SIPART PS2 Manual 6DR5xxx Edition 02/01 Electropneumatic Positioner for Linear and Rotary Actuators
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Contents 0 1 2 3 Information for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0.2 Meaning of safety instructions and warnings . . . . . . . . . . . . . . . . . . . . . 6 0.3 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0.4 Use as intended . . . . . . . . . . . .
3.3.5 3.3.6 Mounting kit ”Rotary actuator” 6DR4004-8D . . . . . . . . . . . . . . . . . . . . . . Assembly procedure (see figure 3-7 and figure 3-8) . . . . . . . . . . . . . . . 42 43 3.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.4.1 3.4.1.1 3.4.1.2 3.4.1.3 Connection variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection variant: not intrinsically safe . . . . . . . . . . . . . .
Information for the Operator Information for the Operator 0 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: - SIPART PS2 without Ex-protection in a metal-- or plastic housing.
Information for the Operator This manual is not a permanent part of the scope of supply. For reasons of clarity, it does not contain every detail about every version of the product described and cannot take every eventuality in installation, operation, maintenance and use in systems into account.
Information for the Operator NOTICE NOTICE used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesireable result or state. . NOTE indicates a reference to a possible advantage when this recommendation is followed. 0.3 Qualified Personnel The result of unqualified intervention in the instrument or nonobservance of the warnings given in this manual or on product labels can be severe personal injury and/or serious material damage.
Information for the Operator ! WARNING The instrument must only be installed and commissioned by qualified personnel. The instrument is designed for connection to functional and safety extra low voltage. 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.
Information for the Operator The following list contains all the documents available for these instruments: 0.6 Title Language Order No.
Information for the Operator 0.8 Standards and Regulations As far as possible, the harmonized European standards were used to specify and manufacture this equipment. If harmonized European standards have not been applied, the standards and regulations of the Federal Republic of Germany apply (see also the Technical Data in Chapter 6, page 101).
Introduction 1 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.
Introduction Degree of protection The device is designed with IP65/NEMA4x degree of protection. Explosion 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. Options The positioner can be expanded with various options modules (chapter 2.5, page 25).
Introduction 1 4 2 3 5 1 2 3 4 5 Figure 1-1 Actuator Positioner, single action in metal housing Lantern Manometer block, single action Valve Positioner mounted on linear actuator (single action) 3 1 2 1 2 3 Figure 1-2 Positioner double action in plastic housing Rotary actuator Manometer block, double action Positioner mounted on rotary actuator (double action) SIPART PS2 Manual A5E00074631-01 13
Introduction 1 2 4 3 1 2 3 4 Figure 1-3 Actuator Positioner, single action in metal housing Lantern Manometer block, single action Explosion proof positioner mounted on linear actuator (single action) 1 3 2 1 2 3 Figure 1-4 14 Positioner double action in plastic housing Rotary actuator Manometer block, double action Explosion proof positioner mounted on rotary actuator (double action) SIPART PS2 Manual A5E00074631-01
Design and Functional Principle Design and Method of Operation 2 The following chapter describes the mechanical and electrical design, the instrument components and method of operation of the positioner. 2.1 Overview Introduction 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.
Design and Functional Principle puts respond even when the power supply fails or the electronics are defective. The actuator can also be blocked or driven to its final positions depending on the configuration for example by an external event via a 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.
Design and Functional Principle 3 9 6.1 1 12 7 10 - 10 1 2 3 4 5 6.1 6.2 *) 238 9 138 1 2 + 6.
Design and Functional Principle 2.2.3 Pneumatic Connections The pneumatic connections are on the right hand side of the positioner (figure 2-3 and figure 2-4).
Design and Functional Principle The exhaust air output E can be provided for supplying dry instrument air to the tapping chamber and spring chamber to prevent corrosion. Figure 2-5, page 20 shows the pneumatic connection variants for the different actuator types, the positioning action and the safety position after power failure.
Design and Functional Principle Positioning pressure Connection Actuator type Y1 Closed Safety position after power failure electrical pneumatic Closed Closed Open Open Open In rotary actuators the direction of rotation counterclockwise looking onto the actuating shaft of the valve is usually defined as ”Open”.
Design and Functional Principle 2.2.4 Mounting Kit The positioner can be mounted on almost all actuators with the appropriate mounting kit. 2.2.5 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 2-6). 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.
Design and Functional Principle 2.3 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 rotary actuators and the command variable w is the actuating current of a controller or a manual control station of 4 to 20 mA.
Design and Functional Principle . NOTE The exhaust air valve is always open when there is no current.
Design and Functional Principle 1 HART 2 BE1 3 Supply Zuluft air _ 3V _ + I W+ y pZ y + Exhaust Abluft air +24 V p1 +5 V p1 W A D A y0 +U p2 Micro- I W- controller p2 D Abluft Exhaust air _ + W x0 4 x U U 6 I 5 BE2 A1 A2 I I 9 8 p2 7 A1 A2 p1 p1 stroke 1 2 3 4 5 6 7 8 9 stroke Motherboard with microcontroller and input circuit Control panel with LC-display and momentary action switch Piezo--valve unit, always built--in Valve unit with double action positioner
Design and Functional Principle 2.4 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 action versions are prepared at the factory as ordered. The pneumatic connections on the rear are sealed. 2.5 Options modules 2.5.
Design and Functional Principle Alarm module Insert the alarm module (4) in the top pcb rails of the container, establish the electrical connection with the enclosed ribbon cable (5). SIA-module (Slot Initiator Alarm module) Proceed as follows for installation: 1. Remove all the electrical connections from the basic electronics (2). 2. Loosen the two fixing screws (2.1) of the basic electronics. 3. Snap out the basic electronic board by carefully bending the four holders. 4.
Design and Functional Principle 15. Drive the actuator to the second desired mechanical position. 16. Adjust the bottom actuating disc (for output terminals 51--52) by hand until the output level 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. 6 1.1 1 5 2.1 2.1 1.1 2 11 10 4 7 3 7.1 1 2 2.
Design and Functional Principle 2.5.2 Options modules in explosion proof version The options modules are protected and mechanically fixed by a module cover ((1), see figure 2-11, page 29). . NOTE The housing must be opened to install the options modules. The degree of protection IP65/NEMA4x is not guaranteed as long as the positioner is open.
Design and Functional Principle 1.1 1 13.1 1.1 2 11 4 3 12 10 13.1 7 5 6 13 8 1 1.1 2 3 4 5 6 Module cover Fixing screws PA module Jy module with ribbon cable Alarm module with ribbon cable Ribbon cable for alarm module Ribbon cable for Jy module Figure 2-11 7 8 10 11 12 13 13.1 Transmission ratio selector Adjusting wheel for slipping clutc Housing Screw--on cover Safety catch Rack Fixing screws Installation of the options modules in the explosion proof version 2.5.
Design and Functional Principle The SPART PS2 is integrated in the following parameterization tools: - Handheld communicatorR - PDM (Process Device Manager) - AMS (Asset Management System; update in preparation) - Cornerstone . NOTE Operation on the positioner has priority over the settings via the HART inetrface. Communication is aborted by a power failure at the positioner. 2.5.
Design and Functional Principle Installation The alarm module is pushed in underneath the motherboard into the module rack up to the stop and connected by the enclosed 8-wire ribbon cable (5) to the motherboard (see figure 2-10, page 27). 2.5.5 Jy-module Function With the Jy-option module, the current actuator position can be output as a two wire signal Jy= 4 to 20 mA – potentially isolated from the standard controller. The dynamic control of the Jy-module makes it also error self--reporting.
Design and Functional Principle 2.5.7 Accessories Y1 Y1 PZ Figure 2-12 PZ Y2 Manometer block (left for single--acting, right for double--acting actuators) Manometer block The manometer block for single--acting actuator contains two manometers which are screwed to the lateral pneumatic connection of the positioner with O--rings. The values for the input pressure (supply air PZ) and output pressure (actuating pressure Y1) are displayed.
Preparing for Operation 3 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 105. Installation of any modules required is described in chapter 2.5, page 25 of this technical manual. 3.
Preparing for Operation 90 79,5 50 20,5 9,5 14 3x G 1/4 or 1/4” NPT 9 12 25 2xM6 29,5 58,75 82 M4 Thread depth 5.5 5 3,5 5 10 5,3 9,5 Figure 3-2 Dimensional drawing terminal strip for plastic housing 12 6,5 Y1 50 x 4 x M6 59 14 27,5 34,5 E 29,5 29,5 84 29 7 Y1 2 65 9 deep M8, 9 deep PZ 23 All air connections G 1/4 or 1/4” NPT 58 11,2 13,5 96,6 182 8 M20 x 1.
Preparing for Operation All air connections G1/4 or 1/4”NPT 10,25 7 25 12 19,25 50 60 1) M6, 8 deep (2x) Æ M6, 11 deep (4x) 33,5 4,5 7,75 34 43 65 E 33,5 23 M8, 14 deep (4x) M20, M25 or 1/ ”NPT (2x) 2 87,2 7,5 25,7 14,3 129,5 3,5 Connection 238/Y2 only in double action version 82,5 Æ 136.5 158,5 1) 235,3 Æ 8 h9 Figure 3-4 3.
Preparing for Operation . 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.
Preparing for Operation 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 IP65 degree of protection is inadequate protection for this.
Preparing for Operation - Mount the above mentioned plastic hose on the screw--type gland and check the good fit. - Fix the plastic hose with a cable strap to the fitting so that the opening faces downwards. - Make sure that the hose has no kinks and the exhaust air can flow out unhindered. 3.3.
Preparing for Operation 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 3-6, page 41): Ser. no.
Preparing for Operation 8. Fit the mounting bracket (1) with two hexagon head screws (9), lock washer (10) and flat washer (11) on the rear of the positioner. 9. Selection of the row of holes depends on the width of the actuator yoke. The roll (5) should engage in the pick--up bracket (2) as close as possible to the spindle but may not touch the clamping assembly. 10. Hold the positioner with the mounting bracket on the actuator so that the pin (4) is guided within the pick--up bracket (2). 11.
Preparing for Operation 17 2 16 12 16 19 18 6 12 14 22 17 3 13 1) 2) 15 45 Without explosion proof version 10 11 9 1 11 10 9 3) Explosion proof version: 10 11 9 1 11 3) 9 10 Figure 3-6 Assembly procedure (linear actuator) SIPART PS2 Manual A5E00074631-01 41
Preparing for Operation 1 11 10 8 10 8 Mounting on yoke with plane surface Mounting on yoke 11 with ledge 11 10 Mounting on yoke with columns 7 21 4) as required Figure 3-6 Assembly procedure (linear actuator) continued 3.3.5 Mounting kit ”Rotary actuator” 6DR4004-8D The scope of delivery of the mounting kit ”Rotary actuator” contains (ser. no. see figures 3-7 and 3-8): Ser. no. 2 42 Pieces 1 Designation Coupling wheel 3 4 1 1 Carrier Multiple plate 4.
Preparing for Operation 3.3.6 Assembly procedure (see figure 3-7 and figure 3-8) SIPART PS2 Manual A5E00074631-01 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.
Preparing for Operation 4.2 15 9 14 2 18 9 1) 2) 16 3 17 3) 2 2 4.
Preparing for Operation 15 14 4.2 9 9 16 1) 3 17 18 2 2) 3) 2 4.
Preparing for Operation CUT A -- B 4.2 14, 15 15 positioner 14, 15 2 A 25 G 1/4 B rotary actuator 3 2 3 4 4.1 4.2 9 Coupling wheel Carrier Multiple plate Scale Pointer mark VDI/VDE 3845-mounting bracket Figure 3-9 46 16, 17 10 4.
Preparing for Operation Befestigungsebene fastening level Stellungsregler positioner M6 4 +0,1 Schwenkantrieb rotary actuator 35 F05-Lkr.
Preparing for Operation 3.4 Electrical Connection . NOTE Any necessary options modules must be installed before electrical connection (see chapter 2.5, page 25). N.B.: The transmission ratio selector can only be set when the positioner is open. Therefore check this setting before sealing the controller.
Preparing for Operation Shield Figure 3-11 Base plate 3.4.1 Connection variants 3.4.1.1 Connection variant: not intrinsically safe The electrical connection of the positioner can be made in the following ways: + 4 to 20 mA 6 7 8 9 10 J E +3 V A Positioner Digital inputs 1 6DR5010-xNxxx 6DR5020-xNxxx 6DR5011-xNxxx 6DR5110-xNxxx 6DR5120-xNxxx 6DR5111-xNxxx Only for: HART Communicator Figure 3-12 6DR5110-xNxxx 6DR5120-xNxxx 6DR5111-xNxxx Two--wire connection non Ex .
Preparing for Operation 3.4.1.2 Connection variant: intrinsically safe . NOTE Only certified intrinsically safe circuits may be connected as power supply, control and signal circuits. Non-hazardous area Hazardous area zone 1 or zone 2 + EEx 4 to 20 mA J Intrinsically safe power source Figure 3-13 6 7 8 9 10 E A Positioner 6DR5010-xExxx 6DR5020-xExxx 6DR5011-xExxx +3 V Digital inputs 1 Two--wire connection standard controller 6DR50xx-xExxx (power supply from signal current) .
Preparing for Operation Non-hazardous area Hazardous area zone 1 or zone 2 + EEx Positioner 2 3 4 5 4 to 20 mA J Intrinsically safe power source 6 7 8 9 10 E 6DR5210-xExxx 6DR5220-xExxx 6DR5211-xExxx A +3 V Digital inputs 1 HART Communicator Figure 3-14 Two--wire connection standard controller 6DR52xx-xExxx Non-hazardous area EEx Hazardous area zone 1 or zone 2 + 18 to 30 V + *) 4 to 20 mA U EEx J Intrinsically safe power sources Positioner 2 3 4 5 *) 6 7 8 9 10 E 6DR5210-xEx
Preparing for Operation Split-range Figure 3-16 3.4.1.3 Series circuit of two positioners, e.g.
Preparing for Operation Digital inputs and outputs Alarm module 6DR4004-8A +13 V + 11 12 +4.
Preparing for Operation 3.4.1.
Preparing for Operation Digital inputs and outputs Alarm module 6DR4004-6A + 11 12 EEx ≥1 +3 V 21 22 +8.2 V Intrinsically safe Switching amplifier to EN 50227 EEx +8.2 V EEx +8.2 V EEx Non--hazardous area Figure 3-21 Digital input 2 2K1 31 32 10K Fault message 2K1 41 42 10K Limit value A1 2K1 51 52 10K Limit value A2 Hazardous area zone 1 or zone 2 Alarm module 6DR4004-6A, Ex Current output SIA module: 6DR4004-6G Intrinsically safe Switching amplifier to EN 50227 +8.2 V EEx +8.
Preparing for Operation 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 76). NOTE Note the air quality! Oil--free industrial air, solid content < 30 μm, pressure dew point 20 K below the lowest ambient temperature. - Connect a manometer block for supply air and actuating pressure if necessary.
Preparing for Operation 3.6 Commissioning Due to the wide range of application possibilities the positioner must be adapted (initialized) to the respective actuator individually after assembly.
Preparing for Operation 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 gear transmission switch (8, figure 2-1, page 16) in the positioner: . Stroke Lever 5 to 20 mm 25 to 35 mm 40 to 130 mm short short long Position of the gear transmission switch 33° (i.e. down) 90° (i.e. up) 90° (i.e. up) 2.
Preparing for Operation 3.6.2 Automatic initialization of linear actuator If you can move the actuator correctly, leave it standing in a central position and start automatic initialization: 1. for longer than 5 s. This brings Press the operation mode key you to the Configuration operating mode. Display: 2. Switch to the second parameter by pressing the operation mode briefly. key Display: .
Preparing for Operation 5. Start initialization by pressing the key Display: for longer than 5 s. During the initialization phase ”RUN1” to ”RUN5” appear one after another in the bottom display (see also structograms figures 3-24, page 68 to figure 3-27, page 71). . NOTE The initialization process may last up to 15 minutes depending on the actuator.
Preparing for Operation 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 displacement path are set manually. The other initialization steps (optimization of the control parameters) run automatically as in automatic initialization. Manual initialization procedure in linear actuator 1. Make preparations as described in chapter 3.6.
Preparing for Operation 5. Switch on to the following display mode key twice: by pressing the operation 6. Start initialization by pressing the increment key than 5 s. Display: 7. After 5 s the display changes to: for longer (The display of the potentiometer setting is shown here and below as an example only). Now move the actuator to the position which you want to define as and decrethe first of the two end positions with the increment ment key. Then press the operation mode key .
Preparing for Operation 8. If step 7 was successful, the following display appears: Now move the actuator to the position which you want to define as the second end position with the increment and decrement key. Then press the operation mode key the current position as end position 2. . . This enters NOTE If the message “RANGE” appears in the bottom line, the selected end position is outside the permissible measuring range.
Preparing for Operation 3.6.4 Preparations for rotary actuator . NOTE Very important: Switch the transmission ratio selector in the positioner (8, figure 2-1, page 16) to position 90° (normal angle for rotary actuator). . 1. Mount the positioner with the appropriate mounting kit (see chapter 3.3.5, page 42). 2. Connect the actuator and the positioner with the pneumatic lines and supply pneumatic power to the positioner (figure 2-3 and 2-4, page 18). 3.
Preparing for Operation 2. Set the parameter with the Display: -key to ”turn” 3. Switch to the second parameter by pressing the operation mode key briefly. This has set automatically to 90°. Display: 4. Switch on to the following display with the operation mode key 5. Start initialization by pressing the key Display: : for longer than 5 s.
Preparing for Operation The following display appears after pressing the operation mode key briefly: To exit the Configuration mode, press the operation mode key for longer than 5 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.
Preparing for Operation 4. . Switch to the second parameter by pressing the operation mode key briefly. Display: NOTE Make sure that the transmission ratio selector is in position 90 °! 5. Switch on to the following display by pressing the operation mode key twice: The following steps are identical with the steps 6) to 9) for initialization of linear actuators. After successful initialization the determined rotary range appears in the top display. “5.
Preparing for Operation Figure 3-24 68 Automatic initialization, part 1 SIPART PS2 Manual A5E00074631-01
Preparing for Operation Figure 3-25 Automatic initialization part 2 (in rotary actuators) SIPART PS2 Manual A5E00074631-01 69
Preparing for Operation Figure 3-26 70 Automatic initialization part 2 (in rotary actuators) SIPART PS2 Manual A5E00074631-01
Preparing for Operation Figure 3-27 Automatic initialization, part 3 SIPART PS2 Manual A5E00074631-01 71
Preparing for Operation 3.7 Copying initialization data (positioner exchange) With this function you have the possibility of starting up a positioner without running the initialization routine. This allows for example a positioner to be changed on a running system in which automatic or manual initialization cannot be performed without disturbing the process.
Operation 4 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 display depends on the selected operating mode (see chapter 4.3, page 76) .
Operation Figure 4-1 Meaning of the various display options . NOTE The degree of protection IP 65/NEMA4x is not guaranteed as long as the positioner is open.
Operation 1 2 1 2 3 4 3 4 Display Operation mode key Decrement key Increment key Figure 4-2 Display and input keys of the positioner Explanations of the input keys - The operation mode key (manual key) serves to switch over the operating mode and pass on parameters. . NOTE By pressing and holding the operation mode key and additionally pressing the decrement key, you can select the parameters in reverse order.
Operation 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.
Operation 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 57 “Commissioning”. P-manual mode (ex--factory state) Output of alarms and position feedback is possible after successful initialization.
Operation Manual mode (MAN) . In this operating mode you can move the actuator with the decrement ( ) and increment keys ( ) and the current position is held regardless of the setpoint current and any leakages. NOTE You can move the actuator quickly by pressing the other direction key additionally whilst keeping the direction key selected first pressed.
Operation Parameter name Display 2.YAGL Function Parameter values Rated angle of rotation of feedback Set transmission ratio selector (7) appropriately (see view of device) 1) 90° 33° Factory setting Driver pin must be set to the value of the actuator travel or, if this value is not scaled, to the next larger scale value. 4.INITA Initialization (automatically) 5.
Operation Positioning actuator type 1.YFCT Selection of used actuator: Linear actuator (WAY), rotary actuator (turn). The unlinearity which exists in linear actuators due to the conversion of linear movement to rotational movement is compensated by the positioner when 1.YFCT = WAY is selected. If an external, linear potentiometer is used for displacement measuring, “1.YFCT” is set to LWAY. However, no way is displayed after initialization.
Operation . NOTE The specification “YWAY” must match the mechanical lever arm transmission. The carrier must be set to the value of the actuator stroke, if this is not scaled to the next highest scaled value. 4.INITA Automatic initialization (see chapter 3.6, page 57) for at least 5 By selecting “Strt” and pressing the increment key seconds, automatic initialization is started. The initialization process is displayed by “RUN 1” to “RUN 5” (see figure 3-24, page 68 to figure 3-27, page 71).
Operation y=x 100 % Positioner 1 6.SDIR = FALL Total setting range Positioner 2 6.SDIR = riSE 0% 100 %--SPRE 100 %--SPRA SPRA Positioner 1 Setting range 1 SPRE Positioner 2 Setting range 2 Figure 4-7 Example: Split range-operation with two positioners 10.TSUP Setpoint ramp UP and Setpoint ramp DOWN 11.TSDO 100 % JW [0 % to 100 %] The setpoint ramp is effective in automatic operation and limits the speed of alteration of the active setpoint.
Operation Figure 4-8 - inverse equal percentage 1 : 33 (12.SFCT = n1 --33) - inverse equal percentage 1 : 50 (12.
Operation 13.SL0 to 33.SL20 Setpoint vertex points (see figure 4-8, page 83) A flow parameter can be assigned to the respective setpoint vertex 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. The setpoint vertex values can only be input at You may only enter a strictly monotonous characteristic, the vertex values of which differ by at least 0.2%.
Operation YNRM = MPOS or YNRM = FLOW Presetting: YA = 0% and YE = 100% 50% 4mA 7.2mA 0% 20% 0mm 16mm 10.4mA 13.6mA 40% 60% 32mm 48mm 16.8mA 80% 20mA 100% 64mm 80mm YA = 0% Input current (setpoint) X display W display Mechan. Stroke (actual value) YE = 100% Example: YNRM = MPOS with YA = 10 % and YE = 80 % 50% 4mA 0% 0mm 7.2mA 10.4mA 13.6mA 20% 40% 60% 16mm 32mm 80% 48mm YA = 10% 7.2mA 0% 0mm 20% 16mm 100% 64mm 80mm X display W display Mechan.
Operation 40.YCDO Value for sealing bottom When the sealing function bottom (see parameter“39.YCLS”is activated, it can be set below which setpoint the bottom sealing is activated with this parameter. 41.YCUP Value for sealing top When the sealing function top (see parameter“39.YCLS”is activated, it can be set above which setpoint the top sealing is activated with this parameter. 42.BIN1 43.
Operation 44.AFCT 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 contacts) is related to the MPOS-scaling (see figure 4-9, page 85). 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.
Operation 50. STRK Limit value for monitoring the way integral A limit value for the way integral can be set here. If the way integral exceeds the limit value, the fault message output (optional) is activated. This function enables a preventive maintenance of the fitting, see also chapter 4.5 “Diagnostics”, page 90. This monitoring function can be deactivated with the OFF setting (factory setting). 51.
Operation . NOTE But the monitors of the bottom and top hard stop do not only react to valve errors. Adjustment of the position feedback is also detected as an error if the tolerance values are exceeded as a result. 54. DEBA Limit value for monitoring the dead zone adaptation The automatic adaptation of the dead zone can be monitored with this value (%). If the dead zone exceeds the set value, the fault message output (optional) is activated.
Operation 4.5 Diagnosis 4.5.1 Diagnostic display You go to the diagnostic display from automatic or manual operation by simultaneously pressing all three keys for at least two seconds. Table 3-1, page 91 shows an overview of the displayable values. In the third column the corresponding English term from which the abbreviation is derived is shown next to the German meaning unless this is self explanatory. The diagnostic display has a similar structure to in the ”Configuration” operating mode.
Operation No. Abbreviation Meaning Displayable values Unit 28 T7 Number of operating hours in Temperature range 7 0 to 4.29E9 Hours 29 30 T8 T9 Number of operating hours in Temperature range 8 Number of operating hours in Temperature range 9 0 to 4.29E9 0 to 4.29E9 Hours Hours 31 32 VENT1 VENT2 Number of cycles pre--controlvalve 1 Number of cycles pre--controlvalve 2 0 to 4.29E9 0 to 4.
Operation 7 WAY Determined actuating way This value indicates the actuating way determined during initialization according to the display at the end of an initialization. Prerequisite in linear actuator: Specification of the lever arm with the parameter “3.YWAY”. 8 TUP 9 TDOWN Travel time up and travel time down These values show the travel times which have been determined during initialization. The unit is seconds.
Operation Current temperature 19 TEMP Current temperature in the positioner housing The sensor is on the electronics board. Minimum temperature (drag pointer) and Maximum temperature (drag pointer) 20 TMIN 21 TMAX The minimum and maximum temperature inside the housing is determined and stored continuously in a kind of drag pointer. 22 T1 to 30 T9 Number of operating hours in temperature range T1 to T9 Statistics how long operation takes place in which temperature ranges is kept in the instrument.
Operation Table 3-2, page 94 shows which events can activate the fault message output, how the parameters must be set for this event to be monitored, when the fault message disappears again and where the possible causes of the fault lie. In automatic and manual operation response of the fault message output on the display shows which is the fault message trigger. The two digits at the bottom left indicate the corresponding error code.
Operation Explanations of column “Error codes”: 1 Monitoring of control error In automatic operation the error between setpoint and actual value is monitored continuously. The fault message is activated with unchanged control error according to the setting of the parameters 48. TIM, monitoring time for setting the fault messages and 49 LIM, response threshold of the fault message. As soon as the control error drops back below the response threshold, the fault message is reset.
Operation The fault message remains activated until either a subsequent monitoring remains within the tolerance or a new initialization is performed. The deactivation of the monitoring (“52. ZERO”=OFF) also clears any existing fault message. This monitoring function supplies no useful results when the stops have not been determined automatically in initialization but the limits set manually (manual initialization“5.INITM”). An appropriate diagnosis is made for the top hard stop.
Operation Figure 4-10 Configuration block diagram SIPART PS2 Manual A5E00074631-01 97
Operation 98 SIPART PS2 Manual A5E00074631-01
Care and Maintenance Service and Maintenance 5 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.
Care and Maintenance 8. Replace the cover and screw it tight. 9. Re--connect the pipes and supply pneumatic energy. ! 100 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.
6 Technical Data General data for basic device 6DR5xxx-xx Travel range (linear actuators) 3 to 130 mm (angle of feedback shaft 16 to 90°) Angle or rotation (part-turn actuators) 30 to 100° Installation • On linear actuators • On part-turn actuators Supply (inlet air) • Pressure 1.4 to 7 bar: sufficiently larger than max.
Technical data Binary input BI1 SIPART PS2 Explosion protection to EN 50 014 and EN 50 020 Mounting location Permissible ambient temperature for operation See "General data", page 101 Weight, basic device EEx n II 3G Ex nV II T4 Zone 2 Approx. 0.9 kg • Metal casing Approx. 1.3 kg Dimensions See Fig.
Technical data Option modules Electrical data Explosion protection to EN 50 014 and EN 50 020 Mounting location Permissible ambient temperature for operation Alarm module Binary alarm outputs A1, A2 and alarm output Signal status High (not triggered) Signal status Low3) (triggered) Internal capacitance Ci Internal inductance Li Power supply UH Connection to intrinsically-safe switching amplifier to DIN 19 234 Binary input BI2 • Electrically connected to basic device - Signal status 0 - Signal status 1 - Co
Technical Data 104 SIPART PS2 Manual A5E00074631-01
Scope of deliver 7 Scope of Delivery The positioner and its options modules are delivered as separate units and in different versions. positioners and options modules for operation in hazardous areas and non--hazardous areas are available. These versions are identified respectively by a special rating plate. WARNING ! 7.
Scope of delivery 7.2 Scope of delivery of options Option Order number SIA module non Ex 6DR4004-8G SIA module Ex (CENELEC / FM) 6DR4004-6G Alarm module non Ex 6DR4004-8A Alarm module Ex Alarm module Ex (PTB)1) (FM)2) 6DR4004-6A 6DR4004-7A Jy-module non Ex 6DR4004-8J Jy-module Ex (PTB)1) Jy-module Ex (FM)2) 6DR4004-6J 6DR4004-7J 1) 2) EC-type examination certificate of the PTB (see appendix 3) Approval Report of Factory Mutual System (see appendix 3) 7.
A Appendix A1 Index A Accessories, 32 Alarm function, 87 Alarm module, 30 Ex, 55 non Ex, 53 Application positioner in a wet environment, 36 under great accelerations and vibrations, 38 Assembly, 35 Screw--type gland with plastic hose, 37 Assembly procedure, 39, 43 linear actuator, 41 rotary actuator, 44, 45 Automatic, Changing the operating mode, 78 B Base plate, 49 Block diagram, Mode of operation, 24 C Commissioning, 57 Configuration, changing the operating mode, 77 Current output, Electrical Connect
Appendix Linear actuator, 13, 14 automatic initialization, 59 manual initialization, 61 preparation, 58 M Maintenance, 99 Manometer block, 32 Manual mode Changing the operating mode, 78 P manual mode, 77 Method of operation, 15, 22 Mounting kit linear actuator, 39 rotary actuator, 42 O Operating mode AUT, 78 MAN, 78 Operating Modes, 76 Operating modes, Change ~, 76 Operation, 73 Options, 12, 25 P Parameter table, SIPART PS2, 79 Parameters, 78 PDM (Process Device Manager), 72, 93 Personnel, Qualification,
Appendix A2 Literature and Catalog No.
Appendix EC Declaration of Conformity 110 SIPART PS2 Manual A5E00074631--01
1P A5E00074631 Q1 Siemens AG Bereich Prozessinstrumentierung und -analytik Geschäftsgebiet A&D PI D-76181 Karlsruhe Siemens Aktiengesellschaft E Siemens AG 2001 Subject to change without prior notice Order No.
