Siemens Sipart Ps2 6Dr50Xx Users Manual S3 4

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SIPART PS2 Manual

SIPART PS2 Manual

A5E00074630--06

SIPART PS2

6DR50xx

6DR51xx

6DR52xx

6DR53xx

Edition 10/2006

Manual

Electropneumatic Positioner for

Linear and Part-Turn Actuators

2SIPART PS2 Manual

A5E00074630--06

The reproduction, transmission or use of this docu-

ment or its contents is not permitted without ex-

press written authority. Offenders will be liable for

damages. All rights, including rights created by pa-

tent grant or registration of a utility model or design,

are reserved.

Siemens AG

Bereich Automatisierungs-- und Antriebstechnik

Geschäftsgebiet Prozessinstrumentierung-- und

Analytik

D--76181 Karlsruhe

Disclaimer of Liability

We have checked the contents of this manual for

agreement with the hardware and software descri-

bed. Since deviations cannot be precluded entirely,

we cannot guarantee full agreement. However, the

data in this manual are reviewed regularly and any

necessary corrections included in subsequent edi-

tions. Suggestions for improvement are welcomed.

eSiemens AG 2006

Technical data subject to change.

Trademarks

SIMATIC, SIPART, SIREC, SITRANS are registered trademarks of Siemens AG.

Third parties using for their own purposes any other names in this document which refer to trade-

marks might infringe upon the rights of the trademark owners.

SIPART PS2 Manual

A5E00074630--06

Contents

0 Information for the Operator 5.............................................

0.1 General information 5...........................................

0.2 Classification of Safety Related Notices 6.........................

0.3 Qualified Personnel 7...........................................

0.4 Use as intended 9..............................................

0.5 Technical Documentation 9......................................

0.6 Warranty Information 9..........................................

0.7 Delivery Notes 10...............................................

0.8 Standards and Regulations 10....................................

1 Introduction 11............................................................

1.1 General information about the positioner 11.........................

2 Design and Method of Operation 15........................................

2.1 Overview 15....................................................

2.2 Design name plate 17............................................

2.3 Instrument Components 17.......................................

2.3.1 Motherboard 18.................................................

2.3.2 Electrical Connections 18.........................................

2.3.3 Pneumatic Connections 19.......................................

2.3.4 Mounting Kit 22.................................................

2.3.5 Purge air switching (not in the explosion proof version) 22............

2.3.6 Restrictors 22...................................................

2.4 Method of Operation 23..........................................

2.5 HART-function 26...............................................

2.6 State as supplied 26.............................................

2.7 Installation of options modules 27.................................

2.7.1 Installation of options modules in normal and intrinsically

safe versions 27................................................

2.7.2 Installation of options modules in explosion proof version 29..........

2.7.3 Iy-module 31...................................................

2.7.4 Alarm module 32................................................

2.7.5 SIA module 33..................................................

2.7.6 Mechanical limit switch module 35.................................

2.7.7 EMC filter module 38............................................

2.7.8 Accessories 39.................................................

3 Preparing for Operation 41.................................................

3.1 Instrument identification (type key) 41..............................

3.2 Dimensional drawings 41.........................................

3.3 Assembly 43....................................................

3.3.1 Instructions for using positioners in a wet environment 44.............

3.3.2 Instructions for using positioners which are exposed to strong

accelerations or vibrations 46.....................................

3.3.3 Mounting kit “linear actuator” 6DR4004-8V and 6DR4004-8L 49.......

3.3.4 Assembly procedure (see figure 3-7, page 51) 50....................

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A5E00074630--06

3.3.5 Mounting kit “part-turn actuator” 6DR4004-8D 52....................

3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) 53...............

3.4 Electrical Connection 57..........................................

3.4.1 Connection in non-intrinsically safe and explosion proof version 59.....

3.4.2 Connection in intrinsically safe version 62...........................

3.4.3 Connection in type of protection “n” version 68......................

3.5 Pneumatic Connection 71........................................

3.6 Commissioning 72...............................................

3.6.1 Preparations for linear actuators 73................................

3.6.2 Automatic initialization of linear actuator 74.........................

3.6.3 Manual initialization of linear actuator 76............................

3.6.4 Preparations for part-turn actuator 79..............................

3.6.5 Automatic initialization of part-turn actuator 79......................

3.6.6 Manual initialization of part-turn actuators 81........................

3.6.7 Automatic initialization (structograms) 82...........................

3.7 Copying initialization data (positioner exchange) 87..................

4 Operation 89..............................................................

4.1 Display 89......................................................

4.2 Input keys 89...................................................

4.3 Operating modes 92.............................................

4.4 Parameters 95..................................................

4.5 Diagnostics 122..................................................

4.5.1 Diagnostic display 122............................................

4.5.2 Meaning of the diagnostic values 123...............................

4.5.3 Online diagnostics 131............................................

4.5.4 Fault correction 136..............................................

4.6 Meaning of the other display text 139...............................

4.7 Optimizing the controller data 143..................................

5 Service and Maintenance 145................................................

6 Technical Data 147.........................................................

7 Scope of Delivery 153.......................................................

7.1 Scope of delivery of standard controller 154..........................

7.2 Scope of delivery of options 154....................................

7.3 Scope of delivery of accessories 155................................

7.4 List of Spare Parts 156............................................

8 Index 158..................................................................

9 Appendix 160..............................................................

9.1 Literature and catalogs 160........................................

Information for the Operator

SIPART PS2 Manual

A5E00074631--06

Information for the Operator

Dear customer,

Please read this manual before starting work!

It contains important information and data which, when observed,

ensure full availability of the equipment and save service costs. This

simplifies handling of this control instrument considerably and provides

accurate measuring results.

You have purchased an instrument which can be installed in various

configurations:

SSIPART PS2 without Ex-protection in a metal- or plastic housing.

SSIPART PS2 with EEx ia/ib-protection in a metal- or plastic hous-

ing.

SSIPART PS2 EEx d in a pressurized explosion proof housing

This manual takes each of these possibilities into consideration.

Any differences between the devices are indicated specially.

Scope of delivery, see chapter 7, page 153.

0.1 General information

The product described in this manual left the factory in a perfectly safe

and tested condition. To maintain this condition and to achieve perfect

and reliable operation of this product, it must only be used in the way

described by the manufacturer. Successful and safe operation of this

equipment is dependent on proper handling, installation, operation and

maintenance.

Information for the Operator

SIPART PS2 Manual

A5E00074631--06

This manual contains the information required for use as intended of

the product it describes. It is addressed to technically qualified person-

nel specially trained or having relevant knowledge of instrumentation

and control technology, hereafter called automation technology.

Familiarity with and proper technical observance of the safety notes

and warnings contained in this manual are essential for safe installation

and commissioning and for safety in operation and maintenance of the

product described. Only qualified personnel as defined in Chapter 0.3

has the necessary specialist knowledge to interpret the general safety

notes and warnings given in this document in specific cases and to

take the necessary action.

The documentation supplied with the instrument is listed in Chapter 0.5.

This manual is not a permanent part of the scope of supply. For reasons

of clarity, it does not contain every detail about every version of the

product described and cannot take every eventuality in installation, op-

eration, maintenance and use in systems into 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 informa-

tion from your local Siemens office or the office responsible for you.

Functionality, commissioning and operation are described in this

manual.

Please pay special attention to the Warning and Note texts. These are

separated from the remaining text by horizontal lines and specially

marked with symbols (see Chapter 0.2).

0.2 Classification of Safety Related Notices

This manual contains notices which you should observe to ensure your

own personal safety, as well as to protect the product and connected

equipment. These notices are highlighted in the manual by a warning

triangle and are marked as follows according to the level of danger:

!DANGER

indicates an immenently hazardous situation which, if not avoided, will

result in death or serious inury.

!WARNING

indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

Information for the Operator

SIPART PS2 Manual

A5E00074631--06

!CAUTION

used with the safety alert symbol indicates a potentially hazardous si-

tuation which, if not avoided, may result in minor or moderate injury.

CAUTION

used without the safety alert symbol indicates a potentially hazardous

situation which, if not avoided, may result in property damage.

NOTICE

indicates a potential situation which, if not avoided, may result in an

undesirable result or state.

.NOTE

highlights important information on the product, using the product,

or part of the documentation that is of particular importance and that

will be of benefit to the user.

0.3 Qualified Personnel

The result of unqualified intervention in the instrument or nonobser-

vance of the warnings given in this manual or on product labels can be

severe personal injury and/or serious material damage. Therefore only

properly qualified personnel must make changes and settings in the

instrument.

For the purpose of the safety information in this manual and on the

product labels, qualified personnel are those who

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

authorized to perform work on electrical circuits of equipment

subject to explosion hazard.

Sif they are configuration personnel, are familiar with the safety

concepts of automation technology

Sif they are operating personnel, have been instructed in the handling

of automation equipment and know the content of this manual

relating to operation

Sif 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.

Sand instructed additionally in first aid

Information for the Operator

SIPART PS2 Manual

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!WARNING

The instrument must only be installed and commissioned by qualified

personnel.

The device may be used solely for the purposes described in this

manual.

The instrument is designed for connection to functional and safety

extra low voltage.

Electrical safety depends only on the power supply equipment.

Pneumatic actuators exert considerable positioning forces. The safety

precautions of the actuator used must therefore be scrupulously

observed during installation and commissioning in order to prevent

injuries.

We explicitly draw your attention to the necessity of observing safety

regulations regarding operation in zones subject to explosion hazard,

if applicable.

The specifications of the examination certificate valid in your country

must be observed. Laws and regulations valid in your country must be

observed for the electrical installation in explosions hazardous areas.

In Germany these are for example:

-- Working reliability regulations

-- Regulations for installing electrical equipment in hazardous areas,

DIN EN 60079-14 (in the past VDE 0165, T1).

It should be checked whether the available power supply, insofar as

this is required, is compliant with the power supply specified on the

rating plate and specified in the examination certificate valid in your

country.

Take care to avoid electrostatic discharges within the hazardous area,

such as can arise if a dry cloth is used to clean the positioner in the

plastic housing.

Devices with the protection type “flameproof enclosure” may only be

opened when the power is off.

!WARNING

Devices with the protection type “intrinsically safe” lose their certifica-

tion as soon as they are operated with circuits that do not conform to

the specifications laid down in the examination certificate valid in your

country.

The successful and safe operation of this equipment is dependent

upon its proper handling, installation, operation and maintenance.

Information for the Operator

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!WARNING

The device may not be operated while the leaflets are in the housing.

0.4 Use as intended

Use as intended for the purpose of this manual means that this product

must only be used for the applications described in the technical de-

scription (see also Chapter 3 of this manual).

The product described in this manual has been developed, manufac-

tured, tested and documented observing the relevant safety standards.

If the handling rules and safety information for configuration, installa-

tion, use as intended and maintenance are observed, there is normally

no danger with regard to material damage or for the health of person-

nel. Extra low voltages that are connected must be fed in by safe isola-

tion.

0.5 Technical Documentation

The operating instructions are a constituent part of the enclosed CD

“sipartp ps2 POSITIONERS” (order number A5E00214567) and is

available on the Internet at:

www.siemens.com/sipartps2

Click on “More Info” and --> “Instructions and Manuals”.

On the enclosed CD, you will find an extract of the catalog FI 01 “Field

devices for process automation” with the current order data. The entire

FI 01 catalog is also available at the above Web address.

0.6 Warranty Information

We should like to point out that the content of this manual is not part of

and does not modify a previous or current agreement, undertaking or

legal relationship. Siemens is bound solely by the contract of sale,

which also contains the complete and exclusive warranty. The con-

tractual warranty conditions are neither extended nor restricted by this

document.

Information for the Operator

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0.7 Delivery Notes

The scope of delivery is listed on the dispatch papers accompanying

the delivery in accordance with the valid contract of sale.

When you open the packaging please observe the information on the

packaging. Check that the delivery is complete and undamaged.

If possible, compare the order number on the rating plates with the or-

dering data.

For the scope of delivery please see Chapter 7, page 153.

0.8 Standards and Regulations

As far as possible, the harmonized European standards were used to

specify and manufacture this equipment. If harmonized European stan-

dards have not been applied, the standards and regulations of the Fed-

eral Republic of Germany apply (see also the Technical Data in Chap-

ter 6, page 147).

If this product is used outside the area of applicability of these stan-

dards and regulations, please observe the standards and regulations in

force in the country where the product is operated.

Introduction

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Introduction

1.1 General information about the positioner

The positioner is used to adjust and control pneumatic actuators.

The controller operates electropneumatically with compressed air as an

energy supply.

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

Swith linear actuator (figure 1-1, page 13) or

Swith part-turn actuator VDI/VDE 3845 (figure 1-2, page 13)

Different mounting types are available for linear actuators:

SNAMUR or IEC 534

Sintegrated mounting to ARCA

Sintegrated mounting to SAMSON (non-explosion-proof version)

This means the positioner can be installed and operated on all common

actuator systems.

The positioner is available for the following actuators:

Sdouble-acting and

Ssingle-acting

For following applications:

Spotentially explosive or

Snot potentially explosive applications.

The electronics with display, position feedback and valve block are inte-

grated in the housing.

The housing is available in three versions:

SPlastic housing for single and double-acting actuators

SMetal housing for single-acting actuators

SExplosion proof housing for single and double-acting actuators

Purpose

Versions

Housing

Introduction

12 SIPART PS2 Manual

A5E00074631--06

The device is designed with IP66/NEMA4x degree of protection.

The intrinsically safe version can be used in hazardous areas in zone 1

or zone 2.

The explosion proof version can be used in hazardous areas in zone 1

or zone 2.

The version with the type of protection “n” can be used in hazardous

areas of zone 2.

The SIPART PS2 positioners in the variations 6DR501*, 6DR511*,

6DR521* and 6DR531* (i.e. with 0/4 up to 20 mA control signal in the

single-acting design) are also suitable for positioning on fittings with

pneumatic actuators, which satisfy the special requirements for safety

devices up to SIL 2 to IEC 61508/ IEC 61511-1. For this, the SIL safety

instructions (see “SIPART PS2 SIL safety manual” A5E00442120) must

be followed.

The positioner can be expanded with various options modules (chap-

ter 2.7, page 27). The following modules are available in all:

SIy-module: Two-wire current output 4 to 20 mA for position feedback

SAlarm module: 3 digital outputs and 1 digital input

SSIA module: one digital output for fault messages, two digital out-

puts for limit value alarms

SManometer block: 2 or 3 manometers for single and double-acting

positioners

SConnection block (NAMUR) for safety valve block

SMounting kits for linear and part-turn actuator

For decentralized installation of the positioner and position sensor:

SExternal position detection system

SNon-Contacting Position Sensor (NCS)

Only environmentally friendly materials have been used in the construc-

tion of the positioner.

The technical manual is printed on chlorine-free bleached paper.

Degree of

protection

Explosion

Protection

SIL applications

Options

Accessories

Environmental

Protection

Introduction

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1 Actuator

2 Positioner, single-acting in metal housing

3 Lantern

4 Manometer block, single-acting

5Valve

Figure 1-1 Positioner mounted on linear actuator (single-acting)

1 Positioner double-acting in plastic housing

2 Part-turn actuator

3 Manometer block, double-acting

Figure 1-2 Positioner mounted on part-turn actuator (double-acting)

Introduction

14 SIPART PS2 Manual

A5E00074631--06

1 Actuator

2 Positioner, single-acting in explosion proof housing

3 Lantern

4 Manometer block, single-acting

Figure 1-3 Explosion proof version of the positioner mounted on linear actuator (single-acting)

1 Positioner double-acting in explosion proof housing

2 Part-turn actuator

3 Manometer block, double-acting

Figure 1-4 Explosion proof version of the positioner mounted on part-turn actuator (double-acting)

Table 1-1

Design and Functional Principle

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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 actuator is detected by a

servo potentiometer and fed back as actual value x. The setpoint and

actual value are output simultaneously on the display.

The setpoint w is formed by a current fed to the positioner which at

the same time serves to supply the positioner in two-wire operation.

In 3/4-wire operation the supply comes from a 24 V voltage input.

The positioner operates as a predictive five-point switch by the output

variable ±∆y of which the integrated actuating valves are controlled with

pulse length modulation.

These actuating signals cause fluctuations in pressure in the actuator

chamber(s) and thus adjustment of the actuator until the control error is

zero.

Operation (manual) and configuration (structuring, initialization and

parameterization) is effected by three keys and a display with the hous-

ing cover removed.

The standard controller has one digital input (DI1). This can be config-

ured individually and can be used for blocking the operating modes for

example.

With the Iy-option module, the current actuator position can be output

as a two wire signal Iy=4to20mA.

In addition the actuator can be monitored for two programmable limit

values which respond on exceeding or dropping below the stroke or

angle of rotation.

The limit value alarms are output by the alarm option module which can

monitor and report the function of the positioner and the actuator addi-

tionally through a fault message output. The value of the control differ-

ence dependent on the travel time is monitored in automatic mode. The

fault signal is always set when the control error cannot be leveled after

a certain time because for example the valve is blocked or the mains

pressure is insufficient. The three digital outputs are implemented as

semiconductor outputs and are error self-reporting, i.e. the outputs re-

Introduction

Design and Functional Principle

16 SIPART PS2 Manual

A5E00074631--06

spond even when the power supply fails or the electronics are defec-

tive.

The actuator can also be blocked or driven to its final positions depend-

ing on the configuration for example by an external event via a digital

input (DI2) on the alarm module.

If you require electrically independent limit value messages from the

standard controller, you will have to use the SIA module with the slot

initiators instead of the alarm module.

Communication with the controller is possible via the optional HART

interface.

To be able to use the positioner with a variety of different part-turn and

linear actuators, it has a friction clutch and switchable gearing.

The switchable gearing allows you to adjust the positioner for small and

large lifts. You can switch using the yellow switch (8, Fig. 2-11, page 28)

between 33_(as delivered) and 90_.

The friction clutch (8, Fig. 2-11, page 28) allows you to set the working

range, particularly for linear actuators, after installation. You thus do not

have to ensure symmetrical mounting during the installation.

As it is not allowed to open the housing of an explosion-proof version in

a potentially explosive atmosphere, the shaft has an externally fitted,

additional friction clutch (8, Fig. 2-12, page 31).

NOTICE

for the explosion-proof version:

Only adjust the outer friction clutch (8, Fig. 2-12, page 31). The internal

friction clutch (8, Fig. 2-11 page 28) is fixed and, for the explosion-

proof version, must not be adjusted.

Design and Functional Principle

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2.2 Name plate design

(7)(1)

(3)

(2)

(5) (6)

(4)

(8)

(1) Order number (5) Serial number

(2) Manufacturer (6) Place of manufacture

(3) Product name (7) Protection class

(4) Technical data (8) Observe manual

Figure 2-1 Design name plate, example with protection class EEx ia/ib

2.3 Instrument Components

314

90°

33°

6.1 6.2

7891011

4...20 mA

0/4...20 mA

3/4 W2W

DI1

1 Input: Supply air 7 Silencer

2 Output: Actuating pressure Y1 8 Transmission ratio selector

3 Display 9 Adjusting wheel for frichtion clutch

4 Output: Actuating pressure Y2 *) 10 Terminals options modules

5 Operating keys 12 Dummy plug

6 Restrictor 13 Screw-type cable gland

6.1 Restrictor Y1 14 Terminal plate on cover

6.2 Restrictor Y2 *) 15 Purging air switch

*) in double-acting actuators

Figure 2-2 View of the positioner in normal version (cover open)

Design and Functional Principle

18 SIPART PS2 Manual

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6.2

6.1

----

138238 9

2121

1 Input: Supply air 7 Transmission ratio selector

2 Output: Actuating pressure Y1 (only possible with positioner open)

3 Display 8 Adjusting wheel for friction clutch

4 Output: Actuating pressure Y2 *) 9 Terminals standard controller

5 Operating keys 10 Terminals options modules

6.1 Restrictor Y1 12 Safety catch

6.2 Restrictor Y2 *)

*) in double-acting actuators

Figure 2-3 View of the explosion proof version of the positioner

2.3.1 Motherboard

The motherboard contains all the electronic elements such as the CPU,

memory, A/D converter. It also contains the display and the operating

keys.

In addition, the terminal strips for connecting the options modules are

also on the motherboard.

2.3.2 Electrical Connections

The terminals of the standard controller, the Iy- and alarm-option mod-

ule are arranged at the left-hand front edges and offset against each

other in staircase form.

A module cover protects the modules from being pulled out and pre-

vents incorrect installation.

Design and Functional Principle

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2.3.3 Pneumatic Connections

The pneumatic connections are on the right hand side of the positioner

(figure 2-4 and figure 2-5).

1 Actuating pressure Y1 in single- and double-acting actuators

2 Feedback shaft

3 Supply air Pz

4 Actuating pressure Y2 in double-acting actuators

5 Exhaust air output E with silencer on the bottom of the instrument

Figure 2-4 Pneumatic connection in normal version

1 Restrictor Y2 *) 5 Actuating pressure Y1

2 Restrictor Y1 6 Exhaust air output E

3 Actuating pressure Y2 *) 7 Housing ventilation (2x)

4 Supply air PZ

*) in double-acting actuators

Figure 2-5 Pneumatic connection in explosion proof version

In addition, there are pneumatic connections on the back of the posi-

tioner for integrated installation in single-acting linear actuators.

SActuating pressure Y1

SExhaust air output E (not in explosion proof version)

In the ex-factory state, these connections are sealed by screws

(see figure 3-1, page 41, figure 3-3, page 42 and figure 3-4, page 43).

Design and Functional Principle

20 SIPART PS2 Manual

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The exhaust air output E can be provided for supplying dry instrument

air to the tapping chamber and spring chamber to prevent corrosion.

Figure 2-6, page 21 shows the pneumatic connection variants for the

different actuator types, the positioning action and the safety position

after power failure.

Design and Functional Principle

SIPART PS2 Manual

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down

Safety position after power failure

electrical pneumatic

Down Down

Up Up

Down

Open

Closed

Closed Closed

Open Open

Closed

Open

Last position

(before power

failure)

Actuator type

Positioning

pressure

Connection

In part-turn actuators the

direction of rotation

counterclockwise looking

onto the actuating shaft of

the valve is usually defined

as “Open”.

Open

Closed

up down

Open

Closed

OpenClosed

Last position

(before power

failure)

Figure 2-6 Pneumatic connection positioning

Design and Functional Principle

22 SIPART PS2 Manual

A5E00074631--06

2.3.4 Mounting Kit

The positioner can be mounted on almost all actuators with the ap-

propriate mounting kit.

2.3.5 Purge air switching (not in the explosion proof version)

The purge air switch is accessible above the pneumatic terminal strip

with the housing open (figure 2-7). In the IN position the inside of the

housing is purged with very small amounts of clean, dry instrument air.

In the OUT position the purge air is fed directly to the outside air.

Figure 2-7 Purge air switch on the valve block, view of the positioner onto pneumatic connection side

with cover open

2.3.6 Restrictors

In order to achieve travel times of > 1.5 s in small actuators, the air rate

can be reduced with the restrictors Y1 and Y2 (figure 2-8, in explosion

proof version, see figure 2-5, page 19). By turning to the right the air

rate is reduced up to shutting off. To set the restrictors it is advisable to

close them and then open them slowly (see initialization RUN3).

In the case of double-acting valves make sure that both chokes are set

approximately equal.

Y1 Y2

Hexagon socket 2.5 mm

Figure 2-8 Restrictors

Design and Functional Principle

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2.4 Method of Operation

The electropneumatic positioner SIPART PS2 forms a control circuit

with the pneumatic actuator in which the actual value x is the position

of the actuator bar in linear actuators or the position of the actuator

shaft in part-turn actuators and the command variable w is the

actuating current of a controller or a manual control station of 4 to

20 mA.

The stroke or part-turn movement of the actuator is transferred by the

appropriate mounting accessories, the feedback shaft and a play-free

switchable gearwheel to a high quality conductive plastic potentiometer

and to the analog input of the microcontroller. The current position can

also be preset for the positioner via an external sensor. The detection

of the stroke or rotation andle is performed by a non-contacting posi-

tion sensor (Non Contacting Position Sensor) directly at the actuator.

This may correct the angle error of the stroke tap, compares the

potemtiometer voltage as actual value x with the setpoint w fed in at

the terminals 3 and 7 and calculates the manipulated variable

increments Δy. Depending on the size and direction of the control

error (x-w) the piezo-controlled supply air or exhaust air valve is

opened. The volume of the actuator integrates the positioning

increments to actuating pressure y open which moves the actuator bar

or actuator shaft approximately proportionally. These positioning

increments change the actuating pressure until the control error

becomes zero.

The pneumatic actuators are available in single and double-acting

versions. Only one pressure chamber is aerated or deaerated in the

single-acting version. The resulting pressure operates against a spring.

In the double-acting version, two pressure chambers are counteractive.

In this case the one volume is deaerated when the other volume is

aerated. See the block diagram figure 2-10, page 25.

The control algorithm is an adaptive predictive five-point switch

(see figure 2-9, page 24).

The valves are controlled with continuous contact at large control errors

(fast step zone). At medium control errors the valve is controlled by

pulse length modulated pulses (short step zone).

No actuating pulses are output in the small control error zone (adaptive

dead zone). The dead zone adaptation and the continuous adaptation

of the minimum pulse lengths in automatic operation cause the best

possible control accuracy to be achieved at the lowest switching fre-

quency. The start parameters are determined during the initialization

phase and stored in a non-volatile memory. These are basically the real

travel with the mechanical limit stops, the travel times, the size of the

dead zone etc.

In addition the number of fault messages, changes in direction and the

number of strokes are determined and stored every 15 minutes during

operation. These parameters can be read out and documented by the

communication programs such as PDM and AMS. Conclusions as to

the wear on the fitting can be drawn (diagnostic function) especially by

comparing the old value with the currently determined values.

Design and Functional Principle

24 SIPART PS2 Manual

A5E00074631--06

Figure 2-10, page 25 shows the block diagrams for single- and double-

acting actuators with the linear actuator as an example.

.NOTE

The exhaust air valve is always open when there is no current.

Figure 2-9 Method of operation five-point switch

Design and Functional Principle

SIPART PS2 Manual

A5E00074631--06

3 V

IW+

IW-

A1 A2

Zuluft

Abluft

A1 A2

HART

BE1

Micro-

controller

BE2

+24 V

+5 V

Exhaust air

Exhaust

air

Supply air

stroke stroke

1 Motherboard with microcontroller and input circuit

2 Control panel with LC-display and momentary action switch

3 Piezo-valve unit, always built-in

4 Valve unit with double-acting positioner always built-in

5 Iy-module for positioner SIPART PS2

6 Alarm module for three alarm outputs and one digital input

7 SIA-module (Slot Initiator-Alarm-module)

8 Spring-loaded pneumatic actuator (single-acting)

9 Spring-loaded pneumatic actuator (double-acting)

Figure 2-10 Block diagram of the electro-pneumatic positioner, functional diagram

.NOTE

Alarm module (6) and SIA module (7) can only be used alternatively.

Design and Functional Principle

26 SIPART PS2 Manual

A5E00074631--06

2.5 HART-function

The positioner is also available with built-in HART-functions. The HART

protocol allows you to communicate with your instrument with a hand-

held communicatorR, PC or programming unit. This enables you to

configure your instrument comfortably, save configurations, call diag-

nostic data, display online measured values and much more. Commu-

nication takes place as frequency modulation over the existing signal

lines for the command variable from 4 to 20 mA.

The SPART PS2 is integrated in the following parameterization tools:

SHandheld communicatorR

SPDM (Process Device Manager)

SAMS (Asset Management System)

SCornerstone (without diagnostic values/-functions)

.NOTE

Operation on the positioner has priority over the settings via the HART

interface.

Communication is aborted by a power failure at the positioner.

2.6 State as supplied

There are no mechanical mounting accessories on the controller in the

state as supplied. These must be ordered and installed according to

the “operating instructions” depending on the application.

The respective connections for single or double-acting versions are

prepared at the factory as ordered.

The pneumatic connections on the rear are sealed.

Function

Design and Functional Principle

SIPART PS2 Manual

A5E00074631--06

2.7 Installation of options modules

2.7.1 Installation of options modules in normal and intrinsically safe

versions

The following option modules are available for the positioner in the

standard and the intrinsically safe version:

-- ly-module

-- Alarm module

-- SIA-module

-- Mechanical limit switch module

-- EMC filter module

The installation of the options modules is described below:

The option modules are secured by a assembly covering ((1), see

figure 2-11, page 28) and mechanically fixed.

.NOTE

To install the option modules the housing of the positioner needs to be

opened. As soon as the positioner is opened, the IP66 degree of

protection is not guaranteed.

To open the positioner, the four screws of the housing cover must be

loosened with a Phillips screwdriver.

Disconnect or isolate the power supply cables.

Remove the module cover (1). To do this, the two screws (1.1) must be

removed with a screwdriver.

.NOTE

To prevent premature wearing of the fixture by the self-tapping screws

(1.1), the following method of mounting the module cover (1) has

proven effective.

1. Turn the screws counterclockwise until you feel them snap into the

thread

2. Tighten both screws carefully in clockwise direction

Installation

Open positioner

Design and Functional Principle

28 SIPART PS2 Manual

A5E00074631--06

1.1

2.1

7.1 8 9

1.1

2.1

7.2 7.3

1 Module cover 7 SIA-module and mechanical limit switch module

1.1 Fixing screws 7.1 Special screw

2 Motherboard 7.2 Actuating disc for A1 (terminals 41 and 42)

2.1 Fixing screws 7.3 Actuating disc for A2 (terminals 51 and 52)

y-module with ribbon cable (6) 8 Adjusting wheel for friction clutch

4 Alarm module with ribbon cable (5) 9 Transmission ratio selector

5 Ribbon cable for alarm module 10 Insulating cover

6 Ribbon cable for Iy-module 11 Pneumatic block

12 Actuating disc bearings

Figure 2-11 Installation of Options Modules

Design and Functional Principle

SIPART PS2 Manual

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2.7.2 Installation of options modules in explosion proof version

The following option modules are available for the positioner in the ex-

plosion-proof version:

-- Iy-module

-- Alarm module

The options modules are protected and mechanically fixed by a module

cover ((1), see figure 2-12, page 31).

.NOTE

The housing must be opened to install the options modules. The

degree of protection IP66/NEMA4x is not guaranteed as long as the

positioner is open.

!WARNING

In areas in which the atmosphere may be potentially explosive, the

explosion-proof positioner may only be supplied with electrical auxiliary

power when the housing is closed and when built-in, approved elec-

tronics are used.

The feed-though openings for the electronic connections must be

sealed with EEX-d 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.

See figure 2-12, page 31. Disconnect or isolate the power supply

cables first.

To open the positioner, the safety catch (12) must be opened and the

screw-on cover unscrewed.

After loosening the four fixing screws (13.1) the complete rack (13) can

be removed. The actuator may have to be turned so that the clutch can

be easily disengaged.

Remove the module cover (1). To do this, the two screws (1.1) must be

removed with a screwdriver.

Installation

Open the

positioner

Design and Functional Principle

30 SIPART PS2 Manual

A5E00074631--06

.NOTE

To prevent premature wearing of the fixture by the self-tapping screw

(1.1) next to the display, the following method of mounting the module

cover (1) has proven effective.

1. Turn the screws counterclockwise until you feel them snap into the

thread.

2. Tighten both screws carefully in clockwise direction.

Design and Functional Principle

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1.1

13.1

1 Module cover 7 Transmission ratio selector

1.1 Fixing screws 8 Adjusting wheel for friction clutch

2 PA module 10 Housing

ymodule with ribbon cable 11 Screw-on cover

4 Alarm module with ribbon cable 12 Safety catch

5 Ribbon cable for alarm module 13 Rack

6 Ribbon cable for Iymodule 13.1 Fixing screws

Figure 2-12 Installation of the options modules in the explosion proof version

2.7.3 Iy-module

With the Iyoption 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 Iymodule makes it also

error self-reporting.

Function

Design and Functional Principle

32 SIPART PS2 Manual

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Insert the Iymodule (3) in the lower slot of the rack up to the stop and

use the 6-pin flat ribbon cable (6) provided to connect it to the

motherboard (see figure 2-11, page 28).

2.7.4 Alarm module

The alarm module contains

S3 digital outputs and

S1 digital input

The digital outputs serve to output fault messages and alarms. The

configuration is described in chapter 4.4, page 95, with the para-

meters 44 to 54.

By an external signal applied at digital input (DI2) the actuator can be

blocked or driven to its limit positions for example depending on the

configuration. The configuration is described in chapter 4.4, page 95,

with the parameters 43.

The alarm module is available in two versions:

Sexplosion protected for connecting to switching amplifier

EN 60947-5-6

Snon-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.

Sone potential isolated for voltage level

Sone not potential isolated for floating contacts

These two inputs are designed as logic OR links.

Insert the alarm unit (4) below the motherboard in the rack up to the

stop and use the 8-pin flat ribbon cable (5) to connect it to the mother-

board (see figure 2-11, page 28).

Installation

Function

Installation

Design and Functional Principle

SIPART PS2 Manual

A5E00074631--06

2.7.5 SIA module

The SIA module contains:

Sone binary output

Stwo binary outputs

A collected fault message (see alarme module) is output via the binary

output. The floating digital output is implemented as a self error report-

ing semiconductor output.

The two binary outputs are used to report two mechanically adjustable

limit values (L1, L2) via slot initiators. These two outputs are electrically

independent of the rest of the electronics.

(Slot Initiator Alarm module) Proceed as follows for installation

(figure 2-11, page 28)::

1. Remove all the electrical connections from the motherboard (2).

2. Loosen the two fixing screws (2.1) of the motherboard.

3. Snap out the motherboard by carefully bending the four holders.

4. Insert the SIA module (7) from above until it reaches the upper

circuit board rail of the rack.

5. Push the SIA module into the circuit board rail of the rack approx.

3 mm towards the right.

6. Screw the special screw (7.1) through the SIA module into the axle

of the positioner (Torque: 2 Nm):

CAUTION

The pin pressed into the actuating disc bearing (12) must be adjusted

to just before touching with the special screw. The actuating disc bea-

ring and the special screw must then be turned simultaneously so that

the pins slot into the special screw.

7. Place the insulating cover (10) over the SIA module underneath

the surface of the motherboard at the container wall on one side.

The recesses in the insulating cover must slot into the correspond-

ing lugs on the container wall. Place the insulating cover on the

SIA module by carefully bending the container walls.

8. Snap the motherboard into the four holders and screw it tight again

with the two fixing screws (2.1).

Function

Installation

Design and Functional Principle

34 SIPART PS2 Manual

A5E00074631--06

9. Make all the electrical connections between the motherboard and

the options with the ribbon cables provided and between the mo-

therboard and potentiometers with the potentiometer cable.

10. Fix the enclosed module cover instead of the standard version with

the two screws (1.1).

11. Select the plates which already exist on the standard version of the

module cover from the set of plates enclosed. Stick the selected

plates according to the standard version to the mounted module

cover. In the case of the version which doesn’t feature explosion

protection, stick the warning sign onto the side of the ground plate

opposite the name plate.

12. Make the electrical connections.

Setting the two limit values:

.NOTE

Connect a suitable display instrument such as the Initiator-Tester

type 2/Ex made by Peperl+Fuchs to the terminals 41 and 42 or termi-

nals 51 and 52 of the SIA module to be able to see the switching state

of the slot initiators.

1. Drive the actuator to the first desired mechanical position.

2. Adjust the top actuating disc (7.2) by hand until the output signal

on terminals 41 and 42 changes.

3. Drive the actuator to the second desired mechanical position.

4. Adjust the bottom actuating disc (7.3) by hand until the output sig-

nal on terminals 51 and 52 changes.

.NOTE

If you turn the actuating disc beyond the switching point up to the next

switching point, you can set a high-low or a low-high change.

To avoid the actuating discs being accidentally adjusted during opera-

ting, they are relatively sluggish. The following remedy might be of help

if you are having trouble with the adjustment: open and close the ac-

tuator several times while holding the actuating discs. This temporarily

reduces the friction. This allows an easier and finer adjustment.

Design and Functional Principle

SIPART PS2 Manual

A5E00074631--06

2.7.6 Mechanical limit switch module

The mechanical limit switch module contains the following:

SA binary output for the output of a group error message)

STwo switches for signaling two limit values that can be set mechani-

cally. These two switches are electrically independent from the rest

of the electronic system.

The installation has to be carried as follows (figure 2-11, page 28):

!WARNING

When the mechanical limit switch module is run with AC > 16 V or

DC > 35 V (low voltage), the housing must be protected against

mechanical actions of > 1 Joule, since otherwise the proper functioning

of the IP66 protective system is not guaranteed.

!DANGER

When the module is supplied with low voltage, you must observe the

basic safety rules before beginning work on the device, such as:

1. Deenergizing the module by disconnecting it via the disconnecting

device located directly upstream from the module

2. Securing it against being turned on again

3. Ensuring that the module is disconnected from the voltage supply

CAUTION

The following maximal values only refer to the clamps 41 and 42 as

well as the clamps 51 and 52.

Maximal voltage (not Ex) AC 250 V or DC 24 V

Maximal current (not Ex) AC/DC 4 A

Maximal voltage (Ex) DC 30 V

Maximal current (Ex) DC 100 mA

When you supply one circuit breaker with extra-low voltage (AC <16 V

or DC 35 < V) and the other with low voltage, you ensure that the ca-

ble insulation is doubled.

When operating the switch with low voltage, you must position the low

voltage circuits so that they are separated from the extra-low voltage

circuits.

Installation

Design and Functional Principle

36 SIPART PS2 Manual

A5E00074631--06

Follow the instructions below for installation:

1. Remove all electrical connections on the motherboard (2).

2. Loosen carefully both fixing screws (2.1) for the motherboard.

3. Insert the limit switch module (7) from above until it reaches the

upper printed circuit board rail of the container.

4. Insert the mechanical limit switch module (7) from above until it

reaches the upper circuit board rail of the rack.

5. Push the mechanical limit switch module (7) into the circuit board

rail of the rack approx. 3 mm towards the right.

6. Screw the special screw (7.1) through the mechanical limit switch

module into the axle of the positioner (torque: 2 Nm).

CAUTION

The pin pressed into the actuating disc bearing (12) must be adju-

sted just before it touches the special screw. In order that the pin

slot into the special screw, you must then turn the actuating disc

bearing and the special screw simultaneously

7. Place the insulating cover (10) over the mechanical limit switch

module underneath the surface of the motherboard onto the con-

tainer on the wall. The recesses in the insulating cover must slot

into the corresponding lugs on the container wall. Place the insulat-

ing cover on the mechanical limit switch module by carefully bend-

ing the container walls.

8. Snap the motherboard board into the four holders and screw it tight

again with the two fixing screws (2.1).

9. Make sure all electrical connections between the motherboard and

the options using the ribbon cables provided and between the mo-

therboard and potentiometer using the potentiometer cable.

10. Fix the enclosed module cover (1) instead of the standard version

using the two screws (1.1).

.NOTE

To prevent premature wearing of the fixture by the self-tapping screws

(1.1), the following method of mounting the module cover (1) has pro-

ven effective:

STurn the screws counterclockwise until you feel them snap into the

thread.

STighten both screws carefully in a clockwise direction.

Design and Functional Principle

SIPART PS2 Manual

A5E00074631--06

.NOTE

Before connecting up the limit contact module, ensure that:

Sonly qualified personnel connect and set the limit contact module.

Sall cables are de-energized.

Sthe cables are stripped so that the insulation is flush with the termi-

nal when plugging in the wires.

Sthe ends of stranded wires have sleeves.

Sthe connection cables are insulated according to the permitted cur-

rent load.

Sthe permissible working temperature of the cables exceeds the

maximal ambient temperature by >25 _C.

Sthe Ex-version is only allowed to be operated in intrinsically safe

circuits with approved switching amplifiers.

Connection

1. Loosen the screw (1) on the cover (2).

2. Push the cover (2) till it reaches the front stop.

3. Screw each cable tight in the appropriate terminal.

4. Push the cover (2) till it stops at the motherboard.

5. Tighten the screw (1) of the cover (2).

6. Fix the cables of each switch in pairs on the mounting eye using

the cable binders provided (3).

Figure 2-13 Cable connection

Design and Functional Principle

38 SIPART PS2 Manual

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Setting the two limit values:

1. Drive the actuator to the first desired mechanical position.

2. Adjust the top actuating disc (7.2) by hand until the output signal

on terminals 41 and 42 changes.

3. Drive the actuator to the second desired mechanical position.

4. Adjust the bottom actuating disc (7.3) by hand until the output sig-

nal on terminals 51 and 52 changes.

.NOTE

To avoid the actuating discs (7.2/7.3) being accidentally adjusted du-

ring operation, they are relatively sluggish. The following remedy might

be of help if you are having trouble with the adjustment: open and

close the actuator several times while holding the actuating discs. This

temporarily reduces the friction. This allows an easier and finer adjust-

ment.

2.7.7 EMC filter module

The positioner can also be driven by an external position sensor (po-

tentiometer or NCS) (see page 46 “3.3.2 Instructions for using position-

ers which are exposed to strong accelerations or vibrations”). An EMC

filter module, order number C73451-A430-D23, is required for this.

Design and Functional Principle

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2.7.8 Accessories

Figure 2-14 Manometer block (left for single-acting, right for double-acting actuators)

The manometer block for single-acting actuator contains two mano-

meters which are screwed to the lateral pneumatic connection of the

positioner with O-rings. The values for the input pressure (supply air

PZ) and output pressure (actuating pressure Y1) are displayed.

The manometer block for double-acting actuators contains three

manometers which are screwed to the lateral pneumatic connection of

the positioner with O-rings. The values for the input pressure (supply

air PZ) and output pressure (actuating pressure Y1 and Y2) are

displayed.

Manometer block

Design and Functional Principle

40 SIPART PS2 Manual

A5E00074631--06

Table 2-1 Scopetuator”

Preparing for Operation

SIPART PS2 Manual

A5E00074631--06

Preparing for Operation

This chapter describes all the preparations necessary for operating the

positioner.

3.1 Instrument identification (type key)

The order number of the positioner is printed on the rating plate and on

the packaging. Compare this with the order number in chapter 7.1,

page 154.

Installation of any modules required is described in chapter 2.7,

page 27 of this technical manual.

3.2 Dimensional drawings

11,2

50x4xM6

All air connections

G 1/4 or 1/4” NPT

9 deep

M8, 9 deep

182

29,5 29,5

3729

M20 x 1.5 or NPT-adapter

88,5

96,6

13,5

14,5

38,5

Y1 E

Figure 3-1 Dimensional drawing version plastic housing 6DR5xx0

Preparing for Operation

42 SIPART PS2 Manual

A5E00074631--06

79.5

20.5

G1/4or

1/4” NPT

9.5

29.5

58.75

Thread depth 5.5

2xM6

5.3

9.5

3.5

Figure 3-2 Dimensional drawing terminal strip for plastic housing

11.2

50x4xM6

M8, 9 deep

88.5

All air connections

G 1/4 or 1/4” NPT

9 deep

182

34.5

27.5

29.5

96.5

13.5 65

14.5

38.5

6.5

29,5

M20 x 1.5 or NPT-adapter

Figure 3-3 Dimensional drawing version metal housing 6DR5xx1

Preparing for Operation

SIPART PS2 Manual

A5E00074631--06

M8, 14 deep (4x)

129.5

∅8h9

3.5

235,3

M6, 11 deep (4x)

All air connections

G1/4or 1/4”NPT

7.5 25.7 14,3

M6, 8 deep (2x)

M20, M25 or

1/2”NPT (2x)

87.2

7.75

∅

∅136.5

4.5

10.25

19,25

33.5 33.5

82,5

158.5

1) Connection 238/Y2 only

in double action version

Figure 3-4 Dimensional drawing for positioner with metal housing in explosion proof

version 6DR5xx5

3.3 Assembly

!WARNING

To avoid injury or mechanical damage to the positioner/mounting kit,

the following order must be observed for assembly:

1. Mechanical fitting of positioner this chapter

2. Connection of electric power supply see chapter 3.4, p. 57

3. Connection of pneumatic power supply see chapter 3.5, p. 71

4. Put into operation see chapter 3.6, p. 72

Please also observe the warning on page 58!

General

Preparing for Operation

44 SIPART PS2 Manual

A5E00074631--06

.NOTE

The positioner will be equipped at the factory and delivered complete

with the necessary options at the customer’s request. Options modules

may only be retrofitted by our service technicians.

The positioner must be assembled – especially in a moist environment

– in such a way as to rule out freezing of the positioner axle at low

ambient temperature.

The operating keys must be covered to prevent liquid getting in.

!WARNING

In the combination of components it must be ensured that only

positioners and options modules are combined which are approved

for the respective area of application. This applies especially for safe

operation of the positioner in areas in which the atmosphere is poten-

tially explosive (zone 1 and 2). The instrument categories (2 and 3) of

the instrument itself and those of its options must be observed.

In addition, you must always make sure that no water gets into an open

housing or screw-type gland. This may be the case for example when

the positioner cannot be finally assembled and connected immediately.

It generally applies that the positioner may only be operated with dry

compressed air. Therefore use the normal water traps. An additional

drying unit may even be necessary in extreme cases. This is particu-

larly important when operating the positioner at low ambient tempera-

tures. Please set the purge air switch (on the valve block above the

pneumatic terminals) additionally to the “OUT” position.

Use a sufficiently rugged console (e.g. plate thickness > 4 mm with

reinforcements) for part-turn actuators and the mounting kit “linear

actuator” or integrated connection for linear actuators.

3.3.1 Instructions for using positioners in a wet environment

This information gives you important instructions for the assembly and

operation of the positioner in a wet environment (frequent, heavy rain

and/or prolonged tropical condensation) in which the IP66 degree of

protection is no longer sufficient and especially when there is a danger

that water may freeze.

To prevent water getting into the instrument in normal operation (e.g.

through the exhaust air openings) or the display being poorly legible,

please avoid the unfavorable installation positions illustrated in

figure 3-5.

Preparing for Operation

SIPART PS2 Manual

A5E00074631--06

Figure 3-5 Favorable and unfavorable installation positions

If conditions oblige you to operate the positioner in a unfavorable

installation position, you can take additional precautionary measures to

prevent penetration by water.

.NOTE

Never clean the positioner with a high pressure water jet because the

IP66 degree of protection is inadequate protection for this.

The necessary additional measures to prevent penetration by water

depend on the installation position chosen and you may additionally

require:

Sscrew-type gland with sealing ring (e.g. FESTO: CK –1 / 4–PK–6)

Splastic hose approx. 20 to 30 cm (e.g. FESTO PUN- 8X1,25 SW)

Scable straps (number and length depends on local conditions)

Procedure

SConnect the pipes in such a way that rain water which runs along

the pipes can drip off before it reaches the terminal strip of the posi-

tioner.

SCheck the electrical connections for perfect firm contact.

SCheck the seal in the housing cover for damage and contamination.

Clean and replace if necessary.

SMount the positioner if possible so that the sinter bronze silencer

faces downwards on the underside of the housing (vertical installa-

tion position). If this is not possible, the silencer should be replaced

by a suitable screw-type gland with a plastic hose.

Preparing for Operation

46 SIPART PS2 Manual

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Assembly of the screw-type gland with plastic hose

SUnscrew the sinter bronze silencer from the exhaust air opening on

the underside of the housing.

SScrew the screw-type gland mentioned above into the exhaust air

opening.

SMount the above mentioned plastic hose on the screw-type gland

and check the good fit.

SFix the plastic hose with a cable strap to the fitting so that the open-

ing faces downwards.

SMake sure that the hose has no kinks and the exhaust air can flow

out unhindered.

3.3.2 Instructions for using positioners which are exposed to strong

accelerations or vibrations

NOTICE

for explosion-proof versions:

Only adjust the outer friction clutch (8, Fig. 2-12, page 31). The internal

friction clutch (8, Fig. 2-11, page 28) is fixed and, for the explosion-

proof version, must not be adjusted.

The electro-pneumatic positioner SIPART PS2 has a friction clutch and

switchable gearing and can thus be used universally for part-turn and

linear actuators. This means that, for part-turn actuators you don’t have

to worry about the zero point and for linear actuators, you don’t have to

worry about symmetrical mounting, as you can adjust the working

range after installation, with the help of the friction clutch.

The switchable gearing allows you to also adjust the positioner for

small or large lifts.

Occasionally it can happen, that in the rough environment of process

systems (e.g. due to incorrectly fitted valves or if “steam pulses” occur)

that the shaft to monitor the position of the SIPART PS2 positioner is

exposed to extreme acceleration, which far exceeds its specified load

limits, and which could result in an unwanted shift in the friction clutch

or in the gears in the position monitoring jumping briefly out.

For cases like this, as standard, the SIPART PS2 positioner is fitted

with a locking device for the friction clutch and you can also lock the

setting of the transmission ratio selector. This means that an unwanted

change to the position monitoring due to the above mentioned effects

can be reliably prevented.

Both of these locking options are labeled via additional tags inside the

device (see Figure 3-6, page 47). Note that these locks are only re-

quired if extreme acceleration or strong vibration might be present

within your process.

Preparing for Operation

SIPART PS2 Manual

A5E00074631--06

Procedure After you have installed the positioner and put it fully into operation, you

can set the torque for the friction clutch as follows:

SOn the module cover, insert an ordinary 4 mm wide screwdriver into

a slot on the yellow wheel.

SNow use the screwdriver to move the yellow wheel to the left, until

you can feel that it clicks in. This increases the torque of the friction

clutch.

SYou can recognize a locked friction clutch by an approx. 1 mm wide

gap between the yellow and black wheels.

SIf you have to set the zero pint e.g. after exchanging the actuator,

first reduce the torque by turning the yellow wheel to the right until

you hit the stop. After setting the zero point, you can refix the friction

clutch as described above.

Starting from the neutral setting (as delivered), you can lock the trans-

mission ratio selector as follows:

SAdjust the yellow wheel underneath the terminals with an ordinary

4 mm wide screwdriver to correspond to the setting that you would

like (33_or 90_), turning to the left or right, until you can feel that it

clicks in.

SPlease note that you can only adjust the transmission ratio selector

after releasing the fixing.

For this reason you first have to put the yellow ring into the neutral

position, if you have to adjust the transmission ratio selector

e.g. after exchanging the actuator).

33

90

(1)

(3)

(2)

(4)

33_

90_

(1) Transmission ratio selector interlock

(2) Open

(3) Friction clutch

(4) Close

Figure 3-6 Locking and fixing mechanisms

Preparing for Operation

48 SIPART PS2 Manual

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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:

SThe external position detection system (order no.

C73451-A430-D78). This consists of a SIPART-PS2-housing with

integrated friction clutch, built-in potentiometer and various dummy

plugs and seals.

Sor a Non-Contacting Position Sensor (e.g. 6DR4004-6N).

SThe controller unit, any positioner version.

SThe EMC filter module, this is is a set together with cable clips

and M-20 screw-type cable gland and has the order number

C73451-A430-D23. The EMC filter module must be installed in the

positioner. The installation instructions enclosed with the EMC filter

module explain how to assemble the components.

SA 3-wire cable for connecting the components.

This EMC filter module should always be used for the controller unit

when any actuator-mounted potentiometer (resistance 10 kΩ)isto

be used instead of the position detection system C73451-A430-D78.

!WARNING

The explosion-proof version may not be run together with the external

position detection system.

External position

displacement

sensor

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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 3-7, page 51):

Ser. no. pieces Designation Note

1 1 NAMUR mounting kit bracket

IEC 534

Standardized connection for mounting console with

ledge, column or plane surface

2 1 Pick-up bracket Guides the roller with carrier pin and turns lever

arm

3 2 Clamping assembly Mounting of pick-up bracket on actuator spindle

4 1 Carrier pin Assembly with roll (5) on lever (6)

5 1 Roll Assembly with driver pin (4) on lever (6)

6 1 Lever NAMUR Forstrokerange3mmto35mm

For stroke ranges> 35 mm to 130 mm (special deli-

very), lever 6DR4004-8L is required additionally

7 2 U bolt Only for actuators with columns

8 4 Hexagon head screw M8 x 20 DIN 933-A2

9 2 Hexagon head screw M8 x 16 DIN 933-A2

10 6Lock washer A8 -- DIN 127-A2

11 6Flat washer B 8,4 -- DIN 125-A2

12 2Flat washer B 6,4 -- DIN 125-A2

13 1Spring VD--115E 0.70 x 11.3 x 32.7 x 3.5

14 1Spring washer A6 -- DIN 137A-A2

15 1Lock washer 3.2 -- DIN 6799-A2

16 3Spring washer A6 -- DIN 127-A2

17 3Socket cap screw M6 x 25 DIN 7984-A2

18 1Hexagon nut M6 -- DIN 934-A4

19 1Square nut M6 -- DIN 557-A4

21 4Hexagon nut M8 -- DIN 934-A4

Table 3-1 Scope of delivery of the mounting kit “linear actuator”

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3.3.4 Assembly procedure (see figure 3-7, page 51)

1. Mount clamping assembly (3) with hexagon socket cap screws

(17) and lock washer (16) on the actuator spindle.

2. Insert the pick-up bracket (2) into the recesses of the clamping

assembly. Set the necessary length and tighten the screws so that

the pick-up bracket can still be shifted.

3. Insert the pin (4) in the lever (6) and assemble with nut (18), spring

washer (14) and washer (12).

4. The value of the stroke range specified on the actuator or if this

does not exist as a scaling value, the next greatest scaling value is

set. The center of the pin must be in line with the scaling value.

The same value can be set later under parameter 3.YWAY in

commissioning to display the way in mm after initialization.

5. Assemble the hexagon socket cap screw (17), spring washer (16),

washer (12) and square nut (19) on the lever.

6. Push the premounted lever onto the positioner axis up to the stop

and fix with the hexagon socket cap screw (17).

7. Fit the mounting bracket (1) with two hexagon head screws (9),

lock washer (10) and flat washer (11) on the rear of the positioner.

8. Selection of the row of holes depends on the width of the actuator

yoke. The pin (4) should engage in the pick-up bracket (2) as close

as possible to the spindle but may not touch the clamping

assembly.

9. Hold the positioner with the mounting bracket on the actuator so

that the pin (4) is guided within the pick-up bracket (2).

10. Tighten the pick-up bracket.

11. Position the mounting parts according to the type of actuator.

-- Actuator with ledge: Hexagon head screw (8), flat washer (11)

and lock washer (10).

-- Actuator with plane surface: Four hexagon head screws (8), flat

washer (11) and lock washer (10).

-- Actuator with columns: Two U bolts (7), four hexagon nuts (21)

with flat washer (11) and lock washer (10).

12. Secure positioner onto the yoke using the previously positioned

mounting parts.

.NOTE

Set the height of the positioner so that the horizontal lever position is

reached as close to the stroke center as possible. You can use the

lever scale as orientation. It must be guaranteed that the horizontal

lever position is passed through within the stroke range.

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3) 9

10 11

3) 9

10 11

Explosion-proof version:

Without explosion-proof version:

Figure 3-7 Assembly procedure (linear actuator)

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11 10

as required

Mounting on yoke

with columns

Mounting on yoke

with plane surface

Mounting on yoke

with ledge

Figure 3-7 Assembly procedure (linear actuator) continued

3.3.5 Mounting kit “part-turn actuator” 6DR4004-8D

The scope of delivery of the mounting kit “part-turn actuator” contains (ser. no. see figures 3-8

and 3-9):

Ser. no. Pieces Designation Note

2 1 Coupling wheel Mounting on position feedback shaft of the

SIPART PS2

3 1 Carrier Mounting on end of actuator shaft

4 1 Multiple plate Indication of actuator position, comprising 4.1

and 4.2

4.1 8Scales Different divisions

4.2 1Pointer mark Reference point for scale

14 4Hexagon head screw DIN 933 -- M6 x 12

15 4Lock washer S6

16 1Fillister head screw DIN84--M6x12

17 1Washer DIN125–6.4

18 1Hexagon socket head screw Premounted with coupling wheel

19 1Allen key For item 18

Table 3-2 Scope of delivery of the mounting kit “part-turn actuator”

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3.3.6 Assembly procedure (see figure 3-8 and figure 3-9)

1. Attach VDI/VDE 3845 mounting console ((9), actuator-specific,

scope of delivery actuator manufacturer) onto rear of positioner

and secure using hexagon head screws (14) and lock washers

(15).

2. Adhere pointer (4.2) onto mounting console in the center of the

centering hole.

3. Push the coupling wheel (2) onto positioner axis, pull back by

about 1 mm and tighten the hexagon socket head screw (18) with

the Allen key provided.

4. Place the carrier (3) onto the end of the actuator and secure using

Fillister head screw (16) and washer (17).

5. Carefully place positioner with mounting console onto the actuator

such that the pin of the coupling wheel engages in the actuator.

6. Align the positioner/mounting console assembly in the center of the

actuator and screw tight.

(Screws not included in delivery; they are part of the actuator

mounting console!)

7. Following startup as described in Chapter 3.6, page 72: Drive the

actuator to the end position and adhere scale (4.1) on the coupling

wheel (2) according to direction of rotation and part-turn actuator.

The scale is self--adhesive!

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0%20 40 60 80 100%

1) 2)

4) 5)

4.1

Figure 3-8 Assembly procedure (part-turn actuator)

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0%20 40 60 80 100%

4.1

Figure 3-9 Assembly procedure for explosion proof version (part-turn actuator)

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positioner

part-turn actuator

3 16, 17 10 4.1 9

14, 15

CUT A -- B

4.2 14, 15

G1/4

2 Coupling wheel 10 Feedback shaft

3 Carrier 14 Hexagon head screw M6 x 12

4 Multiple plate 15 Lock washer S6

4.1 Scale 16 Fillister head screw M6 x 12

4.2 Pointer mark 17 Washer

9 VDI/VDE 3845-mounting bracket 18 Hexagon socket head screw

Figure 3-10 Mounted positioner for part-turn actuator

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M6 4

Schwenkantrieb

Befestigungsebene

Stellungsregler

F05-Lkr.- 50

+0,1

fastening level

positioner

part-turn actuator

Figure 3-11 Attachment of part-turn actuator, mounting console (scope of delivery actuator manufacturer),

dimensions

3.4 Electrical Connection

.NOTE

Any necessary options modules must be installed before electrical

connection (see chapter 2.7, page 27).

N.B.: The transmission ratio selector can only be set when the

positioner is open. Therefore check this setting before closing the

controller.

!WARNING

The specifications of the examination certificate valid in your country

must be observed.

Electrical connection in hazardous areas

The national directives and laws which apply in your country for haz-

ardous areas, must be followed for electrical installations. In Germany

these are, for example:

-- Working reliability regulations

-- Regulations for installing electrical equipment in hazardous areas,

DIN EN 60079-14 (in the past VDE 0165, T1).

-- The EC type examination certificates

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!WARNING

If the intrinsically safe version is operated with a higher operating vol-

tage by mistake, the positioner must no longer be used for intrinsically

safe application.

The explosion-proof positioner may only be supplied with electrical

power in areas in which the atmosphere may be potentially explosive

when the housing is closed. Where power supply is required, we

recommend checking the power supply to ensure that it corresponds

with that on the name plate and with the test certification valid for your

country.

The feed-though openings in the explosion-proof version for the

electronic connections must be 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 3-12,

page 58.

Please bear in mind that this protection can only be effective if you con-

nect at least one of these bushes with grounded fittings by electrically

conductive (blank) mounting parts.

Shield

Figure 3-12 Base plate

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.NOTE

Use standard M20 x 1.5 cable gland nuts to ensure leakage (IP-protec-

tion of the housing) and for the necessary tensile strength use only

cables with a cable diameter ≥8 mm, or for smaller diameters use a

suitable sealing insert.

For the NPT version, the positioner will be delivered with an adapter.

Make sure that when fitting a part into the adapter, that the maximum

permissible torque of 10 Nm is not exceeded.

NOTE for use in zone 2:

Non-sparking equipment for Zone 2 may not be connected or discon-

nected under power in normal operation.

However, during installation or repair work the positioner may be con-

nected or disconnected even under power (see also certificate for

zone 2).

NOTE for use in two-wire systems:

Never connect the current input (terminal 6 and 7) to a voltage source

as this could destroy the positioner.

Always use a current source with a maximum output current of 20 mA.

To maintain the power supply, the input current must be ≥3.6 mA.

3.4.1 Connection in non-intrinsically safe and explosion proof version

4to20mA Positioner

Digital input 1

Only for:

6DR51x0-xNxxx

6DR5111-xNxxx

6DR51x5-xExxx

HART Communicator

E6DR50x0-xNxxx

6DR5011-xNxxx

6DR51x0-xNxxx

6DR5111-xNxxx

6DR50x5-xExxx

6DR51x5-xExxx

Figure 3-13 Two-wire connection

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+4to20mA 6DR53x0-xNxxx

6DR52x5-xExxx

6DR53x5-xExxx

Positioner

HART Communicator Only for:

6DR52x5-xExxx

Digital input 1

Figure 3-14 Two-wire connection

0/4to20mA

6DR53x0-Nxxx

6DR52x5-Exxx

6DR53x5-Exxx

Positioner

Digital input 1

*) only for three-wire connection

18 to 30 V

HART Communicator Only for:

6DR52x5-xExxx

Figure 3-15 Three-/four-wire connection

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UH61

62 J

≤35 V

Iy module:

6DR4004-8J

Figure 3-16 Iy-module 6DR4004-8J, not Ex

Digital inputs and outputs

+13 V

+4,5 V ≥1Digital input 2

+3 V

Alarm module

6DR4004-8A

35 V

≤30 V

Fault

message

Limit value A1

Limit value A2

Figure 3-17 Alarm module 6DR4004-8A, not Ex

Current output

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SIA module

6DR4004-8G

1K21

10K

<35 V

8.2 V

Fault

message

Limit value A1

Limit value A2

Switching amplifier according to EN 60947-5-6

Figure 3-18 SIA module 6DR4004-8G, not Ex

Mechnical limit switch module

Limit switch module

6DR4004-8K

1K21

10K

<35 V

DC 24 V



max. AC 250 V

AC/DC 4 A

DC 24 V

max. AC 250 V

AC/DC 4 A

Fault

message

Limit value A1

Limit value A2

Figure 3-19 Mechanical limit switch module 6DR4004-8K, not Ex

3.4.2 Connection in intrinsically safe version

.NOTE

Only certified intrinsically safe circuits may be connected as power

supply, control and signal circuits.

SIA module

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Standard controller

4to20mA

6DR5010-xExxx

6DR5020-xExxx

6DR5011-xExxx

EEx

Non-hazardous

area

Intrinsically

safe power

source

Hazardous area zone 1 or zone 2

Positioner

Digital input 1

Figure 3-20 Two-wire connection, EEx i

+6DR5210-xExxx

6DR5220-xExxx

6DR5211-xExxx

4to20mA

EEx

Hazardous area zone 1 or zone 2

Non-hazardous

area

Intrinsically

safe power

source

Positioner

Digital input 1

HART Communicator

Figure 3-21 Two-wire connection, EEx i

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+18 to 30 V

6DR5210-xExxx

6DR5220-xExxx

6DR5211-xExxx

*) Only for three-wire connection

4to20mA

EEx

HART Communicator

Hazardous area zone 1 or zone 2

Non-hazardous

area

Intrinsically

safe power

source

Positioner

Digital input 1

Figure 3-22 Three-/four-wire connection, EEx i

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L+

Instrument 1

6DR5210-xExxx

6DR5220-xExxx

6DR5211-xExxx

6DR5210-xExxx

6DR5220-xExxx

6DR5211-xExxx

EEx

+18to30V

+0/4 to 20 mA

Power supply

intrinsically safe feed sources

Instrument 2

Positioner

setting range 1

setting range 2

Digital input 1

Hazardous area zone 1 or zone 2Non-hazardous

area

total setting

range Iy

Figure 3-23 Series circuit of two positioners, e.g. split range (separate power supply), EEx i

Split-range

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UH61

62 J

Iymodule

6DR4004-6J

EEx

≤30 V

Non-hazardous area

Intrinsically safe power source

Hazardous area zone 1 or zone 2

Figure 3-24 Iy-module 6DR4004-6J, EEx i

Digital inputs and outputs

Alarm module

6DR4004-6A

12 ≥1

EEx

2K1

10K

8.2 V

≤25.2 V

Hazardous area zone 1 or zone 2

Non-hazardous area

Digital

input 2

Fault

message

Limit value A1

Limit value A2

Intrinsically safe

switching

amplifier to DIN

EN 60947-5-6

Figure 3-25 Alarm module 6DR4004-6A, EEx i

Current output

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SIA module

6DR4004-6G

EEx

2K1

10K

8.2 V

Hazardous area zone 1 or zone 2

Non-hazardous area

Fault

message

Limit value A1

Limit value A2

Intrinsically safe

Switching ampli-

fier to DIN EN

60947-5-6

Figure 3-26 SIA module 6DR4004-6G, EEx i

Mechnical limit switch module

Mechanical limit switch module

6DR4004-6K

2K1

10K

max. DC 8,2 V

Umax DC 30 V

=Imax 100 mA

Umax DC 30 V

Imax 100 mA

EEx

Hazardous area zone 1 or zone 2

Non-hazardous area

Intrinsically safe

Switching ampli-

fier to DIN EN

60947-5-6

Fault

message

Limit value A1

Limit value A2

Figure 3-27 Mechnical limit switch module 6DR4004-8K, EEx i

SIA module

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3.4.3 Connection in type of protection “n” version

Standard controller

4to20mA 6DR5010-xGxxx

6DR5020-xGxxx

6DR5011-xGxxx

Hazardous area zone 2

Non-hazardous area

Positioner

Digital input 1

Figure 3-28 Two-wire connection, EEx n

+4to20mA 6DR5210-xGxxx

6DR5220-xGxxx

6DR5211-xGxxx

HART Communicator

Hazardous area zone 2

Non-hazardous area

Positioner

Digital input 1

Figure 3-29 Two-wire connection, EEx n

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0/4to20mA

6DR5210-Gxxx

6DR5220-Gxxx

6DR5211-Gxxx

*) Only for three-wire connection

18 to 30 V

HAR Communicator

Hazardous area zone 2

Non-hazardous area

Positioner

Digital input 1

Figure 3-30 Three-/Four-wire connection, EEx n

UH61

62 I

Iymodule

6DR4004-6J

≤30 V

Non-hazardous area Hazardous area zone 1 or zone 2

Figure 3-31 Iy-module 6DR4004-6J, EEx n

Current output

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Digital inputs and outputs

12 ≥1

+3 V

Alarm module

6DR4004-6A

2K1

10K

2K1

10K

2K1

10K

8.2 V

Hazardous area zone 2

Non-hazardous area

Digital

input 2

Fault

message

Limit value A1

Limit value A2

Figure 3-32 Alarm module 6DR4004-6A, EEx n

SIA module

6DR4004-6G

2K1

10K

8.2 V

Hazardous area zone 2

Non-hazardous area

Fault

message

Limit value A1

Limit value A2

Figure 3-33 SIA module 6DR4004-6G, EEx n

SIA module

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3.5 Pneumatic Connection

!WARNING

For reasons of safety, the pneumatic power may only be supplied after

assembly when the positioner is switched to operating level P manual

operation with electrical signal applied (as-delivered state, see

figure 4-4, page 92).

.NOTE

Note the air quality! Oil-free industrial air, solid content < 30 μm, pressure

dew point 20 K below the lowest ambient temperature (chapter 7 “Techni-

cal Data”, page 153).

SConnect a manometer block for supply air and actuating pressure if

necessary.

SConnection by female thread G 1/4 DIN 45141 or 1/4” NPT:

PZSupply air 1.4 to 7 bar

Y1 Actuating pressure 1 for single- and double-acting actuators

Y2 Actuating pressure 2 for double-acting actuators

E Exhaust air outlet (remove silencer if necessary)

see figure 2-4 and 2-5, page 19.

SSafety position when the electric power supply fails:

single-acting: Y1 deaerated

double-acting: Y1 Max. Actuating pressure

(supply air pressure)

Y2 deaerated

SConnect actuating pressure Y1 or Y2 (only in double-acting actua-

tors) according to the desired safety position.

SConnect supply air to PZ.

.NOTE

In order for spring-loaded pneumatic actuators to be able to reliably

exploit the maximum possible travel, the supply pressure must be

sufficiently greater than the maximum required final pressure of the

actuator.

After installing the device, check the pneumatic connections of the entire

assembly for leakage. Any leakage would cause not only continuous

consumption of compressed air but also would cause the positioner to

continually endeavor to compensate for the variance in position, leading

in time to premature wear of the whole control mechanism.

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3.6 Commissioning

Once the positioner has been fitted to a pneumatic actuator, it must be

provided with electrical and pneumatic auxiliary power.

Then you can then adapt the position controller to the respective actua-

tor by parameterizing and initializing it.

Mode” operating mode (which can also if necessary be attained by

“PRST”) -- “NOINI” will flash.

If the positioner has not been initialized it will be in the “P Manual

Mode“ operating mode (which can also if necessary be attained by

“PRST”) -- “NOINI“ will flash.

This initialization can be effected in three different ways:

SAutomatic initialization

Initialization takes place automatically. Hereby the positioner deter-

mines the direction of action, the stem travel and the angle of rota-

tion, the travel times of the actuator one after the other and adapts

the control parameters to the dynamic behavior of the actuator.

SManual initialization

The stem travel or angle of rotation of the actuator can be set

manually, the other parameters are determined as in automatic init-

ialization. This function is useful in actuators with soft limit stops.

SCopying initialization data (positioner exchange)

In the devices with HART function the initialization data of a posi-

tioner can be read out and copied to another positioner. This en-

ables a defective device to be changed without having to interrupt

an ongoing process by initialization.

Only a few parameters need to be set in the positioner prior to initializa-

tion. The others are defaulted so that they do not normally need to be

adjusted. You will have no problems with commissioning if you observe

the following points.

The possible operating modes and parameters, together with the

adjustment capabilities and their effects are described in chapter 4,

page 89 “Operation“.

.NOTE

N.B.: The operating pressure should be at least one bar greater than is

necessary for closing/opening the valve during initialization. However,

the operating pressure may not be higher than the maximum permis-

sible operating pressure of the actuator.

N.B.: The transmission ratio selector can only be set when the

positioner is open. Therefore check this setting before closing the

housing.

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3.6.1 Preparations for linear actuators

1. Assemble the positioner with the appropriate mounting kit

(see chapter 3.3.3, page 39).

.NOTE

Particularly important is the position of the transmission ratio selec-

tor (8, figure 2-2, page 17) in the positioner:

Stroke Lever Position of the transmission ratio

selector

5to20mm short 33°(i.e. down)

25 to 35 mm short 90°(i.e. up)

40 to 130 mm long 90°(i.e. up)

2. Push the carrier pin (4, figure 3-7 (page 51) 2) onto the lever

(6, figure 3-7, 2) to the scale position corresponding to the rated

stroke or next highest position and screw the carrier pin tight with

the nut (18, figure 3-7, 2).

3. Connect the actuator and the positioner with the pneumatic lines

and supply pneumatic power to the positioner (figure 2-4 and 2-5,

page 19).

4. Connect a suitable current or voltage source (see figure 3-13,

page 59 and figure 3-20, page 63).

5. The positioner is now in the operating mode “P-manual opera-

tion” The current potentiometer voltage (P) is displayed in percent

in the top line of the display, e.g.: “P12.3”, and “NOINI” flashes in

the bottom line:

6. Check the free running of the mechanics in the whole actuating

range by moving the actuator with the keys and and driving

to the respective end position.

.NOTE

You can move the actuator quickly by pressing the other direction key

additionally whilst keeping the direction key selected first pressed.

7. Now move the actuator to the horizontal position of the lever.

A value between P48.0 and P52.0 should be visible in the display.

If this is not the case, adjust the friction clutch (8, figure 2-11, page

28 or in frameproof enclosure 8, figure 2-12, page 31) until “P50.0”

is displayed with a horizontal lever. The more accurately you hit

this value, the more exactly the positioner can determine the path.

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NOTICE

for the explosion-proof version:

Only adjust the outer friction clutch (8, Fig. 2-12, page 31). The internal

friction clutch (8, Fig. 2-11 page 28) is fixed and, for the explosion-

proof version, must not be adjusted.

3.6.2 Automatic initialization of linear actuator

If you can move the actuator correctly, leave it standing in a central

position and start automatic initialization:

1. Press the operation mode key for longer than 5 s. This brings

you to the Configuration mode.

Display:

2. Switch to the second parameter by pressing the operation mode

key briefly.

Display:

.NOTE

It is vital that this value corresponds to the setting of the transmission

ratio selector (8, figure 2-2, page 17) (33°or 90°).

3. Switch on to the following display with the operation mode key :

You only need to set this parameter if you want to have the total

stroke in mm displayed at the end of the initialization phase. To do

this, select the same value in the display to which you have set the

carrier pin to the scale on the lever.

4. Switch on to the following display with the operation mode key :

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5. Start initialization by pressing the key for longer than 5 s.

Display:

During the initialization phase “RUN1”to“RUN5” appear one after

another in the bottom display (see also structograms figure 3-35,

page 83 to figure 3-38, page 86).

.NOTE

The initialization process may last up to 15 minutes depending on the

actuator.

The initialization is complete when the following display appears:

The following display appears after pressing the operation mode key

briefly:

To 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 para-

meters are reset to the factory setting only after performing a “Preset”.

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3.6.3 Manual initialization of linear actuator

The positioner can be initialized with this function without the actuator

being driven hard against the limit stop. The start and end positions of

the travel are set manually. The other initialization steps (optimization

of the control parameters) run automatically as in automatic initializa-

tion.

1. Make preparations as described in chapter 3.6.1, page 73 for

linear actuator. In particular, make sure by manually driving the whole

travel that the displayed potentiometer setting moves in the permis-

sible range between P5.0 and P95.0.

Press the operation mode key for longer than 5 s. This brings

you to the Configuration mode.

Display:

3. Switch to the second parameter by pressing the operation key

briefly. One of the following displays appears:

.NOTE

It is vital that this value corresponds to the setting of the transmission

ratio selector (33_or 90°).

4. Switch on to the following display with the operation mode key:

You only need to set this parameter if you want to have the total

stroke in mm displayed at the end of the initialization phase. To do

this, select the same value in the display to which you have set

the carrier pin to the scale on the lever or the next highest position

in intermediate positions.

Manual initializa-

tion procedure in

linear actuator

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5. Switch on to the following display by pressing the operation

mode key twice:

6. Start initialization by pressing the increment key for longer

than5s.

Display:

7. After 5 s the display changes to:

(The display of the potentiometer setting is shown here and below

as an example only).

Now move the actuator to the position which you want to define as

the first of the two end positions with the increment and decre-

ment key. Then press the operation mode key . This accepts

the current position as end position 1 and switches on to the next

position.

.NOTE

If the message “RANGE” appears in the bottom line, the selected end

position is outside the permissible measuring range. There are several

ways to correct the error:

SAdjust the friction clutch until “OK” appears and press the operation

mode key again or

Smove to another end position with the increment and decrement key

Sabort initialization by pressing the operation mode key. You then have

to change to P manual operation and correct the travel and the posi-

tion detection according to step 1.

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8. If step 7 was successful, the following display appears:

Now move the actuator to the position which you want to define

as the second end position with the increment and decre-

ment key. Then press the operation mode key . This enters

the current position as end position 2.

.NOTE

If the message “RANGE” appears in the bottom line, the selected end

position is outside the permissible measuring range. There are several

ways to correct the error:

Smove to another end position with the increment and decrement key

Sabort initialization by pressing the operation mode key. You then have

to change to P manual operation and correct the travel and the posi-

tion detection according to step 1.

.NOTE

If the message “Set Middl” appears, the lever arm must be driven to

horizontal position using the increment and decrement key and then

the operation mode key pressed. This sets the reference point of the

sine correction in linear actuators.

9. The rest of the initialization now runs automatically. “RUN1” to

“RUN5” appear one after another in the bottom line of the display.

The following display appears on successful completion of initiali-

zation:

The first line additionally contains the determined stroke in millimeters if

the set lever length was specified with parameter 3 YWAY.

5 INITM appears in the bottom line again after pressing the operation

mode key briefly. This brings you back to the Configuration

operating mode.

To exit the Configuration mode, press the operation mode key for

longer than 5 seconds. The software version is displayed after about

5 seconds. The instrument is in manual operation after releasing the

operation mode key.

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3.6.4 Preparations for part-turn actuator

.NOTE

Very important: Switch the transmission ratio selector in the

positioner (8, figure 2-2, page 17) to position 90°(normal angle for

part-turn actuator).

1. Mount the positioner with the appropriate mounting kit

(see chapter 3.3.5, page 52).

2. Connect the actuator and the positioner with the pneumatic lines

and supply pneumatic power to the positioner (figure 2-4 and 2-5,

page 19).

3. Connect a suitable current or voltage source (see figure 3-13,

page 59 and figure 3-20, page 63).

4. The positioner is now in the operating mode “P-manual

operation” The current potentiometer voltage (P) is displayed in %

in the top line of the display, e.g.: “P12.3“, and “NOINI” flashes in

the bottom line:

5. Check the free running of the mechanics in the whole actuating

range by moving the actuator with the keys and and driving

to the respective end position.

.NOTE

You can move the actuator quickly by pressing the other direction key

additionally whilst keeping the direction key selected first pressed.

3.6.5 Automatic 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. Press the operation mode key for longer than 5 s. This brings

you to the configuration operating mode.

Display

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2. Set the parameter with the -key to “turn”

Display:

3. Switch to the second parameter by pressing the operation mode

key briefly. This has set automatically to 90°.

Display:

4. Switch on to the following display with the operation mode key :

5. Start initialization by pressing the key for longer than 5 s.

Display:

During the initialization phase “RUN1”to“RUN5” appear one after

another in the bottom display (see also structograms in figure 3-35,

page 83 to figure 3-38, page 86).

.NOTE

The initialization process may last up to 15 minutes depending on the

actuator.

The initialization is complete when the following display

appears:

The top value indicates the total angle of rotation of the actuator

(example 93.5°).

The following display appears after pressing the operation mode key

briefly:

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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 ope-

ration mode key. Your previous settings are retained. All the parame-

ters are set to the factory setting only after performing a “Preset”.

3.6.6 Manual initialization of part-turn actuators

The positioner can be initialized with this function without the actuator

being driven hard against the limit stop. The start and end positions of

the travel are set manually. The other initialization steps (optimization

of the control parameters) run automatically as in automatic initializa-

tion.

1. Make preparations as described in chapter 3.6.4, page 79 for

part-turn actuators. In particular, make sure by manually driving

the whole travel that the displayed potentiometer setting moves

in the permissible range between P5.0 and P95.0.

2. Press the operation mode key for longer than 5 s. This brings

you to the Configuration mode.

Display:

3. Set the parameter YFCT to “turn” with the decrement key.

Display:

4. Switch to the second parameter by pressing the operation mode

key briefly.

Display:

Manual initializa-

tion procedure in

part-turn actuators

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.NOTE

Make sure that the transmission ratio selector is in position 90 °!

5. Switch on to the following display by pressing the operation mode

key twice:

The following steps are identical with the steps 6) to 9) for initiali-

zation of linear actuators.

After successful initialization the determined part-turn range ap-

pears in the top display.

“5.INITM” appears in the bottom line again after pressing the op-

eration mode key briefly. This brings you back to the Configu-

ration mode.

To exit the Configuration mode, press the operation mode key

for longer than 5 seconds. The software version is displayed after

about 5 seconds. The instrument is in manual operation after re-

leasing the operation mode key.

3.6.7 Automatic initialization (structograms)

Open

Closed

Up Down

part-turn actuator

linear actuator

Figure 3-34 Direction of action of the actuators

The initialization procedure should be taken from the following structo-

gram (figure 3-35 to figure 3-38). The terms Open/Closed and up/down

in the structogram refer to the direction of action of the actuators as

illustrated in figure 3-34.

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configure

piezo valve 1 opens

piezo valve 2 opens

dy > 4 % ?

t>60s?

yes

move the actuator

into the travel range

RUN 1

manual intervention

continue with:

with:

>5s

start: press

Figure 3-35 Automatic initialization, part 1

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yes

continue with:

turn slip clutch

until 0 appears

in the bottom line

of the display

check

mechanics

manual intervention

actuator moves

into open

position

tolerance band

4% > dw >10%?

hard stop

up < 97 % ?

span

up-dw > 25 % ?

RUN 2

actuator

into closed

position

moves

Figure 3-36 Automatic initialization part 2 (in part-turn actuators)

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continue with:

yes

continue with:

correct height

adjustment or

turn friction clutch

until 0 appears

in the bottom line

of the display

set the next lowest travel

value on the lever and

check the setting of the

transmission ratio selector

set the next highest travel

value on the lever and

check the setting of the

transmission ratio selector

has friction

clutch

moved?

been

actuator

into closed

position

moves

was the

vertical position

(to stem) of the lever

driven through

set lever vertical to stem with:arm

RUN 2

actuator moves

into open

position

continue with:

manual intervention

tolerance band

4>d>20%?

hard stop

up < 97 % ?

span

up-dw > 25 % ?

Figure 3-37 Automatic initialization part 2 (in linear actuators)

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determine travel times

within

5s?

within

5s?

yes

continue with:

set restrictor(s) to

change the travel

times

actuator comes to standstill

display travel times

optimizing of transient behavior and

determining of prediction horizon

determine minimum

positioning increments

if setting of travel

times is desired

if leakage test of

actuator is desired

display of leakage

in % / min

display of travel

times in s

display of stroke in mm

or angle of rotation in degrees,

is also the identification for

complete initialization

RUN 3RUN 4RUN 5

after

1 minute

flashes

alternating

flashes

alternating

configure

manual intervention

Figure 3-38 Automatic initialization, part 3

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3.7 Copying initialization data (positioner exchange)

With this function you have the possibility of starting up a positioner

without running the initialization routine. This allows for example a posi-

tioner to be changed on a 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). This step is unnecessary if the

instrument has been parameterized with PDM and the data have

already been stored.

2. Fix the actuator in its momentary position (mechanical or

pneumatic).

3. Read and note the current position actual value of the positioner to

be changed. If the electronics are defective, determine the current

position by measuring on the actuator or valve.

4. Disassemble the positioner. Mount the lever arm of the positioner

on the replacement instrument. Mount the replacement instrument

on the fitting. Move the transmission ratio selector to the same

position as the defective instrument. Copy the instrument data and

initialization data from the PDM or handheld.

5. If the displayed actual value does not match the noted value of the

defective positioner, set the correct value with the friction clutch.

6. The positioner is now ready to operate.

The accuracy and dynamic behavior may be restricted in relation

to correct initialization. The position of the hard stops and the rela-

ted maintenance data may show deviations in particular. Therefore

initialization must be performed at the earliest opportunity.

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Operation

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Operation

The following chapter describes the operation of the positioner.

4.1 Display

The LC display has two lines whereby the lines have different

segmentation. The elements of the top line consist of 7, those of the

bottom line of 14 segments. The contents of the display depend on the

selected operating mode (see chapter 4.3, page 92)

.NOTE

If the positioner is operated in ranges with temperatures below --10 °C

the liquid crystal display becomes sluggish and the display refresh rate

is reduced considerably.

Figure 4-1 shows you the various display options. The meaning of fur-

ther display capabilities is detailed in chapter 4.3 page 139.

4.2 Input keys

The positioner is operated by three keys (figure 4-2, page 91) the

function of which depends on the selected operating mode. In the

explosion proof version of the positioner the input keys are underneath

a key cover which can be lifted up after loosening the cover screw.

.NOTE

The input keys of the explosion proof version must be covered to

prevent liquid getting in. The IP66/NEMA4x degree of protection is not

guaranteed when the housing is open or the key cover is open.

The housing cover must be removed to operate the keys in the normal

and intrinsically safe versions of the positioners.

Operation

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Figure 4-1 Meaning of the various display options

.NOTE

The degree of protection IP 66/NEMA4x is not guaranteed as long as

the positioner is open.

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23 4

1 Display

2 Operation mode key

3 Decrement key

4 Increment key

Figure 4-2 Display and input keys of the positioner

Explanations of the input keys.

SThe operation mode key (manual key) serves to switch over the op-

erating mode and pass on parameters.

.NOTE

By pressing and holding the operation mode key and additionally

pressing the decrement key, you can select the parameters in reverse

order.

SThe decrement key serves to select parameter values in config-

uration and to move the actuator in manual operation.

SThe increment key serves to select parameter values in config-

uration and to move the actuator in manual operation.

The current firmware state is displayed when you exit the configuration

menu.

Figure 4-3 Firmware version, example: 4.00.00

Firmware version

Operation

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4.3 Operating modes

The positioner can be operated in five operating modes.

1. P-manual mode (ex-factory state)

2. Configuration and initialization

3. Manual mode (MAN)

4. Automatic (AUT)

5. Diagnostic display

Figure 4-4 gives you an overview of the possible operating modes and

the change between them.

Figure 4-4 Change between the operating modes

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The display of the positioner shows you the current potentiometer

setting in the top line and “NOINIT” flashes in the second line. You can

move the actuator with the decrement and increment key . In order

to adapt the positioner to your actuator, you have to change to the

Configuration menu. See also chapter 3.6, page 72 “Commissioning”.

Output of alarms and position feedback is possible after successful init-

ialization.

To go to the Configuration menu, press the operation mode key for

at least 5 seconds. In the Configuration menu you can adapt the

positioner individually to your actuator and start initialization. Only a few

parameters need to be set in the positioner prior to initialization. The

others are defaulted so that they do not normally need to be adjusted.

You can block the Configuration menu against manipulation by an

appropriately parameterized and activated digital input. Which

parameters you need to set and all other parameters are explained in

chapter 4.4, page 95 Parameters.

The configuration mode can be reported by outputting a

parameterizable fault message, a position feedback or output of limit

values A1 and A2 is not possible.

.NOTE

If the electric power supply fails during configuration, the positioner

switches back to the first parameter after recovering the power supply,

values which have already been parameterized are retained. When

doing this, please note that the new value will only be saved when

leaving the configuration menu or when another parameter is selected.

Without a power failure you re-enter the configuration menu at the

point you exited it when you call the Configuration menu again.

P-manual mode

(ex-factory state)

Configuration and

initialization

Operation

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at the same time

Figure 4-5 Overview: Configuration

In this operating mode you can move the actuator with the decrement

() and increment keys ( ) and the current position is held regard-

less of the setpoint current and any leakages.

.NOTE

You can move the actuator quickly by pressing the other direction key

additionally whilst keeping the direction key selected first pressed.

The manual mode can be reported by outputting a parameterizable

fault message, a position feedback or output of limit values A1 and A2

is only possible in automatic mode.

.NOTE

The positioner switches over to automatic mode automatically after an

electrical power failure.

The automatic mode is the normal mode. In this mode the positioner

compares the setpoint current with the current position and moves the

actuator until the control deviation reaches the parameterizable dead

zone. Error messages are output if this is not possible for various

reasons.

In this operating mode you can have the current operating data (such

as number of strokes, number of changes in direction, number of faults

messages, etc.) displayed (see table 4-1, page 123).

From the automatic or manual mode you go to the diagnostic display

by simultaneously pressing all three keys for at least two seconds.

Manual mode

(MAN)

Automatic (AUT)

Diagnostic display

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See chapter 4.5, page 122 for further information.

.NOTE

The respective operating mode (MAN or AUT) of the positioner is retai-

ned when you switch to the diagnostic display, i.e. in automatic opera-

tion the specified setpoint is still used for controlling and in manual

operation the position last reached is retained.

4.4 Parameters

All the parameters of the positioner are listed in this chapter. Figure 4-6

shows an overview of the parameters.

The parameter name is shown once in plain text and once as it ap-

pears in the display. The function of the parameter is described briefly

in the “Function” column. In addition, the possible parameter values,

the physical unit and the factory setting of the parameters are shown.

Operation

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Figure 4-6 Parameter table of the positioner

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The following configuration block diagram shows the effects of the pa-

rameters.

Figure 4-7 Configuration block diagram

Operation

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Normally adjustment of the first three following parameters is com-

pletely sufficient to enable a positioner to be operated by an actuator.

If you wish to become familiar with all details of the positioner, try out

incrementally the effects of the remaining parameters by selective

trials.

.NOTE

In particular if the positioner has previously been operated using a

different actuator, it must always be reinitialized in order to restore the

factory settings. Only in this way can the positioner matching process

start from known conditions. The parameter “55.PRST” is provided for

this purpose.

This is also recommended if multiple parameters have been changed

in a single session, the effects cannot be assessed and unintended

consequences may result.

Positioning actuator type

This is to match the positioner with the respective actuator and where

necessary to the position sensor being used. The following adjustment

capabilities are provided:

SYFCT = turn

This adjustment is necessary for the part-turn actuator.

If “turn” is selected, the following parameter “2. YAGL” is automati-

cally set to 90_and cannot be changed.

SYFCT = WAY (Factory setting)

This is necessary for a linear actuator. This allows the positioner to

compensate for the non-linearity that arises due to the conversion of

the linear movement of the linear actuator into the part-turn move-

ment of the feedback shaft. For this the positioner is factory set so

that it shows between “P 49.0 and P 51.0” when the arm on the

feedback shaft is vertical to the linear actuator spindle.

SYFCT = 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.

SYFCT = ncSt

Use this when an NCS is fitted to a part-turn actuator.

SYFCT = -ncSt

This must be set when an NCS is used with a part-turn actuator with

reverse direction of control action.

SYFCT = ncSL

This must be set when an NCS is used with a linear actuator.

1.YFCT

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SYFCT = ncSLL

This must be adjusted if an NCS is to be connected to a linear ac-

tuator with the position converted by an arm into a part--turn move-

ment.

.NOTE

After “LWAY, ncSt, --ncSt or ncSL” have been adjusted, the parameter

“3. YWAY” will not be displayed.

Rated angle of rotation of the feedback shaft

In part-turn actuators, an angle of 90°is preset automatically by

1.YFCT = turn (see above). In linear actuators (1.YFCT = WAY) a

value of 33°or 90°can be selected depending on the stroke range:

S33°for strokes ≤20 mm

S90°for strokes > 20 mm

When using the lever up to 35 mm, both angles of rotation (33°and

90°) are possible.

The long lever (> 35 mm stroke) is only designed for an angle of

rotation setting of 90°. It is not part of the mounting kit set 6DR4004-8V

but must be ordered separately under order number 6DR4004-8L.

.NOTE

The setting of the transmission ratio selector on the positioner (see

figure 2-2, page 17 and figure 2-3, page 18) must correspond to the

angle value selected under “2.YAGL”.

Lever arm transmission

Selection of the lever arm range: serves to display the real stroke after

initialization. The use of this parameter is optional. You only need to set

this parameter if you want to have the way in mm displayed at the end

of the initialization.

If the parameter value “oFF” is selected here, the real stroke is not

displayed after initialization.

.NOTE

The specification “YWAY” must match the mechanical lever arm trans-

mission. The carrier must be set to the value of the actuator stroke,

if this is not scaled to the next highest scaled value.

2.YAGL

3.YWAY

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Automatic initialization (see chapter 3.6, page 72)

By selecting “Strt” and pressing the increment key for at least

5 seconds, automatic initialization is started. The initialization process

is displayed by “RUN 1” to “RUN 5” (see figure 3-35, page 83 to

figure 3-38, page 86).

Manual initialization

By selecting “Strt” and pressing the increment key for at least

5 seconds, manual initialization is started. The manual initialization

process is described in chapter 3.6.3, page 76 and chapter 3.6.6,

page 81.

.NOTE

If the positioner has already been initialized, for INITA and INITM it is

possible to transfer it to its non-initialized state without changing the

remaining parameters by pressing the decrement key for 5 s.

Current range of the setpoint

The selection of the current range depends on the connection type.

“0mA” (0 to 20 mA) is only possible in three-/four-wire connections (see

figure 3-23, page 64).

Setpoint direction (see figure 4-8, page 101)

The setting of the setpoint direction serves to reverse the direction of

action of the setpoint. It is used mainly for the split range mode and in

single-acting actuators with the safety position “up”.

Split range start (see figure 4-8)

and

Split range end (see figure 4-8)

The parameters “8.SPRA” and “9.SPRE” in connection with the

parameter “7.SDIR” serve to restrict the active setpoint range. In this

way split range tasks can be solved with the following characteristics.

Srising / falling

Sfalling / rising

Sfalling / falling

Srising / rising

4.INITA

5.INITM

6.SCUR

7.SDIR

8.SPRA

9.SPRE

Operation

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Positioner 1 Positioner 2

100 %-SPRE 100 %-SPRA SPRA SPRE

[0 % to 100 %]

y=x

100 %

Positioner 1

Positioner 2

6.SDIR = FALL

6.SDIR = riSE

Setting range 1 Setting range 2

Total setting range

100 %

Figure 4-8 Example: Split range-operation with two positioners

Setpoint ramp UP

and

Setpoint ramp DOWN

The setpoint ramp is effective in automatic operation and limits the

speed of alteration of the active setpoint. When switching over from

manual operation to automatic the active setpoint is adjusted to the set-

point on the positioner with the setpoint ramp.

This bumpless manual/automatic switchover avoids excessive pressure

increases on long pipelines.

In the position TSUP = Auto the slower of the two travel times deter-

mined during initialization is used for the setpoint ramp. TSDO is then

ineffective.

Setpoint function (see figure 4-9, page 102)

Non-linear valve characteristics can be linearized with this function and

any flow characteristics simulated in linear valve characteristics.

10.TSUP

11.TSDO

12.SFCT

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Six valve characteristics are stored in the positioner

Slinear (12.SFCT = Lin, factory setting)

Sequal percentage 1 : 25 (12.SFCT = 1:25)

Sequal percentage 1 : 33 (12.SFCT = 1:33)

Sequal percentage 1 : 50 (12.SFCT = 1:50)

Sinverse equal percentage 25 : 1 (12.SFCT = n1:25)

Sinverse equal percentage 33 : 1 (12.SFCT = n1:33)

Sinverse equal percentage 50 : 1 (12.SFCT = n1:50)

Sfreely adjustable (12.SFCT = FrEE)

Setpoint turning points

A flow parameter can be assigned to the respective setpoint turning

value at an interval of 5 %. These points lead to a polygon chain with

20 straight lines which therefore represents a projection of the valve

characteristic.

100%

100

20 30 40 50 60 70 80 90 100 %

9SFCT=Lin

Modulation range

100%

100

20 30 40 50 60 70 80 90 100 %

2106141941217816195131831171520SL 0

12 SFCT = FrEE

Limit for tight closing

Example:

39 YCLS = UP

41 YCUP = 85.0

Limit for tight closing

Example:

39 YCLS = UP

41YCUP = 75.0

Limit for tight closing

Example:

39 YCLS = DO

40YCDO = 10.0

Limit for tight closing

Example:

39 YCLS = DO

40 YCDO = 15.0

Setpoint turning point

Example:

18 SL5 = 45.0

Modulation range

Setpoint Setpoint

Figure 4-9 Setpoint characteristic, manipulated variable standardization and tight closing function

The setpoint vertex values can only be input at 12.SFCT=FrEE. You

may only enter a strictly monotonous characteristic, and two consecu-

tive vertex values must differ by at least 0.2 %.

13.SL0 to 33.SL20

Operation

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Dead zone of the controller

At dEbA = AUto the dead zone in automatic operation is adapted con-

tinuously to the requirements of the control circuit. The dead zone is

gradually increased on detecting a control oscillation. The reverse

adaptation takes place by a time criterion.

In the other discrete settings the fixed value is used for the dead zone.

Manipulated variable limiting start (see figure 4-9 and 4-10)

and

Manipulated variable limiting end (see figure 4-9 and 4-10)

With the parameters “YA” and “YE” the mechanical actuating distance

(from stop to stop) is limited to the set values. In this way the mechani-

cal setting range of the actuator can be limited to the active flow and

the integral saturation of the commanding controller avoided.

.NOTE

YE must always be set to greater than YA.

Manipulated variable standardization (see figure 4-9 and 4-10)

With limiting of the manipulated variable (by “35.YA” and “36.YE”) two

different scalings are produced for the display and the position feed-

back via the current output (MPOS or FLOW).

The MPOS scaling shows the mechanical position (0 to 100%) be-

tween the hard stops of the initialization. This is not affected by the pa-

rameters “35.YA” and “36.YE”. The parameters “35.YA” and “36.YE”

are displayed in the MPOS-scale.

The FLOW-scale is the standardization (0 to 100%) to the range be-

tween “35.YA” and “36.YE”. The setpoint w (0 to 100%) is always re-

ferred to this range. This gives (also by using valve characteristics) a

quasi-flow-proportional display and position feedback Iy.

To calculate the control difference, the setpoint is also shown in the ap-

propriate scale on the display.

34.DEBA

35.YA

36.YE

37.YNRM

Operation

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Example:

YNRM = FLOW with YA = 10 % and YE = 80 %

YNRM = MPOS or YNRM = FLOW

Presetting: YA = 0% and YE = 100%

Input current

(setpoint)

X display

W display

X display

W display

X display

W display

Mechan. Stroke

(actual value)

Mechan. Stroke

(actual value)

Mechan. Stroke

(actual value)

0mm

80mm

16mm

32mm

48mm

64mm

100%

20%

40%

50%

60%

80%

YE = 80%

YE = 100%

YA = 10%

YA = 0%

Example:

YNRM = MPOS with YA = 10 % and YE = 80 %

4mA 20mA7.2mA 10.4mA 13.6mA 16.8mA

Input current

(setpoint)

Input current

(setpoint)

4mA 20mA7.2mA 10.4mA 13.6mA 16.8mA

Figure 4-10 Dependence on the stroke of standardization and on YA and YE in the example of an 80 mm

linear actuator

Manipulated variable direction of action

The direction of action (rising or falling) of the display and the position

feedback (Iy) can be set with this.

Tight closing with manipulated variable (see figure 4-9, page 102)

With this function the valve can be driven to the seat with the maximum

actuating force of the actuator (continuous contact of the piezo-valves).

The tight closing function can be activated on one side or for both limit

positions. YCLS becomes active when the setpoint is below the value

set with parameter “YCDO” or above that set with parameter “YCUP”.

38.YDIR

39.YCLS

Operation

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.NOTE

If the control function to close tightly is activated, for parameter

“49. LIM” the monitoring of the control deviation in each overrun direc-

tion (YCDO: < 0 %, YCUP: > 100 %) is disabled. This function is par-

ticularly useful for valves with a soft seating. For long term monitoring

of the end-stop positions, we recommend activating the parameters

“52. ZERO” and “53. OPEN”.

Value for tight closing, bottom

and

Value for tight closing, top

.NOTE

“40.YCDO” must always be set to less than “41.YCUP”. The tight

closing function has a fixed hysteresis of 1 %. “40.YCDO” and

“41.YCUP” relate to mechanical stops and are independent of the

settings of “7.SDIR” and “38.YDIR”.

Function digital input 1 (see figure 4-6, page 96)

and

Function digital input 2 (see figure 4-6)

The parameters “BIN1” and “BIN2” can be set individually depending

on the purpose. The direction of action can be adapted to an NCC or

an NOC.

SBIN1 or BIN2 = on or --on

Digital messages of the periphery (e.g. pressure or temperature

switches) can be read out via the HART interface or lead to re-

sponding of the fault message output by OR linking with other mes-

sages.

SBIN1 = bLoc1

The Configuration operating mode is locked to prevent it being ad-

justed (e.g. by a wire jumper between terminals 9 and 10).

SBIN1 = bLoc2

If digital input 1 has been activated, manual operation is also locked

in addition to the Configuration operating mode.

SBIN1 or BIN2 = uP or doWn (contact closes) or --uP or --doWn (con-

tact opens).

The actuator drives the linear actuator to the upper or lower stop

when the digital input is activated with continuous contact.

SBIN1 or BIN2 (contact closes) = StoP or --StoP (contact opens).

40.YCDO

41.YCUP

42.BIN1

43.BIN2

Operation

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With activated digital input the piezo-valves are blocked and the ac-

tuator remains in the last position. Leakage messages can then be

executed without initialization function.

SBIN1 oder BIN2 = PSt oder --PSt

Depending on settings, a partial stroke test can be initiated via

binary input 1 or 2 by actuating an opener or closer.

SBIN1 or BIN2 = oFF (factory setting)

no function

special function of DI1: If the digital input 1 is activated in P manual

operation by a jumper between terminals 9 and 10, , when the oper-

ating mode key is pressed the firmware version will be displayed.

line of the display.

If one of the above named functions is selected with the parameters

“BIN1” and “BIN2” simultaneously, then “Blocking” has priority over

“Up” and “Up” priority over “Down”.

Alarm function

The actuator can report the exceeding (max.) or dropping below (min)

of a specified stroke or angle of rotation. The response of the alarms

(limit values) is related to the MPOS-scaling (see figure 4-10,

page 104). The alarms are reported by the alarm module (order no.

6DR4004-6A or -8A). In addition the alarms can be read out through

the HART interface (optional).

The direction of action of the digital outputs can be adapted from high

active to low active sequence systems.

MAXMIN

MAXMAX

MINMIN

--M AX--M IN

--M AX--M AX

--M IN--MI N

Limit

way

A1 A2

A1 = 48

A2 = 52

Travel = 45 Activated

Travel = 50

Travel = 55 Activated

A1 = 48

A2 = 52

Travel = 45 Activated

Travel = 50 Activated Activated

Travel = 55 Activated

A1 = 52

A2 = 48

Travel = 45 Activated

Travel = 50 Activated Activated

Travel = 55 Activated

A1 = 52

A2 = 48

Travel = 45 Activated

Travel = 50

Travel = 55 Activated

AFCT = MIN / MAX

AFCT = --MIN / --MAX

AFCT = MIN / MAX

Alarm module

AFCT = --MIN / --MAX

44.AFCT

Operation

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.NOTE

If you have activated the extended diagnostics (parameter 51.XDIAG)

with On2 or On3, the alarms cannot be output via the alarm unit.

However, the message is possible via HART communication at any

time.

Response threshold alarm 1

and

Response threshold alarm 2

The alarm thresholds are related to the mechanical path (MPOS-scale).

Function of the fault message output

The fault message output serves as a group message for following

faults:

SControl error (e.g. by actuator fault, valve fault, compressed air fail-

ure) with the parameters “48. TIM” and “49. LIM”

SPositioner not in automatic mode

SDigital input activated (see parameter “42.BIN1” and “43.BIN2”)

SExceeding of a limit value (e.g. way integral or valve seat, see pa-

rameter 50 to 54)

It also responds at:

SPower failure

SProcessor fault

The direction of action of the digital outputs can be adapted from high

active to low active sequence systems.

For more information on error messages, see chapter 4.5.3 Online-

Diagnostics, page 131.

45.A1

46.A2

47. FCT

Operation

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Monitoring time for setting the fault messages

The set value(s) is/are for the specification of the time, within which the

positioner must have reached a compensated state. The corresponding

response threshold is preset with “49. LIM”.

If the set time is exceeded, the fault message output is set.

.NOTE

If the tight closing function is activated, for parameter “49. LIM”, the

monitoring of the control deviation in each overrun direction (YCDO:

< 0 %, YCUP: > 100 %) is deactivated. This function is particularly

useful for valves with a soft seat. For the long-term monitoring of the

endstop positions, we recommend activating the parameters

“F. ZERO” and “G. OPEN”.

You can find more information on fault messages in chapter 4.5.3

Online Diagnostics.

Response threshold for fault messages

A value (%) can be set here for the permissible control deviation for

triggering the fault message.

If parameters 48 and 49 are set to “Auto” (factory setting), the fault

message is set if the short step zone is not reached within a certain

time.Within5to95%oftheactuatortravel,thistimeis10to90%of

10 times the initialization actuating time.

Preset

Establishes the factory setting and resets the initialization.

.NOTE

After “Preset” the positioner needs to be re-initialized. All previously

determined maintenance parameters are deleted.

48. TIM

49. LIM

50.PRST

Operation

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Activation of the extended diagnostics

The extended diagnostics is deactivated at the factory, parameter 51 is

therefore at “OFF”. There are three operating modes for activating the

extended diagnostics:

SOn1: The extended diagnostics is activated and the threshold 3

error messages are also output via the fault message output.

SOn2: The extended diagnostics is activated, the threshold 2 error

messages are output via alarm output 2 and the threshold 3 error

messages are also output via fault message output.

SOn3: The extended diagnostics is activated, the threshold 1 error

messages are output via alarm output 1, the threshold 2 error

messages are output via alarm output 2 and the threshold 3 error

messages are also output via the fault message output.

.NOTE

Please note that the menu items of the extended diagnostics from

A. PST to P. PAVG are only displayed in the display after selecting

one of the three On operating modes.

With the factory setting, the parameters of menu items A to P are

deactivated by default (OFF). The corresponding parameters are only

displayed once you have activated the relevant menu item with “On”.

51.XDIAG

Operation

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Partial stroke test

This parameter activates the partial stroke test for the cyclic or manual

partial stroke test of Up/Down and modulating valves.

The partial stroke test can be triggered via keyboard, a binary input or

the HART communication.

Start position

The start position of the partial stroke test is specified here within the

range of 0.0 to 100.0%.

Start tolerance

The start tolerance in relation to the start position is specified here in

the range of 0.1 to 10.0%. That means, with a start position of e.g. 50%

and a start tolerance of 2%, a partial stroke test can only be triggered

during operation if the current position is between 48 and 52%.

Step height

Input of the step height of the partial stroke test within the range of

0.1 to 100.0%. The factory setting is 10.0%.

Step direction

Input of the step direction of the partial stroke test. The following

options are available:

“up”, “do” (down), “up do” (up and down). If “up” is selected, the

actuator is moved in a controlled manner from its start position to the

target position (start position + step height) and then back to the

original position in a controlled way once the target position has been

reached. The procedure for the “do” option is the same but in the

opposite direction. With “up do”, the actuator first travels in a controlled

manner from its start position to the upper target position (start position

+ step height), then controlled from the upper to the lower target

position (start position -- step height). After reaching the lower target

position, it returns to its original position in a controlled manner.

Test int erval

Input of the interval for the cyclic partial stroke test within the range of

one day to 365 days.

A. PST

A1.STPOS

A2.STTOL

A3.STEP

A4.STEPD

A5.INTRV

Operation

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Partial stroke test reference step time

(PSTIN = Partial Stroke Test Initialization)

Measurement of the reference step time for the partial stroke test. After

the initialization of the device, the calculated (C = calculated) average

actuating time of the control valve is displayed in seconds in the form:

C ###.#. This time can be used as reference step time, however it is

only a rough guide value.

That is why it is recommended to measure the reference step time here

after the specification of the partial stroke test (parameters A1 to A5)

by pressing the Greater Than button for five seconds. In doing so,

“rEAL” is shown in the display. The device then automatically moves to

the set start position, performs the desired step and saves the time

required to do this. The time that is measured is the controlled

movement from start position to target position. After the succesful

measurement, this reference step time is shown in the display in the

form: “###.#” seconds.

If a reference step is attempted without previous initialization of the

device, “noini” appears in the display. If the start position cannot be

approached or if the jump destination cannot be reached, “Fdini“

(Failed PST Initialization) is displayed.

Factor 1

Input of the factor for the threshold 1 error message. The factor 1

refers to the reference step time. If a specified partial stroke test results

e.g. in a reference step time of 1.0 second and factor 1 is used in the

factory setting of 1.5, the threshold 1 error message of the partial

stroke test is performed for a measuring time of 1.5 seconds.

Factor 2

Input of the factor for the threshold 2 error message. The factor 2

refers to the reference step time. If a specified partial stroke test results

e.g. in a reference step time of 1.0 second and factor 2 is used in the

factory setting of 3.0, the threshold 2 error message of the partial

stroke test is performed for a measuring time of 3.0 seconds.

Factor 3

Input of the factor for the threshold 3 error message. The factor 3

refers to the reference step time. If a specified partial stroke test results

e.g. in a reference step time of 1.0 second and factor 3 is used in the

factory setting of 5.0, the threshold 3 error message of the partial

stroke test is performed for a measuring time of 5.0 seconds. At the

same time, if this time threshold is exceeded, the excitation signal of

the actuator is cancelled to prevent any sudden breaking free and

overshooting of a valve that might be jammed or rusted in place.

The partial stroke test is thus stopped immediately, a threshold 3 error

is reported and the actuator is moved back to its original position.

A6.PSTIN

A7.FACT1

A8.FACT2

A9.FACT3

Operation

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General control valve malfunction

This parameter activates the dynamic monitoring of the control valve

reaction. To do this, the actual position sequence is compared to the

guide value and the expected position sequence, which allows

conclusions with regard to the correct operational behavior of the

control valve.

When the parameter is activated, the submenu for the general control

valve malfunctions from b1 to b5 opens. The function can be

configured there.

Time constant of the low-pass filter

The time constant of the low-pass filter is determined during the

automatic initialization of the device. In the factory setting, parameter

b1 therefore indicates “Auto”.

If the user is very familiar with the process sequence or desires a

certain filter time constant for application-specific reasons, parameter

b1 can be set from one second to 400 seconds manually. One second

causes no damping, 400 seconds result in a strong damping effect.

Limit for the general control valve malfunction

Sets the limit for the deviation from the model behavior. This limit is a

reference value for the error message factors. Factory setting is 1.0 %.

Factor 1

Input of the factor for the threshold 1 error message. This factor refers

to the limit for the general control valve malfunction. Factory setting for

factor 1 is 5.0. That means, for b2.LIMIT = 1.0% and factor 1 = 5.0, the

first error message is triggered at a control deviation of 5.0 % from the

model behavior.

Factor 2

Input of the factor for the threshold 2 error message. This factor refers

to the limit for the general control valve malfunction. Factory setting for

factor 2 is 10.0. That means, for b2.LIMIT = 1.0% and factor 2 = 10.0,

the second error message is triggered at a control deviation of 10.0 %

from the model behavior.

Factor 3

Input of the factor for the threshold 3 error message. This factor refers

to the limit for the general control valve malfunction. Factory setting for

factor 3 is 15.0. That means, for b2.LIMIT = 1.0% and factor 3 = 15.0,

the third error message is triggered at a control deviation of 15 % from

the model behavior.

b. DEVI

b1.TIM

b2.LIMIT

b3.FACT1

b4.FACT2

b5.FACT3

Operation

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Pneumatic leakage

This parameter is used to activate the function for the detection of a

pneumatic leakage. To do so, the changes of position and the internally

used controller output are recorded and filtered, depending on the

direction. The filter result provides a coefficient that allows the detection

of any leakage.

Note that the detection of a leak can only provided clear results for

spring-loaded actuators.

Limit for the leakage indicator

Sets the limit for the leakage indicator The leakage indicator is scaled

within the range of 0.0 to 100.0. Factory setting for the limit is 30.0.

In other words, there is leakage below this limit. A leak can be

expected if this value is exceeded.

To be able to make full use of the sensitivity of the detection process,

it is recommended to perform a ramp test with a calibrator after the

automatic initialization of the device. The ramp should cover the

standard operating range of the valve and correspond in steepness to

the approximate dynamic requirements of the application. During the

ramp test, parameter 15.ONLK of the diagnosics menu provides

information on the values shown by the leakage indicator. This allows

the limit for the leakage coefficient to be defined above the maximum

ramp test value.

Factor 1

Input of the factor for the threshold 1 error message. This factor refers

to the limit for the leakage indicator. Factory setting for factor 1 is 1.0.

That means, for C1.LIMIT = 30.0 and factor 1 = 1.0, the first leakage

error message is triggered at a leakage indication of 30.0.

Factor 2

Input of the factor for the threshold 2 error message. This factor refers

to the limit for the leakage indicator. Factory setting for factor 2 is 1.5.

That means, for C1.LIMIT = 30.0 and factor 2 = 1.5, the second

leakage error message is triggered at a leakage indication of 45.0.

Factor 3

Input of the factor for the threshold 3 error message. This factor refers

to the limit for the leakage indicator. Factory setting for factor 3 is 2.0.

That means, for C1.LIMIT = 30.0 and factor 3 = 2.0, the third leakage

error message is triggered at a leakage indication of 60.0.

C. LEAK

C1.LIMIT

C2.FACT1

C3.FACT2

C4.FACT3

Operation

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Slipstick effect

This parameter is used to activate the function for the detection of a

slipstick effect. The device tries to detect sudden changes of the valve

position that indicate excess slipstick. If the device detects a slipstick,

the filtered step is saved as slipstick value. When the valve moves

normally again (without detection of a slipstick), the slipstick value is

reduced slowly.

Note that to avoid misinterpretations, for actuators with actuating times

below 1 s, the positioner cannot distinguish reliably between a normal

movement and a sudden change.

Limit for the slipstick detection

Sets the limit for a step caused by a slipstick effect. The limit can be

set within the range of 0.0 to 100.0%. Factory setting for the limit is 1.0.

Factor 1

Input of the factor for the threshold 1 error message. This factor refers

to the limit for the slipstick detection. Factory setting for factor 1 is 2.0.

That means, for d1.LIMIT = 1.0 and factor 1 = 2.0, the first slipstick

error message is triggered when the current slipstick value has reached

2.0.

Factor 2

Input of the factor for the threshold 2 error message. This factor refers

to the limit for the slipstick detection. Factory setting for factor 2 is 5.0.

That means, for d1.LIMIT = 1.0 and factor 2 = 5.0, the second slipstick

error message is triggered when the current slipstick value has reached

5.0.

Factor 3

Input of the factor for the threshold 3 error message. This factor refers

to the limit for the slipstick detection. Factory setting for factor 3 is 10.0.

That means, for d1.LIMIT = 1.0 and factor 3 = 10.0, the third slipstick

error message is triggered when the current slipstick value has reached

10.0.

d. STIC

d1.LIMIT

d2.FACT1

d3.FACT2

d4.FACT3

Operation

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Dead zone monitoring

This parameter activates the monitoring of the dead zone adaptation.

Prerequisite for the function is the setting of parameter “34.DEBA”

= Auto.

Threshold for the monitoring of the dead zone adaptation.

This value (%) can be used for the automatic adaptation of the dead

zone. If the dead zone exceeds the set value, the threshold 3 error

message is triggered. The three-level error message is not imple-

mented for dead zone monitoring.

Zero point offset

This function is for detecting when the lower stop has changed its value

compared to the value during initialization by more than the set

thresholds. Monitoring is only possible if the valve is within the tight

closing function. The activation of the “bottom tight closing function”

(parameter “39.YCLS”) is therefore prerequisite.

Threshold 1

First threshold for monitoring the lower limit stop. If the set absolute

value is exceeded during “bottom tight closing”, this will trigger the

threshold 1 error message.

Threshold 2

Second threshold for monitoring the lower limit stop. If the set absolute

value is exceeded during “bottom tight closing”, this will trigger the

threshold 2 error message.

Threshold 3

Third threshold for monitoring the lower limit stop. If the set absolute

value is exceeded during “bottom tight closing”, this will trigger the

threshold 3 error message.

E. DEBA

E1.LEVL3

F. ZERO

F1.LEVL1

F2.LEVL2

F3.LEVL3

Operation

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Shifting the upper stop

This function is for detecting when the upper stop has changed its

value compared to the value during initialization by more than the

specified tolerance value. Monitoring is only possible if the valve is

within the tight closing function. The activation of the “top tight closing

function” (para“meter “39.YCLS”) is therefore prerequisite.

Threshold 1

First threshold for monitoring the upper limit stop. If the set absolute

value is exceeded during “top tight closing”, this will trigger the thres-

hold 1 error message.

Threshold 2

Second threshold for monitoring the upper limit stop. If the set absolute

value is exceeded during “top tight closing”, this will trigger the thres-

hold 2 error message.

Threshold 3

Third threshold for monitoring the upper limit stop. If the set absolute

value is exceeded during “top tight closing”, this will trigger the thres-

hold 3 error message.

.NOTE

Monitoring of the lower and upper limit stops does not only react to

valve faults. A misadjustment of the position feedback is also detected

as a malfunction if the threshold values are exceeded.

G. OPEN

G1.LEVL1

G2.LEVL2

G3.LEVL3

Operation

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Monitoring of the lower temperature limit

The current temperature in the positioner housing is measured by a

sensor on the electronic circuit board. This parameter is for the

three-level monitoring of the lower temperature limit.

Temperature unit

The temperature unit can be switched over by pressing the Greater

Than or Smaller Than button between °C and °F. Another way of

switching over is the J1.TUNIT parameter for monitoring the upper

temperature limit. The selected unit applies to all temperature-related

parameters.

Threshold 1

First threshold for monitoring the lower temperature limit. The factory

setting is --25.0 °C. If the temperature falls below the set value, the

threshold 1 error message is triggered.

Threshold 2

Second threshold for monitoring the lower temperature limit. The

factory setting is --30.0°C. If the temperature falls below the set value,

the threshold 2 error message is triggered.

Threshold 3

Third threshold for monitoring the lower temperature limit. The factory

setting is --40.0°C. If the temperature falls below the set value,

the threshold 3 error message is triggered.

H. TMIN

H1.TUNIT

H2.LEVL1

H3.LEVL2

H4.LEVL3

Operation

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Monitoring of the upper temperature limit

The current temperature in the positioner housing is measured by a

sensor on the electronic circuit board. This parameter is for the

three-level monitoring of the upper temperature limit.

Temperature unit

The temperature unit can be switched over by pressing the Greater

Than or Smaller Than button between °C and °F. Another way of

switching over is the H1.TUNIT parameter for monitoring the lower

temperature limit. The selected unit applies to all temperature-related

parameters.

Threshold 1

First threshold for monitoring the upper temperature limit. The factory

setting is 75.0°C. If the temperature exceeds the set value, the thres-

hold 1 error message is triggered.

Threshold 2

Second threshold for monitoring the upper temperature limit. The

factory setting is 80.0°C. If the temperature exceeds the set value,

the threshold 2 error message is triggered.

Threshold 3

Third threshold for monitoring the upper temperature limit. The factory

setting is 90.0°C. If the temperature exceeds the set value, the thres-

hold 3 error message is triggered.

J. TMAX

J1.TUNIT

J2.LEVL1

J3.LEVL2

J4.LEVL3

Operation

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Monitoring of the displacement integral

This parameter activates the monitoring of the displacement integral.

This function allows the preventive maintenance of the control valve,

also see chapter 4.5 “Diagnosics”, page 122.

Limit for the number of strokes

Input of the limit for the number of strokes. The parameter can be used

depending on the requirement profile of the user.

On the one hand, it is possible to enter a maximal number for the

strokes and to use factors smaller than one to receive warning

messages when a certain fraction of the maximal number is reached.

On the other hand, a minimum value can be entered for the strokes.

Factors greater than one are then used to receive warning messages

for certain limits above the minimum value. Factory setting for the limit

is 1 000 000.

Factor 1

Input of the factor for the threshold 1 error message. This factor refers

to the limit for the number of strokes. Factory setting for factor 1 is 1.0.

That means, for L1.LIMIT = 1 000 000 and factor 1 = 1.0, the first

stroke counter error message is triggered after 1 000 000 strokes.

Factor 2

Input of the factor for the threshold 2 error message. This factor refers

to the limit for the number of strokes. Factory setting for factor 2 is 2.0.

That means, for L1.LIMIT = 1 000 000 and factor 2 = 2.0, the second

stroke counter error message is triggered after 2 000 000 strokes.

Factor 3

Input of the factor for the threshold 3 error message. This factor refers

to the limit for the number of strokes. Factory setting for factor 3 is 5.0.

That means, for L1.LIMIT = 1 000 000 and factor 3 = 5.0, the third

stroke counter error message is triggered after 5 000 000 strokes.

L. STRK

L1.LIMIT

L2.FACT1

L3.FACT2

L4.FACT3

Operation

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Monitoring of the changes of direction

This parameter activates the monitoring of the changes of direction.

This function allows the preventive maintenance of the control valve,

also see chapter 4.5 “Diagnosics”, page 122.

Limit for the changes of direction

Input of the limit for the number of changes of direction.

On the one hand, it is possible to enter a maximal number for the

changes of direction and to use factors smaller than one to receive

warning messages when a certain fraction of the maximal number is

reached. On the other hand, a minimum value can be entered for the

changes of direction. Factors greater than one are then used to receive

warning messages for certain limits above the minimum value. Factory

setting for the limit is 1 000 000.

Factor 1

Input of the factor for the threshold 1 error message. This factor refers

to the limit for the number of changes of direction. Factory setting

for factor 1 is 1.0. That means, for O1.LIMIT = 1 000 000 and fac-

tor 1 = 1.0, the first direction change error message is triggered after

1 000 000 strokes.

Factor 2

Input of the factor for the threshold 2 error message. This factor refers

to the limit for the number of changes of direction. Factory setting

for factor 2 is 2.0. That means, for O1.LIMIT = 1 000 000 and fac-

tor 2 = 2.0, the second direction change error message is triggered

after 2 000 000 strokes.

Factor 3

Input of the factor for the threshold 3 error message. This factor refers

to the limit for the number of changes of direction. Factory setting

for factor 3 is 5.0. That means, for L1.LIMIT = 1 000 000 and fac-

tor 3 = 5.0, the third direction change error message is triggered after

5 000 000 strokes.

Calculation of the position average

This parameter is used to activate the function for the calculation of the

position average. The function allows the calculation of a reference

average for the position sequence within preset intervals and the

calculation of comparison average values for the following intervals.

If the comparison average values deviate from the reference average,

error messages are displayed, depending on the set thresholds.

O. DCHG

O1.LIMIT

O2.FACT1

O3.FACT2

O4.FACT3

P. PAV G

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Time basis for the formation of the average value

Sets the intervals for the formation of the average value. The following

time intervals are available:

30 minutes

8 hours

5 days

60 days

2.5 years

Status of the calculation of the position average

After activating the function with parameter P. PAVG, the initial status

of the calculation of the position average is “IdLE” (inactive). To start

the calculation of the position average, the Greater Than button is

pressed for five seconds. The display text then switches from “IdLE” to

“rEF” (reference average is calculated) and remains there until the

selected time interval has passed. The reference average is then

shown on the display.

.NOTE

The current comparison average is displayed in the diagnosis menu

under parameter 19.PAVG as soon as the first comparison interval has

passed. During the first comparison interval, “COMP” (comparison

interval) is displayed there.

Threshold 1

First threshold for monitoring the reference average. The factory setting

is 2.0%. If a comparison average deviates from the reference by more

than this value, the threshold 1 error message is triggered.

Threshold 2

Second threshold for monitoring the reference average. The factory

setting is 5.0%. If a comparison average deviates from the reference by

more than this value, the threshold 2 error message is triggered.

Threshold 3

Third threshold for monitoring the reference average. The factory

setting is 10.0%. If a comparison average deviates from the reference

by more than this value, the threshold 3 error message is triggered.

P1.TBASE

P2.STATE

P3.LEVL1

P4.LEVL2

P5.LEVL3

Operation

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4.5 Diagnosis

4.5.1 Diagnostic display

To access the diagnostic display in automatic or manual mode,

press all three buttons for at least two seconds.

This following table gives an overview of the values that can be

displayed. The third column contains the term from which the

abbreviation is derived, unless it is self-explaining.

The structure of the diagnostic display is similar to that in “Configu-

ration” mode: the upper line shows the diagnosis value, the lower line

shows the number and abbreviation of the displayed value.

Use the operating mode button to select the next diagnosis value.

By pressing and holding the operating mode button and simultaneously

pressing the decrement button the diagnosis values can be

selected in reverse order.

Certain values can be set to zero by pressing the increment button

for at least 5 seconds. This is noted in the last table column.

Some diagnosis values can be greater than 99999. In this case, the

display switches to exponential indication. Example: the value for

1234567 is displayed as 1.23E6.

No. Abbre-

viation

Meaning Values than

can be

indicated

Unit Reset

possible

1STRKS Number of strokes (Strokes)0to4.29E9 -- x

2CHDIR Changes of direction (Changes of Direction) 0to4.29E9 -- x

3CNT Number of fault messages ( Counter) 0to4.29E9 -- x

4A1CNT Number of alarms 1 (Alarm 1Counter) 0to4.29E9 -- x

5A2CNT Number of alarms 2 (Alarm 2Counter) 0to4.29E9 -- x

6HOURS Operating hours (Hours)0to4.29E9 hours

7WAY Determined actuator travel (Way)0to130 mm or _

8TUP Actuating time up (Travel Time Up)0 to 1000 s

9TDOWN Actuating time down (Travel Time Down)0 to 1000 s

10 LEAK Leakage (Leakage) P 0.0 to 100.0 %

11 PST Monitoring of the Partial Stroke Test OFF / ###.#,

fdini, notSt,

SdtSt, fdtSt,

notd, Strt

s for ###.#

12 PRPST Time since the last Partial Stroke Test ###, notSt,

Sdtst, fdtSt

days

13 NXPST Time until the next Partial Stroke Test ###, notSt,

SdtSt, fdtSt

days

14 DEVI General control valve malfunction Off, 0.0 to

100.0

15 ONLK Pneumatic leakage Off, 0.0 to

100.0

16 STIC Slipstick effect Off, --100.0 to

100.0

17 ZERO Zero point offset Off, --100.0 to

100.0

18 OPEN Shifting the upper stop Off, --100.0 to

100.0

19 PAVG Average position value 0.0 to 100.0 %

20 P0 Potentiometer value lower stop (0%) 0.0 to 100.0 %

Operation

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No. Reset

possible

UnitValues than

can be

indicated

MeaningAbbre-

viation

21 P100 Potentiometer value upper stop (100%) 0.0 to 100.0 %

22 IMPUP Pulse length up (Impulse Length Up)2to160 ms

23 IMPDN Pulse length down (Impulse Length Down)2to160 ms

24 DBUP Dead zone up (Dead Band Up)0.1 to 10.0 %

25 DBDN Dead zone down (Dead Band Down)0.1 to 10.0 %

26 SSUP Short step zone up (Short Step Zone Up)0.1 to 100.0 %

27 SSDN Short step zone down (Short Step Zone Down)0.1 to 100.0 %

28 TEMP Current temperature --40 to 85 _C

29 TMIN Minimumtemperature (“min/max pointer”) --40 to 85 _C

30 TMAX Maximumtemperature (“min/max pointer”) --40 to 85 _C

31 T1 Number of operating hours in temperature range 10to4.29E9 hours

32 T2 Number of operating hours in temperature range 20to4.29E9 hours

33 T3 Number of operating hours in temperature range 30to4.29E9 hours

34 T4 Number of operating hours in temperature range 40to4.29E9 hours

35 T5 Number of operating hours in temperature range 50to4.29E9 hours

36 T6 Number of operating hours in temperature range 60to4.29E9 hours

37 T7 Number of operating hours in temperature range 70to4.29E9 hours

38 T8 Number of operating hours in temperature range 80to4.29E9 hours

39 T9 Number of operating hours in temperature range 90to4.29E9 hours

40 VENT1 Number of switching operations pilotvallve 10to4.29E9 --

41 VENT2 Number of switching operations pilotvallve 20to4.29E9 --

42 STORE Save current values as “last maintenance”

(press increment button for 5s) (Store)

-- --

43 PRUP Prediction up 1to40 --

44 PRDN Prediction down 1to40 --

45 WT00 Number of operating hours in actuating range WT00 0to4.29E9 hours x

46 WT05 Number of operating hours in actuating range WT05 0to4.29E9 hours x

47 WT10 Number of operating hours in actuating range WT10 0to4.29E9 hours x

48 WT30 Number of operating hours in actuating range WT30 0to4.29E9 hours x

49 WT50 Number of operating hours in actuating range WT50 0to4.29E9 hours x

50 WT70 Number of operating hours in actuating range WT70 0to4.29E9 hours x

51 WT90 Number of operating hours in actuating range WT90 0to4.29E9 hours x

52 WT95 Number of operating hours in actuating range WT95 0to4.29E9 hours x

53 mA Setpoint current 0.0 to 20.0 mA

Table 4-1 Overview of diagnosis values

4.5.2 Meaning of the diagnosis values

Number of strokes

During operation, the actuator movements are added up and can be

read off here as the number of strokes. Unit: 100% strokes, i.e. the

path between 0 and 100 % and back. The value is written into a

non-volatile memory every 15 minutes. It can be set to zero with the

increment button .

Number of changes of direction

1 STRKS

2 CHDIR

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In the controller, every change of direction coming from the dead zone

is noted and added to the number of changes of direction.

The value is written into a non-volatile memory every 15 minutes. It can

be set to zero with the increment button .

Operation

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Number of fault messages

In the controller, every malfunction is noted and added to the number of

fault messages. The counter can be set to zero with the increment

button .

Number of alarms 1

and

Number of alarms 2

The reaction of alarms 1 and 2 is counted with these two counters.

Prerequisite is the activation of the alarms with parameter “44.AFCT”.

The counters can be set to zero with the increment button .

Operating hours

The operating hours counter is incremented every hour as soon as the

positioner is supplied with electrical power.

Determined actuator travel

This value specifies the actuator travel determined during initialization,

according to the indication at the end of an initialization phase.

Prerequisite for linear actuators: Specification of the lever arm with

parameter “3.YWAY”.

Actuating time up

and

Actuating time down

These values indicate the actuating times that were determined during

initialization. The unit is seconds.

Leakage

If a leakage measurement was initiated during initialization, the leakage

value can be read off here in %/min.

3 CNT

4 A1CNT

5 A2CNT

6 HOURS

7WAY

8TUP

9TDOWN

10 LEAK

Operation

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Monitoring of the partial stroke test

The measured step time of the last partial stroke test is displayed here.

A partial stroke test can be triggered manually by pressing the Greater

Than button, or a partial stroke test that is just being performed can be

interrupted.

Thefollowingstatesareshowninthedisplay:

SOFF

The partial stroke test function is deactivated in the configuration

menu.

SFdIni (Failed PST Initialization)

The partial stroke test reference step time measurement failed.

SnotSt (No Test)

No partial stroke test carried out yet.

S###.# (measured step time in seconds)

The last partial stroke test was carried out successfully.

SSdtSt (Stopped Test)

The last partial stroke test was interrupted.

SFdtSt (Failed Test)

The last partial stroke test failed.

The following status messages appear on pressing the Greater Than

button:

SnotoL (No Tolerance)

The control valve is outside the tolerance range for starting the

partial stroke test. No manual partial stroke test has been started.

SStrt (Start)

A manual partial stroke test was started after pressing the button for

five seconds.

SStoP (Stop)

The currently performed partial stroke test is interrupted.

Time since the last partial stroke test

The time that has passed since the last partial stroke test is displayed

here (in days). The following status messages can also appear:

SnotSt (No Test)

No partial stroke test carried out yet.

SSdtSt (Stopped Test)

The last partial stroke test was interrupted.

SFdtSt (Failed Test)

The last partial stroke test failed.

11 PST

12 PRPST

Operation

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Time until the next partial stroke test

The time until the next partial stroke test is displayed here (in days).

Conditions are that the partial stroke test is deactivated in the

configuration menu and a test interval is set. If one of these two

conditions is not fulfilled “OFF” appears in the display.

General control valve malfunction

This value provides information on the current dynamically determined

deviation from the model behavior. If the basic function is deactivated in

the configuration menu “OFF” is displayed.

Pneumatic leakage

The current leakage indicator is displayed here. If the leakage detection

is deactivated in the configuration menu “OFF” is displayed.

Slipstick effect

The filtered step height value cause by slipstick is displayed here in

percent. If the function is deactivated in the configuration menu, “OFF”

is displayed.

Zero point offset

Display of the current displacement of the lower limit stop compared to

its initialization value. Condition for the determination is the activation of

the “bottom tight closing function” (parameter “39.YCLS” in the

configuration menu). If the basic function is deactivated in the

configuration menu “OFF” is displayed.

Shifting the upper stop

Display of the current displacement of the upper limit stop compared to

its initialization value. Condition for the determination is the activation of

the “top tight closing function” (parameter “39.YCLS” in the config-

uration menu). If the basic function is deactivated in the configuration

menu “OFF” is displayed.

13 NXPST

14 DEVI

15 ONLK

16 STIC

17 ZERO

18 OPEN

Operation

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Average position value

The comparison average calculated last is displayed here. There are

also the following status messages:

SOFF

The basic function is deactivated in the configuration menu.

SIdLE (inactive)

The function has not been started yet.

SrEF (reference average is calculated)

The function was started and the reference interval is currently

active.

SCOMP (comparison average is calculated)

The function was started and the comparative interval is currently

active.

Potentiometer value lower stop

and

Potentiometer value upper stop

These two values indicate the measured values of the position

displacement sensor (potentiometer) at the lower or upper limit stop,

as determined during the automatic initialization. With manual initializa-

tion, the values of the manually approached end positions can be found

here.

Pulse length up

and

Pulse length down

During the initialization phase, the smallest pulse lengths are deter-

mined, with which a movement of the actuator can be achieved.

They are determined separately for the “Up” direction and the “Down”

direction and displayed here.

These two parameters can be set for special applications (see chap-

ter 4.7, page 143).

Dead zone up

and

Dead zone down

The dead zone of the controller in “Up” direction or in “Down” direction

is displayed here. The values correspond either to the manually set

value of parameter “34.DEBA” or to the value automatically adapted by

the device if “DEBA” was set to “Auto”.

19 PAVG

20 P0

21 P100

22 IMPUP

23 IMPDN

24 DBUP

25 DBDN

Operation

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Short step zone up

and

Short step zone down

The short step zone is the range of the controller, in which pulse-

shaped excitation signals are output. The pulse length is proportional to

the control deviation. If the control deviation is not within the short step

zone, then the valves are activated in permanent contact.

These two parameters can be set for special applications (see chap-

ter 4.7, page 143).

Current temperature

Current temperature in the positioner housing. The sensor is on the

electronic circuit board.

The temperature display can be switched between _C and _Fby

pressing the decrement button.

Minimum temperature (min/max pointer)

and

Maximum temperature (min/max pointer)

The minimum and maximum temperature in the housing interior is

determined continuously in the form of a min/max pointer and saved

and can only be reset at the factory.

Number of operating hours in temperature range T1 to T9

The device gives statistical information as to how long and in which

temperature ranges it was operated. For this purpose, the measured

temperature is averaged for each hour and the counter that is assigned

to the relevant temperature range is incremented every hour. This

allows conclusions to be made about past operating conditions of the

device and the entire control valve.

The temperature ranges are divided as follows:

T1 T2 T3 T4 T5 T6 T7 T8 T9

Temperature

range [_C] ≥--30

≥--30

<--15

≥--15

≥0

<15

≥15

<30

≥30

<45

≥45

<60

≥60

<75

≥75

Number of switching operations pilot valve 1

and

Number of switching operations pilot valve 2

These two counters add up the activation processes of the pilot valves

and are for the assessment of the switching dependency.

26 SSUP

27 SSDN

28 TEMP

29 TMIN

30 TMAX

31 T1 to

39 T9

40 VENT1

41 VENT2

Operation

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Save maintenance data

Pressing the increment button for at least 5 seconds triggers a

memory function. In doing so, the diagnostic data 7 to 18 is saved in a

non--volatile memory as the “data of the last maintenance”. This

diagnostic data consists of selected values that, when changed,

can provide information on the mechanical wear of the valve.

Normally, this function is operated via PDM, menu item: Device!Save

maintenance info. The comparison of the data of the last maintenance

to the current data is possible via PDM.

Prediction up

Prediction down

see chapter 4.7, page 143.

Number of operating hours in actuating range WT00 to WT95

If the positioner is in automatic mode, statistical information is

generated as to how long a valve or a flap was operated in which

section of the actuating range. For this purpose, the entire actuating

range (0 to 100 %) is divided into 8 sections (actuating ranges). The

positioner registers the current position continuously and increments

the operating hours counter that is assigned to the relevant section

(actuating range) every hour. This allows conclusions to be made about

past operating conditions and is in particular for the assessment of the

control characteristics of the control loop or of the entire control valve.

The actuating range is divided as follows:

Actuating

range

WT00 WT05 WT10 WT30 WT50 WT70 WT90 WT95

Actuating

range

section

<5%

≥5%

<10%

≥10 %

<30%

≥30 %

<50%

≥50 %

<70%

≥70 %

<90%

≥90 %

<95%

≥95 %

The 8 operating hours counters can be set to zero together by pressing

the increment button (for at least 5 seconds).

TIP: Since the actuating ranges are arranged at the end of the

diagnosis menu with numbers 45 to 52, press the decrement button

several times in addition to the operating mode button. That is how you

access diagnosis numbers 45 to 52 quickly.

Setpoint current

You can have the current setpoint displayed here in mA.

.NOTE

All diagnosis values are updated every 15 minutes in the non-volatile

memory so that only the values of the past quarter of an hour are lost

if there is a power failure.

42 STORE

43 PRUP

44 PRDN

45 WT00 to

52 WT95

53 MA

Operation

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4.5.3 Online diagnosis

While the positioner is in operation, some important values and

parameters are monitored on a continuous basis. In “Configuration”

mode, you can configure this monitoring in such a way that the fault

message output is activated when a certain event occurs, such as e.g.

when a limit is exceeded.

Table 4-2, page 133, shows which events can activate the fault

message output and the alarm outputs, how the parameters need to be

set for this event to be monitored, when the fault messages disappears

again and what the possible causes of the malfunction are.

In automatic and manual mode, the display shows what triggered the

fault message when the fault message output reacts. The two numbers

at the bottom left indicate the relevant error code. If several triggers

occur simultaneously, they are display in succession cyclically. The

device status that also includes all fault messages, can be called using

command #48 via HART.

The parameters of the extended diagnostics allow error messages to

be displayed in one, two or three levels. In addition to the fault

message output, alarm outputs 1 and 2 are then used. For this

purpose, para-

meter 51.XDIAG needs to be set according to the following table:

Settings of 51.XDIAG Message by

Off Extended diagnostics not activated

On1 Fault message output for threshold 3 error messages

(one-level)

On2 Fault message output for threshold 3 error messages and

alarm output 2 for threshold 2 error messages (two-level)

On3 Fault message output for threshold 3 error messages and

alarm output 2 for threshold 2 error messages and

alarm output 1 for threshold 1 error messages (three-level)

Operation

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Error

code

three-

level

Event Parameter-

setting

Error message

disappears if...

Possible

causes

1no Remaining control

deviation

always active ... the control

deviation has

disappeared again.

Compressed air

missing, actuator

fault, valve fault

(e.g. blockage).

2no Device not in

automatic mode

47. FCT= nA

or = nAB

... the device is

switched to automatic

mode.

The device is

configured or is in

manual mode.

3no Binary input BE1

or BE2 active

47. FCT= nAB

and binary function

BIN1 or BIN2 at “on”

... the binary input is

no longer activated.

The contact

connected to the

binary input became

active (e.g. stuffing

box monitoring,

overpressure,

temperature switch).

4yes Limit

Stroke number

exceeded

L. STRK¸OFF ... the stroke counter

is reset or the

thresholds are

increased

The sum of the

distance covered by

the actuator exceeds

one of the set

thresholds.

5yes Direction change

limit exceeded O. DCHG¸OFF ... the direction

change counter is

reset or the

thresholds are

increased

The number of

changes of direction

exceeds one of the

set thresholds.

6yes Lower limit stop

limit exceeded F. ZER O¸OFF

39.YCLS = do or up

... the deviation of the

stop disappears or

the device was

re-initialized.

Wear of the valve

seat, deposit or

foreign matter in

the valve seat,

mechanical

misadjustment, friction

clutch misadjusted.

7yes Limit

of upper limit stop

exceeded

G. OPEN¸OFF

39.YCLS = up or up

... the deviation of the

stop disappears or

the device was

re-initialized.

Wear of the valve

seat, deposit or

foreign matter in

the valve seat,

mechanical

misadjustment, friction

clutch misadjusted.

8no Limit

Dead zone

adaptation

exceeded

E. DEBA¸OFF

34.DEBA = Auto

... the value has

fallen below the limit

again.

Increased stuffing box

friction, mechanical

batches of the

position feedback.

9yes Partial stroke test

exceeds reference

step time

A. PST¸OFF ... a partial stroke test

is performed

successfully within

the reference step

time or the function is

deactivated.

Valve jams or is

rusted in place,

increased friction

10 yes General control

valve malfunction b. DEVI¸OFF ... the position is back

within a narrow

corridor between

guide value and

model, or the function

is deactivated.

actuator fault, valve

fault, valve jams,

increased friction,

compressed air drop

11 yes Pneumatic leakage C. LEAK¸OFF ... the leakage falls

below the set

thresholds, or the

function is

deactivated.

Pneumatic leakage

Operation

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Error

code

Possible

causes

Error message

disappears if...

Parameter-

setting

Eventthree-

level

12 yes Slipstick effect

occurs d. STIC¸OFF ... no more slipstick

can be detected,

or the function is

deactivated.

Increased slipstick,

valve no longer

moves constantly but

judders instead

13 yes Temperature

short of H. TMIN¸OFF ... the lower tem-

perature threshold

values are no longer

fallen short of.

Ambient temperature

too low

14 yes Temperature

exceeded J. TMAX¸OFF ... the upper tem-

perature thresholds

are no longer

exceeded.

Ambient temperature

too high

15 yes Position average

deviates from the

reference value

P. PAVG¸OFF ... after a comparison

interval, a position

average is calculated

that is within the

reference value

thresholds or the

function is

deactivated.

In the last comparison

interval, the valve

trajectory changed so

much that a deviating

position average was

calculated.

Table 4-2 Events that can activate the fault message output

Explanations for the “Error codes” column:

1 Control deviation monitoring

In automatic mode, the deviation between the setpoint and actual value

is monitored continuously. According to the setting of parameter

48. TIM, the monitoring time for setting the fault messages, and

49. LIM, the response threshold of the fault message, the fault

message is activated if the control deviation remains. As soon as the

control deviation falls below the response threshold again, the fault

message is cancelled.

2 Automatic mode monitoring

If parameter “47. FCT”, the fault message output function, is set

accordingly, a fault message is generated if the device is not in

automatic mode. In this way, e.g. the control system can be warned if

the device was switched to manual mode or configuration on location.

3 Binary input BE1 or BE2 active

If parameter “47. FCT”, the fault message output function, and

parameter “42.BIN1”, the binary input 1 function, are set accordingly,

a fault message is generated when the binary input is activated. This

can be e.g. a stuffing box monitoring switch, a temperature switch or a

limit switch (e.g. for pressure).

Binary input 2 (for the alarm unit option) can be configured in the same

way.

Operation

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4 Stroke number monitoring

5 Monitoring of the number of changes of direction

The two values, number of strokes and number of changes of direction,

are compared to the threshold values on a continuous basis. These

values result from the parameters “L1.LIMIT” to “L4.FACT3” and

“O1.LIMIT” to “O4.FACT3”. If they are exceeded, depending on the

operating mode of the extended diagnostics, the fault message output

reacts, and possibly also the alarm outputs. The two functions can

be deactivated by the parameter setting “OFF” for “L. STRK” or

“O. DCHG”.

6 Monitoring of the lower limit stop (valve seat)

7 Monitoring of the upper limit stop

The monitoring of the lower limit stop is activated if parameter

“F. ZERO” has a value ¸OFF. This function can be used e.g.

to detect valve seat errors. If the limit is exceeded, this can be an

indication of deposits or foreign particles on the valve seat. If the limit is

fallen short of, wear to the valve seat or reactor body could be the

cause. The mechanical misadjustment of the position feedback can

also trigger this error message.

Monitoring takes place every time the valve is in “bottom tight closing”

position. In doing so, the current position is compared to the position

that was determined as lower end stop during the initialization phase.

The activation of the “bottom tight closing function” (parameter

“39.YCLS”) is therefore prerequisite.

Example: 3% is set as value. For “bottom tight closing”, the 0% position

is normally established. If a value of >3% or <--3% is determined

instead, a fault is reported.

The fault message remains activated until either a subsequent

monitoring process remains within the tolerance range or a

re-initialization is carried out. The deactivation of the monitoring

process (“F. ZERO”=OFF) also deletes any fault messages.

This monitoring function does not provide any useful results if the stops

were not determined automatically during initialization but instead the

limits were set by hand (manual initialization, “5.INITM”).

An appropriate diagnosis was carried out for the upper limit stop. The

parameter “G. OPEN” is used to set this limit. The activation of the

“top tight closing function” (parameter “39.YCLS”) is therefore

prerequisite.

8 Dead zone adaptation monitoring

If, during the automatic adaptation of the dead zone (parameter

34.DEBA=Auto) the dead zone increases disproportionately during

operation, this is an indication of a fault in the system (e.g. significantly

increased stuffing box friction, play in the position displacement sensor,

leakage). Therefore a limit can be specified for this value (“E1.LEVL3”,

threshold for dead zone monitoring) that activates the fault message

output if it is exceeded.

Operation

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9 Partial stroke test exceeds reference step time

This error message appears on the one hand if a manual or cyclic

partial stroke test is triggered and the test cannot be started because

the valve is not within the start tolerance range. The error message

also appears if one of the three thresholds of the partial stroke test that

are a result of the reference step time (A6.PSTIN) times factors

(A7.FACT1 to A9.FACT3) is violated. How serious the error message

is, can be seen at the bar graph on the right side of the display. At the

same time, the severity of the error message is output via the fault

message output or the alarm outputs, according to the operating mode

of the extended diagnostics.

10 General control valve malfunction

The monitoring of the operational behavior triggers if the actual valve

position leaves a narrow corridor between guide value and expected

position sequence. In this case, the deviation between expected and

actual position sequence is filtered and output and compared to the set

thresholds that are the result of the limit (b2.LIMIT) times the factors

(b3.FACT1 to b5.FACT3).

11 Pneumatic leakage

This error message appears if the leakage indicator exceeds the set

thresholds. Note that the function can only take effect with its entire

sensitivity if a ramp test is performed to set the leakage indicator after

initialization (see Explanations on C1.LIMIT).

12 Slipstick effect too high

If the slipstick of the control valve is increased during operation of if an

increasing number of slip jumps are detected, the relevant limits can be

exceeded, resulting in an error message.

13 Temperature fallen short of

This error message appears if the lower temperature limit thresholds

are fallen short of.

14 Temperature exceeded

This error message appears if the upper temperature limit thresholds

are exceeded.

15 Monitoring of the position average

If a position average is calculated when a comparison interval passes

that deviates from the reference value by more than the set thresholds,

this error message triggers.

Operation

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4.5.4 Fault correction

Guide

see Table

In whichoperating mode does the fault occur?

•Initialization 5

•Manual mode and automatic mode 6 7 8 9

In which environment and under which basic conditions does the

fault occur?

•Wet environment (e.g. heavy rain or continuous condensation) 6

•Vibrating (oscillating) control valves 6 9

•Stress due to knocks or shocks (e.g. steam pulses or flaps breaking

away)

•damp (wet) compressed air 6

•dirty compressed air (contaminated with solid particles) 6 7

When does the fault occur?

•constantly (reproducible) 5 6 7 8

•sporadically (not reproducible) 9

•usually after a certain operation time 6 7 9

Operation

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Fault indication

(symptoms)

possible cause(s) Remedies

•SIPART PS2 stops during

“RUN 1”.

•Initialization started from end

position and

•reaction time of max. 1 min.

not waited for.

•Mains pressure not connected

or insufficient.

•Up to 1 min. delay time

required.

•Do not start initialization from

end position.

•Secure the mains pressure.

•SIPART PS2 stops during

“RUN 2”.

•Transmission ratio selector and

parameter 2 (YAGL) as well as

actual stroke do not match.

•Stroke not correctly set for

lever.

•Piezo valve(s) do(es) not

switch (see table 6).

•Check settings:

•see leaflet: figure “device view

(7)” as well as parameters 2

and 3

•Check stroke setting at lever.

•seetable2

•SIPART PS2 stops during

“RUN 3”.

•Actuating time too high. •Open reactor completely

and/or set PZ pressure (1) to

maximum permissible value.

•If necessary, use booster.

•SIPART PS2 stops during

“RUN 5”and does not reach

“FINISH” (delay time:

>5min).

•“Batches” (play) in the

positioner -- actuator -- control

valve system

•Part-turn actuator:

Check if set screw of the

coupling wheel is inserted

firmly

•Linear actuator:

Check if lever is connected

firmly to positioning shaft.

•Eliminate any other play

between actuator and control

valve.

Table 5

Fault indication

(symptoms)

possible cause(s) Remedies

•For SIPART PS2, “CPU

test” flashes in the display

(approx. every 2 sec).

•Piezo valve(s) do(es) not

switch.

•Water in the pneumatic block

(due to wet compressed air)

•At an early stage, this fault can

be eliminated by subsequent

operation with dry air (if ne-

cessary, in the temperature

cabinet at 50 to 70°C).

•In manual or automatic

mode, the actuator cannot

be moved or only in one

direction.

•Moisture in the pneumatic

block

•Otherwise: Repair

(see chapter 5, page 145)

•Piezo valve(s) do(es) not

switch (no quiet “clicking”

can be heard when the + or

–

buttonispressedin

•Screw between shrouding

cover and pneumatic block not

tightened firmly or cover

jammed.

•Tighten screw, if necessary

eliminate jam.

manual mode). •Dirt (chips, particles) in the

pneumatic block

•Repair (see chapter 5,

page 145) or new device;

integrated fine screen,

also replace and clean.

•Deposits on contact(s)

between electronics board and

pneumatic block can develop

due to abrasion as a result of

continuous high vibration

stress.

•Clean all contact surfaces with

spirit; if necessary, re-bend the

pneumatic block springs

slightly.

Table 6

Operation

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Fault indication

(symptoms)

possible cause(s) Remedies

•Actuator does not move •Compressed air < 1.4 bar •Set supply air pressure to

> 1.4 bar.

•Piezo valve(s) do(es) not

switch (quiet “clicking” can

be heard however when

the + or – button is pressed

•Reactor valve(s) closed

(screw(s) at the right-hand

stop)

•Open reactor screw(s) (see

leaflet, figure “device view (6)”

by turning it/them

anti-clockwise.

in manual mode). •Dirt in the pneumatic block •Repair (see chapter 5,

page 145) or new device;

integrated fine screen,

also replace and clean.

•A piezo valve switches

continuously in stationary

automatic mode (constant

setpoint) and in manual

mode.

•Pneumatic leakage in the

positioner – actuator system

Start leakage test in “RUN 3”

(initialization)!!!

•Eliminate leakage in the

actuator and/or supply line

•If the actuator is intact and the

supply line is leak-tight:

Repair (see chapter 5,

page 145) or new device

•Dirt in the pneumatic block

(see above)

•see above

Table 7

Fault indication

(symptoms)

possible cause(s) Remedies

•Both piezo valves switch

continuously and

alternately in stationary

automatic mode (constant

•Too much slipstick of stuffing

box of control valve or actuator

•Reduce slipstick or increase

dead zone of SIPART PS 2

(dEbA parameter) until

oscillation stops.

(

setpoint) and in manual

mode, actuator oscillates

around a mean value.

•Batches (play) in the positioner

-- actuator – control valve

system

•Part--turn actuator:

Check if set screw of the

coupling wheel is inserted

firmly

•Linear actuator:

Check if lever is connected

firmly to positioning shaft.

•Eliminate any other play

between actuator and control

valve.

•Actuator too fast •Increase actuating times via

reactor screws.

•If fast actuating time is

required, increase dead zone

(dEBA parameter) until

oscillation stops.

•SIPART PS 2 does not

“drive” control valve up to

the stop (at 20 mA).

•Supply pressure too low.

•Load of the feeding controller

or system output is too low.

•Increase supply pressure

•Interconnect load converter

•Select 3/4 transmitter

operation

Table 8

Operation

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Fault indication

(symptoms)

possible cause(s) Remedies

•Zero point misadjusts

sporadically (> 3 %).

•Stress caused by knocks or

shocks result in acceleration

values that are so high that the

friction clutch is misadjusted

(e.g. with “steam pulses” in

steam lines)

•Eliminate causes of shock

stress.

•Re-initialize positioner.

•Complete device function

failure: also no indication in

the display

•Electrical power supply

insufficient

•Check electrical power supply.

•In the event of continuous high

vibration stress (vibrations):

•Screws on the electrical

connecting terminals can

loosen.

•Electrical connecting terminals

and/or electronic components

can loosen due to vibrations.

•Tighten screws and secure

them with locking varnish.

•Repair (see chapter 5,

page 145)

•For prevention purposes:

Fit SIPART PS 2 on shock

mounts.

Table 9

4.6 Meaning of the other display text

Remarks on the tables:

nn stands for variable numerical values

Error symbol

/ (slash): the text segments to the left and right of the-

slash flash alternately

Messages before the installation phase (initial start-up):

Upper

line

Lower

line

Meaning/cause Measure

CPU

START

Message after applying the electrical

power supply

SWait

Pnnn.n xPotentiometer voltage when

positioner is not initialized (P manual

mode) (actual position value in % of

measuring range)

SCheck with the “+” and “--” buttons

whether the entire actuator travel can

be moved along and that “P------”is

never displayed

SPerform initialization

P------ xMeasuring range exceeded,

potentiometer is in the inactive zone,

switch transmission ratio selector or

effective lever arm have not been

adapted to the actuator travel

SSwitch transmission ratio selector to

90 degrees for part-turn actuators

SAdjust effective lever length for linear

actuators to measuring range

NOINI xPositioner is not initialized SStart initialization

Operation

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Messages during the installation phase:

Upper

line

Lower

line

Meaning/cause Measure

P---- xSee above See above

RUN 1 xInitialization has been started, part 1

is active

(direction of action is being

determined)

SWait

RUN 2 xInitialization, part 2 is active

(actuator travel check and

determination of the end stops)

SWait

RUN 3 xInitialization, part 3 is active

(determination and display of the

actuating times)

SWait

RUN 4 xInitialization, part 4 is active

(determination of the minimum

actuator increment length)

SWait

RUN 5 xInitialization, part 5 is active

(optimization of the transient

response)

SWait until “FINSH” is displayed

(initialization completed successfully)

SPress the operating mode button

briefly to acknowledge and exit the

configuration level by pressing it

continuously

YEND1 xonly for manual initialization

first end position can be approached

SApproach first end position with the

“+”or“--”button

SPress operating mode button to

acknowledge

YEND2 only for manual initialization

second end position can be

approached

SApproach second end position with

the “+” or “--” button

SPress operating mode button to

acknowledge

RANGE xonly for manual initialization

End position or measuring span are

outside the permitted measuring

range

SPress the “+” and “--” buttons to

approach another end position and

acknowledge with the operating

mode button,

Sadjust the friction clutch until “ok”is

displayed and acknowledge with the

operating mode button

Scancel the initialization by pressing

the operating mode button, switch to

P manual mode and correct the

actuator travel and the position

displacement sensor

ok only for manual initialization

permitted measuring range of the

end positions has been reached

SAcknowledge with the operating

mode button, the remaining steps

(“RUN1”to“FINSH”) run

automatically

RUN 1/

ERROR

xError in RUN 1

no movement e.g. due to insufficient

compressed air

SMake sure there is sufficient

compressed air

SOpen reactor(s)

SRestart initialization

d___U xBar graph display of the zero point

Zero point is outside the tolerance

range

SUsefrictionclutchtosetbetween

“P4.0” and “P9.9”(>0<)

SContinue with the “+” or “--” button

SEt

MIDDL

Friction clutch has been misadjusted;

no “P 50.0” display if the lever is in

horizontal position

SWith linear actuators, press the “+”

and ”--” buttons to move the lever at

right angles to the spindle

SPress operating mode button briefly

to acknowledge (initialization is

continued)

Operation

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MeasureMeaning/cause

Lower

line

Upper

line

UP > x“UP” tolerance range exceeded or

inactive zone of the potentiometer

passed

SIncrease effective lever length for

linear actuators or switch

transmission ratio selector to

90 degrees

SPress operating mode button briefly

to acknowledge

SRestart initialization

90_95 xOnly possible for part-turn actuators:

Actuator travel is not within the range

of 90 to 95%

SUse the “+” and “--” buttons to move it

to the range between 90 and 95%

SPress operating mode button briefly

to acknowledge

U--d> x“Up-Down” measuring span fallen

short of

SReduce effective lever length for

linear actuators or switch

transmission ratio selector to

33 degrees

SPress operating mode button briefly

to acknowledge

SRestart initialization

U nn.n

D-->U

Display of actuating time “Up” SWait, or

Spress the “--” button to interrupt the

initialization process to change the

actuating time, or

Sactivate the leakage test with the “+”

button

d nn.n

U-->d

Display of the actuating time “Down” SWait, or

Spress the “--” button to interrupt the

initialization process to change the

actuating time, or

Sactivate the leakage test with the “+”

button

NOZZL xActuator stationary (initialization was

interrupted with the “--” button during

the indication of the actuating speed)

SActuating time can be changed by

adjusting the reactor(s)

Spress the “--” button to repeat the

determination of the actuating speed

Scontinue with the “+” button

TESt

LEAKG

Leakage test active (“+“ button was

pressed during the indication of the

actuating speed)

SWait one minute

Scontinue with the “+” button

nn.n

_oMIN

Value and unit of the result after the

leakage test

SEliminate if leakage value is too great

Scontinue with the “+” button

nn.n

FINSH

Initialization was completed

successfully, possibly along with the

indication of the actuator travel or

angle

SPress the operating mode button

briefly to acknowledge and exit the

configuration level by pressing it

continuously

Operation

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Messages on exiting configuration mode:

Upper

line

Lower

line

Auto-

matic

Manua

l mode

P manual

mode

Meaning/cause Measure

4.nn.nn

VER

Software version SWait

Error

SLnn

Monotony violation of the

free characteristic curve at

vertice n

SCorrect value

Messages during operation:

Upper

line

Lower

line

Auto-

matic

Manua

l mode

P manual

mode

Meaning/cause Measure

CPU

START

Message after applying the

electrical power supply

SWait

HW /

ERROR

xHardware error SReplace electronics

NOINI x x Positioner is not initialized SStart initialization

nnn.n x x x Actual position [in %] with

initialized positioner. Flashing

decimal point indicates com-

munication with a class 2

master

AUTnn x x Automatic mode

(nn = setpoint)

MANnn xManual mode (nn = setpoint) SPress operating mode

buttontoswitchto

automatic mode

oFL / 127.9 x x x Display range was exceeded.

Possible causes:

Sfriction clutch or

Stransmission ratio selector

were misadjusted or

Spositioner was fitted on

another actuator without

re-initialization.

SAdjust friction clutch in

such a way that the

indication of the actual

value remains between

0.0 and 100.0 on

moving the actuator or

Sswitch over the

transmission ratio

selector or

Sset to the factory setting

(preset) and initialize

EXSTP x x Actuator was stopped via

binary input

EX UP x x Actuator is moved to the

upper stop via binary input

EXDWN x x Actuator is moved to the

lower stop via binary input

EXTPSt Partial stroke test was

activated e.g. via binary input

InPSt cyclic partial stroke test

HTCNF x x x x HARD configuration running

Operation

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4.7 Optimizing the controller data

The data for the control quality that was automatically determined

during initialization is optimized for short compensation with low

overshooting. In special cases (e.g. extremely small and therefore

particularly fast actuators or for operation with boosters), you might

want to modify this data specifically for faster compensation or a

greater damping effect. The following six parameters are available for

this purpose:

This is for defining the smallest pulse lengths with which the actuator is

to move for each actuating direction. The optimal value mainly depends

on the volume of the actuator.

Small values result in small actuating increments and frequent activa-

tion of the actuator. Bear in mind that if the values are too small, there

will be no movement. Large values are advantageous for large actuator

volumes. Also bear in mind that large actuating increments for small

actuators also result in large movements.

The short step zone is the range of the control deviation between the

fast step zone and the dead band in which the actuator is activated by

pulses.

In the case of small control deviations, small values already cause

relatively high actuating speeds and can therefore result in over-

shooting. Large values in particular reduce overshooting in the case of

large changes in the nominal value and result in slow actuating speeds

near the compensated status.

This parameter has the same effect as a damping factor and is used to

set the control dynamics.

Small values cause fast compensation with overshooting. Large values

cause slow compensation without overshooting.

We recommend that you perform an automatic initialization first and only then adapt the

parameter determined by the positioner to your own special requirements.

TIP: To have a fixed reference value, it is helpful if you specify a fixed value for the dead zone

(DEBA parameter) instead of “Auto” for the optimization of your particular controller.

You select the parameters above from the diagnosis menu in the accustomed manner and

activate the joint adjustment by pressing the increment or decrement button for 5 seconds.

If you now adjust the relevant parameter, the new value is activated immediately. You can test

the effects of the new values on the controller results immediately.

When you quit the diagnosis menu, the parameter adjustment option is deactivated again.

13 Pulse length up

14 Pulse length

down

17 Short step zone up

18 Short step zone down

34 Prediction up

35 Prediction down

Operation

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Care and Maintenance

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Service and Maintenance

The positioner is largely maintenance-free. The positioners are fitted

with filters in the pneumatic connections as protection against coarse

particles of dirt. If the pneumatic energy supply contains particles of

dirt, the filters may clog and impair the function of the positioner. In this

case the filters can be cleaned as follows.

Positioner in metal housing and explosion proof version

1. Switch off the pneumatic power supply and remove the pipes.

2. Remove the metal filters carefully from the holes and clean

(e.g. with compressed air).

3. Insert the filters.

4. Re-connect the pipes and supply pneumatic energy.

Positioner in plastic housing

Removal

1. Switch off the pneumatic power supply and remove the pipes.

2. Unscrew the cover

3. Remove the three screws from the pneumatic connector strip.

4. Remove the filters and O-rings behind the connector strip.

5. Clean the filters (e.g. with compressed air).

Installation

6. First insert the filters in the recesses in the plastic housing and then

place the O-rings on the filters.

7. Align the pneumatic connector strip on the two lugs and screw tight

with the three self--tapping screws.

Important:

Make sure that the same thread is used. To do this turn the screws

counterclockwise until they snap into the thread audibly. Only then

should you tighten the screws.

Care and Maintenance

146 SIPART PS2 Manual

A5E00074631--06

8. Replace the cover and screw it tight.

9. Re-connect the pipes and supply pneumatic energy.

!DANGER

Electrostatic charging must be prevented in hazardous areas. These

could be caused by example when cleaning the positioner in plastic

housing with a dry cloth.

Faulty equipment should be sent to the repair department with details

of the fault and its origin. When ordering replacement equipment,

please specify the serial number of the original equipment. You will find

the serial number on the name plate.

Address of the responsible repair location, your contact, lists of spare

parts etc. can all be found on the Internet, under:

www.siemens.com/automation/services&support or

www.automation.siemens.com/partner

Repair/Upgrade

Technical Data

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Technical Data

General data for basic device 6DR50xx

6DR51xx

6DR52xx

6DR53xx

(see following pages)

Technical Data

148 SIPART PS2 Manual

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■

Technical specifications

SIPART PS2 (all versions)

General data

Travel range (linear actuators) 3 ... 130 mm (0.12 ... 5.12 inch)

(angle of feedback shaft 16 ... 90°)

Angle of rotation

(part-turn actuators)

30 ... 100°

Installation

• On linear actuators Using attachment set

6DR4004-8V and where necessary

with an additional lever arm

6DR4004-8L on actuators accord-

ing to IEC 534-6 (NAMUR) with

ribs, bars or flat face

• On part-turn actuators Using attachment set

6DR4004-8D on actuators with

mounting plane according to

VDI/VDE 3845 and DIN 3337:

The required mounting console

has to be provided on the actuator

side; shaft with groove and female

thread M6

Controller

• Five-point switch Self-adjusting

• Dead zone

- dEbA = Auto Self-adjusting or can be set as

fixed value

- dEbA = 0.1 ... 10% Self-adjusting or can be set as

fixed value

A/D converter

• Scan time 10 ms

• Resolution ≤ 0.05%

• Transmission error ≤ 0.2%

• Temperature effect ≤ 0.1%/10 K (≤ 0.1%/18 °F)

Cycle time

• 20 mA/HART device 20 ms

• PA device 60 ms

• FF device 60 ms (min. loop time)

Binary input BE1 (terminals 9/10;

electrically connected to the basic

device)

Suitable only for floating contact;

max. contact load < 5 mA with 3 V

Degree of protection1) IP66 to EN 60 529/NEMA 4x

Mounting position Any; pneumatic connections and

exhaust opening not facing up in

wet environment

CE marking Conformity as regards EMC Direc-

tive 89/336 EC in accordance with

the following standards

EMC requirements EN 61326/A1 Appendix A.1 and

NAMUR NE21 August 98

Material

• Housing

- 6DR5..0-... (plastic) Glass-fiber-reinforced Macrolon

- 6DR5..1-... (metal) GD AISi12

- 6DR5..2-... (stainless steel) Austenitic stainless steel mat.

No. 1.4581

- 6DR5..5-... (metal, pressure-

proof)

GK AISi12

• Pressure gauge block Aluminium AIMgSi, anodized

Vibration resistance

• Harmonic oscillations

(sine-wave) according to

DIN EN 60062-2-6/05.96

3.5 mm (0.14 inch), 2 ... 27 Hz

3 cycles/axis

98.1 m/s² (321.84 ft/s²),

27 ... 300 Hz, 3 cycles/axis

• Bumping (half-sine)

to DIN EN 60068-2-29/03.95

150 m/s² (492 ft/s²), 6 ms,

1000 shocks/axis

• Noise (digitally controlled)

to DIN EN 60068-2-64/08.95

10 ... 200 Hz; 1 (m/s²)²/Hz

(3.28 (ft/s²)²/Hz)

200 ... 500 Hz; 0.3 (m/s²)²/Hz

(0.98 (ft/s²)²/Hz)

4 hours/axis

• Recommended continuous duty

range of the complete fitting

≤ 30 m/s² (≤ 98.4 ft/s²) without res-

onance sharpness

Weight, basic device

• Plastic casing Approx. 0.9 kg (0.90 kg)

• Metal casing, aluminium Approx. 1.3 kg (1.30 kg)

• Metal casing, stainless steel Approx. 3.9 kg (3.90 kg)

• Metal casing EEx d version Approx. 5.2 kg (11.46 lb)

Dimensions See Dimensional drawings

Climate class 4 To DIN EN 60721-3-4

•Storage

2) 1K5, but -40 ... +80 °C

(1K5, but -40 ... +176 °F)

•Transport

2) 2K4, but -40 ... +80 °C

(2K4, but -40 ... +176 °F)

• Operation3) 4K3, but -30 ... +80 °C

(4K3, but -22 ... +176 °F)

Certificate and approvals

Classification according to pres-

sure equipment

directive (DRGL 97/23/EC)

For gases of fluid group 1, com-

plies with requirements of article 3,

paragraph 3 (sound engineering

practice SEP)

Pneumatic data

Power supply (inlet air)

• Pressure 1.4 ... 7 bar (20.3 ... 101.5 psi):

Sufficiently greater than max. drive

pressure (actuating pressure)

Air quality to ISO 8573-1

• Solid particle size and density Class 2

• Pressure dew point Class 2 (min. 20 K (36 °F) below

ambient temperature)

• Oil content Class 2

Unthrottled flow

• Inlet air valve

(ventilate actuator)4)

- 2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm)

- 4 bar (58 psi) 7.1 Nm³/h (31.3 USgpm)

- 6 bar (87 psi) 9.8 Nm³/h (43.1 USgpm)

• Outlet air valve

(ventilate actuator)4)

- 2 bar (29 psi) 8.2 Nm³/h (36.1 USgpm)

- 4 bar (58 psi) 13.7 Nm³/h (60.3 USgpm)

- 6 bar (87 psi) 19.2 Nm³/h (84.5 USgpm)

Valve leakage < 6⋅10-4 Nm³/h (0.0026 USgpm)

Throttle ratio Adjustable up to ∞ : 1

Power consumption in the

controlled state

< 3.6⋅10-2 Nm³/h (0.158 USgpm)

Types of actuators

• In plastic casing Single-action and double-action

• In aluminium casing Single-action

• In flameproof casing Single-action and double-action

• In stainless steel casing Single-action and double-action

1) Impact energy max. 1 Joule for plastic/aluminium casing.

2) During commissioning at ≤ 0 °C (≤ 32 °F) make sure that the valves are

flushed long enough with the dry medium.

3) At ≤ -10 °C (14 °F) the display refresh rate of the LCD is limited. Only T4 is

permissible when using Iy module.

4) With EEx d version (6DR5..5-...) the values are reduced by approx. 20%

Technical Data

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■

Technical specifications

SIPART PS2 Basic device

without Ex protection

Basic device

with EEx-d protection

(flameproof casing)

Basic device

with EEx ia/ib protection

Basic device

with EEx n protection

Explosion protection to

EN 50014, EN 50020 and EN 50021

Without EEx d

II 2 G EEx d II C T6

EEx ia/ib

II 2 G EEx ia/ib II C T6

EEx n

II 3 G EEx nA L [L] II C T6

Mounting location Zone 1 Zone 1 Zone 2

Permissible ambient temperature for

operation

At ≤ -10 °C (+14 °F) the display refresh

rate of the LCD is limited.

(for basic devices with EEX ia/ib and

EEx n protection the following applies:

Only T4 is permissible when using Iy

module.)

-30 ... +80 °C

(-22 ... +176 °F)

T4: -30 ... +80 °C (-22 ... +176 °F)

T5: -30 ... +65 °C (-22 ... +149 °F)

T6: -30 ... +50 °C (-22 ... +122 °F)

Electrical data

Input

2-wire connection (terminals 6/8)

Rated signal range 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA

Current to maintain the power supply ≥ 3.6 mA ≥ 3.6 mA ≥ 3.6 mA ≥ 3.6 mA

Required load voltage

UB (corresponds to Ω at 20 mA)

• Without HART (6DR50..)

- Typical 6.36 V (corresponds to

318 Ω)

6.36 V (corresponds to

318 Ω)

7.8 V (corresponds to

390 Ω)

7.8 V (corresponds to

390 Ω)

- Max. 6.48 V (corresponds to

324 Ω)

6.48 V (corresponds to

324 Ω)

8.3 V (corresponds to

415 Ω)

8.3 V (corresponds to

415 Ω)

• Without HART (6DR53..)

- Typical 7.9 V (corresponds to

395 Ω)

–––

- Max. 8.4 V (corresponds to

420 Ω)

–––

• With HART (6DR51..)

- Typical 6.6 V (corresponds to

330 Ω)

6.6 V (corresponds to

330 Ω)

––

- Max. 6.72 V (corresponds to

336 Ω)

6.72 V (corresponds to

336 Ω)

––

• With HART (6DR52..)

- Typical – 8.4 V (corresponds to

420 Ω)

8.4 V (corresponds to

420 Ω)

8.4 V (corresponds to

420 Ω)

- Max. – 8.8 V (corresponds to

440 Ω)

8.8 V (corresponds to

440 Ω)

8.8 V (corresponds to

440 Ω)

• Static destruction limit ± 40 mA – –

Internal capacitance Ci

• Without HART – – ≤ 22 nF –

• With HART – – ≤ 7 nF –

Internal inductance Li

• Without HART – – ≤ 0.12 mH –

• With HART – – ≤ 0.24 mH –

For connection to power circuits with – – intrinsically safe

Uo ≤ 30 V DC

Ik ≤ 100 mA

P ≤ 1 W

Ui ≤ 30 V DC

Ii ≤ 100 mA

Technical Data

150 SIPART PS2 Manual

A5E00074631--06

3-/4-wire device (terminals 2/4

and 6/8) (6DR52.. and 6DR53..)

• Power supply UH18 ... 35 V DC 18 ... 35 V DC 18 ... 30 V DC 18 ... 30 V DC

• Current consumption IH(UH - 7.5 V)/2.4 kΩ [mA] (UH - 7.5 V)/2.4 kΩ [mA] (UH - 7.5 V)/2.4 kΩ [mA] (UH - 7.5 V)/2.4 kΩ [mA]

• Internal capacitance Ci––≤ 22 nF –

• Internal inductance Li––≤ 0.12 mH –

• For connection to power circuits with – – intrinsically safe

Uo ≤ 30 V DC

Ik ≤ 100 mA

P ≤ 1 W

Ui ≤ 30 V DC

Ii ≤ 100 mA

Current input IW

Rated signal range 0/4 ... 20 mA 0/4 ... 20 mA 0/4 ... 20 mA 0/4 ... 20 mA

Load voltage at 20 mA ≤ 0.2 V (corresponds to

10 Ω)

≤ 0.2 V (corresponds to

10 Ω)

≤ 1 V (corresponds to

50 Ω)

≤ 1 V (corresponds to

50 Ω)

Internal capacitance Ci––≤ 22 nF –

Internal inductance (Li)––≤ 0.12 mH –

For connection to power circuits with – – intrinsically safe

Uo ≤ 30 V DC

Ik ≤ 100 mA

P ≤ 1 W

Ui ≤ 30 V DC

Ii ≤ 100 mA

Electrical isolation between UH and IWbetween UH and IWbetween UH and IW

(2 intrinsically safe cir-

cuits)

between UH and IW

Test voltage 840 V DC (1 s) 840 V DC (1 s) 840 V DC (1 s) 840 V DC (1 s)

Connections

• Electric Screw terminals 2.5

AWG28-12

Cable gland M20 x 1.5 or

½-14 NPT

Screw terminals 2.5

AWG28-12

EEx d certified cable

gland M20 x 1.5,

½-14 NPT or M25 x 1.5

Screw terminals 2.5

AWG28-12

Cable gland M20 x 1.5 or

½-14 NPT

Screw terminals 2.5

AWG28-12

Cable gland M20 x 1.5 or

½-14 NPT

• Pneumatic Female thread G¼

DIN 45141 or ¼-18 NPT

Female thread G¼

DIN 45141 or ¼-18 NPT

Female thread G¼

DIN 45141 or ¼-18 NPT

Female thread G¼

DIN 45141 or ¼-18 NPT

External position sensor (potentiometer or NCS; as option)

•U

o––< 5V< 5V

•I

o– – < 75 mA < 75 mA

•I

s– – <160 mA <160 mA

•P

o– – <120 mW <120 mW

Maximum permissible external capaci-

tance Co

––< 1 µF< 1 µF

Maximum permissible external induc-

tance Lo

– – < 1 mH < 1 mH

SIPART PS2 Basic device

without Ex protection

Basic device

with EEx-d protection

(flameproof casing)

Basic device

with EEx ia/ib protection

Basic device

with EEx n protection

Technical Data

151

SIPART PS2 Manual

A5E00074631--06

■

Technical specifications

Option modules Without Ex protection

(EEx d also)

With Ex protection EEx ia/ib With Ex protection EEx n

Ex protection to EN 50014, EN 50020 and

EN 50021

– II 2G EEx ia/ib II C T4/T5/T6 II 3G EEx nA L [L] II C T6

Mounting location – Zone 1 Zone 2

Permissible ambient temperature for opera-

tion

(For devices with Ex protection: Only in con-

junction with the basic device 6DR5... -.E....

Only T4 is permissible when using Iy module)

-30 ... +80 °C (-22 ... +176 °F) T4: -30 ... +80 °C (-22 ... +176 °F)1)

T5: -30 ... +65 °C (-22 ... +149 °F)1)

T6: -30 ... +50 °C (-22 ... +122 °F)1)

Alarm module 6DR4004-8A (without Ex protec-

tion)

6DR4004-6A (with Ex protection) 6DR4004-6A (with Ex protection)

Binary alarm outputs A1, A2 and alarm output

Signal status High (not responded)

Signal status Low* (responded)

(* Low is also the status when the basic

device is faulty or has not electric power sup-

ply)

Active, R = 1 kΩ, +3/-1%*

Disabled, IR < 60 µA

≥ 2.1 mA

≤ 1.2 mA

≥ 2.1 mA

≤ 1.2 mA

(* When used in the flameproof

casing the current consumption

is limited to 10 mA per output.)

(Switching threshold with sup-

ply to EN 60947-5-6: UH = 8.2 V,

Ri= 1kΩ)

(Switching threshold with sup-

ply to EN 60947-5-6: UH = 8.2 V,

Ri= 1kΩ)

Internal capacitance Ci–≤ 5.2 nF –

Internal inductance Li– Negligible –

Power supply UH≤ 35 V – –

Connection to power circuits with – 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 Floating contact, open Floating contact, open Floating contact, open

- Signal status 1 Floating contact, closed Floating contact, closed Floating contact, closed

- Contact load 3 V, 5 µA3 V, 5 µA3 V, 5 µA

• Electrically isolated from the basic device

- Signal status 0 ≤ 4.5 V or open ≤ 4.5 V or open ≤ 4.5 V or open

- Signal status 1 ≥ 13 V ≥ 13 V ≥ 13 V

- Natural resistance ≥25 kΩ≥25 kΩ≥25 kΩ

Static destruction limit ± 35 V – –

Internal inductance and capacitance – Negligible –

Connection to power circuits – Intrinsically safe Ui ≤ 25.2 V Ui ≤ 25.2 V DC

Electrical isolation The 3 outputs, the input BE2 and the basic device are electrically isolated from each other

Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s

SIA module (not for EEx d version) 6DR4004-8G (without Ex protec-

tion)

6DR4004-6G (with Ex protec-

tion)

6DR4004-6G (with Ex protec-

tion)

Limit transmitter with slot-type initiators and

alarm output

2-wire connection

Ex protection Without II 2 G EEx ia/ib IIC T6 II 3 G EEx nA L [L] IIC T6

Connection 2-wire system to EN 60947-5-6 (NAMUR), for switching amplifier to be connected on load side

2 slot-type initiators Type SJ2-SN Type SJ2-SN Type SJ2-SN

Function NC (normally closed) NC (normally closed) NC (normally closed)

Connection to power circuits with nominal voltage 8 V

Current consumption:

≥ 3 mA (limit value not

responded)

≤ 1 mA (limit value

responded)

Intrinsically safe switching

amplifier EN 60947-5-6

Ui ≤ 15.5 V DC

Ii ≤ 25 mA, Pi ≤ 64 mW

Ui ≤ 15.5 V DC

Pi ≤ 64 mW

Internal capacitance – ≤ 41 nF –

Internal inductance – ≤ 100 mH –

Electrical isolation The 3 outputs are electrically isolated from the basic device

Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s

Alarm output See Alarm module See Alarm module See Alarm module

1) Only in conjunction with the basic device 6DR5...-E..... With Iy module only T4 permitted.

Technical Data

152 SIPART PS2 Manual

A5E00074631--06

Accessory modules Without Ex protection

(EEx d also)

With Ex protection EEx ia/ib With Ex protection EEx n

Limit value contact module 6DR4004-8K 6DR4004-6K 6DR4004-6K

Limit transmitter with mechanical ground

contact and alarm output

Ex protection without II 2 G EEx ia/ib IIC T6 II 3 G EEx nA L [L] IIC T6

Max. switching current AC/DC 4 A Connection to intrinsically safe

power circuits:

Uo ≤ 30 V

Ik ≤ 100 mA,

Pi ≤ 750 mW

Connection to intrinsically safe

power circuits:

Uo ≤ 30 V

Ik ≤ 100 mA,

Pi ≤ 750 mW

Max. switching voltage AC/DC 250 V / 24 V 30 V DC 30 V DC

Internal capacitance Ci– Negligible –

Internal inductance Li– Negligible –

Electrical isolation The 3 outputs are electrically isolated from the basic device

Test voltage 3150 V DC, 2s 3150 V DC, 2 s 3150 V DC, 2 s

Alarm module See Alarm module See Alarm module See Alarm module

Iy module 6DR4004-8J (without Ex protec-

tion)

6DR4004-6J (with Ex protection) 6DR4004-6J (with Ex protection)

DC output for position feedback 2-wire connection 2-wire connection 2-wire connection

Nominal signal range i 4 ... 20 mA, short-circuit-proof 4 ... 20 mA, short-circuit-proof 4 ... 20 mA, short-circuit-proof

Total operating range 3.6 ... 20.5 mA 3.6 ... 20.5 mA 3.6 ... 20.5 mA

Power supply UH+12 ... +35 V +12 ... +30 V +12 ... +30 V

External load RB [kW] ≤ (UH [V] - 12 V) /i [mA] ≤ (UH [V] - 12 V) /i [mA] ≤ (UH [V] - 12 V) /i [mA]

Transmission error ≤ 0.3% ≤ 0.3% ≤ 0.3%

Temperature effect ≤ 0.1%/10 K (≤ 0.1%/18 °F) ≤ 0.1%/10 K (≤ 0.1%/18 °F) ≤ 0.1%/10 K (≤ 0.1%/18 °F)

Resolution ≤ 0.1% ≤ 0.1% ≤ 0.1%

Residual ripple ≤ 1% ≤ 1% ≤ 1%

Internal capacitance Ci–≤ 11 nF –

Internal inductance Li– Negligible –

For connection to power circuits with Intrinsically safe: Ui ≤ 30 V DC

Ii ≤ 100 mA; Pi ≤ 1 W (only T4)

Ui ≤ 30 V DC

Ii ≤ 100 mA; Pi ≤ 1 W (only T4)

Electrical isolation Electrically isolated from the

basic device

Electrically isolated from the

basic device

Electrically isolated from the

basic device

Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s

NCS sensor

(not for EEx d version)

Position range

• Linear actuator 3 ... 130 mm (0.12 ... 5.12 inch),

to 200 mm (7.87 inch) on request

3 ... 130 mm (0.12 ... 5.12 inch),

to 200 mm (7.87 inch) on request

3 ... 130 mm (0.12 ... 5.12 inch),

to 200 mm (7.87 inch) on request

• Part-turn actuator 30° ... 100° 30° ... 100° 30° ... 100°

Linearity (after correction by SIPART PS2)

• Linear actuator ± 1% ± 1% ± 1%

• Part-turn actuator ± 1% ± 1% ± 1%

Hysteresis ± 0.2% ± 0.2% ± 0.2%

Continuous working temperature -40 ... +85 °C (-40 ... +185 °F),

extended temperature range on

request

-40 ... +85 °C (-40 ... +185 °F),

extended temperature range on

request

-40 ... +85 °C (-40 ... +185 °F),

extended temperature range on

request

Degree of protection of casing IP68/NEMA 4X IP68/NEMA 4X IP68/NEMA 4X

Scope of deliver

153

SIPART PS2 Manual

A5E00074631--06

Scope of Delivery

The positioner and its options modules are delivered as separate units

and in different versions. Positioners and options modules for operation

in hazardous areas and non-hazardous areas are available. These ver-

sions are identified respectively by a special rating plate.

!WARNING

In the combination of components it must be ensured that only positio-

ners and options modules are combined which are approved for the

respective area of application. This applies especially for safe

operation of the positioner in areas in which the atmosphere is poten-

tially explosive (zone 1 and 2). The instrument categories (2 and 3) of

the instrument itself and those of its options must be observed.

Scope of delivery

154 SIPART PS2 Manual

A5E00074631--06

7.1 Scope of delivery of standard controller

Versions Housing Valve Ex-protection Order numbers

Plastic housing single action non Ex 6DR5010-xNxxx-0AA0

2L without Plastic housing double action non Ex 6DR5020-xNxxx-0AA0

HART Metal housing single action non Ex 6DR5011-xNxxx-0AA0

Plastic housing single action CENELEC/FM 6DR5010-xExxx-0AA0

Plastic housing double action CENELEC/FM 6DR5020-xExxx-0AA0

2L without Metal housing single action CENELEC/FM 6DR5011-xExxx-0AA0

HART Explosion proof housing single action CENELEC/FM 6DR5015-xExxx-0AA0

Explosion proof housing double action CENELEC/FM 6DR5025-xExxx-0AA0

Plastic housing single action non Ex 6DR5110-xNxxx-0AA0

SIP

RT PS2

Plastic housing double action non Ex 6DR5120-xNxxx-0AA0

Metal housing single action non Ex 6DR5111-xNxxx-0AA0

Plastic housing single action CENELEC/FM 6DR5210-xExxx-0AA0

Plastic housing double action CENELEC/FM 6DR5220-xExxx-0AA0

SIP

RT PS2

Metal housing single action CENELEC/FM 6DR5211-xExxx-0AA0

Explosion proof housing single action CENELEC/FM 6DR5215-xExxx-0AA0

Explosion proof housing double action CENELEC/FM 6DR5225-xExxx-0AA0

Plastic housing single action non Ex 6DR5310-xNxxx-0AA0

4L without Plastic housing double action non Ex 6DR5320-xNxxx-0AA0

HART Metal housing single action non Ex 6DR5311-xNxxx-0AA0

2L corresponds to two-wire operation

4L corresponds to four-wire-operation

--x stands for sub-variant

7.2 Scope of delivery of options

Option Order number

Iy- module without protection against explosion 6DR4004-8J

Iy- module with protection against explosion PTB 1)

Iy- module with protection against explosion FM2) 6DR4004-6J

6DR4004-7J

Alarm unit without protection against explosion 6DR4004-8A

Alarm unit with protection against explosion PTB 1)

Alarm unit with protection against explosion FM 2) 6DR4004-6A

6DR4004-7A

SIA-module without protection against explosion 6DR4004-8G

SIA-module with protection against explosion CENELEC and FM 1)2) 6DR4004-6G

Limit-contact module without protection against explosion 6DR4004-8K

Limit-switch module with protection against explosion CENELEC and

FM 1)2)3) 6DR4004-6K

1) EC-type examination certificate

2) Approval Reports from Factory Mutual System

3) In preparation

Scope of deliver

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7.3 Scope of delivery of accessories

Accessories Order number

Mounting kit set linear actuators IEC 534 -- 6

including lever arm for 3 to 35 mm way

6DR4004-8V

Additional lever for > 35 to 130 mm way 6DR4004-8L

Mounting kit part-turn actuators VDI/VDE 3845 6DR4004-8D

Solenoid valve block for SAMSON actuator (integrated mounting) 6DR4004-1C

Manometer block single acting 6DR4004-1M

Manometer block double acting 6DR4004-2M

Solenoid valve block single acting (NAMUR) 6DR4004-1B

Mounting set for SAMSON actuator (integrated mounting) 6DR4004-8S

NCS-Sensor

not explosion protected

explosion-protected

cable length 6 m

for part-turn actuators

for linear actuators up to 14 mm

6DR4004-_ N_ _ 0

6DR4004-8N

6DR4004-6N

6DR4004-_NN

6DR4004-_N_10

6DR4004-_N_20

EMC filter module C73451-A430-D23

External position detection system C73451-A430-D78

Operating software SIMATIC PDM on request

Scope of delivery

156 SIPART PS2 Manual

A5E00074631--06

7.4 ListofSpareParts

Spare parts list: SIPART PS2 positioner

Description Order No. for version

Cover (plastic enclosure) with

screws (4 pcs) and seal

C73451-A430-D82 6DR4___

6DR5___

Cover (metal enclosure) with screws

(4 pcs) and seal

C73451-A430-D83 6DR4___

6DR5___

Motherboard, two-wire without

HART, without explosion protection

A5E00082459 6DR50__--_N

6DR40__--_N *)

Motherboard, two-wire without

HART, with explosion protection

A5E00082457 6DR50__--_E

Motherboard, two-wire HART, wi-

thout explosion protection

A5E00082458 6DR51__--_N

6DR40__--_N *)

Motherboard, two-,three-,four-wire

HART, with explosion protection

A5E00082456 6DR52__

Motherboard Two-,three-,four-wire

without HART, without expl. protect.

A5E00102018 6DR53__--_N

6DR40__--_N *)

Motherboard PROFIBUS PA,

without explosion protection

A5E00141523 6DR55__--_N..

6DR41__--_N

Motherboard PROFIBUS PA,

with explosion protection

A5E00141550 6DR55__--_E

6DR41__--_E

Motherboard FIELDBUS Founda-

tion, without explosion proof

A5E00215467 6DR56__

Motherboard FIELDBUS Founda-

tion, with explosion protection

A5E00215466 6DR56__

Pneumatic block (Valve single acting

incl. seals and screws)

C73451-A430-D80 6DR4___

6DR5___

Pneumatic block (Valve double ac-

ting incl. seals and screws)

C73451-A430-D81 6DR4___

6DR5___

Potentiometer (complete) C73451-A430-D84 6DR4___

6DR5___

*) 6DR40.. can be used after having clarified whether application with two-wire or three-wire/four-wire

input

Note: For accesories and option modules see Catalog FI 01 “Field

Instruments for Process Automation”

Index

157

SIPART PS2 Manual

A5E00074631--06

Index

Accessories, 39

Actuating ranges, 130

Alarm function, 106

Alarm module, 32, 61, 66, 70

Application

positioner in a wet environment, 44

under great accelerations and vibrations, 46

Assembly, 43

Screw--type gland with plastic hose, 46

Assembly procedure, 50, 53

linear actuator, 51

part--turn actuator, 54, 55

Automatic, Changing the operating mode, 94

Base plate, 58

Block diagram, Mode of operation, 25

Catalogs, 159

Commissioning, 72

Configuration, changing the operating mode,

Controller data, Optimization, 143

Current output, Electrical Connection, 61, 66,

Delivery, 10

Design name plate, 17

Diagnosis, 122

Display, 122

Online, 131

Diagnosis values, Meaning of ~, 123

Diagnostic display, Changing the operating

mode, 94

Digital input, electrical connection, 61, 66, 70

Digital output, electrical connection, 61, 66, 70

Dimensional drawings, 41

Display, 89

Display text, Meaning, 139

Documentation, 9

double--acting, 13, 14

Electrical connection, 18, 57

EMV--filter module, 38

Filters, Cleaning the ~, 145

Firmware version, 91

Four--wire connection, 60, 64, 69

General information, 5

HART module, 26

Housing, 11

Initialization, 100

Automatic ~, Structogram, 83

automatic ~, 72, 74, 79, 82

changing the operating mode, 93

copying ~, 72

manual ~, 72, 76, 81

Initialization data, Copying the ~, 87

Input keys, 89

Installation positions, favorable and

unfavorable, 45, 47

Instrument identification, 41

Iy module, 31, 61, 66, 69

Lever arm transmission, 99

Linear actuator, 13, 14

automatic initialization, 74

manual initialization, 76

preparation, 73

Literature, 159

Maintenance, 145

Index

158 SIPART PS2 Manual

A5E00074631--06

Manometer block, 39

Manual mode

Changing the operating mode, 94

P manual mode, 93

Mechanical limit switch module, 35, 62

EEx i, 67

Mechnical limit switch module, 67

not EEx, 62

Method of operation, 15, 23

Mounting kit

linear actuator, 49

part--turn actuator, 52

Operating mode

AUT, 94

MAN, 94

Operating Modes, 92

Operating modes, Change ~, 92

Operation, 89

Options, 12, 27

Parameter table, SIPART PS2, 96

Parameters, 95

Part--turn actuator, 13, 14, 56, 57

Automatic initialization, 79

manual initialization, 81

preparation, 79

PDM (Process Device Manager), 87

Personnel, Qualification, 7

Pneumatic connection, 19, 71

Positioner exchange, 72, 87

Positioning, 21

Purge air switching, 22

Qualified Personnel, 7

Restrictors, 22

Scope of Delivery, 153

Series circuit, of two positioners, 65

Service, 145

Setpoint, 130

Setpoint characteristic, 102

SIA module, 33, 62, 67, 70

Electrical Connection, 62, 67, 70

single--acting, 13, 14

Split range, 65, 100

Electrical Connection, 65

Standard controller, 63, 68

Standards, 10

Structograms of automatic initialization, 82

Technical data, 147

Three--wire connection, 60, 64, 69

Two--wire connection, 59, 60, 63, 68

Type key, 41

Use as intended, 9

Versions, 11

Vibrations, 46

View of the instrument, 17

Warranty, 9

wet environment, 44

Appendix

159

SIPART PS2 Manual

A5E00074631--06

Appendix

9.1 Literature and catalogs

Nr. Title Issue by Order no.

/1/ Industrial Communication for Au-

tomation and Devices

Catalog IK PI · 2005

Siemens AG E86060--K6710--A101--B4--7600

/2/ Field Instruments for Process

Automation

Catalog FI 01 · 2007

Siemens AG E86060--K6201--A101--A8--7600

/3/ SIMATIC PCS 7 Process Control

System

Catalog ST PCS 7 · 2005

Siemens AG E86060--K4678--A111--A9--7600

Appendix

160 SIPART PS2 Manual

A5E00074631--06

Siemens Sipart Ps2 6Dr50Xx Users Manual S3 4

6DR53xx to the manual 40bc6b8e-54cb-489f-bff3-f15361784489

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