Siemens PS2 6DR53xx, PS2 6DR50xx, PS2 6DR52xx, PS2 6DR51xx User Manual

0 (0)

SIPART PS2

6DR50xx

6DR51xx

6DR52xx

6DR53xx

Edition 10/2006

Manual

Electropneumatic Positioner for Linear and Part-Turn Actuators

SIPART PS2 Manual

1

A5E00074630--06

Copyright e Siemens AG 2006 All rights reserved

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

Siemens AG

Bereich 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 described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed.

e Siemens AG 2006

Technical data subject to change.

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 trademarks might infringe upon the rights of the trademark owners.

2

SIPART PS2 Manual

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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

2.7.1Installation 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

3.3.2Instructions 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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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

4

SIPART PS2 Manual

 

A5E00074630--06

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:

S SIPART PS2 without Ex-protection in a metalor plastic housing.

SSIPART PS2 with EEx ia/ib-protection in a metalor plastic housing.

S SIPART PS2 EEx d in a pressurized explosion proof housing

This manual takes each of these possibilities into consideration.

Any differences between the devices are indicated specially.

Scope of delivery, see chapter 7, page 153.

0.1General 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.

SIPART PS2 Manual

5

A5E00074631--06

Information for the Operator

This manual contains the information required for use as intended of the product it describes. It is addressed to technically qualified personnel specially trained or having relevant knowledge of instrumentation and control technology, hereafter called automation technology.

Familiarity with and proper technical observance of the safety notes and warnings contained in this manual are essential for safe installation and commissioning and for safety in operation and maintenance of the product described. Only qualified personnel as defined in Chapter 0.3 has the necessary specialist knowledge to interpret the general safety notes and warnings given in this document in specific cases and to take the necessary action.

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

This manual is not a permanent part of the scope of supply. For reasons of clarity, it does not contain every detail about every version of the product described and cannot take every eventuality in installation, operation, maintenance and use in systems into account. If you require further information or if problems occur that have not been dealt with in sufficient detail in this document, please request the required information from your local Siemens office or the office responsible for you.

Functionality, commissioning and operation are described in this manual.

Please pay special attention to the Warning and Note texts. These are separated from the remaining text by horizontal lines and specially marked with symbols (see Chapter 0.2).

0.2Classification 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:

!indicates an immenently hazardous situation which, if not avoided, will result in death or serious inury.DANGER

!indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.WARNING

6

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Information for the Operator

!used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION

used without 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.CAUTION

. 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.

0.3Qualified Personnel

The result of unqualified intervention in the instrument or nonobservance of the warnings given in this manual or on product labels can be severe personal injury and/or serious material damage. Therefore only properly qualified personnel must make changes and settings in the instrument.

For the purpose of the safety information in this manual and on the product labels, qualified personnel are those who

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.

S and instructed additionally in first aid

SIPART PS2 Manual

7

A5E00074631--06

Information for the Operator

!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).WARNING

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.

!Devices with the protection type “intrinsically safe” lose their certification as soon as they are operated with circuits that do not conform to the specifications laid down in the examination certificate valid in your country.

The successful and safe operation of this equipment is dependent upon its proper handling, installation, operation and maintenance.WARNING

8

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Information for the Operator

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

0.4Use as intendedWARNING

Use as intended for the purpose of this manual means that this product must only be used for the applications described in the technical description (see also Chapter 3 of this manual).

The product described in this manual has been developed, manufactured, tested and documented observing the relevant safety standards. If the handling rules and safety information for configuration, installation, use as intended and maintenance are observed, there is normally no danger with regard to material damage or for the health of personnel. Extra low voltages that are connected must be fed in by safe isolation.

0.5Technical 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.

0.6Warranty Information

We should like to point out that the content of this manual is not part of and does not modify a previous or current agreement, undertaking or legal relationship. Siemens is bound solely by the contract of sale, which also contains the complete and exclusive warranty. The contractual warranty conditions are neither extended nor restricted by this document.

SIPART PS2 Manual

9

A5E00074631--06

Information for the Operator

0.7Delivery Notes

The scope of delivery is listed on the dispatch papers accompanying the delivery in accordance with the valid contract of sale.

When you open the packaging please observe the information on the packaging. Check that the delivery is complete and undamaged.

If possible, compare the order number on the rating plates with the ordering data.

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

0.8Standards 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 147).

If this product is used outside the area of applicability of these standards and regulations, please observe the standards and regulations in force in the country where the product is operated.

10

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Introduction

Introduction

1

 

1.1General 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.

Purpose

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

 

S with linear actuator (figure 1-1, page 13) or

 

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

 

Different mounting types are available for linear actuators:

 

S NAMUR or IEC 534

 

S integrated mounting to ARCA

 

S integrated mounting to SAMSON (non-explosion-proof version)

 

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

 

actuator systems.

Versions

The positioner is available for the following actuators:

 

S double-acting and

 

S

single-acting

 

For following applications:

 

S

potentially explosive or

 

S not potentially explosive applications.

Housing

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

grated in the housing.

The housing is available in three versions:

S Plastic housing for single and double-acting actuators S Metal housing for single-acting actuators

S Explosion proof housing for single and double-acting actuators

SIPART PS2 Manual

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Introduction

Degree of

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

protection

 

Explosion

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

Protection

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.

SIL applications

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.

Options

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

 

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

 

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

 

S Alarm module: 3 digital outputs and 1 digital input

 

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

 

puts for limit value alarms

Accessories

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

 

positioners

 

S Connection block (NAMUR) for safety valve block

 

S Mounting kits for linear and part-turn actuator

 

For decentralized installation of the positioner and position sensor:

 

S External position detection system

 

S Non-Contacting Position Sensor (NCS)

Environmental

Only environmentally friendly materials have been used in the construc-

Protection

tion of the positioner.

 

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

12

SIPART PS2 Manual

A5E00074631--06

Introduction

1

2

4

3

5

1Actuator

2Positioner, single-acting in metal housing

3Lantern

4Manometer block, single-acting

5Valve

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

1 3

2

1Positioner double-acting in plastic housing

2Part-turn actuator

3Manometer block, double-acting

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

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Introduction

1

2

4

3

1Actuator

2Positioner, single-acting in explosion proof housing

3Lantern

4Manometer block, single-acting

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

1 3

2

1Positioner double-acting in explosion proof housing

2Part-turn actuator

3Manometer block, double-acting

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

14

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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.

2.1Overview

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.

 

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 = 4 to 20 mA.

 

In addition the actuator can be monitored for two programmable limit

 

values which respond on exceeding or dropping below the stroke or

 

angle of rotation.

 

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-

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Design and Functional Principle

spond 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.

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 explosionproof version, must not be adjusted.

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2.2Name plate design

(2)

(1)

(8)

(7)

(3)

(4)

(5)(6)

(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

2.3Instrument Components

14

3

15

 

2 W

3/4 W

O

 

90°

 

 

 

33

 

2

13

4...20 mA

...20 mA

 

 

1

 

0/4

 

 

 

 

 

DI1

O

 

 

 

 

 

90

 

 

 

 

 

 

33°

4

 

 

 

 

 

12

 

 

 

 

 

6.1

 

6.2

 

11

10

9

8

7

6

5

 

 

 

 

 

 

 

 

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)

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9

3

6.1

2

1

12

7

1

138

9

10

--

 

+

238

10

5

6.2

4

8

1Input: Supply air

2Output: Actuating pressure Y1

3Display

4Output: Actuating pressure Y2 *)

5Operating keys

6.1Restrictor Y1

6.2Restrictor Y2 *)

*) in double-acting actuators

7Transmission ratio selector

(only possible with positioner open)

8Adjusting wheel for friction clutch

9Terminals standard controller

10Terminals options modules

12 Safety catch

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 module are arranged at the left-hand front edges and offset against each other in staircase form.

A module cover protects the modules from being pulled out and prevents incorrect installation.

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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

2

3

4

5

1Actuating pressure Y1 in singleand double-acting actuators

2Feedback shaft

3Supply air Pz

4Actuating pressure Y2 in double-acting actuators

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

Figure 2-4 Pneumatic connection in normal version

 

 

 

1

 

 

 

2

 

 

 

3

 

 

 

4

 

 

 

5

 

 

 

6

 

 

 

7

1

Restrictor Y2 *)

5

Actuating pressure Y1

2

Restrictor Y1

6

Exhaust air output E

3

Actuating pressure Y2 *)

7

Housing ventilation (2x)

4

Supply air PZ

 

 

*)

in double-acting actuators

 

 

Figure 2-5 Pneumatic connection in explosion proof version

In addition, there are pneumatic connections on the back of the positioner for integrated installation in single-acting linear actuators.

S Actuating pressure Y1

S Exhaust air output E (not in explosion proof version)

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

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

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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 2-6, page 21 shows the pneumatic connection variants for the different actuator types, the positioning action and the safety position after power failure.

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Design and Functional Principle

Positioning

Actuator type

Safety position after power failure

 

pressure

electrical

pneumatic

 

Connection

 

 

 

 

 

 

In part-turn actuators the

 

 

 

 

direction of rotation

 

 

 

 

counterclockwise looking

Y1

 

Closed

Closed

onto the actuating shaft of

 

 

the valve is usually defined

 

Open

 

 

as “Open”.

Closed

 

 

 

 

 

 

 

Y1

 

 

 

 

 

 

Open

Open

 

Closed

Open

 

 

 

 

 

 

 

Y2

 

 

 

 

Y1

 

Open

 

Closed Open

 

 

 

 

Closed

Open

 

Last position

 

Y1

 

 

(before power

 

 

 

failure)

 

Closed

Y2

Closed Open

Y1

up

Down

Down

 

down

 

 

 

Y1

 

 

 

 

up

Up

Up

 

down

 

 

 

Y2

Y1 up

down Up

 

 

Last position

up

down

 

 

 

 

Y1

 

(before power

 

 

 

failure)

 

 

Y2

up

Down

 

 

 

down

 

 

 

 

 

 

Figure 2-6 Pneumatic connection positioning

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2.3.4 Mounting Kit

The positioner can be mounted on almost all actuators with the appropriate mounting kit.

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

The purge air switch is accessible above the pneumatic terminal strip with the housing open (figure 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.

Hexagon socket 2.5 mm

Y1 Y2

Figure 2-8

Restrictors

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2.4Method 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 position 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 y. Depending on the size and direction of the control error (x-w) the piezo-controlled supply air or exhaust air valve is opened. The volume of the actuator integrates the positioning increments to actuating pressure y open which moves the actuator bar or actuator shaft approximately proportionally. These positioning increments change the actuating pressure until the control error becomes zero.

The pneumatic actuators are available in single and double-acting versions. Only one pressure chamber is aerated or deaerated in the single-acting version. The resulting pressure operates against a spring. In the double-acting version, two pressure chambers are counteractive. In this case the one volume is deaerated when the other volume is aerated. See the block diagram figure 2-10, page 25.

The control algorithm is an adaptive predictive five-point switch (see figure 2-9, page 24).

The valves are controlled with continuous contact at large control errors (fast step zone). At medium control errors the valve is controlled by pulse length modulated pulses (short step zone).

No actuating pulses are output in the small control error zone (adaptive dead zone). The dead zone adaptation and the continuous adaptation of the minimum pulse lengths in automatic operation cause the best possible control accuracy to be achieved at the lowest switching frequency. 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.

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Design and Functional Principle

Figure 2-10, page 25 shows the block diagrams for singleand doubleacting 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

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1

 

 

 

HART

 

 

 

 

 

 

 

 

2

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

BE1

 

 

 

 

 

_

SZuluftpply air

 

 

 

 

 

 

y

 

 

 

3 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

p Z

 

 

 

 

 

 

 

_

 

+

 

 

 

 

 

 

 

+

y

 

 

IW+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ExhaustAbluft

air

 

 

 

 

+24 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+5 V

 

 

 

 

p 1

 

 

 

W

 

 

 

 

 

 

p 1

 

 

 

A D

 

 

 

 

 

 

 

 

 

 

Micro-

 

p 2

 

 

IW-

 

 

 

 

 

 

A

 

 

controller

 

p 2

 

 

 

 

 

 

 

 

 

y

+U

D

 

 

 

 

 

 

 

0

 

 

 

 

 

 

ExhaustAbluft

 

 

 

 

 

 

 

 

 

 

 

 

+

_

 

 

 

 

 

 

air

 

 

 

W

 

 

 

 

 

 

4

 

 

x0

x

 

 

 

 

 

 

 

 

 

 

 

 

 

U

U

 

 

 

 

6

 

 

 

 

I

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BE2

A1

A2

 

 

 

 

 

 

 

 

 

I

I

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

9

 

 

7

 

 

 

 

 

 

 

p 2

 

 

 

 

A1

A2

 

 

p 1

 

p 1

 

 

 

 

 

 

 

 

 

 

stroke

 

 

 

 

 

 

 

 

 

 

stroke

1Motherboard with microcontroller and input circuit

2Control panel with LC-display and momentary action switch

3Piezo-valve unit, always built-in

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

5Iy-module for positioner SIPART PS2

6Alarm module for three alarm outputs and one digital input

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

8Spring-loaded pneumatic actuator (single-acting)

9Spring-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.

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Design and Functional Principle

2.5HART-function

Function

.

The positioner is also available with built-in HART-functions. The HART protocol allows you to communicate with your instrument with a handheld communicatorR, PC or programming unit. This enables you to configure your instrument comfortably, save configurations, call diagnostic data, display online measured values and much more. Communication takes place as frequency modulation over the existing signal lines for the command variable from 4 to 20 mA.

The SPART PS2 is integrated in the following parameterization tools: S Handheld communicatorR

S PDM (Process Device Manager)

S AMS (Asset Management System)

S Cornerstone (without diagnostic values/-functions)

NOTE

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

Communication is aborted by a power failure at the positioner.

2.6State 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.

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2.7Installation of options modules

2.7.1Installation 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:

Installation

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.

 

 

Open positioner 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

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Siemens PS2 6DR53xx, PS2 6DR50xx, PS2 6DR52xx, PS2 6DR51xx User Manual

Design and Functional Principle

6

 

1

 

 

 

1.1

5

 

 

 

 

 

 

 

 

 

 

 

 

2.1

 

 

1.1

 

 

 

2.1

 

 

2

 

 

 

 

 

 

 

 

 

 

12

 

 

10

 

 

 

 

 

4

7

 

 

 

11

 

 

 

 

 

3

 

 

 

 

 

 

 

 

7.1

7.2

7.3

8

9

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)

3

Iy-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

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2.7.2 Installation of options modules in explosion proof version

Installation

.

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.

!In areas in which the atmosphere may be potentially explosive, the explosion-proof positioner may only be supplied with electrical auxiliary power when the housing is closed and when built-in, approved electronics are used.

The feed-though openings for the electronic connections must be sealed with EEX-d certified cable glands or EEx-d certified plugs or

an ignition lock must be mounted at a maximum distance of 46 cm (18 inches) when using the “conduit”-system.WARNING

Open the

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

positioner

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.

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. 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.

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