PS2PA Manual

Manual Edition 03/2006
Electropneumatic Positioner SIPART PS2 PA

6DR55xx
sipart p
SIPART PS2 PA 6DR55xx

Edition 03/2006
Manual Electropneumatic Positioner for Linear and Part--Turn Actuators
SIPART PS2 PA Manual A5E00127926--05
Copyright e Siemens AG 2006 All rights reserved The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. Siemens AG Bereich Automation & Drives Geschftsgebiet Process Instrumentation and Analytics D--76181 Karlsruhe
Disclaimer of Liability We have checked the contents of this manual for agreement with the hardware and software described. 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 editions. Suggestions for improvement are welcomed. e Siemens AG 2006 Technical data subject to change without notice
Trademarks SIMATICe, SIPARTe, SIRECe, SITRANSe are registered trademarks of the Siemens AG Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners.
Contents
0 Information for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.4 2.5 2.6 2.6.1 2.6.2
7 7 8 9 11 11 12 12 12 13 13 17 17 17 18 19 19 23 23 25 25 26 26 27 29 29 29 30 31 31 31 34
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classification of safety--related notices . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use as intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standards and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information about the positioner . . . . . . . . . . . . . . . . . . . . . . . . . General information regarding PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . Transmission method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Properties of the PROFIBUS PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge air switching (not in the explosion--proof version) . . . . . . . . . . . . Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . State as supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of options modules in normal and intrinsically safe versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of options modules in explosion proof version . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design and method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.7 4 4.1 4.2 4.3 4.4
Iy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIA module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical limit switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument identification (type key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for using positioners in a wet environment . . . . . . . . . . . . . Instructions for using positioners which are exposed to great accelerations or vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting kit linear actuator 6DR4004--8V and 6DR4004--8L . . . . . . Assembly procedure (see figure 26, page 55) . . . . . . . . . . . . . . . . . . . . Mounting kit part--turn actuator 6DR4004--8D . . . . . . . . . . . . . . . . . . . Assembly procedure (see figure 27 and figure 28) . . . . . . . . . . . . . . . . . Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection variant: options in positioner in non--intrinsically safe and explosion--proof version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection variant: options in the positioner in intrinsically safe version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection variant: options in the positioner in type of protection n version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations for linear actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic initialization of linear actuator . . . . . . . . . . . . . . . . . . . . . . . . . Manual initialization of linear actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations for part--turn actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic initialization of part--turn actuator . . . . . . . . . . . . . . . . . . . . . . Manual initialization of part--turn actuators . . . . . . . . . . . . . . . . . . . . . . . Automatic initialization (structograms) . . . . . . . . . . . . . . . . . . . . . . . . . . . Copying initialization data (positioner exchange) . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 37 38 39 43 43 45 45 45 47 48 50 53 53 56 57 62 67 69 71 73 74 75 76 78 81 81 83 85 89 91 91 91 94 97
Preparing for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 4.5.1 4.5.2 4.5.3 4.6 4.7 4.8 5 5.1 5.2 5.2.1 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.4 5.2.1.5 5.2.1.6 5.2.1.7 5.2.1.8 5.2.1.9 5.2.1.10 5.3 5.3.1 5.3.1.1 5.3.2 5.3.2.1 5.3.2.2 5.3.3 5.3.4 6 7 8
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meaning of the diagnostic values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Online--diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meanings of other display texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optimization of the control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acyclic data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIMATIC PDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allocate address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load to device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load to PG/PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self--calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Write protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cyclic data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring the user data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User data via PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics acc. to PROFIBUS DP (DDLM_Slave_Diag) . . . . . . . . . . . Condensed Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 113 114 118 122 126 127 131 131 131 131 132 132 132 132 133 134 137 138 138 139 139 139 139 141 148 149 150 152 159 161 167 168 169 169 170 171 173 173 174
Functions/operation via PROFIBUS PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.2 8.3 8.4 Ordering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of delivery of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of delivery of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 10
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.2 Literature and catalogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 housing. S SIPART PS2 EEx n in a metal or plastic housing S SIPART PS2 EEx d in flameproof enclosure (EEx d)
This manual takes each of these possibilities into consideration. Any differences between the devices are indicated specially. Scope of delivery, see chapter 8, page 167.
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.
Information for the operator This manual contains the information required for use as intended of the product it describes. It is addressed to technically qualified personnel 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, operation, maintenance and use in systems into account. 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 information 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 imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesireable 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 nonobservance 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. concepts of automation technology
S if they are configuration personnel, are familiar with the safety 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 WARNING The instrument must only be installed and commissioned by qualified personnel. The instrument is designed for connection to functional and safety extra low voltage. The instrument is designed for connection to operate voltage or 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 certification as soon as they are operated with circuits that do not conform to the specifications laid down in the EC type examination certificate valid in your country. The successful and safe operation of this equipment is dependent upon its proper handling, installation, operation and maintenance.
!
10
WARNING The device may not be operated as long as the quick start guides are inside 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 description (see also Chapter 3 page 45 of this manual). The product described in this manual has been developed, manufactured, tested and documented observing the relevant safety standards. If the handling rules and safety information for configuration, installation, use as intended and maintenance are observed, there is normally no danger with regard to material damage or for the health of personnel. Extra low voltages that are connected must be fed in by safe isolation.
0.5
Technical documentation
The instructions are a constituent part of the enclosed CD sipartp ps2 POSITIONERS (order number A5E00214567). The manual and further documentations are 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. If you need more information or have particular problems which are not covered sufficiently by the operating instructions, contact your local Siemens office. You will find your local Siemens office on the Internet under: www.siemens.com/processinstrumentation Click on Contact and select your closest town.
11
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 contractual warranty conditions are neither extended nor restricted by this document.
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 ordering data. For the scope of delivery please see Chapter 8, page 167.
0.8
Standards and regulations

As far as possible, the harmonized European standards were used to specify and manufacture this equipment. If harmonized European standards have not been applied, the standards and regulations of the Federal Republic of Germany apply (see also Chapter 7 page 161 Technical Data). If this product is used outside the area of applicability of these standards and regulations, please observe the standards and regulations in force in the country where the product is operated.
12
Introduction
Introduction
1
The positioner is used to adjust and control pneumatic actuators. The controller operates electropneumatically with compressed air as an energy supply. The positioner together with the PROFIBUS PA communications interface are components in a digital process automation system. It communicates with the master as a slave via the PROFIBUS PS field bus. The field bus is used not only for communication but also to supply the positioner with electrical power.
1.1
General information about the positioner
Purpose
For example, the positioner can be used to control valves as follows:
S with linear actuator (figure 1, page 15) or S with part--turn actuator VDI/VDE 3845 (figure 2, page 15)
Different mounting types are available for linear actuators:
S NAMUR or IEC534 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. Versions 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.

Housing The electronics with display, position feedback and valve block are integrated in the housing.
13
Introduction 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
Degree of protection Explosion Protection 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. Explosion proof type n versions can be used in explosion hazard zone 2 areas. The positioners (version 6DR551* for single acting actuators) 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 part 1--7 and IEC 61511 part 1--3. For this the SIL safety instructions in the SIL Safety Manual (PA/FF) order number A5E00489773 must be followed. The positioner can be expanded with various options modules (chapter 2.6, page 31). The following modules are available in all:
SIL applications
Options
S Iy module: Two--wire current output 4 to 20 mA for position feedback S Alarm module: three digital outputs and 1 binary input S SIA module: one binary output for fault messages, two binary
outputs for limit value alarms
S Mechnical limit switch module: one binary output for the output of a
group error message, two switches for signalling two limit values that can be set mechanically.
Accessories
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)

Environmental Protection Only environmentally friendly materials have been used in the construction of the positioner. The technical manual is printed on chlorine--free bleached paper.
14
Introduction
1 2 3 4 5
Actuator Positioner, single--acting in metal housing Lantern Manometer block, single--acting Valve
Figure 1
Positioner mounted on linear actuator (single--acting)
1 2 3
Positioner in plastic housing Part--turn actuator Manometer block, double--acting
Figure 2
Positioner mounted on part--turn actuator (double--acting)
15
Introduction
1
2 4
1 2 3 4
Actuator Positioner, single--acting in explosion proof housing Lantern Manometer block, single--acting
Figure 3
Explosion proof positioner mounted on linear actuator (single--acting)
1 2
1 2 3
Positioner double--acting in explosion proof housing Part--turn actuator Manometer block, double--acting
Figure 4
Explosion proof positioner mounted on part--turn actuator (double--acting)
16
Introduction
1.2
General information regarding PROFIBUS

The PROFIBUS PA (PA = Process Automation) is a variant of the PROFIBUS--DP (DP = Decentral Peripheral) which is widely used in manufacturing engineering. The PROFIBUS (Process Field Bus) is an open communication system for automation engineering and thousands are used all over the world. It is specified in the European standard EN 50170.
1.2.1 Transmission method

The PROFIBUS PA has a special transmission method and therefore satisfies the requirements of process automation and manufacturing engineering. This transmission method is defined in the international standard IEC61158--2. The low transmission speed reduces the power loss compared to the PROFIBUS--DP and therefore enables an intrinsically safe technique for use in hazardous areas.
1.2.2 Topology
The bus topology can, to a large extent, be freely selected so that line, star and tree structures are possible, as well as mixtures of these. All kinds of field devices such as transformers, actuators, analyzers, etc. can be connected to the PROFIBUS PA The main advantage is in:
S the saving of installation costs S the possibility of more extensive diagnostics with an increase in the
availability of system parts
S the possibility of automatic tracing of system documentation S the possibility of system optimization in operation
In an automation system, several PROFIBUS PA channels are usually connected to the fast PROFIBUS--DP with coupling units. The process control system is also linked to this. Both bus systems use a uniform protocol layer. This makes the PROFIBUS PA a communication--compatible extension of the PROFIBUS--DP into the field.
17
Introduction
Master (class 1)
Master (class 2)
PROFIBUS-DP
PROFIBUS PA Slaves (Field devices, decentralized peripherals, secondary controls, mains transfer to PROFIBUS PA)
8x
Figure 5
Typical PROFIBUS automation system
Figure 5 shows the section of a typical PROFIBUS automation system. The control system consists of two masters with distributed tasks. The class 1 master looks after the control and regulation functions, while the class 2 master enables operating and monitoring functions. A cyclic exchange of measuring and setting data takes place between master 1 and the field devices. Parallel to this data, the status data of the field devices is transmitted to and evaluated in the class 1master. No field device parameters are set or other device information read during cyclic operation. The information necessary for establishing communication is available to the control system from the stored, device--specific device master data (GS*) files. The files are available on the Internet at: www.siemens.com/sipartps2 Click on More Info and --> Instructions and Manuals. One or more class 2 masters can access the field devices acyclically in addition to the cyclic mode. With this communication type further information can be fetched from the devices or settings made in the devices.
1.2.3 Properties of the PROFIBUS PA

The PROFIBUS PA enables bi--directional communication between a bus master and the field devices via a shielded two--wire line. At the same time the power is supplied to the two--wire field devices on the same lines.
18
Introduction
1.2.4 Profile
Supplementary to the EN standard 50170, the PNO (PROFIBUS Userorganisation) has defined the functionality of the individual field device types in a so--called profile description. This profile defines minimum functional requirements and optional extensions. The device--internal Device Management supplies all the basic information necessary for finding the profile parameters to the control system configuration tool. With this, a parametering tool can operate all profile--conforming devices regardless of type and manufacturer. Depending on the size of the system and thus the number of field devices and the required timing, the system must be implemented with one or more PROFIBUS PA channels. A PROFIBUS PA channel consists of the components shown in Figure 6.
Control room
PROFIBUS-DP Coupler PLS, PC
Field
PROFIBUS-PA
T FD
Power supply
T FD
additional cable termination
T FD PC PLS Figure 6
Terminating resistor Field device Personal computer Process control system PROFIBUS PA architecture
1.2.5 Interfacing
The central process control system PLS or, in the case of low requirements, a PC, is responsible for the control. As a rule the signal conversion DP/PA, bus feeding and bus termination functions are combined in a coupling module. Depending on the number of PROFIBUS PA field devices to be operated in the automation system and the required timing, a DP/PA coupler or, in the case of higher requirements, a more powerful DP/PA link is used.
19
Introduction An additional terminating resistor T must be fitted at the far end of the bus for transmission--technical reasons. When using the recommended bus cable, the theoretically possible line length (sum of all line sections) is a maximum of 1900 mm. In addition, the voltage drop over the lines supplying the field devices must be taken into account in the planning. However, the current requirements of the individual users and voltage drop on the cable must also be taken into account in the planning. The individual field devices FD can be connected almost anywhere in the bus system. Further information can be found in the PROFIBUS PPNO Guide A. DP/PA--coupler or DP/PA--link are supplied by a power supply unit with SELV (Safety Extra Low Voltage). This power supply must have adequate reserves for bridging brief power failures. The maximum number of devices that can be connected to a bus channel depends on their current consumption and the respective conditions of use. When operating in a safe area, the couplers/links can feed up to 400 mA into the bus. In zones subject to explosion hazard, intrinsic safety is only ensured if the maximum power fed into the bus does not exceed certain voltage and current values. See chapter 7 Technical Data (page 161) device in intrinsically safe version.
WARNING To power the intrinsically safe PROFIBUS only certified power supply units (DP/PA couplers or links) must be used. See the EC--Type Examination Certificate for use in Potentially Explosive Atmospheres. When explosion proof versions of positioners are used in areas where the atmosphere is potentially explosive, they may be supplied with auxiliary electrical power only within the enclosed housing. The openings for the electronic connections must be executed with EEx--d--certified cable glands or sealed with EEx--d--certified plugs, or the Conduit Tube System must be used to provide an explosion barrier at a maximum distance of 46 cm (18 inches) from the housing.
The number of devices which can be connected to a bus channel can be determined from the maximum current consumption of the devices connected (according to standards 10 mA per device) and the available current. A current reserve should be planned for safety reasons, otherwise there is a risk that a defective device could overload the bus with its increased current consumption and the power supply and communication with all unaffected users could collapse. The power reserve quantity depends on the current increase in the event of an error specified by the manufacturer. Every device has its own address to distinguish between the connected process devices.
20
Introduction Before operation make sure that the positioner addresses of two or more field devices are set on the bus. So that the addresses are unique, each address must only be assigned once. In principle, an address range from 1 to 125 is possible. In its as--supplied state, address 126 is set. The lower addresses are usually assigned to the masters in PROFIBUS systems. We therefore recommend starting address assignment for the positioners with 30. The address setting is made either on the positioner using operating keys or via the bus with the SIMATIC PDM software. In the latter case, a new positioner is always connected to the bus and the new address set via software. After that, the next positioner is connected to the bus and the same procedure followed. We recommend that you write the set address on the positioner with a permanent felt--tip pen. For more detailed information about the components, assembly guidelines and configuration, see the technical description of the field technology package /2/.
21
Introduction
22
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 positioner forms a control system in connection with an actuator. The current position of the positioner is detected by a servo potentiometer and fed back as actual value x. In addition a separate sensor can be fitted to the positioner for purposes of position detection. The setpoint and actual value are output simultaneously on the display. The setpoint is set by the control system and passed to the positioner by the PROFIBUS PA digitally. The PROFIBUS PA variant of the positioner differs from previous versions in the bus interface. The basic functions of the positioner including operation and display are virtually unchanged. 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 housing cover removed. The standard controller has one binary input (BI1). This can be configured individually and can be used for blocking the operating modes for example. A further input (Shut down) has the function of moving the actuator to a pre--set safety position (end stop). With the Iy-option module, the current actuator position can be output as a two wire signal Iy = 4 to 20 mA. 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.
Introduction
23
Design and method of operation The limit value alarms are output by the alarm option module which can monitor and report the function of the positioner and the actuator additionally through a fault message output. The value of the control difference 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 binary outputs are implemented as semiconductor outputs and are error self--reporting, i.e. the outputs respond even when the power supply fails or the electronics are defective. The actuator can also be blocked or driven to its final positions depending on the configuration for example by an external event via a binary input (BI2) 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. 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 (9, Fig. 8, page 25) between 33_ (as delivered) and 90_. The friction clutch (8, Fig. 8, page 25) 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. 9, page 26).
NOTICE for the explosion proof version: Only adjust the outer friction clutch (8, Fig. 9, page 26). The internal friction clutch (9, Fig. 8 page 25) is fixed and, for the explosion proof version, must not be adjusted.
24
2.2
Design Rating Plate

(2) (3) (1) (8) (7)
(4)
(5) (1) (2) (3) (4) Order number Manufacturer Product name Technical data
(6) (5) (6) (7) (8) Serial number Place of manufacture Protection class Observe manual
Figure 7
Design rating plate, example with protection class EEx ia/ib
2.3
Instrument components
8 1 2 3 4 5 6 6.1 6.2 7
*)
Input: Supply air Output: Actuating pressure Y1 Display Output: Actuating pressure Y2 *) Operating keys Restrictor Restrictor Y1 Restrictor Y2 *) Silencer in double--acting actuators
8 9 10 11 12 13 14 15
Transmission ratio selector Adjustment wheel for friction clutch Motherboard Terminals option modules Ground cable (only for plastic housing) Bus cable Terminal plate on cover Purging air switch
Figure 8
View of the positioner (cover open); plastic housing
25

9 3 6.1 2 1 12 7
--
10
238
10
138
6.2 4
1 2 3 4 5 6.1 6.2
*)
Input: Supply air Output: Actuating pressure Y1 Display Output: Actuating pressure Y2 *) Operating keys Restrictor Y1 Restrictor Y2 *) in double--acting actuators
7 8 9 10 12
Transmission ratio selector (only possible with positioner open) Adjustment wheel for friction clutch Terminals standard controller Terminals option modules Safety catch
Figure 9
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 option modules are also on the motherboard.
2.3.2 Electrical connections

The terminals of the standard controller, the Iy--, SIA-- and alarm--option module 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 prevents incorrect installation.
26
2.3.3 Pneumatic connections

The pneumatic connections are on the right hand side of the positioner (figure 10 and figure 11).
1 2 3 4 5 1 2 3 4 5 Actuating pressure Y1 in single-- and double--acting actuators Feedback shaft Supply air Pz Actuating pressure Y2 in double--acting actuators Exhaust air output E with silencer on the bottom of the instrument
Figure 10
Pneumatic connection in normal version
1 2 3 4 5
6 7 1 2 3 4
*)
Restrictor Y2 *) Restrictor Y1 Actuating pressure Y2 *) Supply air PZ in double--acting actuators
5 6 7
Actuating pressure Y1 Exhaust air output E Housing ventilation (2x)
Figure 11
Pneumatic connection in explosion proof version
In addition, there are pneumatic connections on the back of the positioner 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 20, page 45, figure 22, page 46 and figure 23, page 47).
27
Design and method of operation The exhaust air output E can be provided for supplying dry instrument air to the tapping chamber and spring chamber to prevent corrosion. Figure 12, page 28 shows the pneumatic connection variants for the different actuator types, the positioning acting and the safety position after power failure.
Positioning pressure Connection
Actuator type
Safety position after power failure electrical pneumatic

In part--turn actuators the direction of rotation counterclockwise looking onto the actuating shaft of the valve is usually defined as Open.
Y1
Closed Open
Closed
Closed
Y1
Open
Closed Open
Open
Y2
Open
Closed Open Closed Open
Y1
Y1
Closed
Closed Open
Last position (before power failure)
Y2
Y1
up down
Down
Down
Y1
up down
Up
Up
Y2 Y1
up down
Up
Last position (before power failure)
up down
Y1 Y2
up down
Down
Figure 12
Pneumatic connection positioning
28
2.3.4 Mounting kit

The positioner can be mounted on almost all actuators with the appropriate 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 13). 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 (for more information: see Chapter 3.3, page 47).
Figure 13
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 14, in explosion proof version, see figure 11, page 27). 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.
Hexagon socket 2.5 mm
Y1 Y2 Figure 14 Restrictors
29
2.4
Method of operation
The electropneumatic positioner 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 supplied digitally via the PROFIBUS. 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 of the positioner can also be set using an external sensor. Determining the stroke distance or the angle of rotation is done by an external position detection system (e.g. non--contacting position sensor or a potentiometer) directly on the actuator. The positioner may correct the angle error of the stroke tap, compares the actual value x with the setpoint w 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. The control algorithm is an adaptive predictive five--point switch (see figure 15, page 31). 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 frequency. The start parameters are determined during the initialization phase and stored in a non--volatile memory. These are basically the real actuating path 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 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.
30
NOTE The exhaust air valve is always open when there is no current.
Figure 15
Method of operation five--point switch
2.5
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. The input for the safety shut down is not activated.
2.6
Option modules
2.6.1 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: -- Iy module -- Alarm module -- SIA module -- Mechanical limit switch module -- EMC filter module
31
Design and method of operation Installation The option modules are secured by a assembly covering ((1), see figure 16, page 33) and mechanically fixed. NOTE The housing must be opened to install the options modules. The degree of protection IP66 is not guaranteed as long as the positioner is open.
Opening the instrument
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
32
Design and method of operation 6 5 1 1.1
2.1 1.1 2.1
2 12 10 4 3 7 11
7.1
1 1.1 2 2.1 3 4 5 6 Module cover Fixing screws Motherboard Fixing screws Iy-module with ribbon cable (6) Alarm module with ribbon cable (5) Ribbon cable for alarm module Ribbon cable for Iy-module 7 7.1 7.2 7.3 8 9 10 11 12
7.2
7.3
SIA-module and mechanical limit switch module Special screw Actuating disc for A1 (terminals 41 and 42) Actuating disc for A2 (terminals 51 and 52) Adjusting wheel for friction clutch Transmission ratio selector Insulating cover Pneumatic block Actuating disc bearings
Figure 16
Installation of options modules in normal and intrinsically safe version
33
2.6.2 Installation of options modules in explosion proof version

The following option modules are available for the positioner in the explosion proof version: -- Iy module -- Alarm module Installation The options modules are protected and mechanically fixed by a module cover ((1), see figure 17, page 36). 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 electronics are used. The feed--though openings for the electronic connections must be sealed with EEX-d certified 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.
Open the positioner
See figure 17, page 36. 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.
34
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.
35

1.1
13.1
1.1 2 4 3 11
10
12 13.1 7 5 6 13
1 1.1 2 3 4 5 6
Module cover Fixing screws PA module Iy module with ribbon cable Alarm module with ribbon cable Ribbon cable for alarm module Ribbon cable for Iy module
7 8 10 11 12 13 13.1
Transmission ratio selector Adjusting wheel for friction clutch Housing Screw--on cover Safety catch Rack Fixing screws
Figure 17
Installation of the options modules in the proof version
2.6.3 Iy module
Function
With the Iy-option module, the current actuator position can be output as a two wire signal Iy = 4 to 20 mA potentially isolated from the standard controller. The dynamic control of the Iy module makes it also error self--reporting.
36
Design and method of operation Installation The Iy module (3) is pushed in to the bottom compartment of the module rack up to the stop and connected by the enclosed 6-wire ribbon cable (6) to the motherboard (see figure 16, page 33).
2.6.4 Alarm module

The alarm module contains
S 3 digital outputs and S 1 digital input

Function The digital outputs serve to output fault messages and alarms. The configuration is described in chapter 4.4, page 98, with the parameters 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 98, 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 alarm). The dynamic control 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. Installation The alarm module (4) is pushed in underneath the motherboard into the module rack up to the stop and connected by the enclosed 8-wire ribbon cable (5) to the motherboard (see figure 16, page 33).
37
2.6.5 SIA module

The SIA module contains three digital outputs. Function A collected fault message (see alarme module) is output via a digitaloutput. The floating digital output is implemented as a self error reporting semiconductor output. The other two digital outputs are used for reporting two mechanically adjustable limit values (L1, L2) by slot initiators. The two binary outputs are electrically independent of the rest of the electronics.
Installation
(Slot Initiator Alarm module) Proceed as follows for installation: 1. 2. 3. 4. 5. 6. Remove all the electrical connections from the motherboard (2). Loosen the two fixing screws (2.1) of the motherboard. Snap out the motherboard by carefully bending the four holders. Insert the SIA-module (7) from above up to the top pcb rail of the container. Push the SIA module in the pcb rail of the container about 3 mm to the right. 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 bearing 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 corresponding lugs on the container wall. Place the insulating cover on the SIA module by carefully bending the container walls. Snap the motherboard into the four holders and screw it tight again with the two fixing screws (2.1). Make all the electrical connections between the motherboard and the options with the ribbon cables provided and between the motherboard and potentiometers with the potentiometer cable.
8. 9.
10. Fix the enclosed module cover instead of the standard version with the two screws (1.1).
38
Design and method of operation 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 doesnt feature explosion protection, stick the warning sign (figure 2) onto the side of the ground plate opposite the typeplate. 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 terminals 51 and 52 of the SIA module to be able to see the switching state of the slot initiators. 1. 2. 3. 4. Drive the actuator to the first desired mechanical position. Adjust the top actuating disc (7.2) by hand until the output signal on terminals 41 and 42 changes. Drive the actuator to the second desired mechanical position. Adjust the bottom actuating disc (7.3) by hand until the output signal 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 operating, 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 adjustment.
2.6.6 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 mechanically. These two switches are electrically independent from the rest of the electronic system
39
Design and method of operation Installation 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) Maximal current (not Ex) Maximal voltage (Ex) Maximal current (Ex) AC 250 V or DC 24 V AC/DC 4 A DC 30 V 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 cable 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. Follow the instructions below for installation: 1. 2. 3. 4. 5. 6. Remove all electrical connections on the motherboard (2). Loosen carefully both fixing screws (2.1) for the motherboard. Insert the limit switch module (7) from above until it reaches the upper printed circuit board rail of the container. Snap put the motherboard (2) by carefully bending the four holders. Push the mechanical limit switch module (7) in the printed circuit board rail of the container ca. 3 mm towards the right 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 adjusted just before it touches the special screw (7.1) In order that the pin slot into the special screw, you must then turn the actuating disc bearing and the special screw simultaneously
40
Design and method of operation 7. Place the insulating cover (10) over the mechanical limit switch module underneath the surface of the motherboard onto the container on the wall. The recesses in the insulating cover must slot into the corresponding lugs on the container wall. Place the insulating cover on the mechanical limit switch module by carefully bending the container walls. Snap the motherboard board into the four holders and screw it tight again with the two fixing screws (2.1). Make sure all electrical connections between the motherboard and the options using the ribbon cables provided and between the motherboard and potentiometer using the potentiometer cable.
8. 9.
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 proven effective: S Turn the screws counterclockwise until you feel them snap into the thread. S Tighten both screws carefully in a clockwise direction
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 termiS S S S
nal when plugging in the wires. the ends of stranded wires have sleeves the connection cables are insulated according to the permitted current load. the permissible working temperature of the cables exceeds the maximal ambient temperature by minimum 25 _C. the Ex--version is only allowed to be operated in intrinsically safe circuits with approved switching amplifiers.
Connection 1. 2. 3. 4. 5. 6. Loosen the screw (1) on the cover (2). Push the cover (2) till it reaches the front stop. Screw each cable tight in the appropriate terminal. Push the cover (2) till it stops at the motherboard. Tighten the screw (1) of the cover (2). Fix the cables of each switch in pairs on the mounting eye using the cable binders provided (3).
41
Figure 18
Cable connection
Setting the two limit values: 1. 2. 3. 4. Drive the actuator to the first desired mechanical position. Adjust the top actuating disc (7.2) by hand until the output signal on terminals 41 and 42 changes. Drive the actuator to the second desired mechanical position. Adjust the bottom actuating disc (7.3) by hand until the output signal on terminals 51 and 52 changes.
NOTE To avoid the actuating discs (7.2/7.3) being accidentally adjusted during 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 adjustment.
42
2.6.7 EMC filter module
The positioner can also be driven by an external position sensor (potentiometer or NCS) (see page 50 3.3.2 Instructions for using positioners which are exposed to strong accelerations or vibrations). An EMC filter module, order number C73451--A430--D23, is required for this.
2.6.8 Accessories
Y1 Y1 PZ
PZ
Y2
Figure 19
Manometer block (left for single-acting, right for double-acting actuators)
Manometer block
The manometer block for single-acting actuator contains two 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) 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.
43
44
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 8.1, page 168 Installation of any modules required is described in chapter 2.6, page 31 of this technical manual.
3.2
Dimensional drawings
60 50 x 4 x M6 65 Y1 2 33 48 7 Y1 PZ Y2 29 37 29,5 11,2 29,5 72
80
M8, 9 deep 23 58 182
9 deep
95
All air connections G 1/4 or 1/4 NPT
96,6
13,5
M20 x 1.5 or NPT adapter h9 1
7 38,5 88,5
14,5
Figure 20
Dimensional drawing version plastic housing 6DR5xx0
15
45

90 79,5 3x G 1/4 or 1/4 NPT 50 20,5 9,5
14 25 12 10 5
2xM6 29,5 58,75 82 M4 Thread depth 5.5 3,5 5,3 9,5 5
Figure 21
Dimensional drawing terminal strip for plastic housing

12 6,5 50 x 4 x M6 9 deep Y1 29,5 14 PZ All air connections G 1/4 or 1/4 NPT 182 11,2 SIPART PS2 PA Manual A5E00127926--05 2 Y1
65
29
84
29,5
34,5
M8, 9 deep 23 58
96,6
13,5
M20 x 1.5 or NPT--adapter h9 1
7 38,5 88,5
14,5
Figure 22
Dimensional drawing version metal housing 6DR5xx1
46
15
27,5
59

23
M8, 14 deep (4x)
All air connections G1/4 or 1/4NPT

10,25 33,5 7 4,5 19,25 1) 7,5 25,7 87,2 14,3 33,5 E 12
65
43
M6, 11 deep (4x)
50
7,75
60
M6, 8 deep (2x) M20, M25 or 1/ NPT (2x) 2
129,5 3,5
34
25
1)
Connection 238/Y2 only in double--acting version
136.5 235,3 8 h9
158,5
Figure 23
Dimensional drawing for positioner with metal housing in explosion proof version 6DR5xx5
3.3
Assembly
General
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 2. Connection of electric power supply 3. Connection of pneumatic power supply 4. Put into operation this chapter see chapter 3.4, p. 62 see chapter 3.5, p. 73 see chapter 3.6, p. 74
Please also observe the warning on page 10 and 62!
82,5
47
NOTE The positioner will be equipped at the factory and delivered complete with the necessary options at the customers 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 potentially 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 particularly important when operating the positioner at low ambient temperatures. 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 24.
48
Figure 24 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 positioner.
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 installation position). If this is not possible, the silencer should be replaced by a suitable screw--type gland with a plastic hose.
49
Preparing for operation 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. opening.
S Screw the screw--type gland mentioned above into the exhaust air 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
opening faces downwards. out unhindered.
S Make sure that the hose has no kinks and the exhaust air can flow
3.3.2
Instructions for using positioners which are exposed to great accelerations or vibrations
NOTICE for explosion proof versions: Only adjust the outer friction clutch (8, Fig.17, page 36). The internal friction clutch (8, Fig.16 page 33 ) is fixed and, for the explosion proof version, must not be adjusted. The electro--pneumatic positioner features a friction clutch and a switchable drive and is, therefore, universally applicable for part--turn and linear actuators. Thats why it is not necessary to take a zero--point into consideration when implementing part--turn actuators. Similarly, there is no need to ensure that the extension is symmetrically attached when implementing linear actuators. In both cases, the work space can be adjusted afterwards via the friction clutch. The switchable drive can be used to adjust the positioner for short or long strokes. Large accelerating forces can occur on fittings subject to heavy mechanical wear and tear, such as openings which could break off, valves subject to heavy vibrations as well as beating blast pipes. In some cases, these forces can far exceed the specifications. In extreme cases, these forces could even cause the friction clutch to shift. For these cases, the positioner is equipped with a position--securing device for holding the friction clutch in place. Furthermore, it is also possible to lock the transmission ratio selector into position, thus preventing it from shifting due to the influences stated above. Both setting options are designated accordingly by icons on additional signs (see Fig. 25 page 51).
50
Preparing for operation Procedure After you have mounted the positioner and commissioned it completely, you can set the friction clutch torque as follows:
S Plug a conventional 4 mm wide screwdriver into a slot in the yellow

wheel.
S Then turn the yellow wheel to the left with the screwdriver until it
snaps in audibly. This increases the torque of the friction clutch. gap between the yellow and black wheel.
S A fixed friction clutch is recognizable from an approx. 1 mm wide S If you have to make a zero point setting, e.g. after changing the
drive, please reduce the torque first by turning the yellow wheel to the right stop. After the zero point setting, you can fix the friction clutch as described above.
To lock the transmission ratio selector, takt the unit as factory set and do as follows:
S Using a conventional flat headed screwdriver (approx. 4 mm wide)
turn the yellow wheel underneath the clamps to the left or right according to your chosen setting (either 33_ or 90_) until it snaps in audibly. must first be released. Hence the yellow wheel must first be put into the original factory set position in order to reset the transmission ratio selector if necessary, e.g. after replacing the actuator.
S In order to set the transmission ratio selector any locks in place
(2)
90_
(3) (1)
90 33
33_
(4)
(1) (2) (3) (4) Transmission ratio switch interlock Open Friction clutch Close
Figure 25 Adjustable retaining device for the friction clutch
51
Preparing for operation External position detection 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 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 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 always has to be used for the controller unit whenever the external position detection unit C73451-A430-D78 is to be replaced by a random drive--mounted potentiometer (resistance value 10 kOhm) or if a NCS sensor is to be installed.
WARNING The explosion proof version may not be run together with the external position detection system.
52
3.3.3 Mounting kit linear actuator 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 26, page 55):
Ser. no. 1 2 3 4 6 pieces 1 1 2 1 1 Designation NAMUR mounting kit bracket IEC534 Pick--up bracket Clamping assembly Carrier pin Lever NAMUR Note Standardized connection for mounting console with ledge, column or plane surface Guides the roller with carrier pin and turns lever arm Mounting of pick--up bracket on actuator spindle Assembly with roll (5) on lever (6) For stroke range 3 mm to 35 mm For stroke ranges> 35 mm to 130 mm (special delivery), lever 6DR4004--8L is required additionally Only for actuators with columns M8 x 20 DIN 933--A2 M8 x 16 DIN 933--A2 A8 -- DIN 127--A2 B 8,4 -- DIN 125--A2 B 6,4 -- DIN 125--A2 A6 -- DIN 137A--A2 3.2 -- DIN 6799--A2 A6 -- DIN 127--A2 M6 x 25 DIN 7984--A2 M6 -- DIN 934--A4 M6 -- DIN 557--A4 M8 -- DIN 934--A4
7 8 9 10 11 12 14 15 16 17 18 19 21
2 4 2 6 6 2 1 1 3 3 1 1 4
U bolt Hexagon head screw Hexagon head screw Lock washer Flat washer Flat washer Spring washer Lock washer Spring washer Socket cap screw Hexagon nut Square nut Hexagon nut
3.3.4 Assembly procedure (see figure 26, page 55)

1. 2. Mount clamping assembly (3) with hexagon socket cap screws (17) and lock washer (16) on the actuator spindle. 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. Insert the premounted pin in the lever (6) and assemble with nut (18), spring washer (14) and washer (12). 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. Assemble the hexagon socket cap screw (17), spring washer (16), washer (12) and square nut (19) on the lever. Push the premounted lever onto the positioner axle up to the stop and fix with the hexagon socket cap screw (17). Fit the mounting bracket (1) with two hexagon head screws (9), lock washer (10) and flat washer (11) on the rear of the positioner.
3. 4.
5. 6. 7.
53
Preparing for operation 8. Selection of the row of holes depends on the width of the actuator yoke. The roll (5) should engage in the pick--up bracket (2) as close as possible to the spindle but may not touch the clamping assembly. Hold the positioner with the mounting bracket on the actuator so that the pin (4) is guided within the pick--up bracket (2).
9.
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. If no symmetrical mounting is possible it must be guaranteed that the horizontal lever position is passed through within the stroke range.
54
Preparing for operation 17 16 12

16
18 19
17 3 1) 2)
14 12 6
Without explosion proof version

11
10 9 1
11 10 3) 9
Explosion proof version:
10 9 1
11
11 4) 9 10
Figure 26
Assembly procedure (linear actuator)
55

1 10 8 Mounting on yoke 11 with ledge 11 10 8 Mounting on yoke with plane surface
11
10
Mounting on yoke with columns 7 5) 21 as required
Figure 26
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 27 and 28):
Ser. no. 2 3 4 4.1 4.2 14 15 16 17 18 19 Pieces 1 1 1 8 1 4 4 1 1 1 1 Designation Coupling wheel Carrier Multiple plate Scales Pointer mark Hexagon head screw Lock washer Fillister head screw Washer Hexagon socket head screw Allen key Note Mounting on position feedback shaft of the SIPART PS2 Mounting on end of actuator shaft Indication of actuator position, comprising 4.1 and 4.2 Different divisions Reference point for scale DIN 933 -- M6 x 12 S6 DIN 84 -- M6 x 12 DIN 125 -- 6.4 Premounted with coupling wheel For item 18
56
3.3.6 Assembly procedure (see figure 27 and figure 28)

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). Adhere pointer (4.2) onto mounting console in the center of the centering hole. Push the coupling wheel (2) onto positioner axle, pull back by about 1 mm and tighten the hexagon socket head screw (18) with the Allen key provided. Place the carrier (3) onto the end of the actuator and secure using Fillister head screw (16) and washer (17). Carefully place positioner with mounting console onto the actuator such that the pin of the coupling wheel engages in the driver. 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!) Following startup as described in Chapter 3.6, page 74: 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!
2. 3.
4. 5. 6.
7.
57
15
14 2
1)
9 2) 16 3 17
18
3)
2 2 3
4.1
0%20 40 60 80 100%
4)
5)
Figure 27
Assembly procedure (part--turn actuator)
58
15 14
9 1) 3 16 17 18 2) 2
3)
2 4.1 2
0%20 40 60 80 100%
4)
Figure 28
5)
Assembly procedure for explosion proof version (part--turn actuator)
59

CUT A -- B 4.2 14,15
Positioner
part--turn actuators
2 3 4 4.1 4.2 9
Clutch wheel Driver Multiple--purpose plate Scale Pointer mark VDI/VDE 3845 mounting bracket
10 14 15 16 17 18
Feedback shaft Hexagon--head screw M612 Retaining washer S6 Round--head screw M612 Washer Socket--head cap screw
Figure 29
Mounted positioner for part--turn actuators
60

fastening level positioner 4 mm
M6
4+0,1
part--turn actuator
4 35
F05--Lkr.-- 4 50
Figure 30
Attachment of part--turn actuator, mounting console (scope of delivery actuator manufacturer), dimensions
6,5
12
25
61
3.4
Electrical connection
NOTE Any necessary options modules must be installed before electrical connection (see chapter 2.6, page 31). N.B.: The transmission ratio selector can only be set when the positioner is open. Therefore check this setting before closing the positioner.
WARNING The specifications of the examination certificate valid in your country must be observed. Electrical connection in hazardous areas 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). -The certificate of conformity If the intrinsically safe version is operated with a higher operating voltage 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. The feed--though openings in the explosion proof version for the electronic connections must be sealed with EEX--d certified 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 31, page 63. The specified noise immunity and noise emission are only ensured if the bus shield is fully effective. This includes connecting the shields with the metallic connections of the positioner with PROFIBUS PA, but also routing the shield to the terminal boxes, distributors, DP/PA coupler or DP/PA link.
62
CAUTION To discharge impulses under fault conditions, the positioner must be connected via a low resistance to an equipotential bonding (ground potential). For this the positioner in plastic housing is provided with an additional cable. Connect this cable using the cable clip to the PROFIBUS cable shield and to the equipotential bonding. Devices in metal housings have a corresponding terminal on the outside of the housing, which also must be connected to equipotential bonding. Provide for suitable potential equibonding between the hazardous and non--hazardous areas for applications in areas where there is a risk of explosions.
Shield
Figure 31
Base plate
Fitting the bus cable Normal, intrinsically safe and zone 2 versions. 1. Isolate the bus cable as shown in figure 32, page 64. 2. Open the positioner housing by undoing the four cover screws. 3. Insert the prepared bus cable through the cable gland. 4. Secure the shield with the cable clip and the two screws to the housing. Explosion proof version 1. Isolate the bus cable as shown in figure 32, page 64. 2. To open the positioner, the cover catch (12) must be undone and the screw cover unscrewed. 3. Insert the prepared bus cable through the Ex--d--certified cable gland *) 4. Secure the shield with the cable clip and the two screws to the housing.
63
Preparing for operation 5. Tighten the cable gland. 6. Connect the red and green wires as shown in figure 33, page 65 to terminals 3 and 7 of the motherboard (the polarity is immaterial). 5. Tighten the Ex--d--certified cable gland. *) 6. Connect the red and green wires as shown in figure 35, page 66 to terminals 6 and 7 of the motherboard (the polarity is immaterial).
*) if the Conduit Tube System is being used, refer to the relevant instructions.
for positioner in normal version and in explosion proof version
10
Buscable 6XV1 830--5AH10 or 6XV1 830--5BH10 a = 80 a = 120 Figure 32
Cable shield
in normal version (without Ex and without Ex i) in explosion proof version (Ex d)
Preparation of bus cable
For error--free communication the bus must be terminated at both ends with a bus terminator. At the end nearest the control system, this is already assured by the terminator contained within the coupling or link. At the far end of the bus this must be achieved by fitting an additional terminator. So as to avoid potential differences between individual equipment parts and thus the risk of functional impairment, a suitable potential bonding is to be provided. Information regarding dimensions and types can be found in DIN VDE 0100 parts 410 and 540.
NOTE Use standard M20 x 1.5 cable gland nuts to ensure leakage (IP-protection 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 disconnected under power in normal operation. However, during installation or repair work the positioner may be connected or disconnected even under power (see also certificate for zone 2).
64

for positioner in normal version:
1 2 3 4 5 6 7 8
Bus cable Cable clip Basic PCB Module cover Plate Terminal block Ground potential Cable glands Bus cable connection
Figure 33
for positioner in explosion proof version Base plate
Cable shield Cable clip Figure 34 Bus cable EEx d certified cable inlets
Bus cable connection for positioner in explosion proof version
65

Non--hazardous area Approved associated apparatus or barrier + EEx - 30 V Hazardous area zone 1
81 Input: Safe position 82
PROFIBUS PA EEx DP/PA coupling 24 V
6 7 8 9 10
Positioner + 3V
Binary input 1
Figure 35
Electric connection of basic device with in intrinsically safe version
Non--hazardous area + - 32 V PROFIBUS PA DP/PA coupling 30 V
Hazardous area
81 Input: Safe position 82
6 7 8 9 10
Positioner + 3V
Binary input 1
Figure 36
Electric connection for positioner in explosion proof version or in type of explosion protection n version
Safety position
The positioner is equipped with an additional input (terminal 81 [+] and terminal 82 [--]) for driving to the safety position. After activating this function this input must be supplied with uninterrupt +24 V, to allow normal positioning operation. If this power supply is switched off or drops out, the air exhaust valve is automatically opened and the drive will move to the pre--arranged safety position, so that the drive cannot be activated using the keys on the control unit or by means of the master switch. The communication with the Master is still possible. This function is activated by the coding bridge on the motherboard. This is accessible after removing the module cover and must be moved from the right position (as delivered) to the left position.
66
3.4.1
Connection variant: options in positioner in non--intrinsically safe and explosion proof version
Current output
+
UH
35 V
+
61 62
E J
Iy--module: 6DR4004--8J
Figure 37
Iy--module 6DR4004--8J, non Ex
Binary inputs and outputs

Alarm module 6DR4004--8A +
+13 V +4.5 V
30 V
11 12 21 22 + 3V
1K
Binary input 2
35 V
+
31 32
1K
Fault message
35 V
+
41 42
1K
Limit A1
35 V
51 52
Limit A2
Figure 38
Alarm module 6DR4004--8A, non Ex
67
Preparing for operation SIA module

SIA module: 6DR4004--8G
+ < 35 V 31 32
1K21 10K
Fault message
+ 8.2 V 41 42 Limit A1
+ 8.2 V 51 52 Limit A2
Figure 39
SIA module 6DR4004--8G, non Ex
Mechnical limit switch module

Limit switch module 6DR4004-8K +
1K21
=
+
< 35 V
31 32
10K
Fault message
max. AC 250 V DC 24 V AC/DC 4 A
41 42
Limit A1
max. AC 250 V DC 24 V AC/DC 4 A
Figure 40
51 52
Limit A2
Mechanical limit switch module 6DR4004--8K, non Ex
68
3.4.2
Connection variant: options in the positioner in intrinsically safe version
Current output
Non--hazardous area Hazardous area zone 1 or zone 2
EEx U J
+
UH
30 V
61 62
E J
Iy module: 6DR4004--6J
Intrinsically safe power sources
Figure 41
Iy module 6DR4004--6J, EEx i

Non--hazardous area Hazardous area zone 1 or zone 2 Alarm module 6DR4004--6A + EEx
25.2 V
11 12 21 22 +
2K1
1 3V
Binary input 2
Intrinsically safe Switching amplifier to EN 50227
+ EEx + EEx + EEx 8.2 V 8.2 V 8.2 V
31 32
10K
Fault message
2K1
41 42
10K
Limit A1
2K1
51 52
10K
Limit A2
Figure 42
Alarm module 6DR4004--6A, EEx i
69

Non--hazardous area Hazardous area zone 1 or zone 2 SIA module: 6DR4004--6G + EEx + EEx + EEx 8.2 V 8.2 V 8.2 V
2K1
Intrinsically safe Switching amplifier to EN 50227
31 32
10K
Fault message
2K1
41 42
10K
Limit A1
2K1
51 52
10K
Limit A2
Figure 43
SIA module 6DR4004--8G, EEx i
Mechnical limit switch module

Non-hazardous area Intrinsically safe Switching amplifier to EN 60947--5--6 + EEx + max. DC 8.2 V 31 32 Hazardous area zone 1 or zone 2
Mechanical limit switch module 6DR4004-6K

2K1 10K
Fault message
=
+
Umax DC 30 V Imax 100 mA
41 42
Limit A1
=
Figure 44
Umax DC 30 V Imax 100 mA
51 52
Limit A2
Mechnical limit switch module 6DR4004--6K, EEx i
70
3.4.3
Connection variant: options in the positioner in type of protection n version
Current output
Non--hazardous area
Hazardous area zone 2
UH 30 V
61 62
E J
Iy module 6DR4004--6J
Figure 45
Iy module 6DR4004--6J, EEx n
Non--hazardous area Alarm module 6DR4004--6A + 25,2 V 11 12 21 22 Switching amplifier to EN60947--5--6 + 8.2 V 31 32 +
2K1 10K
Hazardous area zone 2
1 3V
BI2
Alarm
+ 8.2 V 41 42
2K1 10K
Limit A1
+ 8.2 V 51 52
2K1 10K
Limit A2
Figure 46
Alarm module 6DR4004--6A, EEx n
71

Non--hazardous area Hazardous area zone 2 SIA module 6DR4004--6G Switching amplifier to EN60947--5--6 + 8.2 V 31 32
2K1 10K
Fault message
+ 8.2 V
41 42
Limit A1
+ 8.2 V 51 52 Limit A2
Figure 47
SIA module 6DR4004--6G, EEx n
72
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 mode P manual operation with electrical signal applied (as--delivered state, see figure 57, page 94).
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 Technical Data, page 161).
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:

PZ Y1 Supply air 1.4 to 7 bar 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 10 and 11, page 27.
S Safety position when the electric power supply fails:

single--acting: double--acting: Y1 Y1 Y2 deaerated Max. actuating pressure (supply air pressure) deaerated
S Connect actuating pressure Y1 or Y2 (only in double--acting

actuators) according to the desired safety position.
S Connect supply air to PZ.
NOTE In order for spring--loaded pneumatic actuators to be able to reliably exploit the maximum possible actuating path, 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.
73
3.6
Commissioning
Once the positioner has been fitted to a pneumatic actuator, it must be provided with electrical and pneumatic auxiliary power. The electrical auxiliary power can be provided via a bus interface or separate power source with 15 to 30 V DC. Then you can then adapt the positioner to the respective actuator by parameterizing and initializing it and setting the bus address. Communication with a master is not necessary for this. 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 determines the direction of action, the stem path and the angle of rotation, the adjusting times of the actuator one after the other and adapts the control parameters to the dynamic behavior of the actuator. The stem travel or angle of rotation of the actuator can be set manually, the other parameters are determined as in automatic initialization. This function is useful in actuators with soft limit stops. The initialization data of a positioner can be read out and copied to another positioner. This enables a defective device to be changed without having to interrupt an ongoing process by initialization.
S Manual initialization
S Copying initialization data (positioner exchange)
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 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 91 Operation.
NOTE N.B.: The operating pressure should be at least one bar greater than is necessary for closing/opening the valve during initialization. Jedoch darf der Betriebsdruck nicht grer sein als der maximal zulssige Betriebsdruck des Antriebs. N.B.: The transmission ratio selector can only be set when the positioner is open. Therefore check this setting before closing the housing.
74
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 selector (7, figure 8, page 25) in the positioner: Stroke 5 to 20 mm 25 to 35 mm 40 to 130 mm 2. Lever short short long Position of the transmission ratio selector 33 (i.e. down) 90 (i.e. up) 90 (i.e. up)
Push the carrier pin (4, figure 26 (page 55) 2) onto the lever (6, figure 26, 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 26, 2). Connect the actuator and the positioner with the pneumatic lines and supply pneumatic power to the positioner (figure 10 and 11, page 27 ). Connect the positioner to the PROFIBUS line (figure 35, page 66 and figure 36, page 66). The positioner is now in the operating mode P--manual operation 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:
3.
4. 5.
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 16, page 33) 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.
75
NOTICE for the explosion proof version: Only adjust the outer friction clutch (8, Fig. 9, page 26). The internal friction clutch (9, Fig. 8 page 25) 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. for longer than 5 s. This brings Press the operation mode key you to the Configuration operating mode. Display:
2.
Switch to the second parameter by pressing the operation mode briefly. key Display:
or
NOTE It is vital that this value corresponds to the setting of the transmission ratio selector (8, figure 8, page 25) (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.
76
Preparing for operation 4. Switch on to the following display with the operation mode key :
5.
Start initialization by pressing the key Display:
for longer than 5 s.
During the initialization phase RUN1 to RUN5 appear one after another in the bottom display (see also structograms figures 49, page 85 to figure 52, page 88).
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 exit the 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 parameters are reset to the factory setting only after performing a Preset.
77
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 stem path are set manually. The other initialization steps (optimization of the control parameters) run automatically as in automatic initialization. Manual initializ-tion procedure in linear actuator 1. Make preparations as described in chapter 3.6.1, page 75 for linear actuator. In particular, make sure by manuallydriving the whole stem path that the displayed potentiometer setting moves in the permissible range between P5.0 and P95.0. Press the operation mode key you to the Configuration mode. Display: for longer than 5 s. This brings
3.
Switch to the second parameter by pressing the operation mode 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.
78
Preparing for operation 5. Switch on to the following display mode key twice: by pressing the operation
6.
Start initialization by pressing the increment key than 5 s. Display:
for longer
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 and the first of the two end positions with the increment decrement 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 stem path and the displacement detection according to step 1.
79
Preparing for operation 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 decrement key. Then press the operation mode key enters the current position as end position 2. . This
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 displacement path and the displacement detection according to step 1. 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 initialization:
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 briefly. This brings you back to the Configuration mode key 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.
80
3.6.4 Preparations for part--turn actuator
NOTE Very important: Switch the transmission ratio selector in the positioner (8, figure 8, page 25) to position 90 (normal angle for part--turn actuator). 1. 2. Mount the positioner with the appropriate mounting kit (see chapter 3.3.5, page 56). Connect the actuator and the positioner with the pneumatic lines and supply pneumatic power to the positioner (figure 10 and 11, page 27). Connect the positioner to the PROFIBUS line (Figure 35, page 66 and Figure 36, page 66). 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:
3. 4.
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 initialization 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. for longer than 5 seconds. This Press the operation mode key brings you to the Configuration mode. Display
81
Preparing for operation 2. Set the parameter with the Display: key to turn
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 5 seconds. Display:
for longer than
During the initialization phase RUN1 to RUN5 appear one after another in the bottom display (see also structograms in figure 49, page 85 to figure 52, page 88).
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).
82
Preparing for operation The following display appears after pressing the operation mode key briefly:
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.
NOTE You can abort an ongoing initialization at any time by pressing the operation mode key. Your previous settings are retained. All the parameters 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 displacement path are set manually. The other initialization steps (optimization of the control parameters) run automatically as in automatic initialization. Manual initializa-tion procedure in part--turn actuators 1. Make preparations as described in chapter 3.6.4, page 81 for part--turn actuators. In particular, make sure by manually driving the whole displacement path that the displayed potentiometer setting moves in the permissible range between P5.0 and P95.0. for longer than 5 seconds. This Press the operation mode key brings you to the Configuration mode. Display:
2.
3.
Set the parameter YFCT to turn with the decrement Display:
key.
83
Preparing for operation 4. Switch to the second parameter by pressing the operation mode key briefly. Display:
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 initialization of linear actuators. After successful initialization the determined part--turn range appears in the top display. 5.INITM appears in the bottom line again after pressing the briefly. This brings you back to the operation mode key 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.
84
3.6.7 Automatic initialization (structograms)

Linear actuator Part--turn actuator
Up Figure 48
Down
Closed
Open
Direction of action of the actuators
The initialization procedure should be taken from the following structogram (figure 49 to figure 52). The terms Open/Closed and up/down in the structogram refer to the direction of action of the actuators as illustrated in figure 48.
configure
start: press 1
>5s move the actuator into the travel range with:
piezo valve 1 opens
continue with:
RUN 1
no dy > 4 % ? t > 60 s ?
no
yes piezo valve 2 opens
yes
dy > 4 % ?
no
t > 60 s ?
no
yes 2
yes
manual intervention
Figure 49
Automatic initialization, part 1
85
actuator moves into closed position
RUN 2
tolerance band 4% < dw < 10% ? yes actuator moves into open position
no
turn friction clutch until 0 appears in the bottom line of the display continue with:
hard stop up < 97 % ? yes span up--dw > 25 % ? yes 3
no
continue with: no
check mechanics
continue with:
manual intervention
Figure 50
Automatic initialization part 2 (in part--turn actuators)
86
2 set lever arm vertical to stem with:
continue with:
actuator moves into closed position no continue with:
yes
continue with:
has friction clutch been moved?
tolerance band 4% < dw ? RUN 2 yes actuator moves into open position
no
correct height adjustment or turn friction clutch until 0 appears in the bottom line of the display
hard stop up < 97 % ? yes span up--dw > 25 % ? yes was the vertical position (to stem) of the lever driven through ? yes 3
no
set the next lowest travel value on the lever and check the setting of the transmission ratio selector continue with:
no
set the next highest travel value on the lever and check the setting of the transmission ratio selector continue with:
no
manual intervention
Figure 51
Automatic initialization part 2 (in linear actuators)
87
determine travel times
continue with: or
display travel times flashes RUN 3 alternating if setting of travel times is desired
set restrictor(s) to change the travel times
yes within 5s? no yes within 5s? no
flashes alternating display of travel times in s
actuator comes to standstill after 1 minute
display of leakage in % / min
if leakage test of actuator is desired
continue with:
RUN 4
determine minimum positioning increments
RUN 5
optimizing of transient behavior and determining of prediction horizon
or continue with: configure
display of stroke in mm or angle of rotation in degrees, is also the identification for complete initialization
manual intervention
Figure 52
Automatic initialization, part 3
88
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 positioner to be changed on a running system in which automatic 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 (Process Device Manager) or HART--Communicator. This step is unnecessary if the instrument has been parameterized with PDM and the data have already been stored. Fix the actuator in its momentary position (mechanical or pneumatic). 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. 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. If the displayed actual value does not match the noted value of the defective positioner, set the correct value with the friction clutch. 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 related maintenance data may show deviations in particular. Therefore initialization must be performed at the earliest opportunity.
2. 3.
4.
5. 6.
89
90
Operation
Operation
4
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 display depends on the selected operating mode (see chapter 4.3, page 94)
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 54 shows you the various display options. The meaning of further display capabilities is detailed in chapter 4.6 page 122.
4.2
Input keys
The positioner is operated by three keys (figure 55, page 93) 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.
91
Operation
Figure 54
Meaning of the various display options
92
Operation
2
1 2 3 4 Display Operation mode key Decrement key Increment key
Figure 55
Display and input keys of the positioner
Explanations of the input keys
S The operation mode key (manual key) serves to switch over the
operating 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 S The increment key
serves to select parameter values in configuration and to move the actuator in manual operation.
serves to select parameter values in configuration and to move the actuator in manual operation.
Firmware version
The current firmware state is displayed when you exit the configuration menu.
Figure 56
Firmware version
93
Operation
4.3
Operating modes
The positioner can be operated in five operating modes. 1. 2. 3. 4. 5. P--manual mode (ex--factory state) Configuration and initialization Manual mode (MAN) Automatic (AUT) Diagnostic display
Figure 57 gives you an overview of the possible operating modes and the change between them.
Figure 57
Change between the operating modes
94
Operation P--manual mode (ex--factory state) The display of the positioner shows you the current potentiometer setting in the top line and NOINI 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 74 Commissioning. Manual and automatic mode or output of alarms and position feedback are possible after successful initialization. Configuration and initialization for To go to the Configuration menu, press the operation mode key 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 binary input. Which parameters you need to set and all other parameters are explained in chapter 4.4, page 97 Parameterization. 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 in configuration mode.
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.
95
Operation
at the same time
at the same time
to
at the same time at the same time
Figure 58
Overview: Configuration
Manual mode (MAN)
In this operating mode you can move the actuator with the decrement ( ) and increment keys ( ) and the current position is held regardless 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.
Automatic (AUT)
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 1, page 114). From the automatic or manual mode you go to the diagnostic display by simultaneously pressing all three keys for at least two seconds. See chapter 4.5, page 113 for further information.
Diagnostic display
96
Operation
NOTE The respective operating mode (MAN or AUT) of the positioner is retained when you switch to the diagnostic display, i.e. in automatic operation 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 59 shows an overview of the parameters. The parameter name is shown once in plain text and once as it appears 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. The configuration block diagram (figures 60 page 99) shows the effects of the parameters.
97
Operation
SIPART PS2 PA configurations (PROFIBUS version)

Parameter- Function Parameter values Dimenname sion 1. YFCT Type of actuator: part-turn/linear - Part-turn actuator turn - Linear actuator WAY - Linear actuator without sine-wave correction LWAY - Part-turn actuator with NCS ncST - Part-turn actuator with NCS, reverse direction -ncST - Linear actuator with NCS ncSL 1) 2. YAGL Rated angle of feedback 90 De33 grees 3. YWAY 2) Travel range 5 to 130 mm (0.20 to 5.12 inch) - None OFF - Short lever 33 5/10/15/20 mm - Short lever 90 25/30/35 - Long lever 90 40/50/60/70/90/ 110/130 4. INITA Initialization (automatic no commissioning) ###.# Strt FINISH 5. INITM Initialization (manual no commissioning) ###.# Strt FINISH 6. SDIR Setpoint direction rising riSE Setpoint direction falling FALL 7. TSI Setpoint ramp OPEN Auto 0 to 400 s 8. TSD Setpoint ramp CLOSED 0 to 400 s 9. SFCT Setpoint function - Linear Lin - Equal percentage 1-25, 1-33, 1-50 - Equal percentage, reversed n1-25, n1-33, n1-50 - Freely adjustable FrEE 3) 10. SL0 Setpoint interpolation points . with free characteristic . 0.0 to 100.0 % 0 %, 5 %, 10 % ... 100 % 30. SL20 31. DEBA Controller dead zone Auto 0.1 to 10.0 % 32. YA Start of manipulated variable 0.0 to 100.0 % limit 33. YE End of manipulated variable 0.0 to 100.0 % limit 34. YNRM Manipulated variable scaling MPOS mech. travel/flow FLOW 35. YCLS "Tight shut-off" with man. var. - None no - Only up uP: - Only down do - Up and down uP do 36. YCDO Value for "tight shut-off", down 0.0 to 100.0 % 37. YCUP Value for "tight shut-off", up 0.0 to 100.0 % 38. BIN1 4) Function of binary input 1 None OFF NO Only signal on Block configuring bLoc1 Block config. and manual bLoc2 Drive valve to ye uP Drive valve to ya doWn Block movement StoP NC Only signal -on Drive valve to ye -uP Drive valve to ya -doWn Block movement -StoP Figure 59 Parameter table of the positioner
Parameter- Function Parameter values name 39. BIN2 4) Function of binary input 2 OFF None NO on Only signal uP Drive valve to ye doWn Drive valve to ya StoP Block movement NC Only signal -on Drive valve to ye -uP Drive valve to ya -doWn Block movement -StoP 40. AFCT5) Alarm function oFF None Mi:MA min : max: normal Mi:MA inverted Mi:Mi min : min: normal Mi:Mi inverted MA:MA max : max: normal MA:MA inverted 41. A1 Response threshold for alarm 1 0.0 to 100.0 42. A2 Response threshold for alarm 2 0.0 to 100.0 43. FCT 5) Function of alarm output Fault: normal inverted Fault + not Automatic: normal nA inverted - nA Fault + not Automatic + BI: normal nAb inverted - nAb (+ means logical OR operation) 44. TIM Monitoring time for setting of Auto fault signal "Control devia0 to 100 tion" 45. LIM Response threshold of fault Auto signal "Control deviation" 0.0 to 100.0 46. STRK Limit for travel integral 0 to 1.00E9 47. DCHG Limit for change in direction OFF 1 to 1.00E9 48. ZERO Limit for zero limit monitoring OFF 0.0 to 100.0 49. OPEN Limit for open limit monitorOFF ing 0.0 to 100.0 50. DEBA Limit for dead zone monitorOFF ing 0.0 to 10.0 51. PRST Preset (factory setting) no Strt oCAY 52. FSTY Safety setting: Parameterized safety FSVL setpoint FSSP Last setpoint FSAC Open exhaust air valve 53. FSTI Monitoring time for setting of 0 to 100 safety position 54. FSVL Safety setpoint 0 to 100.0 55. STNR Station number 0 to 126 56. IDENT Device mode (Ident No.) 0 - Multi-vendor 1 - Full functionality
1) 2)
Dimension
% %
% % %
s %
Parameter only visible with "turn" or "WAY"; if "turn" is selected, 33 cannot be set. Parameter not visible if 1. YFCT = "turn", "LWAY" or "-ncST" has been selected. 3) Interpolation points only appear if 9.SFCT=FrEE has been selected. 4) NC means: action with opened switch or Low level. NO means: action with closed switch or High level. 5) Normal means: High level without fault. Inverted means: Low level without fault.
98
Operation
setpoint processing setpoint master SDIR TSUF TSDO SFCT SLO..SL20 W
tight closing function YCLS YCDO YCUP
actual value processing position A D YFCT YAGL YWAY YA YB SFCT YNRM X + -Xd
adaptive five--point switch DEBA INIT A INIT M PRST
valve 1 valve 2
BE1
binary signal processing # # BIN1 BIN2
alarm detection FCT TIM LIM STRK DCHG ZERO OPEN DEBA alarm module
alarm module
A1 # # BE2 # limit value detection AFCT A1 A1
A2
Iy module
D A U
U I
Iy
Figure 60
Configuration block diagram
Normally adjustment of the first three following parameters is completely sufficient to enable a positioner to be operated by a drive. If you wish to become familiar with all details of the positioner, try out incrementally the effects of the remaining parameters by selective trials.
99
Operation
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 51 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.
1.YFCT
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 automatically 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 movement 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 adjusted if an NCS is to be connected to a linear actuator with the position measured directly (linear) from the NCS .
S YFCT = ncSLL
This must be adjusted if an NCS is to be connected to a linear actuator with the position converted by an arm into a part--turn movement.
100
Operation
NOTE After LWAY, ncSt, --ncSt or ncSL, ncSLL have been adjusted, both the following parameters 2. YAGL and 3. YWAY will not be displayed.
2.YAGL
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 8, page 25 and figure 9, page 26) must correspond to the angle value selected under 2.YAGL.
3.YWAY
Lever arm transmission
NOTE 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. Selection of the lever arm range: serves to display the real stroke after initialization. This parameter is only relevant for linear actuator. 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 transmission. The carrier must be set to the value of the actuator stroke, if this is not scaled to the next highest scaled value.
101
Operation 4.INITA Automatic initialization (see chapter 3.6, page 74) 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 49, page 85 to figure 52, page 88). 5.INITM 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 78 and chapter 3.6.6, page 83.
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 five seconds.
6.SDIR
Setpoint direction The setting of the setpoint direction serves to reverse the direction of action of the setpoint. It is used mainly in single--acting actuators with the safety position up.
7.TSI 8.TSD
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 setpoint on the positioner with the setpoint ramp. This bumpless manual/automatic switchover avoids excessive pressure increases on long pipelines. In the position TSI = Auto the slower of the two travel times determined during initialization is used for the setpoint ramp. TSD is then ineffective.
12.SFCT
Setpoint function (see figure 61, page 103) Non--linear valve characteristics can be linearized with this function and any flow characteristics simulated in linear valve characteristics.
102
Operation Six valve characteristics are stored in the positioner
S linear S equal percentage S equal percentage S equal percentage S inverse equal percentage S inverse equal percentage S inverse equal percentage S freely adjustable
10.SL0 to 30.SL20 Setpoint turning points
(9.SFCT = Lin, factory setting) 1 : 25 1 : 33 1 : 50 25 : 1 33 : 1 50 : 1 (9.SFCT = 1 : 25) (9.SFCT = 1 : 33) (9.SFCT = 1 : 50) (9.SFCT = n1 : 25) (9.SFCT = n1 : 33) (9.SFCT = n1 --: 50) (9.SFCT = FrEE)
A flow parameter can be assigned to the respective setpoint turning point 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.
x
100% 90 80
Limit for tight closing

Example: 35 YCLS = UP 37 YCUP = 85.0
x
100% 90 80 70 60 50 40 30 20 10 0

Example: 35 YCLS = UP 37YCUP = 75.0
Modulation range
60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 9 SFCT = Lin
9 SFCT = FrEE
Example: 35 YCLS = DO 36 YCDO = 15.0

Example: 35 YCLS = DO 36 YCDO = 10.0
Setpoint w
100 %
10
20
30
40
50
60
70
80
90
Modulation range Setpoint w

100 %
70
Setpoint turning point Example: 15 SL5 = 45.0
SL 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Figure 61
Setpoint characteristic, manipulated variable standardization and tight closing function
The setpoint turning point can only be input at You may only enter a strictly monotonous characteristic, and two consecutive vertex values must differ by at least 0.2 %.
103
Operation 31.DEBA Dead zone of the controller At dEbA = AUto the dead zone in automatic operation is adapted continuously 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. 32.YA 33.YE Manipulated variable limiting start (see figure 61 and 62) and Manipulated variable limiting end (see figure 61 and 62) With the parameters YA and YE the mechanical actuating distance (from stop to stop) is limited to the set values. In this way the mechanical setting range of the actuator can be limited to the active flow and the integral saturation of the commanding controller avoided.
.
34.YNRM
NOTE YE must always be set to greater than YA.
Manipulated variable standardization (see figure 61 and 62) With limiting of the manipulated variable (by 32.YA and 33.YE) two different scalings are produced for the display and the position feedback via the current output (MPOS or FLOW). The MPOS scaling shows the mechanical position (0 to 100 %) between the hard stops of the initialization. This is not affected by the parameters 32.YA and 33.YE. The parameters 32.YA and 33.YE are displayed in the MPOS--scale. The FLOW--scale is the standardization (0 to 100 %) to the range between 32.YA and 33.YE. The setpoint w (0 to 100 %) is always referred 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 appropriate scale on the display.
104
Operation
YNRM = MPOS or YNRM = FLOW Presetting: YA = 0% and YE = 100% 50%
4mA 0% 0mm YA = 0% 7.2mA 20% 16mm 10.4mA 40% 32mm 13.6mA 60% 48mm 16.8mA 80% 64mm 20mA 100% 80mm Input current (setpoint) X display W display Mechan. Stroke (actual value)
YE = 100%
Example: YNRM = MPOS with YA = 10 % and YE = 80 % 50%

4mA 0% 7.2mA 20% 10.4mA 40% 13.6mA 60% 16.8mA 80% 20mA 100% Input current (setpoint) X display W display Mechan. Stroke (actual value)
0mm
16mm YA = 10%
32mm
48mm
64mm YE = 80%
80mm
Example: YNRM = FLOW with YA = 10 % and YE = 80 %
50%
13.6mA 60% 80% 16.8mA 100% 20mA Input current (setpoint) X display W display Mechan. Stroke (actual value)
4mA 0%
7.2mA 20%
10.4mA 40%
0mm
16mm YA = 10%
32mm
48mm
64mm YE = 80%
80mm
Figure 62
Dependence on the stroke of standardization and on YA and YE in the example of an 80 mm linear actuator
35.YCLS
Tight closing with manipulated variable 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 YCDO or above YCUP (figure 61, page 103).
NOTE When the tight closing function is activated, monitoring for the control deviation is switched off for the respective overflow direction (YCDO: < 0 %, YCUP: > 100 %) for parameter 45. LIM. We recommend parameter 48. ZERO and 49. OPEN in the end positions for long--term monitoring.
105
Operation 36.YCDO 37.YCUP Value for tight closing, bottom Value for tight closing, up
NOTE YCDO must always be set to less than YCUP. The tight closing function has a fixed hysteresis of 1 %. 36.YCDO and 37.YCUP relate to mechanical stops and are independent of the settings of 6.SDIR and 38.YDIR.
38.BIN1 39.BIN2
Function binary input 1 and Function binary input 2 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

Binary messages of the periphery (e.g. pressure or temperature switches) can be read out via the communication interface or lead to responding of the fault message output by OR linking with other messages.
S BIN1 = bLoc1
The Configuration mode is locked to prevent it being adjusted (e.g. by a wire jumper between terminals 9 and 10).
S BIN1 = bLoc2
If binary input 1 has been activated, manual operation is also locked in addition to the Configuration mode.
S BIN1 or BIN2 = uP or doWn (contact closes) or --uP or --doWn

(contact opens). When the binary input is activated, the actuator drive controls the actuator in automatic mode through the values held in YA and YE.
S BIN1 or BIN2 (contact closes) = StoP or --StoP (contact opens).

With activated binary input the piezo--valves are blocked in automatic mode and the actuator remains in the last position. Leakage messages can then be executed without initialization function.
S BIN1 or BIN2 = oFF (factory setting)

no function special function of BI1: If the binary input 1 is activated in P manual operation by a jumper between terminals 9 and 10, , when the operating mode key is pressed the firmware version will be displayed. 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.
106
Operation 40.AFCT Alarm function There are 6 setting capabilities available: 1. 2. 3. 4. 5. 6.

Limit A2 A1 = 48 A2 = 52 Travel = 45 Travel = 50 Travel = 55 A1 = 48 A2 = 52 Travel = 45 Travel = 50 Travel = 55 A1 = 52 A2 = 48 Travel = 45 Travel = 50 Travel = 55 A1 = 52 A2 = 48 Travel = 45 Travel = 50 Travel = 55
Min Min Max --Min --Min --Max
Max Min Max --Max --Min --Max
(inverted reporting) (inverted reporting) (inverted reporting)

Alarm module A1 A2 SIMATIC MIN MAX
AFCT = MIN / MAX Activated Activated AFCT = --MIN / --MAX Activated Activated Activated Activated Activated Activated Activated Activated Activated
A1 way MIN MAX
MIN
MIN
MAX
MAX
AFCT = MIN / MAX Activated Activated Activated Activated Activated Activated Activated
--MIN
--MAX
--MIN
--MIN
AFCT = --MIN / --MAX Activated Activated Activated Activated
--MAX
--MAX
Please note: the two limit values in the control system can be individually evaluated only when adjusting 1 or 4, because in the status reports READBACK and POS_D (chapter 5.3.2 page 141) the two limit values A1 and A2 are or linked. the response of the two limit values in the status reports READBACK and POS_D cannot be recognized if the positioneris in manual mode. the direction of control action shown on the alarm module is reversed. the direction of control action is also reversed if A1 is set to greater than A2. the hysteresis of the limit value is 1 % as standard. in the factory setting OFF the output of both alarms A1 and A2 is deactivated.
107
Operation 41.A1 42.A2 Response threshold alarm 1 and Response threshold alarm 2 The alarm thresholds are related to the mechanical path (MPOS--scale). 43. FCT Function of the fault message output If fault messages are used as a monitor for control non--conformities over a period of time, they will be triggered in addition by the following events also:
S Power failure S Processor fault S Actuator fault S Valve fault S Compressed air failure S Responses of the limit values 46 to 50
Note that the fault message cannot be switched off, however it can be suppressed (factory setting), if the actuator is set to non--automatic mode. If it is wished to generate fault messages here also, the parameter FCT must be set to nA. In addition there is also the facility to alternate the fault message using the status of the binary inputs. For this, set the parameter FCT to nAb. Select the setting -- if the fault message is to be sent inverted on the alarm module or SIA module. For more information on fault messages, see chapter 4.5.3 Online---Diagnosis, page 113. 44. TIM Monitoring time for setting the fault messages The set value(s) serves as a specification for the time within which the positioner must have reached the controlled state. The corresponding response threshold is specified with 45. LIM. The fault message output is set on exceeding the set time.
NOTE If the control function to close tightly is activated, for parameter 45. LIM the monitoring of the control deviation in each overrun direction (YCDO: < 0 %, YCUP: > 100 %) is disabled. This function is particularly useful for valves with a soft seating. For long term monitoring of the end--stop positions, we recommend activating the parameters 48. ZERO and 49. OPEN. For more information on fault messages, see chapter 4.5.3 Online-Diagnosis, page 118.
108
Operation 45. LIM Response threshold of the fault message Here a value (%) can be set for the permissible variable of control error for releasing the fault message. If the parameters 44. TIM and 45. LIM are both set to Auto (factory setting), the fault message is set if the slow step zone is not reached within a certain time. This time is 2 times the initialization travel time within 5 to 95% of the actuating path and 10 times this time outside 10 to 90% of the actuating path. When the tight closing function is activated, monitoring for the control deviation is switched off for the respective overflow direction (YCDO: < 0 %, YCUP: > 100 %) for parameter 45. LIM. We recommend parameter 48. ZERO and 49. OPEN in the end positions for long--term monitoring. 46. STRK Limit value for monitoring the travel integral (number of strokes) A limit value for the way integral can be set here. If the way integral exceeds the limit value, the fault message output (optional) is activated. This function enables a preventive maintenance of the fitting, see also chapter 4.5 Diagnostics, page 113. This monitoring function can not be deactivated. 47. DCHG Limit value for monitoring the changes of direction A limit value for the direction change counter can be set here. If this counter exceeds the limit value, the fault message output is activated. This function enables a preventive maintenance of the fitting, see also chapter 4.5 Diagnostics, page 113. This monitoring function can be deactivated with the OFF setting (factory setting). 48. ZERO Tolerance value for monitoring the bottom hard stop With this value a limit value (in percent related to the total mechanical distance) can be preset for the monitoring of the bottom hard stop. If this tolerance value is exceeded or dropped below of, the fault message output (optional) is activated. This function detects when the bottom stop has changed by more than the specified tolerance related to its initialization value. Monitoring takes place when the valve is in tight closing bottom. Activation of the tight closing bottom function (parameter 35.YCLS) is therefore a prerequisite. The fault message remains activated until either a subsequent monitoring remains within the tolerance or a new initialization is performed. This monitoring function can be deactivated with the OFF setting (factory setting). See also chapter 4.5 Diagnostics, page 113.
109
Operation 49. OPEN Tolerance value for monitoring the top hard stop With this value a limit value (in percent related to the total mechanical distance) can be preset for the monitoring of the top hard stop. If this tolerance value is exceeded or dropped below of, the fault message output (optional) is activated. This function detects when the top stop has changed by more then the specified tolerance related to its initialization value. Monitoring takes place when the valve is in tight closing top. Activation of the tight closing top function (parameter 35.YCLS) is therefore a prerequisite. The fault message remains activated until either a subsequent monitoring remains within the tolerance or a new initialization is performed. This monitoring function can be deactivated with the OFF setting (factory setting).
NOTE But the monitors of the bottom and top hard stop do not only react to valve errors. Adjustment of the position feedback is also detected as an error if the tolerance values are exceeded as a result.
50. DEBA
Limit value for monitoring the dead zone adaptation The automatic adaptation of the dead zone can be monitored with this value (%). If the dead zone exceeds the set value, the fault message output is activated. Prerequisite for this function is the setting of the parameter31.DEBA = Auto. This monitoring function can be deactivated with the OFF setting (factory setting).
51.PRST
Preset Establishing the factory setting and resetting the initialization.
NOTE The positioner must be re--initialized after Preset. All previously determined maintenance parameters are cleared.
52.FSTY
Safety position This parameter is used to move the actuator into a set safety position if communication fails.
110
Operation Three settings are possible
S FSVL
the actuator must continue to control with the parameterized safety setpoint. This value will remain effective even after a loss of electrical power.
S FSSP
the actuator must continue to control with the last effective setpoint
S FSAC (factory setting)

here this outlet air valve is opened and the single--acting actuator moves to its final position by spring power. 53.FSTI Monitoring time for moving to the safety position If communications are lost, the positioner will move to the safety position after expiry of the set period of time. 54.FSVL Safety setpoint Specification for the safety setpoint Note that the fail safe value FSVL of 0 % always refers to the mechanical position taken up when the actuator is depressurized. This is particularly important if the parameter SDIR is set to FALL (falling characteristic of the setpoint) and then at 0% setpoint 100 % mechanical position is expected. 55.STNR Station number So that the devices on the bus can be addressed separately, a separate station number must be set on each device. 56.IDENT Device operating mode The SIPART PS2 PA positioner recognizes two device operating modes for its behavior in relation to DP masters class1: [0] profile conformity: exchangeable for positioners from other suppliers to PROFIBUS PA profile 3.0 [1] profile conformity with extensions: full scope of function of SIPART PS2 PA (condition as delivered)
111
Operation
NOTE Each device operating mode has a particular device master data file (GSD) assigned to it. If the configuration of your PROFIBUS PA channel does not correspond to the device operating mode set, the device will not pick up the cyclic data exchange. The station number and device operating mode cannot be changed during communication with a master of class 1.
Successful establishment of communications with a cyclical master (chapter 5.3 page 139) can be recognized by the positioner responding to the set value from the master. A flashing decimal point in the top line of the display denotes an acyclic master (chapter 5.2 page 131).
112
Operation
4.5
Diagnosis
4.5.1 Diagnostic display

You go to the diagnostic display from automatic or manual operation by simultaneously pressing all three keys for at least two seconds. The following table shows an overview of the displayable values. In the third column the corresponding English term from which the abbreviation is derived is shown next to the German meaning unless this is self explanatory. The diagnostic display has a similar structure to in the Configuration operating mode. the top line shows the value of the diagnostic variable, the bottom line the number and abbreviation of the displayed variable. The respective next diagnostic value can be selected with the operation . By pressing and holding the operation mode key and mode key additionally pressing the decrement key diagnostic values in reverse order. you can select the for
Certain values can be set to zero by pressing the increment key at least 5 seconds. This is noted in the last column in the table.
Some diagnostic values may be greater than 99999. In this case the display switches to exponential display. Example: the value 1234567 is displayed as 1.23E6.
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Abbrevia-tion STRKS CHDIR CNT A1CNT A2CNT HOURS WAY TUP TDOWN LEAK P0 P100 IMPUP IMPDN DBUP DBDN SSUP SSDN TEMP TMIN TMAX T1 T2 T3 T4 T5 T6 Meaning Number of strokes (Strokes) Changes of direction (Changes of Direction) Fault counter (Counter ) Alarm counter 1 (Alarm 1 Counter) Alarm counter 2 (Alarm 2 Counter) Operating hours (Hours) Determined actuating path (Way) Travel time up (Travel Time Up) Travel time down (Travel Time Down) Leakage (Leakage) Potentiometer value below stop (0%) Potentiometer value bottom stop (100%) Impulse length up (Impulse Length Up) Impulse length down (Impulse Length Down) Dead zone up (Dead Band Up) Dead zone down (Dead Band Down) Slow step zone up (Slow Step Zone Up) Slow step zone down (Slow Step Zone Down) Current temperature Minimum temperature (drag pointer) Maximum temperature (drag pointer) Number of operating hours in Temperature range 1 Number of operating hours in Temperature range 2 Number of operating hours in Temperature range 3 Number of operating hours in Temperature range 4 Number of operating hours in Temperature range 5 Number of operating hours in Temperature range 6 Displayable values 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 130 0 to 1000 0 to 1000 0.0 to 100.0 0.0 to 100.0 0.0 to 100.0 2 to 100 2 to 100 0.1 to 100.0 0.1 to 100.0 0.1 to 100.0 0.1 to 100.0 --40 to 85 --40 to 85 --40 to 85 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 Unit -----Hours mm or _ s s % % % ms ms % % % % _C _C _C Hours Hours Hours Hours Hours Hours Rest poss. x x x x x
113
Operation
No. 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Abbrevia-tion T7 T8 T9 VENT1 VENT2 STORE PRUP PRDP WT00 WT05 WT10 WT30 WT50 WT70 WT90 WT95 Meaning Number of operating hours in Temperature range 7 Number of operating hours in Temperature range 8 Number of operating hours in Temperature range 9 Number of cycles pre--controlvalve 1 Number of cycles pre--controlvalve 2 Store current values as last maintenance (press increment key for 5 s) (Store) Prediction up Prediction down Number of operating hours in distance class WT00 Number of operating hours in distance class WT05 Number of operating hours in distance class WT10 Number of operating hours in distance class WT30 Number of operating hours in distance class WT50 Number of operating hours in distance class WT70 Number of operating hours in distance class WT90 Number of operating hours in distance class WT95 Displayable values 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 -1 to 40 1 to 40 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 0 to 4.29E9 Unit Hours Hours Hours -----Hours Hours Hours Hours Hours Hours Hours Hours x x x x x x x x Rest poss.
Table 1
Overview diagnostic values
4.5.2 Meaning of the diagnostic values
1 STRKS
Number of strokes (total valve travel) The actuator movements during operation are totaled and can be read here as number of strokes. Unit: 100% stokes, i.e. the distance between 0 to 100 % and backwards. The value is written every 15 minutes in a non--volatile memory. It can be reset to zero with the . increment key
2 CHDIR
Number of direction changes Every change in direction leaving the dead zone is noted in the controller and added to the number of changes of direction. The value is written every quarter of an hour in a non--volatile memory. . It can be reset to zero with the increment key
3 CNT
Fault counter Every fault is noted in the controller and added to the number of fault messages. The counter can be reset to zero with the increment key-- .
114
Operation 4 A1CNT 5 A2CNT Alarm counter 1 and Alarm counter 2 Responses of alarm 1 and alarm 2 are counted with these two counters. The prerequisite is the activation of the alarms with the parameter 40.AFCT. The counters can be reset to zero with the . increment key
6 HOURS
Operating hours The operating hours counter is updated every hour as soon as the positioner has been supplied with electrical power.
7 WAY
Determined actuating way This value indicates the actuating way determined during initialization according to the display at the end of an initialization. Prerequisite in linear actuator: Specification of the lever arm with the parameter 3.YWAY.
8 TUP 9 TDOWN
Travel time up and travel time down These values show the travel times which have been determined during initialization. The unit is seconds.
10 LEAK
Leakage The value of the leakage measurement in %/min. can be read off here. This measurement may take place during the initialisation phase or here in this diagnostic menu. The leakage measurement starts when the increment key is pressed for more than 5 s and then released. During the measurement, the value of the current position or tESt is displayed interchangeably in the upper line of the display. After 1 minute, the position change can be read off in %/minute. Note that the leakage measurement may only be started if the positioner is in manual mode (MAN). If this is not the case, noMAn is displayed in the upper line of the display.
11 P0 12 P100
Potentiometer value bottom stop and Potentiometer value top stop These two values indicate the measured values of displacement measurement (potentiometer) at the bottom and top hard stops as determined in automatic initialization. In manual initialization the values of the manually reached limit positions are indicated here.
115
Operation 13 IMPUP 14 IMPDN Impulse length up and Impulse length down During initialization the smallest impulse lengths are determined with which a movement of the actuator can be achieved. They are determined and displayed here for the Up--direction and the Down--direction. These two parameter can be tuned for special applications (see chapter 4.7 page 126). 15 DBUP 16 DBDN Dead zone up and Dead zone down Here the dead zone of the controller is displayed in Up--direction or in Down--direction. The values correspond either to the manually set value of the parameter 34.DEBA or the value adapted automatically by the instrument when DEBA has been set to Auto. 17 SSUP 18 SSDN Short step zone up and Short step zone down The short step zone is the range of the controller in which pulse--shaped control signals are output. The impulse length here is proportional to the control error. If the control error is outside the short step zone, the valves are controlled in continuous contact. These two parameter can be tuned for special applications (see chapter 4.7 page 126). 19 TEMP Current temperature Current temperature in the positioner housing The sensor is on the electronics board. The temperature display can be switched between _C and _F by pressing the decrement key. 20 TMIN 21 TMAX Minimum temperature (drag pointer) and Maximum temperature (drag pointer) The minimum and maximum temperature inside the housing is determined and stored continuously in a kind of drag pointer and can only be reset in the factory.
116
Operation 22 T1 to 30 T9 Number of operating hours in temperature range T1 to T9 Statistics how long operation takes place in which temperature ranges is kept in the instrument. To do this, the measured temperature over one hour respectively is averaged and incremented in the counter which is assigned to the corresponding temperature range every hour. This enables you to draw conclusions about the past operating conditions and thus the whole fitting. The temperature ranges are divided up as follows: T1 Tempera-ture range [_C] --30 T2 --30 <--15 T3 --15 <0 T4 0 < 15 T5 15 < 30 T6 30 < 45 T7 45 < 60 T8 60 < 75 T9 75
31 VENT1 32 VENT2
Number of cycles pre--control valve 1 and Number of cycles pre--control valve 2 These two counters add up the control processes of the pre--control valves.
33 STORE
Store maintenance data for at A store function is triggered by pressing the increment key least 5 seconds. Here the diagnostic data 7 to 17 are stored in a non--volatile memory as Data of the last maintenance. These diagnostic data are selected values, the changes of which can provide information on the mechanical wear of the valve. Normally this function is operated via PDF (chapter 5.2.1, page 131), menu item Instrument!Store maintenance info. It is possible to compare the data of the last maintenance with the current data via PDM.
34 PRUP 35 PRDN
Prediction up Prediction down see chapter 4.7, page 126.
NOTE All diagnostic values are updated every quarter of an hour to a non-volatile memory, so that in the event of a loss of electrical power only the events of the last hour will be lost.
117
Operation 36 WT00 to 43 WT95 Number of operating hours in distance class WT00 to WT95 If the positioner is in automatic mode, statistics are constantly kept for how long a valve or a flap has been operated in which section of the setting range. To do this, the total setting range (0 to 100 %) is divided into 8 sections (distance classes). The positioner continuously registers the current position and increments the operating hours meter assigned to the corresponding section (distance class) every hour. This allows returns to previous operating conditions and is particularly used to evaluate the control properties of the control circuit or the entire fitting. The setting range is divided as follows: Distance class Setting range section WT00 <5% WT05 5 % <10 % WT10 WT30 WT50 WT70 WT90 WT95 10 % 30 % 50 % 70 % 90 % 95 % <30 % <50 % <70 % <90 % <95 %
You can collectively set the 8 operating hours meters to zero by pressing the increment key (for at least 5 seconds). TIP: As the distance classes at the end of the diagnostic menu have the numbers 36 to 43, in addition to the operating mode key press the decrement key repeatedly. This takes you quickly to the diagnostic numbers 36 to 43.
4.5.3 Online--diagnosis
Some important variables and parameters are monitored continuously during operation. In the Configuration operating mode you can configure this monitoring so that the fault message output is activated when a certain event such as exceeding a limit value occurs. The following table shows which events can activate the fault message output, how the parameters must be set for this event to be monitored, when the fault message disappears again and where the possible causes of the fault lie. In automatic and manual operation response of the fault message output on the display shows which is the fault message trigger. The two digits at the bottom left indicate the corresponding error code. If several triggers occur at the same time, these are displayed cyclically.
Error code 1 Event Parameter setting Remaining con- always active trol error Instrument not in automatic mode 43. FCT= nA or = nAB Fault message disappears when ... ... the control error has disappeared again ... the instrument is brought into automatic mode Possible causes Compressed air missing, actuator fault, valve fault (e.g. blockade). The instrument is configured or is in manual operation.
118
Operation
Error code 3 Event Parameter setting Binary input BI1 43. FCT= nAB or BI2 active and binary function BIN1 or BIN2 to on Fault message disappears when ... ... the binary input is no longer activated Possible causes The contact connected to the binary input has become active (e.g. stuffing box monitoring, excess pressure, temperature switch). The total distance traveled by the actuator exceeded the set limit value. The number of changes of direction exceeded the set limit value. Wear of the valve seat, deposits or foreign bodies in the valve seat, mechanical maladjustment, friction clutch maladjusted. Wear of the valve seat, deposits or foreign bodies in the valve seat, mechanical maladjustment, friction clutch maladjusted. Increased stuffing box friction, mechanical lots of the position feedback
Limit value Number of strokes exceeded Limit value change of direction exceeded Limit value bottom hard stop exceeded
46. STRKOFF
... the stroke counter is reset or the limit value increased ... the change of direction counter is reset or the limit value increased ... the deviation of the stop disappears or the instrument is re-initialized
47. DCHGOFF
48. ZEROOFF 35.YCLS = do or up do
Limit value top hard stop exceeded
49. OPENOFF 35. YCLS = up or up do
... the deviation of the stop disappears or the instrument is re--initialized
Limit value dead zone adaptation exceeded
50. DEBAOFF 31.DEBA = Auto
... the limit value is dropped below again
Table 2
Events which can activate the fault message output
Explanations of column Error codes: 1 Monitoring of control error In automatic operation the error between setpoint and actual value is monitored continuously. The fault message is activated with unchanged control error according to the setting of the parameters 44. TIM, monitoring time for setting the fault messages and 45. LIM, response threshold of the fault message. As soon as the control error drops back below the response threshold, the fault message is reset. 2 Monitoring automatic operation A fault message is generated when the instrument is not in the automatic mode at the appropriate parameter setting 43. FCT. In this way the control system can be warned for example when the instrument has been switched to manual operation or Configuration on site.
119
Operation 3 Binary input BI1 or BI2 active A fault message is generated when the binary input is activated at the the corresponding setting of the parameter 43. FCT, function of the fault message output and the parameter 38.BIN1, function binary input 1. This may be a switch for stuffing box monitoring, a temperature switch or a limit value switch for example. Binaryinput 2 (on the alarm module option) can be configured in the same way. 4 Monitoring of number of strokes 5 Monitoring of number of changes of direction The two values number of strokes and number of changes of direction are compared continuously with the limit values which are specified with the parameters 46. STRK and 47. DCHG. The fault message output responds when exceeded. Both functions can be deactivated with the parameter setting OFF. 6 Monitoring of the bottom hard stop (valve seat) 7 Monitoring of the top hard stop Monitoring of the bottom hard stop is activated when the parameter 48. ZERO has a valueOFF. Errors of the valve seat can be detected with this function for example. Exceeding of the limit value may hint at deposits or foreign bodies in the valve seat. Exceeding the limit value may be caused by wear of the valve seat. Mechanical maladjustment of the position feedback may also trigger this error message. Monitoring takes place every time the valve is in position tight closing bottom. The current position is compared with the one determined during initialization as a bottom end stop. Activation of the tight closing bottom function (parameter 39.YCLS) is therefore a prerequisite. Example: 3 % is set as a value. Normally the setting 0 % is adopted when closed. If a value >3 % or <--3 % is determined instead, a fault is reported. The fault message remains activated until either a subsequent monitoring remains within the tolerance or a new initialization is performed. The deactivation of the monitoring (48. ZERO=OFF) also clears any existing fault message. This monitoring function supplies no useful results when the stops have not been determined automatically in initialization but the limits set manually (manual initialization 5.INITM). An appropriate diagnosis is made for the top hard stop. The limit value for this is set with the parameter 49. OPEN. Activation of the tight closing top function (parameter 35.YCLS) is therefore a prerequisite.
120
Operation 8 Monitoring of the dead zone adaptation If the dead zone increases unproportionally in operation in automatic adaptation of the dead zone (parameter 31.DEBA = Auto) this points to an error in the system (e.g. a marked increase in stuffing box friction, play in the displacement detection, leakage). Therefore a limit value can be specified for this value (50. DEBA, limit value for dead zone monitoring) which activates the fault message output when it is exceeded.
121
Operation
4.6
Meanings of other display texts
Notes on the tables: nn / stands for variable numerical values Fault symbol (slash): the texts to the left and right of the slash flash alternately
Reports before initializing (first commissioning):

Upper line Lower line Meaning/Cause Actions
CPU START P nnn.n
x x
Report after connecting the electrical auxiliary power Potentiometer voltage for non-initialized positioner (P manual mode) (Setting actual value in % of measurement range) Measurement range exceeded, potentiometer is in the inactive zone, transmission ratio selector or effective lever arm are not matched to the actuator travel
S Wait S Check using the + and -- keys whether the overall actuator travel can be traversed without ever P------ being displayed Perform initialization Set transmission ratio selector to 90 degrees, in particular for part--turn actuators Match effective arm length for thrust drives to measurement range Start initialization
P------
S S
S S
NOINI
Positioner not initialized
Messages during initialization:

Lower line Upper line Meaning/Cause Actions
P---RUN 1 RUN 2 RUN 3 RUN 4 RUN 5
x x x x x x
See above Initialization started, part 1 active (direction of control action being determined) Initialization part 2 active (actuator travel check and determination of the end stops) Initialization part 3 active (determination and display of positioning times) Initialization part 4 active (determination the minimum positioning increment length) Initialization part 5 active (optimization of the behavior on transients) only during manual initialization first end position can be moved to
See above S Wait Wait Wait Wait Wait until FINSH is displayed (initialization completed successfully) Press operating mode key briefly to acknowledge or longer to quit configuration mode Move to first end position using the + or -- key Press operating mode key to acknowledge
S S
YEND1
S S
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Operation
Lower line Upper line Meaning/Cause Actions
YEND2
only during manual initialization second end position can be moved to x only during manual initialization End position or measurement span are outwith the permitted measurement range
S S S
Move to second end position using the + or -- key Press operating mode key to acknowledge Using + and -- keys move to the other end position and press opera-ting mode key to acknowledge, or Adjust friction clutch until ok is displayed and press operating mode key to acknowledge or Interrupt initialization by pressing the operating mode key, switch to P manual mode and correct the actuator travel and position sensing Press operating mode key to acknowledge, the remaining steps (RUN1 to FINSH) will run through automatically Ensure compressed air is sufficient Open any choke(s) Re--start initialization With friction clutch set to P 4.0 to P 9.9 ( >0< ) Continue using the + or -- key For thrust drives, use the + and -- keys to bring the arm to the correct angle on the spindle Press operating mode key briefly to acknowledge (initialization will resume) Increase effective arm length with linear actuators or set transmission ratio selector to 90 degrees Press operating mode key briefly to acknowledge Re--start initialization Use the + and -- keys to move into the range of 90 to 95% Press operating mode key briefly to acknowledge Reduce effective arm length for thrust drives or set transmission ratio selector to 33 degrees Press operating mode key briefly to acknowledge Re--start initialization Wait, or To change the positioning time interrupt initialization with the -- key, or Activate the leakage test with the + key
RANGE
ok
only during manual initialization permitted measurement range for end positions reached x
RUN 1/ ERROR d___U SEt MIDDL x
Fault in RUN 1 S no movement e.g. no compressed air S S Bar display of the zero point S Zero point is outwith the tolerance range S Friction clutch misaligned; P 50.0 S no displayed when arm horizontal S
UP >
UP -- tolerance range exceeded or inactive zone of potentiometer entered
S S S S S
90_95
Only applies to part--turn drives: Actuator travel is not within range 90 to 95% Measurement span Up--Down is insufficient
U--d>
S S S S
U nn.n D-->U
x x
Display the positioning time Up
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Operation
Meaning/Cause Actions
d nn.n U-->d
x x
Lower line
Upper line
Display the positioning time Down
S S
Wait, or To change the positioning time interrupt initialization with the -- key, or Activate the leakage test with the + key Positioning time can be adjusted by varying the choke(s) Use the -- key to repeat the determination of the positioning speed Continue using the + key Wait 1 minute Continue with the + key Remove leakage if value is too high. Continue with the + key Press operating mode key briefly to acknowledge or longer to quit configuration mode
S NOZZL x Actuator stationary (initialization inter- S rupted with the -- key during actuation speed display) S
TESt LEAKG nn.n
x x x x x x
_oMIN
nn.n FINSH
Leakage test active initialization interrupted with the + key during actuation speed display) Value and units of results of the leakage test Initialization completed successfully, with display of the actuator travel or positioning angle as appropriate
S S S S S S
Reports on leaving configuration operating mode:

Manual mode Upper line P manual mode Meaning/Cause Actions Lower line Automatic
Cn VER Error SLnn MA ---- ----
x x x x x x
Software version
Wait Correct value Press operating mode key to change to automatic mode Check station address Start communication Wait Exchange electronics Start initialization
Monoticity transgression of S the free characteristic line at support point n No communication in S manual mode Air discharge valve will be opened S S S S S
CPU START HW / ERROR NOINI nnn.n
x x x x x x x x
Message after applying auxiliary electrical power Fault in the hardware Positioner not initialized Setting actual value [in %] for initialized positioners. Flashing decimal point indicates communication with a class 2 master Automatic mode (nn = setpoint) Manual mode (nn = setpoint)
AUnn MAnn
x x
Press operating mode key to change to automatic mode
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Operation
Manual mode Upper line P manual mode Meaning/Cause Actions
Lower line x
Automatic x
FS ---- ----
Fail safe (air discharge valve opened). Possible causes S No communication with master S Target mode set to MA Master sending incorrect status Set to parameterized fail safe setting (cause: see above) Positioner is in manual mode
S
S S
S S
Correct station address Set target mode to automatic with class 2 master Send status 0x80 (good) see above Set target mode to automatic with class 2 master Send status 0x80 (good) Set target mode to automatic with class 2 master Send status 0x80 (good) Set target mode to automatic with class 2 master Send status 0x80 (good) Adjust friction clutch so that when moving the drive the actual value display remains within 0.0 to 100.0 or Change transmission ratio selector or Carry out factory setting (preset) and initialization
FS nn MM nn
x x
x x
S LO nn x x Positioner is in local over- S ride mode S OS ---x x Positioner is in out of service mode S
S oFL / 127.9 x x x Display range exceeded. S Possible causes: S Friction clutch or S Transmission ratio selector changed or S Positioner installed S without reinitialization, having previously been S fitted to another drive Actuator stopped by binary input Actuator moved by binary input to upper stop Actuator moved by binary input to lower stop
EXSTP EX UP EXDWN
x x x
x x x
125
Operation
4.7
Optimization of the control data

The data automatically determined during initialization for control quality are optimized for short duration commands with small overshoots. In special cases (e.g. extremely small and specially quick actuators or when operating with boosters) it can however occur that these data need to be revised to achieve quick responses or heavy damping. The following six parameters are available for this purpose:
This determines for any sense of actuation the smallest drive 13 Pulse length up 14 Pulse length down movement pulse length. The optimum value is dependent particularly on the volume of the drive. Small values will lead to small actuation increments and frequent control drive activations. Note that if the value is too small no movement will result. If drive volumes are large, then it is better to use larger actuation increments. Note also that large actuation increments will still lead to large movements for small drives.
17 Short step zone up 18 Short step zone down The short step zone is the range in which the control variation between the fast step zone and the dead band. In this zone the drive is activated in pulses. If the value is small, even small changes of setpoint will evoke relatively large positioning speeds and can thus lead to overshoots. If the value is large, the overshoots will be reduced, particularly on large changes of setpoint but will lead to slow positioning speeds, particularly as the target setpoint is approached closely.
34 Prediction up 35 Prediction down
These parameters operate on the damping factor and have the effect of adjusting the control dynamics. If the value is small, responses will be quick but with overshoots. If the value is large, response will be slow but without overshoots.
It is recommended that the firstly an automatic initialization is performed and only thereafter that the positioner parameters are matched to any special requirements. TIP: So as to have a fixed reference value, it is advantageous for special control optimization to set a fixed value for the dead zone (parameter DEBA) instead of Auto. The above parameters are usually selected from the diagnostics menu and activated for general adjustment by pressing the increment or decrement key. Any adjustment to a parameter will be immediately effective. This means the effect of the new values on the control results can be immediately tested. On leaving the diagnostic menu the activation of the parameter for adjustment will be deactivated again.
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Operation
4.8
Fault correction
Diagnostics indicator
see In which operating mode did the fault occur? Initialization Manual mode and automatic mode Under which circumstances and conditions did the fault occur? Wet environment (e.g. heavy rain or constant condensation) Vibrating fittings Under impact or shock (e.g. steam jets or breakaway flaps) Damp (wet) compressed air Dirty (contaminated with solid particles) compressed air Constantly (reproducibly) Sporadically (not reproducible) Usually after a certain operating period Table
3 4 4 4 5 4 4 3 7 4 5 7 5 4 5 6 7 5 6 7
When does the fault occur?
Fault description (symptoms) Positioner comes to a halt in RUN 1
Possible cause(s) Initialization started from the final stop and Reaction time of max. 1 min. not waited Network pressure not connected or too low Transmission ratio selector and parameter 2 (YAGL) and true stroke did not correlate Stroke on the lever incorrectly set Piezo valve(s) do not switch (see Table 4) Positioning times for up and down exceeded
Corrective actions Up to 1 min. waiting time required Do not start initialization from an end stop Confirm network pressure
Positioner comes to a halt in RUN 2
Check settings: See leaflet: Figure Device view (7) and parameters 2 and 3 Check stroke setting on the lever see Table 4
Positioner comes to a halt in RUN 3
Positioner comes to a halt in RUN 5, does not reach FINISH (waiting time > 5 min)
Play in the positioner, actuator, fittings system
Open restrictor fully and/or set pressure PZ(1) to the highest permissible value Use booster if necessary part--turn actuator: Check seating of the stud screw of the coupling wheel Linear actuator: Check seating of the lever on the positioner shaft Correct any other play between the actuator and the fittings
Table 3
Events which can activate the fault message output
127
Operation
Fault description (symptoms) CPU test blinks in the display of the positioner (ca. every 2 secs) Piezo valve(s) do not switch Actuator cannot be moved in manual or automatic mode, or only in one direction Possible cause(s) Water in the valve manifold (from wet compressed air) Corrective actions At the early stages the fault can be corrected by subsequent operation with dry air (when necessary, in a temperature cupboard at 50 to 70 C) Otherwise: Repair see page 160.
Dampness in the valve manifold
Piezo valve(s) do not switch (no soft clicking can be heard when the + or -- keys are pressed in manual mode)
Screw between cover hood and the valve manifold is not tight or the hood is jammed Dirt (swarf, particles) in the valve manifold
Tighten screw, or release cause of jamming when necessary Repair see page 160. New device with integrated fine filter which can be replaced and cleaned Clean all contact surfaces with alcohol: when necessary bend the valve manifold contact springs back into place
Deposits on the contact(s) between the electronics board and the valve manifold can occur from abrasion through continuous stresses from strong vibrations
Table 4
Fault description (symptoms) Actuator does not move
Possible cause(s) Compressed air < 1.4 bar Restrictor(s) closed down (screw(s) at the right end stop)
Corrective actions Set inlet air pressure to > 1.4 bar Open restrictor screw(s) (see leaflet, Figure View of device (6)) by turning to the left
Piezo valve(s) do not switch (although a soft clicking can be heard when the + or -keys are pressed in manual mode)
Dirt in the valve manifold
Repair see page 160. New device with integrated fine filter which can be replaced and cleaned Fix leak in the actuator and/or supply line If the actuator and supply line are intact: Repair see page 160 or new device See above
One piezo valve constantly switches in stationary automatic mode (constant setpoint) and in manual mode
Pneumatic leak in the positioner, actuator system, start leak test in RUN 3 (Initialization)
Dirt in the valve manifold (see above)
Table 5
128
Operation
Fault description (symptoms) Possible cause(s) Corrective actions Reduce static friction or increase dead zone of positioner (parameter dEbA) until the oscillating movements stop. Linear actuator: Check seating of the stub screw of the coupling wheel part--turn actuator: Check seating of the lever on the positioner shaft Correct any other play between the actuator and fittings Increase positioning times by means of restrictor screws If fast positioning times are required, increase dead zone (parameter dEbA) until the oscillating movements stop.
The two piezo valve constantly switch alternately in stationary automatic mode (constant setpoint), actuator oscillates around a middle point
Static friction on the packing glands of the fittings or actuator too high Play in the positioner, actuator, fittings system
Actuator too fast
Table 6
Fault description (symptoms) Zero point shifts sporadically (> 3 %)
Possible cause(s)
Corrective actions Shut off the cause of the shocks Reinitialize the positioner Upgrade see page 160 mount reinforced friction clutch (order number C73451--A430--D14) Check electrical supply
Such high accelerations have occurred through impact or shock that the friction clutch has shifted (e.g. through steam jets in the steam pipelines)
Device function breaks Insufficient electrical supply down totally: no disWith very high continuous stresses play by vibrations, the following can occur: Screws of the electrical terminals can loosen The electrical terminals and/or electronic modules can be shaken loose
Tighten screws and secure with sealing varnish Repair see page 160 Prevention: Mount the positioner on rubber metal
Table 7
129
Operation
130
Functions/operation via PROFIBUS PA
5.1
System integration
The positioner can be controlled and monitored by acyclic and cyclic data transmission by a control system (master). So that the positioner can be in communication as slave with the master, its address must be set up in advance. The PROFIBUS address is factory set to 126. This can be changed at the device (chapter 4.4 page 97) or with a parameter tool such as the SIMATIC PDM or by HW configuration over the bus.
5.2
Acyclic data transmission

Acyclic data transmission is mainly used for transmitting parameters during commissioning, maintenance, batch processes, or for displaying further variables which do not take part in cyclic user data traffic. Data traffic occurs between a class--2 Master and the field device with so--called C2 connections. So that several class--2 Masters can simultaneously access the same positioner, the device supports up to four C2 connections. However, you must ensure that they are not writing to the same data. Acyclic data transmission is best performed with the SIMATIC PDM software package.
5.2.1 SIMATIC PDM

SIMATIC PDM is a software package for designing, parameterizing, commissioning, diagnosing and maintaining the positioner and other process devices. SIMATIC PDM contains a simple process monitoring of the process values, alarms and status signals of the device.
131
Functions/operation via PROFIBUS PA With SIMATIC PDM the process device data can be
S displayed, S adjusted, S changed, S compared, S checked for plausibility S administered and S simulated
In general, we recommend the following procedure:
S First of all read the current settings from the device, by initiating the
action Load to PG/PC,
S Check the current settings, S Check the required settings, S Load the parameter settings into the device and also save the
parameter settings offline. In the PDM menu bar there are menu headers File, Device, View, Extras and Help. In the following description the device menu will be described in detail. Under these headers there are further submenus.
5.2.1.1
Allocate address
Here the positioner can be allocated a new address. Note that this can only be done if the slave is not yet in cyclical operation.
5.2.1.2
Load to device
and
5.2.1.3
Load to PG/PC
These can be performed simply by clicking on the respective symbol (Icon) in the menu bar. .
Load at PG/PC allows the parameters of the positioner to be read, changed as necessary and then using Load to device sent to the positioner.
5.2.1.4
Read maintenance information

This gives information regarding the current values set during the last initialization of the positioner. By comparing them with reference values the values set during the last maintenance can be saved and the status of the fitting assessed.
132
Functions/operation via PROFIBUS PA To see the values displayed, open the Device menu and open the Read maintenance information submenu. Because there is so much information, these are divided amongst several registers:
S Maintenance information 1 and 2
here the initialization values such as zero point P0, end value P100, positioning times etc. are displayed. gives information regarding number of strokes, changes of direction, fault messages etc. In addition limit values can be entered and transmitted to the device. displays the minimum, current and maximum temperature. displays the total service time and the service times at different temperature bands. This parameter shows the revision issue of data associated with the respective PROFIBUS block. After each parameter change the revision issue in the respective PROFIBUS block is incremented.
S Maintenance data
S Operating temperature S Service times
S Static data revision number
5.2.1.5
Set maintenance information

This allows maintenance information to be saved and reset. Open the Device menu and open the Set maintenance information submenu. The following registers are displayed:
S Save / reset maintenance information S Reset counter

To save the current initialization values, enter a valid date into the field Date of SIPART maintenance and then press the Save maintenance information key. This leads to a double column display of the maintenance information in the Read maintenance information menu (see above). If the positioner is subsequently re--initialized, the current values will be determined and these can be compared with the previously saved values. By pressing the Reset maintenance information key, the Values at the last maintenance will be reset (cleared down). Resetting the maintenance parameters is done by setting the Date of last maintenance to a nonsensical value (1.1.00). This deceives the PDM into believing that there is no last maintenance data. TIP: if a valid data is then re--input, the old values will once again be displayed. and
133
Functions/operation via PROFIBUS PA Only by confirming the register Reset counter by pressing the Reset maintenance counter key will the following maintenance counters be reset:
S Number of 100% strokes (STRKS) S Number of changes of direction (CHDIR) S Number of fault messages (\CNT) S Number of alarms 1 and 2 (A1CNT / A2CNT) 5.2.1.6 Operation
The following target modes (operating modes) are available:
S Automatic S Manual S Local overlay (LO)) S Not in service (OS)

Note that the target modes refer to the operating modes of the function blocks in the PROFIBUS PA block model and are not interchangeable with the positioner operating modes Automatic and Manual. The above target modes take effect when the positioner is in automatic operation (AUT). If the positioner is in manual mode (MAN) they will take effect only after a local changeover to automatic operation (AUT). These target modes are saved in the positioner and are non--volatile in the event of power loss.
Automatic
Provided the positioner has not yet been linked in as a slave in cyclical operation, a cyclic setpoint can be sent to it using PDM. Perform the following settings:
S Open the Operating mode register S Set the target mode to Automatic S Enter a value between 0 and 100% for the setpoint, quality Good
and status OK.
S Upload the settings into the positioner.

The positioner will now control to the desired setpoint until a cyclic master takes up communication with this slave or the positioner is locally set to manual mode.
134
NOTE Note that the positioner will respond after the transmission with the quality Bad and the status value constant. On leaving this target mode and if no further master sends a setpoint to the positioner, the positioner after the set monitoring period will adopt the parameterized fail safe value.
Manual
Even if cyclic communication is running, a setpoint can be sent to the positioner using PDM. For this precedence over the cyclical master must previously have been set up. Perform the following settings:
S Open the Operating mode register S Set the target mode to Manual. S Enter an initial value between 0 and 100%, quality Good and
Status OK.

The positioner will now control to the desired initial value and will report this in manual mode by showing MM in the display. Note that in manual mode the initial value entered will be written without proportioning directly into the initial block of the positioner. Set the positioner locally into manual mode and adjust the drive using the keys. The setpoint will then be set to the current readback. After switching back into automatic operation, the manual mode and the exact current setting will be maintained. After a loss of electrical power the positioner will perform in manual mode according to the direction of control action of the drive on the set values for YA or YE.
NOTE For the cyclical masters setpoints to take effect again, the target mode must be set to Automatic.
135
Functions/operation via PROFIBUS PA Local Overlay (LO) To allow the drive to insist on maintaining the current position, the positioner can be set using the PDM to Local Overlay. In this mode the positioner valves will not be activated, although they can detect any leakage. Perform the following settings:
S Open the Operating mode register S Set the target mode to Local Overlay (LO). S Upload the settings into the positioner.
Successful uploading will the reported in the positioner display by LO. On loss of electrical power, the drive will discharge the air and remain in this position until power is restored.
NOTE Return the device to the target mode Automatic in order to re--establish the effectiveness of the cyclic master setpoints.
Out of Service (O/S)
Irrespective of the cyclical communications the positioner can be taken out of service using the PDM. CAUTION To avoid personal injuries and equipment damage, note that this action will cause the drive air to be discharged. Perform the following settings:
S Open the Operating mode register S Set the target mode to Out of Service (O/S). S Upload the settings into the positioner.
Successful uploading will be reported in the positioner display by OS ----. Even in this target mode the positioner can be switched locally into manual mode and the drive operated using the keys. The display will then show MAN ----. After switching back into automatic mode the Not in service mode (display OS ----) will be maintained. After switching back into automatic mode the Not in service mode (display OS ----) will be maintained. After a loss of electrical power the drive will remain depressurized.
NOTE For the cyclical masters setpoints to take effect again, the target mode must be set to Automatic.
136
Functions/operation via PROFIBUS PA Simulation of readbacks Simulation functions are of assistance during commissioning pieces of equipment and positioner. Process values can be generated without output of real positional values. Equally the outputs from the alarm modules and the position value of the Iy module will not be affected by them. The value range of the simulated process values can be fully exploited. Faults can also be simulated. Perform the following settings:
S Open the Simulation readbacks register. S Set the simulation to Approved. S Enter for the desired simulation value a value between 0 and 100%,
quality Good and status OK.

The positioner will now control to the masters setpoint, the feedback of the readback will however show the simulated value.
.
5.2.1.7 Reset
NOTE After concluding the simulation, do not forget to restore the value to Blocked again.
Reset to factory settings
If the positioner settings have been changed set so that it can no longer fulfill its control task, this function allows the factory settings to be restored. All parameters with the exception of the PROFIBUS address are restored to the factory settings. The reset is shown in the diagnostics report as Restart performed. After this all parameters must be set afresh and an initialization performed.
Re-start (Warm start)
Warm start permits the positioner to be switched off and restarted. This means the communication will be broken off and then re--established. This re--start will be shown by the diagnostic report Re--start performed. If no measurement value is yet available, the automation and control system will show the status Indeterminate, initial value, value constant.
Reset the PROFIBUS address to 126
If no other device in the system has the pre--set address 126, the PROFIBUS line can be extended to include this positioner whilst the automation and control systems are running. Following this, the address of the newly attached device should be changed to another value.
137
Functions/operation via PROFIBUS PA To remove an positioner from the PROFIBUS line, its address should be restored to 126 using this function, so that in future it can be linked into this or another system if necessary. If a cyclic master is already in communication with the positioner, the address cannot be reset. Operating lock To prevent unwanted changes made by an acyclic master, the device can be write protected. To do this, enter the information On in the write protect submenu for the positioner.
5.2.1.8
Initialization parameters
In this menu the initialization parameters can be displayed, and also selectively changed. This should however be performed only by specialists (see chapter 4.7 page 126 Optimizing the control data). This function is also required if the electronics have to be changed but at that time no initialization can be undertaken (see chapter 3.7 page 89).
5.2.1.9
Self--calibration
Using SIMATIC PDM, you can also initialize the position controller for the first time. This is initiated by going into the Device menu and then into the Self--calibration sub--menu. Press the Start calibration button in the window that is opened. A warning notice which you absolutely must adhere to in order to prevent personal or equipment damage will appear. Note that the self--calibration can also be started from the acyclic master, even if the position controller is in automatic mode and contains the set value from a cyclic master.
WARNING Since you are not situated on--site, you must perform the respective safety procedures before starting the self--calibration to prevent damage to personnel or equipment. You must also ensure that the self--calibration can only be aborted on the machine itself by activating the operating mode button or by cutting off the supply power. The self--calibration is started after you have confirmed the warning notice. The progress can be viewed in the SIMATIC PDM window. After the initialization is complete, the position controller will carry on working in the operating mode that the self--calibration was started in. If an error message is generated, the correction must be made on--site.
138
5.2.1.10 Write protection

After completing the commissioning, the write protect can be set to prevent an acyclic master from making unwanted changes. Locally the positioner parameters can however be changed just as they could previously. To do this, enter the information On in the write protect submenu for the positioner. If anyone then attempts to write, the PDM will display the report Communication aborted.
NOTE If ON has already been set using this Hardware Write Protect screen, the binary input 1 in the positioner will already be parameterized to bLoc1 or bLoc2 and active. This means that writing using PDM is inhibited.
5.3
Cyclic data transmission

Using cyclic data transmission, the user data relevant for process automation is transferred between the class 1 Master (control or automation system) and the positioner.
5.3.1 Configuration
Information on the input and output range, as well as the consistency of the cyclically transmitted data is defined in the DeviceMasterData file (GSD file), tested with the devices configuration message and, if appropriate, declared to be valid. During the design, the user data which will be transmitted in cyclic operation is set. This means that it is possible to optimise the quantity of data to be transmitted. The GSD files for all common devices are already stored in the Siemens control system, however they are also accessible over the Internet and can be subsequently imported. The files are available on the Internet at: www.siemens.com/sipartps2 Click on More Info and --> Instructions and Manuals.
5.3.1.1
Configuring the user data

The user data which is made available to the control system or the open--loop control via the PROFIBUS depends on the desired configuration selected.
NOTE For STEP 7, the configuring tool is HW--Konfig. For STEP 5, it is COM_PROFIBUS.
139

PC or PG (Master class 2)
Power supply
PROFIBUS DP
Bus termination PROFIBUS PA
MPI cable (is required for commission-ing and monitoring)
DP/PA Coupler DP/PA Link
Splitters
CPU SIMATIC S7 (Master class 1)
PA devices Figure 64 Example of a small PROFIBUS DP/PA system
Here is a small STEP 7 program that established cyclic data transmission with the positioner with PROFIBUS PA.
Figure 65
STEP 7 example program
140
Functions/operation via PROFIBUS PA In this example all fies supported by the device are transmitted in the input or output direction. 256 (W#16#100) is selected as the initial I/O address. Legend Byte 15 15 bytes of input data consisting of the following: READBACK 5 Byte RCAS_OUT 5 Byte CHECKBACK 3 Byte POS_D 2 Byte Byte 10 10 bytes of output data consisting of the following: SP 5 Byte RCAS_IN 5 Byte
5.3.2 User data via PROFIBUS

The positioner can exchange a combination of the following cyclic useful data with the PROFIBUS. German name English name Abbreviation Direction from the point of view of the positioner Input Output Input Input Input Input Length in Byte Consisting of
Sollwert Istwert Diskrete Postion Aktorzustand Fernkaskade Eingang Fernkaskade Ausgang
Setpoint Readback Position discrete Checkback Remote Cascade Input Remote Cascade Output
SP RB POS_D CB RCAS_IN RCAS_OUT
5 5 2 3 5 5
Value/Status Value/Status Value/Status Value Value/Status Value/Status
Setpoint
The setpoint consists of a floating--point value (4 bytes and the associated status (1 byte, see below). The readback indicates the position of the valve. The readback consists of a floating--point value (4 bytes) and the associated status (1 byte). The discrete position of the valve is displayed as a value (1 byte) with the following meaning: 0 = not initialized 1 = valve closed 2 = valve open 3 = valve in intermediate state There is a status for this value too (1 byte)
Readback
Position discrete
141
Functions/operation via PROFIBUS PA Checkback

Bit 0 0 1 2 3 4 5 6 7
The checkback is displayed bit--coded in 3 bytes:

Meaning for 1 Device in failsafe position Request for local operation Device is operated locally Emergency operation active Deviation of the motion direction Stop reached (valve not completely open) Stop reached (valve not completely closed) Operating timeout Notes Position determined by parameter 46 (FSTY) Reports that a key has been pressed Device locally parameterized (e.g. 1 YFCT) or is not initialized Device is in manual mode (display : Man or P) Not required for the positioner Not required for the positioner Not required for the positioner Device cannot be adjusted (monitoring time and monitoring threshold exceeded, parameters 43 TIM and 44 LIM) due to lack of compressed air. Setting command Supply air to actuator sent Setting command Exhaust air from actuator sent Set a short time after quitting Configuration mode, if one or more parameters have been changed Simulation mode has been approved. Master class 2 can overwrite actual data values, e.g. for purposes of testing the response at the limits of the control system Not required for the positioner Not required for the positioner Not required for the positioner Will be set if the limit value set for travel integral is exceeded. Binary input 1 is activated Binary input 2 is activated
0 1 2 3
Valve is opened Valve is closed Parameters have been changed Simulation operation
4 5 6 7 2 0 1 2
Is not preset in Profile 3 Fault in the contrl Control inactive Self test active Path integral exceededn Additional input active Additional input active
Remote cascade input
In remote cascade mode (actual mode = remote cascade), the remote cascade input is used as the setpoint. Remote cascade input consists of a floating-point value (4 bytes) and status (1 bytes). This output provides the current setpoint in AUTO mode and remote cascade. The status is used especially for the transition from AUTO to remote cascade. In conjunction with the parameter input variable (primary value scale) you cannot only set the setpoints to the positioner as a percentage of the valve position but also in physical quantities such as cubic meters per day or liters per minute. It is also possible to adapt the readbacks to this scaling.
Remote cascade output
142
Functions/operation via PROFIBUS PA Status The status provides information about the quality of the input or output value. The format of the status is always 7 Quality 6 5 4 3 2 1 0 Additional information Limit value bits
Quality
0: bad 1: uncertain 2: good 3: good (cascade)
Grenzwertbit
0: good 1: lower limit value reached, exceeded or limited to lower limit value 2: upper limit value reached, exceeded or limited to upper limit value 3: value is fixed, no measured value
Additional information 7 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 6 0 0 0 0 1 1 1 1 0 0 0 1 1 1 1 1 1 1 5 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 4 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 1 1 0 3 0 1 0 1 0 0 1 1 0 0 0 0 0 1 1 1 1 0
The additional information depends on the quality. 2 0 1 0 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0 1 s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. s. a. 0 Meaning bad device fault sensor fault bad, out of service uncertain uncertain, last useful value uncertain, substituted value uncertain, initial value good good, active block alarm (change of parameters) good, go into failsafe position (command) good (cascade) good (cascade), initialization confirmed good (cascade), initialization requested good (cascade), not requested good (cascade), local operation has priority good (cascade), device is in failsafe position good (cascade), go into failsafe position (command)
143
Functions/operation via PROFIBUS PA Possible combinations of useful data and position in the address space. For communication of cyclic useful data between the master and the positioner you can select a combination of values during configuration: SP Setpoint Output (master view) Initial address 0 1 2 3 4 RCAS_OUT, RCAS_IN SP -- status SP -Floating--point number
Remote cascade output, remote cascade input Input (master view) Initial address 0 1 2 3 4 Output (master view) Initial address 0 1 2 3 4 RCAS_IN -- status RCAS_IN -Floating--point number RCAS_OUT -- status RCAS_OUT -Floating--point number
READBACK, POS_D, SP
Readback, position discrete, setpoint Input (master view) Initial address 0 1 2 3 4 5 6 READBACK -- status POS_D POS_D -- status READBACK -Floating--point number
144
Functions/operation via PROFIBUS PA Output (master view) Initial address 0 1 2 3 4 Checkback, setpoint Input (master view) Initial address 0 1 2 Output (master view) Initial address 0 1 2 3 4 SP -- status SP -Floating--point number CHECKBACK SP -- status SP -Floating--point number
Checkback, SP
READBACK, CHECKBACK, POS_D, SP
Readback, position discrete, checkback, setpoint Input (master view) Initial address 0 1 2 3 4 5 6 7 8 9 Output (master view) Initial address 0 1 2 3 4 SP -- status SP -Floating--point number CHECKBACK READBACK -- status POS_D POS_D -- status READBACK -Floating--point number
145
Functions/operation via PROFIBUS PA RCAS_OUT, CHECKBACK, RCAS_IN Remote cascade output, checkback, remote cascade input Input (master view) Initial address 0 1 2 3 4 5 6 7 Output (master view) Initial address 0 1 2 3 4 RCAS_IN -- status RCAS_IN -Floating--point number CHECKBACK RCAS_OUT -- status RCAS_OUT -Floating--point number
READBACK, RCAS_OUT, POS_D, CHECK-BACK, SP, RCAS_IN
Readback, remote cascade output, position discrete, checkback, setpoint, remote cascade input Input (master view) Initial address 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CHECKBACK RCAS_OUT -- status POS_D POS_D -- status RCAS_OUT -Floating--point number READBACK -- status READBACK -Floating--point number
146
Functions/operation via PROFIBUS PA Ouptut (master view) Initial address 0 1 2 3 4 5 6 7 8 9 RCAS_IN -- status RCAS_IN -Floating--point number SP -- status SP -Floating--point number
5.3.2.1
Status
Status gives information regarding: 1. Whether the measured values can be used in the application program 2. The device status (self--diagnostics/system diagnostics) 3. Additional process information (process alarms) The status byte coding is listed on the following pages. In addition, the possible causes of faults are listed together with remedies to resolve them.
Summary of status codes

Hex 00 Dez 00 Accompanying status code READBACK, POS_D PDM display bad Cause Will be used if no other infor-mation is to hand.Device not present or cyclic connection broken off. Will be generated by the DP/ PA link. The values obtained from the initialization run are unusable. The start and finish values on the entry range are the same. Permitted actuator travel exceeded Device has an irreparable fault e.g. memory fault) The controller is in the initialization phase Action Check the connection.
04
04
READBACK, POS_D
bad, configu-ration fault bad, configu-ration fault bad, device fault bad, device fault bad, out of service
Perform initialization again. Check relevant parameter settings. Enter different start and finish values. Check transmission ratio selector Exchange the electronics Wait until the end of the initialization phase
07 OC
07 12
READBACK, POS_D READBACK, POS_D
OF 1C
15 28
READBACK, POS_D READBACK, POS_D
147

Hex 1F Dez 31 Accompanying status code READBACK, POS_D PDM display Cause Action For normal operation reinstate target mode AUTO
bad, Function block has been out of service, disabled by command. Device value will move to safety position constant uncertain, last useful value, value constant Connection is disconnected or the SETPOINT status is not Good. Positioner will move to safety position, the para-meterized safety setting is set to retain last valid value Connection is disconnected or the SETPOINT status is not Good. Positioner will move to safety position, the parameterized safety setting is set to issue default value
47
71
READBACK, POS_D
Check the connection and make sure that the SETPOINT (SP) is accompanied by a status of 80 hex., 128 decimal (Good) Check the connection and make sure that the SETPOINT (SP) is accompanied by a status of 80 hex., 128 decimal (Good)
48
75
READBACK, POS_D
uncertain, substituted value, value constant
4F
75
READBACK, POS_D
uncertain, iinitial value, value constant uncertain, value uncertain Good
After powering up an initial Discard the value in the value is entered ion the device application program memory Device will be controlled locally Normal operation ------
53
83
READBACK, POS_D
80
128
SETPOINT (SP), READBACK, POS_D READBACK, POS_D
84
132
Good, update event
A parameter relevant to the device has been changed. This display will expire after 10 sec. Out of tolerance below lower parameterized alarm limit. Alarm output A1 or A2 will be activated ------
8D
141
READBACK,
Good, alarm value fallen below Good, alarm value exceeded Good, Go to Fail--Safe Good, maintenance requested
8E
142
READBACK, POS_D
Out of tolerance above upper -----parameterized alarm limit.Alarm output A1 or A2 will be activated Command to take up the safety position The travel integral limit value has been exceeded by the absolute travel integral For normal operation the status 80 hex., 128 decimal (Good) must be restored Perform maintenance and reset the reports using SIMATIC PDM
A3
163
SETPOINT (SP)
A4
164
READBACK, POS_D
Table 9
Status codes
5.3.2.2
Diagnostics
As well as status information the device can also report active information regarding the device condition. Diagnostics are important information which can be used in an automation system purposes of determining remedial action.
148
Functions/operation via PROFIBUS PA To communicate diagnostic information standard mechanisms within the PROFIBUS--DP can be called upon and an active report made to the class 1 master. PROFIBUS--DP provides a protocol for this to convey information that is of higher precedence than operating data to the class 1 master. The contents of the Device Status parameter from the physical block, together with information whether a change of status has occurred (event gained / event lost). The diagnostics object comprises four bytes. For the positioner only the first two bytes are relevant.
5.3.3 Diagnostics acc. to PROFIBUS DP (DDLM_Slave_Diag)

The positioner provides diagnostic data in the following form: Input (master view) Initial address 0 1 2 3 4 5 6 7 8 9 Station_status_1 Station_status_2 Station_status_3 Diag_Master_Add Ident_Number Ident_Number Header Status_Type Slot_Number Specifier Diagnostics object of the physical block Status coding acc. to DP/V1 Standard DP -diagnostics
10 Diagnostics (0) 11 Diagnostics (1) 12 Diagnostics (2) 13 Diagnostics (3) Specifier 1: raised event 2: cleared event Diagnostics
Byte Byte 0 Bit 0 1 2 3 Meaning for 1 ----Cause Action
149

Byte Bit 4 Meaning for 1 Memory error Cause During operation the memory is continually checked for check sum errors and read / write errors. If an error occurs, this report is generated. The initialization run required for the device to function has not yet been successfully performed. The values obtained from the initialization run are unusable Action Exchange the electronics.
5 6
-Device not initialized Perform initialization.
Initialization fault
Perform initialization again. Check relevant parameter settings. Check the compressed air supply, check the supply connections. Check the cabling and the power source.
Byte 1
0 1
-Compressed air supply fault A response time fault has been detected. Most probably the compressed air supply has failed Electrical power connection made to the device, or a warm start has been triggered using SIMATIC PDM or the internal Watchdog has operated. The device will be restored to its factory settings. The travel integral limit value has been exceeded by the absolute travel integral The parameterized characteristic curve lacks the necessary mono--ticity, number of support points, or the x--values are not at 5% intervals etc., the original characteri--stic curve will continue to be used. The parameter PROFIBUS Identity Number has been changed during cyclic operation. The device reports the infringement of the Identity Number and displays a warning of imminent failure. If re--started without changing the equipment configuration the device will not longer be included in the cyclic operating data traffic. Perform maintenance and reset the reports using SIMATIC PDM. Check the support points.
2 3
-Restart executed (after 10 s goes to 0)
4 5
Restart executed (after 10 s goes to 0) Maintenance required
Invalid characteristic curve
Identity number changed
Make a change to the equipment configuration data (change the GSD), so that it is consistent with the Identity Number held in the device.
Table 10
Diagnostics
NOTE The device status can be simulated using the SIMATIC PDM (chapter 5.2.1 page 131). This allows the reaction of the automation in the event of a fault to be checked.
150
5.3.4 Condensed Status

Each of the three process variables (FEEDBACK_VALUE, READBACK und POS_D) which the SIPART PS2 PA positioner sends to the Master is accompanied by a status. The condensed status, however, redefines the meaning of this status. The user can reposition or reallocate the meaning of each diagnosis event to the diagnosis byte (DIAGNOSIS) and the quality status (status byte) (see Fig. 66). In this way, the user can emphasize the importance of the individual diagnosis events according to need, therefore minimizing the amount of status and diagnosis information. The user can choose between the old meaning of the status according to the PROFIBUS PA profile and the new meaning. The status type (parameter COND_STATUS_DIAG) can be selected either in the Class 1 Master (see Fig. 67) or on the SIMATIC PDM user interface (see Fig. 68).
NOTE The SIPART PS2 PA positioner supports the functionality of the adjustable status as of firmware D1 (Version 4.00.00).
The user can reposition each individual diagnosis event to the desired diagnosis class
Good (no bit is set, no message) Maintenance requirement Maintenance demand Failure Invalid process condition Function check DIAGNOSIS
Single diagnostic events of the device
Repositioning to diagnosis
Repositioning to status
DIAG_EVENT_SWITCH
Good (no bit is set, no message) Maintenance requirement Maintenance demand Failure The user can reposition each individual diagnosis event to the desired status code Invalid process condition Function check Status Byte
Figure 66
Repositioning the diagnosis event
151
Figure 67
Choosing the status type when parameterizing the device according to the example HW--config with SIMATIC S7
152
Figure 68
Selecting the status type when parameterizing the device according to the example SIMATIC PDM
When evaluating the devices status and diagnosis messages by means of SIMATIC PDM, the results are displayed on the user interface as clear text and as a pictogram. Table 11, page 154 shows the meaning of the pictograms and their appearance.
Meaning No diagnosis support Out of service Manual operation Simulation or substitute value Maintenance alarm Maintenance demand Maintenance requirement Configuration error Icon Priority highest
153

Configuration warning Configuration changed Process value error Process value uncertain Process value out of tolerance Normal operation Table 11 Icon definitions lowest
Diagnosis events and status / DIAGNOSIS
As shown in Figure 66, each diagnosis event can influence both the variables status and the bits in the DIAGNOSIS byte. If the parameter COND_STATUS_DIAG is activated, the parameter DIAG_EVENT_SWITCH defines the relationship between diagnosis events and the values for status and the DIAGNOSIS byte. Table 14 shows the default relationships. The Tables 12 und 13 show the configuration which is available for the diagnosis byte DIAGNOSIS and the quality status.
Meaning No bit is set Check request Immediate check request Invalid process condition Function check or local operation Group -M M M P F
DIAGNOSIS bit -DIA_MAINTENANCE_REQUIRED DIA_MAINTENANCE_ALARM DIA_INV_PRO_COND DIA_FUNCTION_CHECK Table 12
DIA_MAINTENANCE_DEMANDED Failure
Usable DIAGNOSIS bits
Quality status Good, ok Good, maintenance requirement Good, maintenance demand Uncertain, maintenance demand Bad, failure Uncertain, process related, no maintenance Bad, process related, no maintenance Bad, function check or local override Good, function check or local override Table 13 Usable quality status
MEANING O.K. Maintenance demand Immediate maintenance request Immediate maintenance request Failure Invalid process condition Invalid process condition Function check Function check
Group -M M M M P P F F
154
Functions/operation via PROFIBUS PA The following two tables show the configurable diagnosis events. The available option is specified in the Option column. An M, for example, means that only the DIAGNOSIS bits and the quality status with the option M are available. The meanings of M, F and P have been defined in the two previous tables.
Event Default values of DIAG_EVENT_SWITCH Quality Status Code Run--time error of the drive Device not in automatic mode Binary input BIN1 is active (only signal) Action triggered by binary input 1 Binary input BIN2 is active (only signal) Action triggered by binary input 2 Limit value for path integral (100% strokes) exceeded Limit value for direction changes exceeded Limit value for the bottom hard stop monitoring exceeded Limit value for the top hard stop monitoring exceeded Limit values for dead zone monitoring exceeded Permissible temperature inside the device exceeded Table 14 Bad, maintenance alarm Bad, function check Good, maintenance demand Good, maintenance demand Good, maintenance requirement Good, maintenance demand Good, maintenance requirement Good, maintenance requirement Good, maintenance requirement Good, maintenance requirement Good, maintenance requirement Uncertain, process related DIAGNOSIS bit DIA_MAINTENANCE_ALARM DIA_FUNCTION_CHECK DIA_MAINTENANCE_DEMANDED DIA_MAINTENANCE_ALARM DIA_MAINTENANCE_DEMANDED DIA_MAINTENANCE_ALARM DIA_MAINTENANCE_REQUIRED DIA_MAINTENANCE_REQUIRED DIA_MAINTENANCE_DEMANDED DIA_MAINTENANCE_REQUIRED DIA_MAINTENANCE_REQUIRED DIA_INV_PRO_COND M F M,F,P M,F,P M,F,P M,F,P M Possible selection (Group)
M M
M,P
Configurable diagnostic events and their default representation in status and DIAGNOSIS
Event Quality Status Code Limit for A1 exceeded Limit for A2 exceeded Error in electronic of device The device is not yet operational (not initialized) The device is not yet operational (initializing error) Function block out of service Function block out of service Device in MAN mode Good, active critical alarm Good, active critical alarm Bad, maintenance alarm Bad, maintenance alarm Bad, maintenance alarm Bad, passivated Bad, passivated
Fixed settings DIAGNOSIS bit DIAG_PROCESS_TOLERANCE DIAG_PROCESS_TOLERANCE DIA_MAINTENANCE_ALARM DIA_MAINTENANCE_ALARM DIA_MAINTENANCE_ALARM
Depends on simulated quality status
DIA_FUNCTION_CHECK
155

Simulation mode Device in TRACE mode Simulation: diagnosis Table 15 Depends on simulated quality status Depends on simulated quality status -DIA_FUNCTION_CHECK DIA_FUNCTION_CHECK Depends on simulated value
Non configurable diagnostic events and their representation in status and DIAGNOSIS
DIAGNOSIS and DIAGNOSIS_ EXTENSION
Each diagnosis event has its own bit in the parameters DIAGNOSIS_EXTENSION and ACTUAL_DIAGNOSIS_EXTENSION. The parameter ACTUAL_DIAGNOSIS_EXTENSION always represents the original (unfiltered status) of the device and the parameter DIAGNOSIS_EXTENSION represents the filtered information. The following table shows the position of the diagnosis event bits in the parameters DIAGNOSIS_EXTENSION and ACTUAL_DIAGNOSIS_EXTENSION
Diagnosis event Other error Local operation Binary input BIN1 active Action has been triggered via binary input BIN2 Binary input BIN2 is active Action has been triggered via binary input BIN2 Device in failsafe position Limit value for strokes exceeded Limit values for direction change exceeded Limit value for bottom hard stop monitoring exceeded Limit values for top hard stop monitoring exceeded Limit value for dead zone (\\DEBA) exceeded The temperature range of the electronics exceeded/undershot Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Limit value A1 exceeded Limit value A2 exceeded Memory error Device not initialized Initializing error FB not operational FB not operational FB in manual mode 3 2 1 Byte 0 Bit 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4
156

Simulation mode Device in TRACE mode Diagnosis simulation Table 16 Position of the diagnosis event bits in the parameters DIAGNOSIS_EXTENSION and ACTUAL_DIAGNOSIS_EXTENSION 5 6 7
157
158
Service and maintenance
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. This dirt will be deposited under pressure on to the filter and 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.
159
Service and maintenance 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. 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.
Repair/Upgrade
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 type 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
160
Technical data
Technical data
(see following pages)
161
Technical data
Technical specifications
SIPART PS2 (all versions) General data Travel range (linear actuators) Angle of rotation (part-turn actuators) Installation On linear actuators Using attachment set 6DR4004-8V and where necessary with an additional lever arm 6DR4004-8L on actuators according to IEC 534-6 (NAMUR) with ribs, bars or flat face 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 Self-adjusting Self-adjusting or can be set as fixed value Self-adjusting or can be set as fixed value 10 ms 0.05% 0.2% 0.1%/10 K ( 0.1%/18 F) 20 ms 60 ms 60 ms (min. loop time) 3 ... 130 mm (0.12 ... 5.12 inch) (angle of feedback shaft 16 ... 90) 30 ... 100
Bumping (half-sine) to DIN EN 60068-2-29/03.95 Noise (digitally controlled) to DIN EN 60068-2-64/08.95
150 m/s (492 ft/s), 6 ms, 1000 shocks/axis 10 ... 200 Hz; 1 (m/s)/Hz (3.28 (ft/s)/Hz) 200 ... 500 Hz; 0.3 (m/s)/Hz (0.98 (ft/s)/Hz) 4 hours/axis
Recommended continuous duty range of the complete fitting Weight, basic device Plastic casing Metal casing, aluminium Metal casing, stainless steel Metal casing EEx d version Dimensions Climate class 4 Storage2) Transport2) Operation3) Certificate and approvals Classification according to pressure equipment directive (DRGL 97/23/EC) Pneumatic data Power supply (inlet air) Pressure
30 m/s ( 98.4 ft/s) without resonance sharpness Approx. 0.9 kg (0.90 kg) Approx. 1.3 kg (1.30 kg) Approx. 3.9 kg (3.90 kg) Approx. 5.2 kg (11.46 lb) See Dimensional drawings To DIN EN 60721-3-4 1K5, but -40 ... +80 C (1K5, but -40 ... +176 F) 2K4, but -40 ... +80 C (2K4, but -40 ... +176 F) 4K3, but -30 ... +80 C (4K3, but -22 ... +176 F) For gases of fluid group 1, complies with requirements of article 3, paragraph 3 (sound engineering practice SEP)
On part-turn actuators
Controller Five-point switch Dead zone - dEbA = Auto - dEbA = 0.1 ... 10% A/D converter Scan time Resolution Transmission error Temperature effect Cycle time 20 mA/HART device PA device FF device
1.4 ... 7 bar (20.3 ... 101.5 psi): Sufficiently greater than max. drive pressure (actuating pressure) Class 2 Class 2 (min. 20 K (36 F) below ambient temperature) Class 2
Air quality to ISO 8573-1 Solid particle size and density Pressure dew point Oil content Unthrottled flow Inlet air valve (ventilate actuator)4) - 2 bar (29 psi) - 4 bar (58 psi) - 6 bar (87 psi) Outlet air valve (ventilate actuator)4) - 2 bar (29 psi) - 4 bar (58 psi) - 6 bar (87 psi) Valve leakage Throttle ratio Power consumption in the controlled state
Binary input BE1 (terminals 9/10; Suitable only for floating contact; electrically connected to the basic max. contact load < 5 mA with 3 V device) Degree of protection1) Mounting position IP66 to EN 60 529/NEMA 4x Any; pneumatic connections and exhaust opening not facing up in wet environment Conformity as regards EMC Directive 89/336 EC in accordance with the following standards EN 61326/A1 Appendix A.1 and NAMUR NE21 August 98
4.1 Nm/h (18.1 USgpm) 7.1 Nm/h (31.3 USgpm) 9.8 Nm/h (43.1 USgpm)
CE marking
8.2 Nm/h (36.1 USgpm) 13.7 Nm/h (60.3 USgpm) 19.2 Nm/h (84.5 USgpm) < 610-4 Nm/h (0.0026 USgpm) Adjustable up to : 1 < 3.610-2 Nm/h (0.158 USgpm)
EMC requirements Material Housing - 6DR5..0-... (plastic) - 6DR5..1-... (metal) - 6DR5..2-... (stainless steel) - 6DR5..5-... (metal, pressureproof) Pressure gauge block Vibration resistance Harmonic oscillations (sine-wave) according to DIN EN 60062-2-6/05.96
Glass-fiber-reinforced Macrolon GD AISi12 Austenitic stainless steel mat. No. 1.4581 GK AISi12 Aluminium AIMgSi, anodized 3.5 mm (0.14 inch), 2 ... 27 Hz 3 cycles/axis 98.1 m/s (321.84 ft/s), 27 ... 300 Hz, 3 cycles/axis
Types of actuators In plastic casing In aluminium casing In flameproof casing In stainless steel casing
Single-action and double-action Single-action Single-action and double-action 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 Iy module. 4) With EEx d version (6DR5..5-...) the values are reduced by approx. 20%
162
Technical data
SIPART PS2 PA Basic device without Ex protection Without Basic device with EEx-d protection (flameproof casing) Basic device Basic device with EEx ia/ib protection with EEx n protection EEx n II 3 G EEx nA L [L] II C T6 Zone 2 Explosion protection to EN 50014, EN 50020 and EN 50021 Mounting location -30 ... +80 C Permissible ambient temperature for (-22 ... +176 F) operation At -10 C (+14 F) the display refresh rate of the LCD is limited. (for basic devices with Ex protection the following applies: Only T4 is permissible when using Iy module.) Electrical data Input Power supply (terminals 6/7) Bus voltage Bus connection with FISCO supply unit, ia or ib group IIC or IIB - Max. supply voltage Uo - Max. short-circuit current Io - Max. power Po Bus connection with barrier, ia or ib group IIC or IIB - Max. supply voltage (Uo) - Max. short-circuit current (Io) - Max. power Po Current consumption Fault current Effective internal inductance Effective internal capacitance Connection Safety shutdown can be activated with coding bridge (terminals 81/82; electrically isolated from the basic device) Input resistance Signal status "0" (shutdown active) Signal status "1" (shutdown not active) Effective Internal capacitance Ci Effective internal inductance Li - Max. supply voltage Ui - Max. short-circuit current Ii - Maximum power Pi Electrical isolation > 20 k 0 ... 4.5 V or unused 13 ... 30 V Between basic device and the input for safety shutdown, as well as the outputs of the option modules 840 V DC, 1 s > 20 k 0 ... 4.5 V or unused 13 ... 30 V Between basic device and the input for safety shutdown, as well as the outputs of the option modules 840 V DC, 1 s > 20 k 0 ... 4.5 V or unused 13 ... 30 V Negligible Negligible Intrinsically safe < 30 V <100 mA <1W The basic device and the input to the safety shutdown, as well as the outputs of the option modules, are individual, intrinsically-safe circuits 840 V DC, 1 s > 20 k 0 ... 4.5 V or unused 13 ... 30 V < 30 V <100 mA Between basic device and the input for safety shutdown, as well as the outputs of the option modules 840 V DC, 1 s 10.5 mA 10% 0 mA 10.5 mA 10% 0 mA 24 V 250 mA 1.2 W 10.5 mA 10% 0 mA Li 8 H Negligible 10.5 mA 10% 0 mA Bus-supplied 9 ... 32 V 9 ... 32 V 9 ... 24 V 9 ... 32 V EEx d EEx ia/ib II 2 G EEx d II C T4/T5/T6 II 2 G EEx ia/ib II C T6 Zone 1 or zone 2 Zone 1
T4: -30 ... +80 C (-22 ... +176 F) T5: -30 ... +65 C (-22 ... +149 F) T6: -30 ... +50 C (-22 ... +122 F)
17.5 V 380 mA 5.32 W
Certified intrinsically safe circuit
For connection to power supply with
Test voltage
163
Technical data
SIPART PS2 PA
Basic device without Ex protection
Basic device with EEx-d protection (flameproof casing)
Basic device Basic device with EEx ia/ib protection with EEx n protection
Communication
Layers 1 and +2 according to PROFIBUS PA, transmission technique according to IEC 1158-2; slave function; layer 7 (protocol layer) according to PROFIBUS DP, EN 50170 standard with the extended PROFIBUS functions (all data acyclic, manipulated variable, feedbacks and status also cyclic) Four connections to master class 2 are supported, automatic connection setup 60 s after break in communication; PROFIBUS PA profile B, version 3.0, more than 150 objects Typical 10 ms 126 (when delivered) SIMATIC PDM; supports all device objects. The software is not included in the scope of delivery Screw terminals 2.5 AWG28-12 Cable gland M20 x 1.5 or -14 NPT Female thread G DIN 45141 (-18 NPT) Screw terminals 2.5 AWG28-12 EEx d certified cable gland M20 x 1.5, -14 NPT or M25 x 1.5 Female thread G DIN 45141 (-18 NPT) Screw terminals 2.5 AWG28-12 Cable gland M20 x 1.5 or -14 NPT Female thread G DIN 45141 (-18 NPT) Screw terminals 2.5 AWG28-12 Cable gland M20 x 1.5 or -14 NPT Female thread G DIN 45141 (-18 NPT)
C2 connections Device profile Response time to master message Device address PC parameterizing software Connections Electric
Pneumatic External position sensor (potentiometer or NCS; as option) Uo Io Is Po Maximum permissible external capacitance Co Maximum permissible external inductance Lo
<5V <75 mA <160 mA <120 mW < 1 F < 1 mH
<5V <75 mA <160 mA <120 mW < 1 F < 1 mH
164
Technical data
Option modules Ex protection to EN 50014, EN 50020 and EN 50021 Mounting location Without Ex protection (EEx d also) With Ex protection EEx ia/ib II 2G EEx ia/ib II C T4/T5/T6 Zone 1 With Ex protection EEx n II 3G EEx nA L [L] II C T6 Zone 2 T4: -30 ... +80 C (-22 ... +176 F)1) T5: -30 ... +65 C (-22 ... +149 F)1) T6: -30 ... +50 C (-22 ... +122 F)1)
Permissible ambient temperature for opera- -30 ... +80 C (-22 ... +176 F) tion (For devices with Ex protection: Only in conjunction with the basic device 6DR5... -.E.... Only T4 is permissible when using Iy module) Alarm module 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 supply) Internal capacitance Ci Internal inductance Li Power supply UH Connection to power circuits with Active, R = 1 k, +3/-1%* Disabled, IR < 60 A 2.1 mA 1.2 mA
6DR4004-8A (without Ex protec- 6DR4004-6A (with Ex protection) 6DR4004-6A (with Ex protection) tion) 2.1 mA 1.2 mA
(* When used in the flameproof (Switching threshold with sup(Switching threshold with supcasing the current consumption ply to EN 60947-5-6: UH = 8.2 V, ply to EN 60947-5-6: UH = 8.2 V, Ri = 1k) is limited to 10 mA per output.) Ri = 1k) 35 V 5.2 nF Negligible intrinsically safe switching amplifier EN 60947-5-6 Uo 15.5 V DC Ik 25 mA, P 64 mW Ui 15.5 V DC
Binary input BE2 Electrically connected to the basic device - Signal status 0 - Signal status 1 - Contact load Electrically isolated from the basic device - Signal status 0 - Signal status 1 - Natural resistance Static destruction limit Internal inductance and capacitance Connection to power circuits Electrical isolation Test voltage SIA module (not for EEx d version) Limit transmitter with slot-type initiators and alarm output Ex protection Connection 2 slot-type initiators Function Connection to power circuits with Floating contact, open Floating contact, closed 3 V, 5 A 4.5 V or open 13 V 25 k 35 V 840 V DC, 1 s Floating contact, open Floating contact, closed 3 V, 5 A 4.5 V or open 13 V 25 k Negligible Intrinsically safe Ui 25.2 V 840 V DC, 1 s Floating contact, open Floating contact, closed 3 V, 5 A 4.5 V or open 13 V 25 k Ui 25.2 V DC 840 V DC, 1 s 6DR4004-6G (with Ex protection)
The 3 outputs, the input BE2 and the basic device are electrically isolated from each other 6DR4004-8G (without Ex protec- 6DR4004-6G (with Ex protection) tion) 2-wire connection Without Type SJ2-SN NC (normally closed) nominal voltage 8 V Current consumption: 3 mA (limit value not responded) 1 mA (limit value responded) 840 V DC, 1 s See Alarm module II 2 G EEx ia/ib IIC T6 Type SJ2-SN NC (normally closed) Intrinsically safe switching amplifier EN 60947-5-6 Ui 15.5 V DC Ii 25 mA, Pi 64 mW 41 nF 100 mH 840 V DC, 1 s See Alarm module II 3 G EEx nA L [L] IIC T6 Type SJ2-SN NC (normally closed) Ui 15.5 V DC Pi 64 mW
2-wire system to EN 60947-5-6 (NAMUR), for switching amplifier to be connected on load side
Internal capacitance Internal inductance Electrical isolation Test voltage Alarm output
840 V DC, 1 s See Alarm module
The 3 outputs are electrically isolated from the basic device
1) Only in conjunction with the basic device 6DR5...-E..... With Iy module only T4 permitted.
165
Technical data
Accessory modules Limit value contact module Limit transmitter with mechanical ground contact and alarm output Ex protection Max. switching current AC/DC
Without Ex protection (EEx d also) 6DR4004-8K
With Ex protection EEx ia/ib 6DR4004-6K
With Ex protection EEx n 6DR4004-6K
without 4A
II 2 G EEx ia/ib IIC T6 Connection to intrinsically safe power circuits: Uo 30 V Ik 100 mA, Pi 750 mW 30 V DC Negligible Negligible 3150 V DC, 2 s See Alarm module 6DR4004-6J (with Ex protection) 2-wire connection 4 ... 20 mA, short-circuit-proof 3.6 ... 20.5 mA +12 ... +30 V (UH [V] - 12 V) /i [mA] 0.3% 0.1%/10 K ( 0.1%/18 F) 0.1% 1% 11 nF Negligible Intrinsically safe: Ui 30 V DC Ii 100 mA; Pi 1 W (only T4)
II 3 G EEx nA L [L] IIC T6 Connection to intrinsically safe power circuits: Uo 30 V Ik 100 mA, Pi 750 mW 30 V DC 3150 V DC, 2 s See Alarm module 6DR4004-6J (with Ex protection) 2-wire connection 4 ... 20 mA, short-circuit-proof 3.6 ... 20.5 mA +12 ... +30 V (UH [V] - 12 V) /i [mA] 0.3% 0.1%/10 K ( 0.1%/18 F) 0.1% 1% Ui 30 V DC Ii 100 mA; Pi 1 W (only T4) Electrically isolated from the basic device 840 V DC, 1 s
Max. switching voltage AC/DC Internal capacitance Ci Internal inductance Li Electrical isolation Test voltage Alarm module Iy module DC output for position feedback Nominal signal range i Total operating range Power supply UH External load RB [kW] Transmission error Temperature effect Resolution Residual ripple Internal capacitance Ci Internal inductance Li For connection to power circuits with Electrical isolation Test voltage NCS sensor (not for EEx d version) Position range Linear actuator Part-turn actuator
250 V / 24 V 3150 V DC, 2s See Alarm module 6DR4004-8J (without Ex protection) 2-wire connection 4 ... 20 mA, short-circuit-proof 3.6 ... 20.5 mA +12 ... +35 V (UH [V] - 12 V) /i [mA] 0.3% 0.1%/10 K ( 0.1%/18 F) 0.1% 1%
The 3 outputs are electrically isolated from the basic device
Electrically isolated from the basic device 840 V DC, 1 s
Electrically isolated from the basic device 840 V DC, 1 s
3 ... 130 mm (0.12 ... 5.12 inch), 3 ... 130 mm (0.12 ... 5.12 inch), 3 ... 130 mm (0.12 ... 5.12 inch), to 200 mm (7.87 inch) on request to 200 mm (7.87 inch) on request to 200 mm (7.87 inch) on request 30 ... 100 30 ... 100 1% 1% 0.2% -40 ... +85 C (-40 ... +185 F), extended temperature range on request IP68/NEMA 4X 30 ... 100 1% 1% 0.2% -40 ... +85 C (-40 ... +185 F), extended temperature range on request IP68/NEMA 4X
Linearity (after correction by SIPART PS2) Linear actuator 1% Part-turn actuator 1% Hysteresis Continuous working temperature 0.2% -40 ... +85 C (-40 ... +185 F), extended temperature range on request IP68/NEMA 4X
Degree of protection of casing
166
Scope of delivery
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 versions are identified respectively by a special rating plate.
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 potentially explosive (zone 1 and 2). The instrument categories (2 and 3) of the instrument itself and those of its options must be observed.
167
Scope of delivery
8.1
Ordering data
Order No. 6 DR 5 777 - 0 7777 - 77A7
Selection and ordering data

Electropneumatic positioner SIPART PS2, PS2 PA and PS2 FF Version 2-wire Without HART (4 to 20 mA) } With HART, not explosion-protected } (except EEx d) 2-, 3-, 4-wire With HART, explosion-protected } Without HART, not explosion} protected PROFIBUS PA connection FOUNDATION Fieldbus connection (not EEx n) For actuator Single-action Double-action Casing Plastic Aluminum; only single-action Stainless steel; not for EEx d version: not FM/CSA and not EEx n Aluminum; EEx d housing (flameproof)1), not CSA } } } } } }
Selection and ordering data

Electropneumatic positioner SIPART PS2, PS2 PA and PS2 FF Customer-specific design Without } }
Order No. 6 DR 5 777 - 0 7777 - 77A7
0 A B 0 1 2 3 4
0 1
Brief instructions German/English French/Spanish/Italian Mounted pressure gauge block Without Single-action G Double-action G Single-action -18 NPT Double-action -18 NPT Further designs 1 2 0 1 2 5 Add "-Z" to Order No. and specify Order Code. Version with stainless steel sound absorbers not for EEx d version; standard with stainless steel enclosures Customized preset bus address (max. 126) and/or software tag No. for PROFIBUS PA and FOUNDATION Fieldbus version, for plastic enclosures, for metal enclosures on request. } Available ex stock G
1) EEx d version without cable gland.
2 3 5 6
A40
Y25
Explosion protection Without } With explosion protection EEx ia/ib or EEx d (CENELEC/FM/CSA) With explosion protection EEx n (CENELEC) Connection thread electrical/pneumatic M20 x 1.5 / G } -14 NPT / -18 NPT M20 x 1.5 / -18 NPT -14 NPT / G M25 x 1.5 / G (only EEx d version)1) With PROFIBUS plug M12 / G2) With PROFIBUS plug M12 / -18 NPT2) M20 x 1.5 / VDI/VDE 3847 Limit monitor Installed, incl. 2nd cable gland3) Without } Alarm module; electronic (6DR4004-.A) SIA module; slot-type initiators (6DR4004-.G); not for EEx d version) Limit value contact module (mechanical switching contacts (6DR4004-.K); not for EEx d version Optional modules Installed, incl. 2nd cable gland3) Without } Iy module for position feedback signal (4 ... 20 mA) (6DR4004-.J) EMC filter module for external position sensor (C73451-A430-D23), (not for EEx d version) Iy module and EMC filter module for external position sensor, not for EEx d version
N E
2) Not for EEx d, FM/CSA approval, EEx ia/ib (CENELEC) on request
G N M P Q R S V
0 1 2 3
0 1 2 3
168
Scope of delivery
8.2
Scope of delivery of options

Bestellnummer 6DR4004-8J 6DR4004-6J 6DR4004-7J 6DR4004-8A 6DR4004-6A 6DR4004-7A 6DR4004-8G FM 1)2) 6DR4004-6G 6DR4004-8K 6DR4004-6K
Option Iy module without explosion protection Iy module with explosion protection PTB 1) Iy modulel with explosion protection FM 2) Alarm module without explosion protection Alarm module with explosion protection Alarm module with explosion protection PTB 1) FM 2)
SIA module without explosion protection SIA module with explosion protection CENELEC and Mechanical limit switch module without explosion protection Mechanical limit switch module with explosion protection CENELEC and FM 1)2)3)
1) 2) 3)
EC--type examination certificates Approval Reports of Factory Mutual System In preparation
8.3
Scope of delivery of accessories

Order number 6DR4004--8V 6DR4004--8L 6DR4004--8D 6DR4004--1C 6DR4004--1M 6DR4004--2M 6DR4004--1B 6DR4004--8S 6DR4004--_ N_ _ 0 6DR4004--8N 6DR4004--6N 6DR4004--_NN 6DR4004--_N_10 6DR4004--_N_20 6DR4004--_N_30 C73451--A430--D23 C73451--A430--D78 on request
Accessories Mounting kit set linear actuators IEC 534--6 including lever arm for 3 to 35 mm way Additional lever for > 35 to 130 mm way Mounting kit part--turn actuators VDI/VDE 3845 Solenoid valve block for SAMSON actuator (integrated mounting) Manometer block single--acting Manometer block double--acting Solenoid valve block single--acting (NAMUR) Mounting set for SAMSON actuator (integrated mounting) NCS--Sensor non explosion--proof explosion--proof cable length 6 m (19.68 ft) for part--turn actuators for linear actuators up to 14 mm (0.55 inch) (on request) for linear actuators > 14 mm (0.55 inch) EMC filter rmodule External position detection system Operating software SIMATIC PDM
169
Scope of delivery
8.4
List of Spare Parts
Spare parts list: SIPART PS2 positioner Description Cover (plastic enclosure) with screws (4 pcs) and seal Order No. C73451--A430--D82 for version 6DR4___ 6DR5___
Cover (metal enclosure) with screws C73451--A430--D83 (4 pcs) and seal Motherboard, two--wire without HART, without explosion protection Motherboard, two--wire without HART, with explosion protection Motherboard, two--wire HART, without explosion protection Motherboard, two--,three--,four--wire HART, with explosion protection Motherboard Two--,three--,four--wire without HART, without expl. protect. Motherboard PROFIBUS PA, without explosion protection Motherboard PROFIBUS PA, with explosion protection Motherboard FIELDBUS Foundation, without explosion proof Motherboard FIELDBUS Foundation, with explosion protection A5E00082459 A5E00082457 A5E00082458 A5E00082456 A5E00102018 A5E00141523 A5E00141550 A5E00215467 A5E00215466
6DR4___ 6DR5___ 6DR50__--_N 6DR40__--_N *) 6DR50__--_E 6DR51__--_N 6DR40__--_N *) 6DR52__ 6DR53__--_N 6DR40__--_N *) 6DR55__--_N.. 6DR41__--_N 6DR55__--_E 6DR41__--_E 6DR56__ 6DR56__ 6DR4___ 6DR5___
Pneumatic block (Valve single acting C73451--A430--D80 incl. seals and screws)
Pneumatic block (Valve double acting 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
170
Index
Index A
Accessories, 43 Alarm function, 107 Alarm module, 37, 71 Ex, 69 non Ex, 67 Application positioner in a wet environment, 48 under great accelerations or vibrations, 50 Assembly, 47 Screw--type gland with plastic hose, 50 Assembly procedure, 53, 57 linear actuator, 55 part--turn actuator, 58, 59 Automatic, Changing the operating mode, 96 Dimensional drawings, 45 Display, 91 Distance class, 118 Documentation, 11 double--acting, 15, 16
9
E
Electrical connection, 26, 62 EMV--filter module, 43
F
Fault correction, 127 Filters, Cleaning the ~, 159 Firmware version, 93 Frichtion clutch, adjustable retaining device, 51 Functions, PROFIBUS PA, 131
B
Base plate, 63 Binary input, electrical connection, 69, 71 Binaryl input, electrical connection, 67 Binary output, electrical connection, 67, 69, 71
G
General information, 7
H
Housing, 13
C
Catalogs, 173 Certificates, 174 Commissioning, 74 Configuration, changing the operating mode, 95 Current output Electrical Connection, 67, 69 electrical connection, 71
I
Initialization, 102 Automatic ~, Structogram, 85 automatic ~, 74, 76, 81, 85 changing the operating mode, 95 copying ~, 74 manual ~, 74, 78, 83 Initialization data, Copying the ~, 89 Input keys, 91 Installation positions, favorable and unfavorable, 49 Instrument identification, 45 Iy module, 36, 67 Ex, 69, 71
D
Delivery, 12 Diagnosis, 113 Online, 118 Diagnostic, Display, 113 Diagnostic display, Changing the operating mode, 96 Diagnostic values, Meaning of the ~, 114
L
Lever arm transmission, 101 171
Index Linear actuator, 15, 16 automatic initialization, 76 manual initialization, 78 preparation, 75 Literatur, 173 Purge air switching, 29
Q
Qualified Personnel, 9
M
Maintenance, 159 Manometer block, 43 Manual mode Changing the operating mode, 96 P manual mode, 95 Mechanical limit switch module, 39, 68 EEx i, 70 Mechnical limit switch module, 70 not EEx, 68 Method of operation, 23, 30 Mounting kit linear actuator, 53 part--turn actuator, 56
R
Rating Plate, 25 Regulations, 12 Reset, 110 Restrictors, 29 Rotary actuator automatic initialization, 81 mounted, 60 preparation, 81
S
Safety--Related Notices, 8 Scope of Delivery, 167, 171, 173 Service, 159 Setpoint characteristic, 103 SIA module, 38 Electrical Connection, 68, 70 electrical connection, 72 Ex, 70, 72 non Ex, 68 single--acting, 15 Standards, 12 Structograms of automatic initialization, 85
O
Operating mode AUT, 96 MAN, 96 Operating Modes, 94 Operating modes, Change ~, 94 Operation, 91 via PROFIBUS PA, 131 Option, modules, 31 Options, 14 Ordering data, 168
T
Technical data, 161 Terminating resistor T, 20 Type key, 45
P
Parameter table, SIPART PS2, 98 Parameters, 97 Part--turn actuator, 15, 16, 61 manual initialization, 83 PDM (Process Device Manager), 89, 117 Personnel, Qualification, 9 Pneumatic connection, 27, 73 positioning, 28 Positioner exchange, 74, 89 Preset, 110 PROFIBUS Bus topology, 17 Transmission method, 17 PROFIBUS PA, functions and operation, 131
U
Use as intended, 11
V
Versions, 13 Vibrations, 50 View of the instrument, 25
W
Warranty, 12 wet environment, 48
172
Appendix
Appendix
10.1 Literature and catalogs
No. /1/ Title
PNO guide PROFIBUS PA
10
Issued by
PNO-Technologiefabrik Haid-und-Neu-Str. 7 D--76131 Karlsruhe Siemens AG
Order number
2.091
/2/
SIMATIC field technology package
Internet address: http://www.ad.siemens.de:80 80/virlib/html_00/ doc/index.htm on: Profibus descriptions (free) / system description / PA system description, German E86060--K4660--A101--A3
/3/ /4/
ST PI catalog PROFIBUS and AS Interface Field bus components ST 50 catalog SIMATIC SIMATIC S5/PC/505 Automation Systems ST 70 catalog SIMATIC S7/M7/C7 Automation Systems ST 80 catalog SIMATIC HMI Operating and monitoring products IK 10 catalog SIMATIC NET Communication networks ST PCS 7 catalog SIMATIC SIMATIC PCS 7 process control system
Siemens AG
Siemens AG
E86060--K4650--A111--A7
/5/ /6/ /7/ /8/
Siemens AG
E86060--K4670--A111--A4
Siemens AG
E86060--K4680--A101--A5
Siemens AG
E86060--K4710--A101--A7
Siemens AG
E86060--K4678--A111--A2
173
Appendix
10.2 Certificates
The certificates are enclosed as a collection of loose leaves in the operating instructions (or on CD).
174
@1PA5E00127926@
A5E00127926
Siemens Aktiengesellschaft Automation and Drives Process Instrumentation and Analytics 76181 KARLSRUHE GERMANY www.siemens.com/processinstrumentation
A5E00127926-05

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Manual Edition 03/2006

Electropneumatic Positioner SIPART PS2 PA

SIPART PS2 PA 6DR55xx

Manual Electropneumatic Positioner for Linear and Part--Turn Actuators

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

Design and method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIPART PS2 PA Manual A5E00127926--05

Functions/operation via PROFIBUS PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

Information for the operator

Information for the operator

SIPART PS2 PA Manual A5E00127926--05

Classification of safety--related notices

SIPART PS2 PA Manual A5E00127926--05

Information for the operator

S in the case of ex--proof equipment, are trained, instructed or

S if they are commissioning and/or service personnel, are trained to

S and instructed additionally in first aid

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

Information for the operator

SIPART PS2 PA Manual A5E00127926--05

Information for the operator

Standards and regulations

SIPART PS2 PA Manual A5E00127926--05

General information about the positioner

For example, the positioner can be used to control valves as follows:

S double--acting and S single--acting

S potentially explosive or S not potentially explosive applications.

SIPART PS2 PA Manual A5E00127926--05

Introduction The housing is available in three versions:

S Manometer block: 2 or 3 manometers for single and double-acting positioners

S External position detection system S Non-Contacting Position Sensor (NCS)

SIPART PS2 PA Manual A5E00127926--05

Positioner mounted on linear actuator (single--acting)

Positioner in plastic housing Part--turn actuator Manometer block, double--acting

Positioner mounted on part--turn actuator (double--acting)

SIPART PS2 PA Manual A5E00127926--05

Explosion proof positioner mounted on linear actuator (single--acting)

Explosion proof positioner mounted on part--turn actuator (double--acting)

SIPART PS2 PA Manual A5E00127926--05

General information regarding PROFIBUS

1.2.1 Transmission method

SIPART PS2 PA Manual A5E00127926--05

Typical PROFIBUS automation system

1.2.3 Properties of the PROFIBUS PA

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

Design and method of operation

Design and method of operation

SIPART PS2 PA Manual A5E00127926--05

SIPART PS2 PA Manual A5E00127926--05

Design and method of operation

Restrictor Y2 ) Restrictor Y1 Actuating pressure Y2 ) Supply air PZ in double--acting actuators