Siemens 6DR50 Series, 6DR53 Series, 6DR51 Series, 6DR52 Series, SIPART PS2 Operating Instructions Manual
SIPART
Electropneumatic positioners
SIPART PS2 with and without HART
Operating Instructions
Edition 09/2014
Answers for industry.
SIPART PS2 with and without HART
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________
___________________
___________________
SIPART
Electropneumatic positioners
SIPART PS2 with and without
HART
Operating Instructions
6DR50.. - Positioner without HART
6DR51..
6DR52..
6DR53..
proof
09/2014
A5E00074631
Introduction
1
Safety information
2
Description
3
Installing/mounting
4
Connection
5
Operating
6
Commissioning
7
Functional safety
8
Parameterizing/addressing
9
Alarm, error, and system
messages
10
Service and maintenance
11
Technical data
12
Dimension drawings
13
Spare
parts/accessories/scope of
delivery
14
Appendix
A
Abbreviations
B
- Positioner with HART, not explosion-proof
- Positioner with HART, explosion-proof
- Positioner without HART, not explosion-
-12
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E00074631
Ⓟ
Copyright © Siemens AG 2014.
All rights reserved
Legal information
Warning notice system
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
Qualified Personnel
personnel qualified
Proper use of Siemens products
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
Disclaimer of Liability
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
The product/system described in this documentation may be operated only by
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Note the following:
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
for the specific
10/2014 Subject to change
Table of contents
1 Introduction ........................................................................................................................................... 11
2 Safety information ................................................................................................................................. 15
3 Description ............................................................................................................................................ 19
4 Installing/mounting ................................................................................................................................ 31
1.1 Purpose of this documentation ............................................................................................... 11
1.2 History ..................................................................................................................................... 11
1.3 Purpose ................................................................................................................................... 12
1.4 Checking the consignment ..................................................................................................... 12
1.5 Transportation and storage ..................................................................................................... 13
1.6 Product information ................................................................................................................. 13
1.7 Notes on warranty ................................................................................................................... 13
2.1 Requirements for safe use ...................................................................................................... 15
2.1.1 Warning symbols on the device .............................................................................................. 15
2.1.2 Laws and directives ................................................................................................................ 16
2.1.3 Conformity with European directives ...................................................................................... 16
2.2 Improper device modifications ................................................................................................ 16
2.3 Requirements for special applications .................................................................................... 17
2.4 Use in hazardous areas .......................................................................................................... 17
3.1 Function .................................................................................................................................. 19
3.2 Structure ................................................................................................................................. 19
3.2.1 Overview of structure .............................................................................................................. 19
3.2.2 Nameplate layout .................................................................................................................... 22
3.3 Device components ................................................................................................................ 24
3.3.1 Overview of device components ............................................................................................. 24
3.3.2 Basic electronics ..................................................................................................................... 25
3.4 Mode of operation ................................................................................................................... 26
3.4.1 Control algorithm ..................................................................................................................... 27
3.4.2 Block circuit diagram for single-acting or double-acting actuators ......................................... 28
3.4.3 Mode of operation of the HART function ................................................................................ 29
3.4.4 HART system configuration .................................................................................................... 29
3.4.5 SIMATIC PDM ........................................................................................................................ 30
4.1 Basic safety instructions ......................................................................................................... 31
4.1.1 Proper mounting ..................................................................................................................... 34
4.2 Mounting the linear actuator ................................................................................................... 34
4.3 Mounting the part-turn actuator .............................................................................................. 40
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
3
Table of contents
5 Connection ........................................................................................................................................... 69
6 Operating ............................................................................................................................................. 103
4.4 Using the positioner in a humid environment ......................................................................... 44
4.5 Positioners subjected to fast acceleration or strong vibration ............................................... 45
4.6 External position detection ..................................................................................................... 48
4.7 Installing option modules ....................................................................................................... 48
4.7.1 General information on installing option modules .................................................................. 48
4.7.1.1 Installing optional modules in the standard and intrinsically safe version ............................. 49
4.7.1.2 Installing the optional modules in the "flameproof enclosure" version ................................... 52
4.7.2 Position feedback module ...................................................................................................... 56
4.7.3 Alarm module ......................................................................................................................... 57
4.7.4 Slot initiator alarm module ..................................................................................................... 59
4.7.4.1 Setting the limits of the slotted initiator alarm module ........................................................... 61
4.7.5 Mechanical limit switch module .............................................................................................. 62
4.7.5.1 Setting the limits of the mechanical limit switch module ........................................................ 64
4.7.5.2 Label set for limit contact module .......................................................................................... 65
4.7.6 EMC filter module................................................................................................................... 66
4.7.7 Accessories ............................................................................................................................ 68
5.1 Basic safety instructions ........................................................................................................ 69
5.2 Electric ................................................................................................................................... 73
5.2.1 Device 6DR5..0/1/2/3-0N or 6DR5..5-0E ............................................................................... 73
5.2.1.1 Basic electronics with 6DR5..0/1/2/3-0N or 6DR5..5-0E ....................................................... 73
5.2.1.2 Option modules with 6DR5..0/1/2/3-0N or 6DR5..5-0E ......................................................... 77
5.2.2 Device 6DR5..0/1/2/3-0E/D/F/G/K ......................................................................................... 81
5.2.2.1 Breakdown of the article numbers 6DR5..0/1/2/3-0E/D/F/G/K .............................................. 81
5.2.2.2 Basic electronics with 6DR5..0/1/2/3-0E/D/F/G/K .................................................................. 82
5.2.2.3 Option modules with 6DR5..0/1/2/3-0E/D/F/G/K ................................................................... 86
5.2.3 Connecting NCS to EMC filter module .................................................................................. 91
5.2.4 Connecting the external position detection system to the EMC filter module ....................... 93
5.3 Pneumatic .............................................................................................................................. 95
5.3.1 Pneumatic connections .......................................................................................................... 95
5.3.1.1 Pneumatic connection for 6DR5..0/1/2/3 ............................................................................... 95
5.3.1.2 Integrated pneumatic connection ........................................................................................... 95
5.3.1.3 Pneumatic connection for 6DR5..5-0E... ............................................................................... 96
5.3.1.4 Reaction to failure of auxiliary powers ................................................................................... 97
5.3.2 Pneumatic connection .......................................................................................................... 100
5.4 Restrictors ............................................................................................................................ 101
6.1 Operating elements .............................................................................................................. 103
6.1.1 Display ................................................................................................................................. 103
6.1.2 Buttons ................................................................................................................................. 105
6.1.3 Firmware version.................................................................................................................. 106
6.2 Operating modes.................................................................................................................. 106
6.2.1 Overview of operating modes .............................................................................................. 106
6.2.2 Changing the operating mode .............................................................................................. 107
6.2.3 Overview of configuration .................................................................................................... 108
6.2.4 Description of operating modes ........................................................................................... 108
6.2.5 Optimization of controller data ............................................................................................. 111
SIPART PS2 with and without HART
4 Operating Instructions, 09/2014, A5E00074631-12
Table of contents
7 Commissioning ................................................................................................................................... 113
8 Functional safety ................................................................................................................................. 139
9 Parameterizing/addressing .................................................................................................................. 145
7.1 Basic safety instructions ....................................................................................................... 113
7.2 Commissioning overview ...................................................................................................... 115
7.3 Sequence of automatic initialization ..................................................................................... 117
7.4 Purge air switching ................................................................................................................ 122
7.5 Commissioning linear actuators ............................................................................................ 123
7.5.1 Preparing linear actuators for commissioning ...................................................................... 123
7.5.2 Automatic initialization of linear actuators............................................................................. 125
7.5.3 Manual initialization of linear actuators ................................................................................. 127
7.6 Commissioning part-turn actuators ....................................................................................... 131
7.6.1 Preparing part-turn actuators for commissioning .................................................................. 131
7.6.2 Automatic initialization of part-turn actuators ........................................................................ 132
7.6.3 Manual initialization of part-turn actuators ............................................................................ 134
7.7 Device replacement .............................................................................................................. 137
8.1 Range of applications for functional safety ........................................................................... 139
8.2 Safety function ...................................................................................................................... 139
8.3 Safety Integrity Level (SIL) ................................................................................................... 141
8.4 Settings ................................................................................................................................. 142
8.5 Safety characteristics ............................................................................................................ 143
8.6 Maintenance/check ............................................................................................................... 144
9.1 Parameter chapter ................................................................................................................ 145
9.2 Configuration schematic for parameter operating principle .................................................. 146
9.3 Parameter overview .............................................................................................................. 147
9.3.1 Overview of initialization parameters 1 to 5 .......................................................................... 147
9.3.2 Overview of application parameters 6 to 52 ......................................................................... 148
9.3.3 Overview of advanced diagnostics parameters A to P ......................................................... 152
9.4 Description of parameters ..................................................................................................... 156
9.4.1 Description of initialization parameters 1 to 5 ....................................................................... 156
9.4.1.1 '1.YFCT' Type of actuator ..................................................................................................... 156
9.4.1.2 '2.YAGL' Rated angle of rotation of feedback ....................................................................... 157
9.4.1.3 '3.YWAY' Range of stroke..................................................................................................... 158
9.4.1.4 '4.INITA' Initialization (automatically) .................................................................................... 158
9.4.1.5 '5.INITM' Initialization (manual) ............................................................................................. 159
9.4.2 Description of application parameters 6 to 52 ...................................................................... 159
9.4.2.1 '6.SCUR' Current range of setpoint ...................................................................................... 159
9.4.2.2 '7.SDIR' Setpoint direction .................................................................................................... 160
9.4.2.3 '8.SPRA' Setpoint split range start / '9.SPRE' Setpoint split range end ............................... 160
9.4.2.4 '10.TSUP' Setpoint ramp UP / '11.TSDO' Setpoint ramp DOWN ......................................... 161
9.4.2.5 '12.SFCT' Setpoint function .................................................................................................. 162
9.4.2.6 '13.SL0' ... '33.SL20' Setpoint turning point .......................................................................... 162
9.4.2.7 '34.DEBA' Deadband of closed-loop controller ..................................................................... 163
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
5
Table of contents
10 Alarm, error, and system messages ..................................................................................................... 199
9.4.2.8 '35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit ........ 164
9.4.2.9 '37.YNRM' Standardization of manipulated variable............................................................ 164
9.4.2.10 '38.YDIR' Direction of manipulated variable for display and position feedback ................... 166
9.4.2.11 '39.YCLS' Tight closing with manipulated variable .............................................................. 166
9.4.2.12 '40.YCDO' Lower value for tight closing / '41.YCUP' Upper value for tight closing ............. 166
9.4.2.13 '42.BIN1' / '43.BIN2' Function binary inputs ......................................................................... 167
9.4.2.14 '44.AFCT' Alarm function ..................................................................................................... 169
9.4.2.15 '45.A1' / '46.A2' Response threshold of alarms ................................................................... 170
9.4.2.16 '47._FCT' Function fault message output ............................................................................ 171
9.4.2.17 '48._TIM' Monitoring time for setting of fault message "Control deviation" .......................... 172
9.4.2.18 '49._LIM' Response threshold for fault message "Control deviation" .................................. 172
9.4.2.19 '50.PRST' Preset .................................................................................................................. 173
9.4.2.20 '51.PNEUM' Fail in place ..................................................................................................... 174
9.4.2.21 '52.XDIAG' Activating for extended diagnostics ................................................................... 174
9.4.3 Description of advanced diagnostics parameters A to P ..................................................... 175
9.4.3.1 Partial stroke test "A._PST" ................................................................................................. 175
9.4.3.2 Monitoring of dynamic control valve behavior "b._DEVI" ..................................................... 181
9.4.3.3 Monitoring pneumatic leakage "C._LEAK" ........................................................................... 183
9.4.3.4 Monitoring the stiction (slipstick) "d._STIC" ......................................................................... 185
9.4.3.5 Monitoring the deadband "E._DEBA"................................................................................... 187
9.4.3.6 Monitoring the lower endstop "F._ZERO" ............................................................................ 188
9.4.3.7 Monitoring the upper endstop "G._OPEN" ........................................................................... 190
9.4.3.8 Monitoring the lower limit temperature "H._TMIN" ............................................................... 192
9.4.3.9 Monitoring the upper limit temperature "J._TMAX" .............................................................. 193
9.4.3.10 Monitoring the number of total strokes "L._STRK" .............................................................. 194
9.4.3.11 Monitoring the number of changes in direction "O._DCHG" ................................................ 195
9.4.3.12 Monitoring the position average value "P._PAVG" .............................................................. 197
10.1 Output of system messages in the display .......................................................................... 199
10.1.1 System messages before initialization ................................................................................. 199
10.1.2 System messages during initialization ................................................................................. 200
10.1.3 System messages when exiting the Configuration mode .................................................... 203
10.1.4 System messages during operation..................................................................................... 204
10.2 Diagnostics ........................................................................................................................... 205
10.2.1 Display of diagnostics values ............................................................................................... 205
10.2.2 Overview of diagnostics values ............................................................................................ 206
10.2.3 Meaning of the diagnostics parameters ............................................................................... 209
10.2.3.1 Diagnostics parameter '1.STRKS' Number of total strokes ................................................. 209
10.2.3.2 Diagnostics parameter '2.CHDIR' Number of changes in direction ..................................... 209
10.2.3.3 Diagnostics parameter '3._CNT' Number of fault messages ............................................... 209
10.2.3.4 Diagnostics parameters '4.A1CNT' Number of alarms 1 / '5.A2CNT' Number of alarms
2 ........................................................................................................................................... 209
10.2.3.5 Diagnostics parameter '6.HOURS' Number of operating hours .......................................... 210
10.2.3.6 Diagnostics parameter '7.HOURR' Resettable operating hours counter ............................. 210
10.2.3.7 Diagnostics parameter '8.WAY' - Determined travel ............................................................ 210
10.2.3.8 Diagnostics parameters '9.TUP' Travel time UP / '10.TDOWN' Travel time DOWN ........... 210
10.2.3.9 Diagnostics parameter '11.LEAK' Leakage test ................................................................... 211
10.2.3.10 Diagnostics parameter '12.PST' Monitoring of partial stroke test ........................................ 212
10.2.3.11 Diagnostics parameter '13.PRPST' Time since last partial stroke test ................................ 212
10.2.3.12 Diagnostics parameter '14.NXPST' Time until next partial stroke test ................................ 213
10.2.3.13 Diagnostics parameter '15.DEVI' General control valve fault .............................................. 213
SIPART PS2 with and without HART
6 Operating Instructions, 09/2014, A5E00074631-12
Table of contents
10.2.3.14 Diagnostics parameter '16.ONLK' Pneumatic leakage ......................................................... 213
10.2.3.15 Diagnostics parameter '17.STIC' Stiction (slipstick) ............................................................. 214
10.2.3.16 Diagnostics parameter '18.ZERO' Lower endstop ................................................................ 214
10.2.3.17 Diagnostics parameter '19.OPEN' Displacement of upper end stop .................................... 214
10.2.3.18 Diagnostics parameter '20.PAVG' Position average ............................................................ 215
10.2.3.19 Diagnostics parameters '21.P0' Potentiometer value of bottom end stop / '22.P100'
Potentiometer value of top end stop ..................................................................................... 216
10.2.3.20 Diagnostics parameters '23.IMPUP' Impulse length UP / '24.IMPDN' Impulse length
DOWN ................................................................................................................................... 218
10.2.3.21 Diagnostics parameter '25.PAUTP' Interpulse period .......................................................... 218
10.2.3.22 Diagnostics parameters '26.DBUP' Deadband UP / '27.DBDN' Deadband DOWN ............. 218
10.2.3.23 Diagnostics parameters '28.SSUP' Slow step zone UP / '29.SSDN' Slow step zone
DOWN ................................................................................................................................... 219
10.2.3.24 Diagnostics parameter '30.TEMP' Current temperature ....................................................... 219
10.2.3.25 Diagnostics parameters '31.TMIN' Minimum temperature / '32.TMAX' Maximum
temperature ........................................................................................................................... 219
10.2.3.26 Diagnostics parameters '33.T1' ... '41.T9' Number of operating hours in the
temperature range 1 to 9 ...................................................................................................... 220
10.2.3.27 Diagnostics parameters '42.VENT1' / '43.VENT2' ................................................................ 220
10.2.3.28 Diagnostics parameters '44.VEN1R' / '45.VEN2R' ............................................................... 221
10.2.3.29 Diagnostics parameter '46.STORE' Save maintenance data ............................................... 221
10.2.3.30 Diagnostics parameters '47.PRUP' Prediction UP / '48.PRDN' Prediction DOWN .............. 222
10.2.3.31 Diagnostics parameters '49.WT00' ... '56.WT95' Number of operating hours in the
travel range WT00 to WT95 .................................................................................................. 222
10.2.3.32 Diagnostics parameter '57.mA' Setpoint current .................................................................. 222
10.3 Online diagnostics ................................................................................................................. 223
10.3.1 Overview of online diagnostics ............................................................................................. 223
10.3.2 Overview of error codes ........................................................................................................ 224
10.3.3 XDIAG parameter ................................................................................................................. 226
10.3.4 Meaning of error codes ......................................................................................................... 226
10.3.4.1 1 Remaining control deviation .............................................................................................. 226
10.3.4.2 2 Device not in "Automatic" mode ........................................................................................ 226
10.3.4.3 3 Binary input BIN1 or BIN2 active ....................................................................................... 226
10.3.4.4 4 Monitoring the number of total strokes .............................................................................. 227
10.3.4.5 5 Monitoring the number of changes in direction .................................................................. 227
10.3.4.6 6 Monitoring the lower endstop / 7 Monitoring the upper endstop ....................................... 227
10.3.4.7 8 Monitoring deadband ......................................................................................................... 228
10.3.4.8 9 Partial stroke test ............................................................................................................... 228
10.3.4.9 10 Monitoring of dynamic control valve behavior ................................................................. 228
10.3.4.10 11 Monitoring the pneumatic leakage ................................................................................... 228
10.3.4.11 12 Monitoring of stiction (slipstick) ........................................................................................
228
10.3.4.12 13 Monitoring the lower limit temperature............................................................................. 228
10.3.4.13 14 Monitoring the upper limit temperature ............................................................................ 228
10.3.4.14 15 Monitoring the position average value ............................................................................. 229
10.3.4.15 16 Monitoring the plausibility of values for the partial stroke test ......................................... 229
10.4 Fault correction ..................................................................................................................... 229
10.4.1 Fault identification ................................................................................................................. 229
10.4.2 Remedial measures table 1 .................................................................................................. 230
10.4.3 Remedial measures table 2 .................................................................................................. 231
10.4.4 Remedial measures table 3 .................................................................................................. 232
10.4.5 Corrective measures Table 4 ................................................................................................ 233
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
7
Table of contents
11 Service and maintenance ..................................................................................................................... 235
12 Technical data ..................................................................................................................................... 241
13 Dimension drawings ............................................................................................................................. 259
14 Spare parts/accessories/scope of delivery ............................................................................................ 265
10.4.6 Remedial measures table 5 ................................................................................................. 234
11.1 Basic safety instructions ...................................................................................................... 235
11.2 Cleaning of the screens ....................................................................................................... 236
11.2.1 Positioners with Makrolon enclosure 6DR5..0, aluminum enclosure 6DR5..3, and
flameproof aluminum enclosure 6DR5..5 ............................................................................ 236
11.2.2 Positioners with stainless steel enclosure 6DR5..2 and narrow aluminum enclosure
6DR5..1 ................................................................................................................................ 237
11.3 Fail in Place: replacing the basic electronics ....................................................................... 238
11.4 Repair/Upgrading ................................................................................................................. 238
11.5 Return procedure ................................................................................................................. 239
11.6 Disposal ............................................................................................................................... 239
12.1 Rated conditions .................................................................................................................. 241
12.2 Pneumatic data .................................................................................................................... 242
12.3 Construction ......................................................................................................................... 243
12.4 Controller .............................................................................................................................. 245
12.5 Certificates, approvals, explosion protection ....................................................................... 246
12.6 Electrical data ....................................................................................................................... 247
12.7 Technical data for natural gas as actuator medium ............................................................. 249
12.8 Option modules .................................................................................................................... 250
12.8.1 Alarm module ....................................................................................................................... 250
12.8.2 Position feedback module .................................................................................................... 251
12.8.3 SIA module ........................................................................................................................... 252
12.8.4 Mechanical limit switch module ............................................................................................ 253
12.8.5 EMC filter module................................................................................................................. 254
12.8.6 Non-contacting position sensor ............................................................................................ 255
12.8.7 External position detection system ...................................................................................... 256
13.1 Positioner with Makrolon enclosure 6DR5..0 and stainless steel enclosure 6DR5..2 ......... 259
13.2 Positioner with narrow aluminum enclosure 6DR5..1 .......................................................... 260
13.3 Positioner with aluminum enclosure 6DR5..3 ...................................................................... 261
13.4 Terminal strip for positioners with Macrolon enclosure 6DR5..0 and aluminum
enclosure 6DR5..3 ............................................................................................................... 262
13.5 Positioner with flameproof aluminum enclosure 6DR5..5 .................................................... 263
14.1 Overview .............................................................................................................................. 265
14.2 Spare parts ........................................................................................................................... 267
14.3 Scope of delivery of small part sets ..................................................................................... 268
SIPART PS2 with and without HART
8 Operating Instructions, 09/2014, A5E00074631-12
Table of contents
A Appendix............................................................................................................................................. 273
B Abbreviations ...................................................................................................................................... 277
Glossary ............................................................................................................................................. 281
Index................................................................................................................................................... 291
14.4 Scope of delivery of external position detection system ....................................................... 270
14.5 Scope of delivery of mechanical limit switch module ............................................................ 270
14.6 Scope of delivery EMC filter module ..................................................................................... 271
14.7 Accessories ........................................................................................................................... 272
A.1 Operation with boosters ........................................................................................................ 273
A.2 Certificates ............................................................................................................................ 274
A.3 Literature and catalogs ......................................................................................................... 274
A.4 Technical support .................................................................................................................. 274
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
9
Table of contents
SIPART PS2 with and without HART
10 Operating Instructions, 09/2014, A5E00074631-12
1
1.1
Purpose of this documentation
1.2
History
Edition
Firmware identifier nameplate
09/2014
As of FW 5.00.00
Edition
Note
These instructions contain all information required to commission and use the device. Read
the instructions carefully prior to installation and commissioning. In order to use the device
correctly, first review its principle of operation.
The instructions are aimed at persons mechanically installing the device, connecting it
electronically, configuring the parameters and commissioning it, as well as service and
maintenance engineers.
This history establishes the correlation between the current documentation and the valid
firmware of the device.
The documentation for this revision is applicable for the following firmware:
The most important changes in the documentation compared with the previous edition are
shown in the following table.
09/2014
1. Chapter "Parameter overview (Page 147)"
New parameters and values:
– 1.YFCT - Actuator > Initialization of actuators with inverted direction of action
is now possible.
– 50.PRST - Preset > Resetting of individual parameter groups is now possi-
ble.
– 51.PNEUM > Fail in place function can now be activated with appropriate
pneumatic system.
2. Chapter "Parameter overview (Page 147)"
New functions for the advanced diagnostics parameters:
– A5.RPMD and A6.RPRT > Partial stroke test is now possible in ramp mode.
– A7.FLBH > Response following failed PST can now be defined.
3. Chapter "Diagnostics (Page 205)"
Functions for the diagnostics values:
– 7.HOURR - Resettable operating hours counter added
– 11 LEAK > Offline leakage test added.
– 21 P0 and 22 P100 > Modification of upper and lower end stops now possi-
ble without initialization.
– 25 PAUTP > Adjustable no-pulse period added.
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
11
Introduction
See also
1.3
Purpose
1.4
Checking the consignment
WARNING
Using a damaged or incomplete device
1.3 Purpose
Structure (Page 19)
Construction (Page 243)
Positioner with flameproof aluminum enclosure 6DR5..5 (Page 263)
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic actuators in the following industries.
● Chemicals
● Oil and gas
● Energy production
● Food and beverages
● Pulp and paper
● Water/waste water
● Pharmaceutical industry
● Offshore plants
Operate the device according to the specifications in Chapter "Technical data (Page 241)".
For additional information, refer to the operating instructions for the device.
1. Check the packaging and the delivered items for visible damage.
2. Report any claims for damages immediately to the shipping company.
3. Retain damaged parts for clarification.
4. Check the scope of delivery by comparing your order to the shipping documents for
correctness and completeness.
Danger of explosion in hazardous areas.
• Do not use damaged or incomplete devices.
SIPART PS2 with and without HART
12 Operating Instructions, 09/2014, A5E00074631-12
Introduction
1.5
Transportation and storage
CAUTION
Insufficient protection during storage
1.6
Product information
See also
1.7
Notes on warranty
1.5 Transportation and storage
To guarantee sufficient protection during transport and storage, observe the following:
● Keep the original packaging for subsequent transportation.
● Devices/replacement parts should be returned in their original packaging.
● If the original packaging is no longer available, ensure that all shipments are properly
packaged to provide sufficient protection during transport. Siemens cannot assume
liability for any costs associated with transportation damages.
The packaging only provides limited protection against moisture and infiltration.
• Provide additional packaging as necessary.
Special conditions for storage and transportation of the device are listed in "Technical data"
(Page 241).
The programming manual is an integral part of the CD, which is either supplied or can be
ordered. The programming manual is also available on the Siemens homepage.
On the CD, you will also find the catalog extract with the ordering data, the Software Device
Install for SIMATIC PDM for additional installation, and the required software.
SIPART PS2 product information (http://www.siemens.com/sipartps2)
Contacts (http://www.siemens.com/processinstrumentation/contacts)
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
The contents of this manual shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. The sales contract contains all obligations on
the part of Siemens as well as the complete and solely applicable warranty conditions. Any
statements regarding device versions described in the manual do not create new warranties
or modify the existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right
to make technical changes in the course of further development.
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
13
Introduction
1.7 Notes on warranty
SIPART PS2 with and without HART
14 Operating Instructions, 09/2014, A5E00074631-12
2
2.1
Requirements for safe use
2.1.1
Warning symbols on the device
Symbol
Meaning
This device left the factory in good working condition. In order to maintain this status and to
ensure safe operation of the device, observe these instructions and all the specifications
relevant to safety.
Observe the information and symbols on the device. Do not remove any information or
symbols from the device. Always keep the information and symbols in a completely legible
state.
Consult operating instructions
Hot surface
Isolate the device from power using a circuit-breaker
Protect the device from shocks (otherwise the specified degree of protection is not guaranteed)
Protective insulation; device in protection class II
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
15
Safety information
2.1.2
Laws and directives
See also
2.1.3
Conformity with European directives
Electromagnetic Compat
ity EMC
2004/108/EC
Directive of the European Parliament and of the Council on the
approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC.
Atmosphère explosible
ATEX
94/9/EC
Directive of the European Parliament and the Council on the
approximation of the laws of the Member States concerning
equipment and protective systems intended for
ly explosive atmospheres.
LVD 2006/95/EC
Directive of the European Parliament and of the Council of the
harmonisation of the laws of Member States relating to electr
cal equipment designed for use within certain voltage limits.
2.2
Improper device modifications
WARNING
Improper device modifications
2.2 Improper device modifications
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation. These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)
● Canadian Electrical Code (CEC) (Canada)
Further provisions for hazardous area applications are for example:
● IEC 60079-14 (international)
● EN 60079-14 (EC)
Certificates (http://www.siemens.com/processinstrumentation/certificates)
The CE marking on the device shows conformity with the regulations of the following
European guidelines:
ibil-
The applied standards can be found in the EC conformity declaration of the device.
use in potential-
i-
Danger to personnel, system and environment can result from modifications to the device,
particularly in hazardous areas.
• Only carry out modifications that are described in the instructions for the device. Failure
to observe this requirement cancels the manufacturer's warranty and the product
approvals.
SIPART PS2 with and without HART
16 Operating Instructions, 09/2014, A5E00074631-12
Safety information
2.3
Requirements for special applications
Note
Operation under special ambient conditions
We highly recommend that you contact your Siemens representative or our application
department b
encountered in nuclear power plants or when the device is used for research and
development purposes.
2.4
Use in hazardous areas
Qualified personnel for hazardous area applications
WARNING
Unsuitable device for the hazardous area
2.3 Requirements for special applications
Due to the large number of possible applications, each detail of the described device
versions for each possible scenario during commissioning, operation, maintenance or
operation in systems cannot be considered in the instructions. If you need additional
information not covered by these instructions, contact your local Siemens office or company
representative.
efore you operate the device under special ambient conditions as can be
Persons who install, connect, commission, operate, and service the device in a hazardous
area must have the following specific qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures,
aggressive, and hazardous media.
● They are authorized, trained, or instructed in carrying out work on electrical circuits for
hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the pertinent safety regulations.
Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and
labelled accordingly.
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
17
Safety information
WARNING
Loss of safety of device with type of protection "Intrinsic safety Ex i"
2.4 Use in hazardous areas
If the device has already been operated in non-intrinsically safe circuits or the electrical
specifications have not been observed, the safety of the device is no longer ensured for use
in hazardous areas. There is a danger of explosion.
• Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe
circuit.
• Observe the specifications for the electrical data on the certificate and/or in Chapter
"Technical data (Page 241)".
SIPART PS2 with and without HART
18 Operating Instructions, 09/2014, A5E00074631-12
3
3.1
Function
3.2
Structure
3.2.1
Overview of structure
● The electropneumatic positioner, in combination with the actuator, forms a control
system. The current position of the actuator is detected using a potentiometer and
returned as the actual value x. The setpoint and actual value are output simultaneously
on the display.
● The setpoint w forms a current applied to the positioner, which in two-wire mode is also
used to power the positioner. In 3- and 4-wire mode, power is supplied through a 24-V
power input.
● The positioner works as a predictive five-point controller, through whose output value ±Δy
the integrated valves can be controlled by pulse length modulation.
● These positioning signals cause pressure changes in the actuator chamber(s) and thus
repositioning of the actuator until the control deviation returns to zero.
● Using three buttons and the display with the enclosure cover removed, operation (manual
mode) and configuration (structuring, initialization, and parameter assignment) can be
performed.
● By default, the basic electronics has a binary input (BIN1). This binary input can be
individually configured and used e.g. to block the control levels.
● To be able to use the positioner in a variety of mechanically different rotational and linear
actuators, it has a friction clutch and a switchable gear.
● In the case of positioners with the "Fail in Place" function, the current position of the
actuator is held if the electric and/or pneumatic auxiliary power fails. Does not function in
conjunction with SIL.
The following sections describe the mechanical and electrical structure, components, and
principle functionality of the positioner.
The positioner is used to move and control pneumatic actuators. The positioner works
electropneumatically, using compressed air as auxiliary power. The positioner is used to
control valves, for example, with:
● Linear actuator
● Part-turn actuator VDI/VDE 3845
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
19
Description
①
Pressure gauge block, single-acting
②
Valve
③
Yoke / actuator yoke
④
Single-acting positioner in non-flameproof aluminum enclosure
⑤
Actuator
①
Part-turn actuator
②
Pressure gauge block, double-acting
③
Double-acting positioner in Makrolon enclosure
3.2 Structure
Various add-on extensions are available for linear actuators:
● IEC 60534-6-1 (NAMUR)
● Integrated addition to ARCA
● Integrated addition to SAMSON in non-flameproof aluminum enclosure
Figure 3-1 Positioner attached to a single-acting linear actuator
Figure 3-2 Positioner attached to double-acting part-turn actuator
SIPART PS2 with and without HART
20 Operating Instructions, 09/2014, A5E00074631-12
Description
①
Single-acting positioner in flameproof aluminum enclosure
②
Pressure gauge block, single-acting
③
Yoke / actuator yoke
④
Actuator
①
Part-turn actuator
②
Double-acting positioner in flameproof aluminum enclosure
③
Pressure gauge block, double-acting
3.2 Structure
Figure 3-3 Positioner in flameproof aluminum enclosure attached to linear actuator
Figure 3-4 Positioner in flameproof aluminum enclosure attached to part-turn actuator
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
21
Description
3.2.2
Nameplate layout
Layout of the nameplate
①
Manufacturer
⑧
Software/hardware version
②
Safety class
⑨
Place of manufacture
③
Consult operating instructions
⑩
Auxiliary power
④
Conformity with country-specific directives
⑪
Ordering supplement (Order code)
⑤
⑫
⑥
Serial number
⑬
Product name
⑦
Auxiliary power (supply air PZ)
Layout of Ex nameplate
①
Approvals
③
FM/CSA marking for hazardous area
②
④
area of the corresponding temperature class
3.2 Structure
Built-in option module
Figure 3-5 Nameplate layout, example
Article number
ATEX/IECEx marking for hazardous area
Figure 3-6 Ex nameplate layout, example
SIPART PS2 with and without HART
22 Operating Instructions, 09/2014, A5E00074631-12
Permitted ambient temperature for the hazardous
Description
Explanation of Ex information
①
④
ture class)
②
Type of protection
⑤
Device protection level
③
Group (gas, dust)
3.2 Structure
Category for operating range
Figure 3-7 Explanation of Ex information
Maximum surface temperature (tempera-
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
23
Description
3.3
Device components
3.3.1
Overview of device components
①
Input: Supply air PZ
⑩
Transmission ratio selector 2)
②
Output: Actuating pressure Y1
⑪
Friction clutch adjustment wheel
③
Display
⑫
Basic electronics
④
Output: Actuating pressure Y2 1)
⑬
Connecting terminals of option modules
⑤
Buttons
⑭
Dummy plug
⑥
Restrictor Y1 for single-acting actuators
⑮
Cable gland
⑦
Restrictor Y1 for double-acting actuators
⑯
Wiring diagram on module cover
⑧
Restrictor Y2 for double-acting actuators
⑰
Purging air selector
⑨
Exhaust air outlet with a sound absorber
for double-acting actuators
only possible when positioner is open
3.3 Device components
1)
2)
Figure 3-8 View of positioner with cover open
SIPART PS2 with and without HART
24 Operating Instructions, 09/2014, A5E00074631-12
Description
①
Input: Supply air PZ
⑧
Restrictor Y2 1)
②
Output: Actuating pressure Y1
⑨
Friction clutch adjustment wheel
③
Display
⑩
Connecting terminals of option modules
④
Output: Actuating pressure Y2 1)
⑪
Connecting terminals of basic electronics
⑤
Buttons
⑫
Safety catch
⑥
Transmission ratio selector 2)
⑬
Ground terminal
⑦
Restrictor Y1
1) for double-acting actuators
only possible when positioner is open
3.3.2
Basic electronics
3.3 Device components
2)
Figure 3-9 View of positioner in flameproof enclosure, cover opened
Figure 3-10 Basic electronics, schematic representation
The basic electronics contains:
● CPU
● Memory
● Analog-to-digital converter
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
25
Description
3.4
Mode of operation
Control loop
N
See also
3.4 Mode of operation
● Display
● Buttons
● Terminal strips to connect the option module to the basic electronics
The electropneumatic positioner forms a control loop with the pneumatic actuator:
● The actual value x represents the position of the actuator spindle for linear actuators or
the position of the actuator shaft for part-turn actuators.
● The control value w represents the positioning current of a closed-loop controller or a
manual control station from 0/4 to 20 mA.
The stroke or rotary movement of the actuator is transferred to a potentiometer using
suitable attachments, positioner shaft and a backlash-free, switchable gear drive, and then to
the analog input of the microcontroller.
The current position can also be forwarded to the positioner using an external sensor. A
on-Contacting Position Sensor (NCS) is used to record the stroke or rotary angle directly
on the actuator.
The microcontroller:
● Corrects the angle error of the shaft pick-up if necessary.
● Compares the potentiometer voltage as actual value x with the setpoint w. The setpoint w
is connected to terminals 6 and 7 by means of PROFIBUS communication.
● Calculates the manipulated variable increments ±∆y.
The piezo-controlled inlet or exhaust air valve is opened depending on the magnitude and
direction of the control deviation (x-w). The actuator volume integrates the controller
increment for the actuating pressure y which is proportional to the drive rod or the drive
shaft. This controller increment change the actuating pressure until the control deviation
becomes zero.
Pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is ventilated and depressurized. The pressure
developed works against a spring. In a double-acting version, two pressure chambers work
against each other. Ventilating the volume of one chamber simultaneously depressurizes the
volume of the other.
Block circuit diagram for single-acting or double-acting actuators (Page 28)
SIPART PS2 with and without HART
26 Operating Instructions, 09/2014, A5E00074631-12
Description
3.4.1
Control algorithm
3.4 Mode of operation
The control algorithm is an adaptive, predictive five-point controller.
In case of large control deviations, the valves are controlled using permanent contact. This
takes place in the so-called fast step zone.
In case of medium control deviations, valves are controlled using pulse-length modulated
pulses. This takes place in the so-called slow step zone.
Figure 3-11 Functional principle of five-point controller
Small control deviations do not send control pulses in the zone. This takes place in the socalled adaptive deadband. The deadband adaptation and the continuous adaptation of
minimum pulse lengths in "Automatic" mode ensure the best possible control accuracy with
the smallest number of operating cycles. The start parameters are determined during the
initialization phase and stored in the non-volatile memory. The most important start
parameters are:
● The real actuator travel with end positions
● Travel times
● The deadband size
The number of fault messages, changes in direction, and the number of strokes are
continuously determined during operation and saved every 15 minutes. You can read and
document these parameters using communication programs such as PDM and AMS. By
comparing the old values with the current ones, you can draw conclusions about the wear
and tear of the valve. You can use the diagnostics function for this.
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
27
Description
3.4.2
Block circuit diagram for single-acting or double-acting actuators
①
Basic electronics with microcontroller and input circuit
②
Control pad with display and buttons
③
Single-acting or double-acting pneumatic block
④
Position feedback module for positioner
⑤
Alarm module for three alarm outputs and one binary input
⑥
SIA module (slot initiator alarm module)
⑦
Spring-loaded pneumatic actuator (single-acting)
⑧
Pneumatic actuator (double-acting)
Note
Alarm module and SIA module
Alarm module
3.4 Mode of operation
Figure 3-12 Block circuit diagram for the electropneumatic positioner, functional diagram
SIPART PS2 with and without HART
28 Operating Instructions, 09/2014, A5E00074631-12
⑤ and SIA module ⑥ can only be alternatively used.
Loading...