing - 6dr5..0-... (plastic) glass-fiber-reinforced macrolon - 6dr5..1-... (metal) gd aisi12 - 6dr5..2-... (stainless steel) austenitic stainless steel mat. no. 1.4581 - 6dr5..5-... (metal, pressure- proof) gk aisi12 pressure gauge block aluminium aimgsi, anodized vibration resistance harmonic oscillations (sine-wave) according to din en 60062-2-6/05.96 3.5 mm (0.14 inch), 2 ... 27 hz 3 cycles/axis 98.1 m/s2 (321.84 ft/s2), 27 ... 300 hz, 3 cycles/axis bumping (half-sine) to din en 60068-2-29/03.95 150 m/s2 (492 ft/s2), 6 ms, 1000 shocks/axis noise (digitally controlled) to din en 60068-2-64/08.95 10 ... 200 hz; 1 (m/s2)2/hz (3.28 (ft/s2)2/hz) 200 ... 500 hz; 0.3 (m/s2)2/hz (0.98 (ft/s2)2/hz) 4 hours/axis recommended continuous duty range of the complete fitting 30 m/s2 ( 98.4 ft/s2) without res- onance sharpness weight, basic device plastic casing approx. 0.9 kg (0.90 kg) metal casing, aluminium approx. 1.3 kg (1.30 kg) metal casing, stainless steel approx. 3.9 kg (3.90 kg) metal casing eex d version approx. 5.2 kg (11.46 lb) dimensions see dimensional drawings climate class 4 to din en 60721-3-4 storage 2) 1k5, but -40 ... +80 c (1k5, but -40 ... +176 f) transport 2) 2k4, but -40 ... +80 c (2k4, but -40 ... +176 f) operation 3) 4k3, but -30 ... +80 c (4k3, but -22 ... +176 f) certificate and approvals classification according to pres- sure equipment directive (drgl 97/23/ec) for gases of fluid group 1, com- plies with requirements of article 3, paragraph 3 (sound engineering practice sep) pneumatic data power supply (inlet air) pressure 1.4 ... 7 bar (20.3 ... 101.5 psi): sufficiently greater than max. drive pressure (actuating pressure) air quality to iso 8573-1 solid particle size and density class 2 pressure dew point class 2 (min. 20 k (36 f) below ambient temperature) oil content class 2 unthrottled flow inlet air valve (ventilate actuator) 4) - 2 bar (29 psi) 4.1 nm3/h (18.1 usgpm) - 4 bar (58 psi) 7.1 nm3/h (31.3 usgpm) - 6 bar (87 psi) 9.8 nm3/h (43.1 usgpm) outlet air valve (ventilate actuator) 4) - 2 bar (29 psi) 8.2 nm3/h (36.1 usgpm) - 4 bar (58 psi) 13.7 nm3/h (60.3 usgpm) - 6 bar (87 psi) 19.2 nm3/h (84.5 usgpm) valve leakage < 6 ? 10 -4 nm3/h (0.0026 usgpm) throttle ratio adjustable up to : 1 power consumption in the controlled state < 3.6 ? 10 -2 nm3/h (0.158 usgpm) types of actuators in plastic casing single-action and double-action in aluminium casing single-action in flameproof casing single-action and double-action in stainless steel casing single-action and double-action 1) impact energy max. 1 joule for plastic/aluminium casing. 2) during commissioning at 0 c ( 32 f) make sure that the valves are flushed long enough with the dry medium. 3) at -10 c (14 f) the display refresh rate of the lcd is limited. only t4 is permissible when using i y module. 4) with eex d version (6dr5..5-...) the values are reduced by approx. 20%
technical data 149 sipart ps2 manual a5e00074631--06 technical specifications sipart ps2 basic device without ex protection basic device with eex-d protection (flameproof casing) basic device with eex ia/ib protection basic device with eex n protection explosion protection to en 50014, en 50020 and en 50021 without eex d ii 2 g eex d ii c t6 eex ia/ib ii 2 g eex ia/ib ii c t6 eex n ii 3 g eex na l [l] ii c t6 mounting location zone 1 zone 1 zone 2 permissible ambient temperature for operation at -10 c (+14 f) the display refresh rate of the lcd is limited. (for basic devices with eex ia/ib and eex n protection the following applies: only t4 is permissible when using i y module.) -30 ... +80 c (-22 ... +176 f) t4: -30 ... +80 c (-22 ... +176 f) t5: -30 ... +65 c (-22 ... +149 f) t6: -30 ... +50 c (-22 ... +122 f) electrical data input 2-wire connection (terminals 6/8) rated signal range 4 ... 20 ma 4 ... 20 ma 4 ... 20 ma 4 ... 20 ma current to maintain the power supply 3.6 ma 3.6 ma 3.6 ma 3.6 ma required load voltage u b (corresponds to ? at 20 ma) without hart (6dr50..) - typical 6.36 v (corresponds to 318 ?) 6.36 v (corresponds to 318 ?) 7.8 v (corresponds to 390 ?) 7.8 v (corresponds to 390 ? ) - max. 6.48 v (corresponds to 324 ?) 6.48 v (corresponds to 324 ?) 8.3 v (corresponds to 415 ?) 8.3 v (corresponds to 415 ? ) without hart (6dr53..) - typical 7.9 v (corresponds to 395 ?) ??? - max. 8.4 v (corresponds to 420 ?) ??? with hart (6dr51..) - typical 6.6 v (corresponds to 330 ?) 6.6 v (corresponds to 330 ?) ?? - max. 6.72 v (corresponds to 336 ?) 6.72 v (corresponds to 336 ?) ?? with hart (6dr52..) - typical ? 8.4 v (corresponds to 420 ?) 8.4 v (corresponds to 420 ?) 8.4 v (corresponds to 420 ? ) - max. ? 8.8 v (corresponds to 440 ?) 8.8 v (corresponds to 440 ?) 8.8 v (corresponds to 440 ? ) static destruction limit 40 ma ? ? internal capacitance c i without hart ? ? 22 nf ? with hart ? ? 7 nf ? internal inductance l i without hart ? ? 0.12 mh ? with hart ? ? 0.24 mh ? for connection to power circuits with ? ? intrinsically safe u o 30 v dc i k 100 ma p 1 w u i 30 v dc i i 100 ma
technical data 150 sipart ps2 manual a5e00074631--06 3-/4-wire device (terminals 2/4 and 6/8) (6dr52.. and 6dr53..) power supply u h 18 ... 35 v dc 18 ... 35 v dc 18 ... 30 v dc 18 ... 30 v dc current consumption i h (u h - 7.5 v)/2.4 k ? [ma] (u h - 7.5 v)/2.4 k ? [ma] (u h - 7.5 v)/2.4 k ? [ma] (u h - 7.5 v)/2.4 k ? [ma] internal capacitance c i ?? 22 nf ? internal inductance l i ?? 0.12 mh ? for connection to power circuits with ? ? intrinsically safe u o 30 v dc i k 100 ma p 1 w u i 30 v dc i i 100 ma current input i w rated signal range 0/4 ... 20 ma 0/4 ... 20 ma 0/4 ... 20 ma 0/4 ... 20 ma load voltage at 20 ma 0.2 v (corresponds to 10 ?) 0.2 v (corresponds to 10 ?) 1 v (corresponds to 50 ?) 1 v (corresponds to 50 ?) internal capacitance c i ?? 22 nf ? internal inductance (l i )? ? 0.12 mh ? for connection to power circuits with ? ? intrinsically safe u o 30 v dc i k 100 ma p 1 w u i 30 v dc i i 100 ma electrical isolation between u h and i w between u h and i w between u h and i w (2 intrinsically safe cir- cuits) between u h and i w test voltage 840 v dc (1 s) 840 v dc (1 s) 840 v dc (1 s) 840 v dc (1 s) connections electric screw terminals 2.5 awg28-12 cable gland m20 x 1.5 or ?-14 npt screw terminals 2.5 awg28-12 eex d certified cable gland m20 x 1.5, ?-14 npt or m25 x 1.5 screw terminals 2.5 awg28-12 cable gland m20 x 1.5 or ?-14 npt screw terminals 2.5 awg28-12 cable gland m20 x 1.5 or ?-14 npt pneumatic female thread g? din 45141 or ?-18 npt female thread g? din 45141 or ?-18 npt female thread g? din 45141 or ?-18 npt female thread g? din 45141 or ?-18 npt external position sensor (potentiometer or ncs; as option) u o ??< 5 v< 5 v i o ? ? < 75 ma < 75 ma i s ? ? <160 ma <160 ma p o ? ? <120 mw <120 mw maximum permissible external capaci- tance c o ??< 1 f< 1 f maximum permissible external induc- tance l o ? ? < 1 mh < 1 mh sipart ps2 basic device without ex protection basic device with eex-d protection (flameproof casing) basic device with eex ia/ib protection basic device with eex n protection
technical data 151 sipart ps2 manual a5e00074631--06 technical specifications option modules without ex protection (eex d also) with ex protection eex ia/ib with ex protection eex n ex protection to en 50014, en 50020 and en 50021 ? ii 2g eex ia/ib ii c t4/t5/t6 ii 3g eex na l [l] ii c t6 mounting location ? zone 1 zone 2 permissible ambient temperature for opera- tion (for devices with ex protection: only in con- junction with the basic device 6dr5... -.e.... only t4 is permissible when using i y module) -30 ... +80 c (-22 ... +176 f) t4: -30 ... +80 c (-22 ... +176 f) 1) t5: -30 ... +65 c (-22 ... +149 f) 1) t6: -30 ... +50 c (-22 ... +122 f) 1) alarm module 6dr4004-8a (without ex protec- tion) 6dr4004-6a (with ex protection) 6dr4004-6a (with ex protection) binary alarm outputs a1, a2 and alarm output signal status high (not responded) signal status low* (responded) (* low is also the status when the basic device is faulty or has not electric power sup- ply) active, r = 1 k ? , +3/-1%* disabled, i r < 60 a 2.1 ma 1.2 ma 2.1 ma 1.2 ma (* when used in the flameproof casing the current consumption is limited to 10 ma per output.) (switching threshold with sup- ply to en 60947-5-6: u h = 8.2 v, r i = 1k ?) (switching threshold with sup- ply to en 60947-5-6: u h = 8.2 v, r i = 1k ?) internal capacitance c i ? 5.2 nf ? internal inductance l i ? negligible ? power supply u h 35 v ? ? connection to power circuits with ? intrinsically safe switching amplifier en 60947-5-6 u o 15.5 v dc i k 25 ma, p 64 mw u i 15.5 v dc binary input be2 electrically connected to the basic device - signal status 0 floating contact, open floating contact, open floating contact, open - signal status 1 floating contact, closed floating contact, closed floating contact, closed - contact load 3 v, 5 a3 v , 5 a3 v , 5 a electrically isolated from the basic device - signal status 0 4.5 v or open 4.5 v or open 4.5 v or open - signal status 1 13 v 13 v 13 v - natural resistance 25 k ? 25 k ? 25 k ? static destruction limit 35 v ? ? internal inductance and capacitance ? negligible ? connection to power circuits ? intrinsically safe u i 25.2 v u i 25.2 v dc electrical isolation the 3 outputs, the input be2 and the basic device are electrically isolated from each other test voltage 840 v dc, 1 s 840 v dc, 1 s 840 v dc, 1 s sia module (not for eex d version) 6dr4004-8g (without ex protec- tion) 6dr4004-6g (with ex protec- tion) 6dr4004-6g (with ex protec- tion) limit transmitter with slot-type initiators and alarm output 2-wire connection ex protection without ii 2 g eex ia/ib iic t6 ii 3 g eex na l [l] iic t6 connection 2-wire system to en 60947-5-6 (namur), for switching amplifier to be connected on load side 2 slot-type initiators type sj2-sn type sj2-sn type sj2-sn function nc (normally closed) nc (normally closed) nc (normally closed) connection to power circuits with nominal voltage 8 v current consumption: 3 ma (limit value not responded) 1 ma (limit value responded) intrinsically safe switching amplifier en 60947-5-6 u i 15.5 v dc i i 25 ma, p i 64 mw u i 15.5 v dc p i 64 mw internal capacitance ? 41 nf ? internal inductance ? 100 mh ? electrical isolation the 3 outputs are electrically isolated from the basic device test voltage 840 v dc, 1 s 840 v dc, 1 s 840 v dc, 1 s alarm output see alarm module see alarm module see alarm module 1) only in conjunction with the basic device 6dr5...-e..... with iy module only t4 permitted.
technical data 152 sipart ps2 manual a5e00074631--06 accessory modules without ex protection (eex d also) with ex protection eex ia/ib with ex protection eex n limit value contact module 6dr4004-8k 6dr4004-6k 6dr4004-6k limit transmitter with mechanical ground contact and alarm output ex protection without ii 2 g eex ia/ib iic t6 ii 3 g eex na l [l] iic t6 max. switching current ac/dc 4 a connection to intrinsically safe power circuits: u o 30 v i k 100 ma, p i 750 mw connection to intrinsically safe power circuits: u o 30 v i k 100 ma, p i 750 mw max. switching voltage ac/dc 250 v / 24 v 30 v dc 30 v dc internal capacitance c i ? negligible ? internal inductance l i ? negligible ? electrical isolation the 3 outputs are electrically isolated from the basic device test voltage 3150 v dc, 2s 3150 v dc, 2 s 3150 v dc, 2 s alarm module see alarm module see alarm module see alarm module i y module 6dr4004-8j (without ex protec- tion) 6dr4004-6j (with ex protection) 6dr4004-6j (with ex protection) dc output for position feedback 2-wire connection 2-wire connection 2-wire connection nominal signal range i 4 ... 20 ma, short-circuit-proof 4 ... 20 ma, short-circuit-proof 4 ... 20 ma, short-circuit-proof total operating range 3.6 ... 20.5 ma 3.6 ... 20.5 ma 3.6 ... 20.5 ma power supply u h +12 ... +35 v +12 ... +30 v +12 ... +30 v external load r b [kw] (u h [v] - 12 v) /i [ma] (u h [v] - 12 v) /i [ma] (u h [v] - 12 v) /i [ma] transmission error 0.3% 0.3% 0.3% temperature effect 0.1%/10 k ( 0.1%/18 f) 0.1%/10 k ( 0.1%/18 f) 0.1%/10 k ( 0.1%/18 f) resolution 0.1% 0.1% 0.1% residual ripple 1% 1% 1% internal capacitance c i ? 11 nf ? internal inductance l i ? negligible ? for connection to power circuits with intrinsically safe: u i 30 v dc i i 100 ma; p i 1 w (only t4) u i 30 v dc i i 100 ma; p i 1 w (only t4) electrical isolation electrically isolated from the basic device electrically isolated from the basic device electrically isolated from the basic device test voltage 840 v dc, 1 s 840 v dc, 1 s 840 v dc, 1 s ncs sensor (not for eex d version) position range linear actuator 3 ... 130 mm (0.12 ... 5.12 inch), to 200 mm (7.87 inch) on request 3 ... 130 mm (0.12 ... 5.12 inch), to 200 mm (7.87 inch) on request 3 ... 130 mm (0.12 ... 5.12 inch), to 200 mm (7.87 inch) on request part-turn actuator 30 ... 100 30 ... 100 30 ... 100 linearity (after correction by sipart ps2) linear actuator 1% 1% 1% part-turn actuator 1% 1% 1% hysteresis 0.2% 0.2% 0.2% continuous working temperature -40 ... +85 c (-40 ... +185 f), extended temperature range on request -40 ... +85 c (-40 ... +185 f), extended temperature range on request -40 ... +85 c (-40 ... +185 f), extended temperature range on request degree of protection of casing ip68/nema 4x ip68/nema 4x ip68/nema 4x
scope of deliver 153 sipart ps2 manual a5e00074631--06 scope of delivery the positioner and its options modules are delivered as separate units and in different versions. positioners and options modules for operation in hazardous areas and non-hazardous areas are available. these ver- sions are identified respectively by a special rating plate. ! warning in the combination of components it must be ensured that only positio- ners and options modules are combined which are approved for the respective area of application. this applies especially for safe operation of the positioner in areas in which the atmosphere is poten- tially explosive (zone 1 and 2). the instrument categories (2 and 3) of the instrument itself and those of its options must be observed. 7
scope of delivery 154 sipart ps2 manual a5e00074631--06 7.1 scope of delivery of standard controller versions housing valve ex-protection order numbers s i p a r t p s 2 plastic housing single action non ex 6dr5010-xnxxx-0aa0 s i p a r t p s 2 2l without plastic housing double action non ex 6dr5020-xnxxx-0aa0 2 l w i t h o u t hart metal housing single action non ex 6dr5011-xnxxx-0aa0 plastic housing single action cenelec/fm 6dr5010-xexxx-0aa0 s i p a r t p s 2 plastic housing double action cenelec/fm 6dr5020-xexxx-0aa0 s i p a r t p s 2 2l without metal housing single action cenelec/fm 6dr5011-xexxx-0aa0 2 l w i t h o u t hart explosion proof housing single action cenelec/fm 6dr5015-xexxx-0aa0 explosion proof housing double action cenelec/fm 6dr5025-xexxx-0aa0 s i p a r t p s 2 plastic housing single action non ex 6dr5110-xnxxx-0aa0 sip a rt ps2 2 l w i t h h a r t plastic housing double action non ex 6dr5120-xnxxx-0aa0 2 l w i t h h a r t metal housing single action non ex 6dr5111-xnxxx-0aa0 plastic housing single action cenelec/fm 6dr5210-xexxx-0aa0 s i p a r t p s 2 plastic housing double action cenelec/fm 6dr5220-xexxx-0aa0 sip a rt ps2 4 l w i t h h a r t metal housing single action cenelec/fm 6dr5211-xexxx-0aa0 4 l w i t h h a r t explosion proof housing single action cenelec/fm 6dr5215-xexxx-0aa0 explosion proof housing double action cenelec/fm 6dr5225-xexxx-0aa0 s i p a r t p s 2 plastic housing single action non ex 6dr5310-xnxxx-0aa0 s i p a r t p s 2 4l without plastic housing double action non ex 6dr5320-xnxxx-0aa0 t o u t hart metal housing single action non ex 6dr5311-xnxxx-0aa0 2l corresponds to two-wire operation 4l corresponds to four-wire-operation --x stands for sub-variant 7.2 scope of delivery of options option order number i y - module without protection against explosion 6dr4004-8j i y - module with protection against explosion ptb 1) i y - module with protection against explosion fm 2) 6dr4004-6j 6dr4004-7j alarm unit without protection against explosion 6dr4004-8a alarm unit with protection against explosion ptb 1) alarm unit with protection against explosion fm 2) 6dr4004-6a 6dr4004-7a sia-module without protection against explosion 6dr4004-8g sia-module with protection against explosion cenelec and fm 1)2) 6dr4004-6g limit-contact module without protection against explosion 6dr4004-8k limit-switch module with protection against explosion cenelec and fm 1)2)3) 6dr4004-6k 1) ec-type examination certificate 2) approval reports from factory mutual system 3) in preparation
scope of deliver 155 sipart ps2 manual a5e00074631--06 7.3 scope of delivery of accessories accessories order number mounting kit set linear actuators iec 534 -- 6 including lever arm for 3 to 35 mm way 6dr4004-8v additional lever for > 35 to 130 mm way 6dr4004-8l mounting kit part-turn actuators vdi/vde 3845 6dr4004-8d solenoid valve block for samson actuator (integrated mounting) 6dr4004-1c manometer block single acting 6dr4004-1m manometer block double acting 6dr4004-2m solenoid valve block single acting (namur) 6dr4004-1b mounting set for samson actuator (integrated mounting) 6dr4004-8s ncs-sensor not explosion protected explosion-protected cable length 6 m for part-turn actuators for linear actuators up to 14 mm 6dr4004-_ n_ _ 0 6dr4004-8n 6dr4004-6n 6dr4004-_nn 6dr4004-_n_10 6dr4004-_n_20 emc filter module c73451-a430-d23 external position detection system c73451-a430-d78 operating software simatic pdm on request
scope of delivery 156 sipart ps2 manual a5e00074631--06 7.4 listofspareparts spare parts list: sipart ps2 positioner description order no. for version cover (plastic enclosure) with screws (4 pcs) and seal c73451-a430-d82 6dr4___ 6dr5___ cover (metal enclosure) with screws (4 pcs) and seal c73451-a430-d83 6dr4___ 6dr5___ motherboard, two-wire without hart, without explosion protection a5e00082459 6dr50__--_n 6dr40__--_n *) motherboard, two-wire without hart, with explosion protection a5e00082457 6dr50__--_e motherboard, two-wire hart, wi- thout explosion protection a5e00082458 6dr51__--_n 6dr40__--_n *) motherboard, two-,three-,four-wire hart, with explosion protection a5e00082456 6dr52__ motherboard two-,three-,four-wire without hart, without expl. protect. a5e00102018 6dr53__--_n 6dr40__--_n *) motherboard profibus pa, without explosion protection a5e00141523 6dr55__--_n.. 6dr41__--_n motherboard profibus pa, with explosion protection a5e00141550 6dr55__--_e 6dr41__--_e motherboard fieldbus founda- tion, without explosion proof a5e00215467 6dr56__ motherboard fieldbus founda- tion, with explosion protection a5e00215466 6dr56__ pneumatic block (valve single acting incl. seals and screws) c73451-a430-d80 6dr4___ 6dr5___ pneumatic block (valve double ac- ting incl. seals and screws) c73451-a430-d81 6dr4___ 6dr5___ potentiometer (complete) c73451-a430-d84 6dr4___ 6dr5___ *) 6dr40.. can be used after having clarified whether application with two-wire or three-wire/four-wire input note: for accesories and option modules see catalog fi 01 ?field instruments for process automation?
index 157 sipart ps2 manual a5e00074631--06 index a accessories, 39 actuating ranges, 130 alarm function, 106 alarm module, 32, 61, 66, 70 application positioner in a wet environment, 44 under great accelerations and vibrations, 46 assembly, 43 screw--type gland with plastic hose, 46 assembly procedure, 50, 53 linear actuator, 51 part--turn actuator, 54, 55 automatic, changing the operating mode, 94 b base plate, 58 block diagram, mode of operation, 25 c catalogs, 159 commissioning, 72 configuration, changing the operating mode, 93 controller data, optimization, 143 current output, electrical connection, 61, 66, 69 d delivery, 10 design name plate, 17 diagnosis, 122 display, 122 online, 131 diagnosis values, meaning of ~, 123 diagnostic display, changing the operating mode, 94 digital input, electrical connection, 61, 66, 70 digital output, electrical connection, 61, 66, 70 dimensional drawings, 41 display, 89 display text, meaning, 139 documentation, 9 double--acting, 13, 14 e electrical connection, 18, 57 emv--filter module, 38 f filters, cleaning the ~, 145 firmware version, 91 four--wire connection, 60, 64, 69 g general information, 5 h hart module, 26 housing, 11 i initialization, 100 automatic ~, structogram, 83 automatic ~, 72, 74, 79, 82 changing the operating mode, 93 copying ~, 72 manual ~, 72, 76, 81 initialization data, copying the ~, 87 input keys, 89 installation positions, favorable and unfavorable, 45, 47 instrument identification, 41 iy module, 31, 61, 66, 69 l lever arm transmission, 99 linear actuator, 13, 14 automatic initialization, 74 manual initialization, 76 preparation, 73 literature, 159 m maintenance, 145 8
index 158 sipart ps2 manual a5e00074631--06 manometer block, 39 manual mode changing the operating mode, 94 p manual mode, 93 mechanical limit switch module, 35, 62 eex i, 67 mechnical limit switch module, 67 not eex, 62 method of operation, 15, 23 mounting kit linear actuator, 49 part--turn actuator, 52 o operating mode aut, 94 man, 94 operating modes, 92 operating modes, change ~, 92 operation, 89 options, 12, 27 p parameter table, sipart ps2, 96 parameters, 95 part--turn actuator, 13, 14, 56, 57 automatic initialization, 79 manual initialization, 81 preparation, 79 pdm (process device manager), 87 personnel, qualification, 7 pneumatic connection, 19, 71 positioner exchange, 72, 87 positioning, 21 purge air switching, 22 q qualified personnel, 7 r restrictors, 22 s scope of delivery, 153 series circuit, of two positioners, 65 service, 145 setpoint, 130 setpoint characteristic, 102 sia module, 33, 62, 67, 70 electrical connection, 62, 67, 70 single--acting, 13, 14 split range, 65, 100 electrical connection, 65 standard controller, 63, 68 standards, 10 structograms of automatic initialization, 82 t technical data, 147 three--wire connection, 60, 64, 69 two--wire connection, 59, 60, 63, 68 type key, 41 u use as intended, 9 v versions, 11 vibrations, 46 view of the instrument, 17 w warranty, 9 wet environment, 44
appendix 159 sipart ps2 manual a5e00074631--06 appendix 9.1 literature and catalogs nr. title issue by order no. /1/ industrial communication for au- tomation and devices catalog ik pi 2005 siemens ag e86060--k6710--a101--b4--7600 /2/ field instruments for process automation catalog fi 01 2007 siemens ag e86060--k6201--a101--a8--7600 /3/ simatic pcs 7 process control system catalog st pcs 7 2005 siemens ag e86060--k4678--a111--a9--7600 9
appendix 160 sipart ps2 manual a5e00074631--06

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