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Manual Edition 03/2006
Electropneumatic Positioner
SIPART PS2 PA
6DR55xx
p
sipart
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SIPART PS2 PA
6DR55xx
Edition 03/2006
Manual
Electropneumatic Positioner for
Linear and Part--Turn Actuators
SIPART PS2 PA Manual
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Copyright e Siemens AG 2006 All rights reserved
Disclaimer of Liability
The reproduction, transmission or use of this
document or its contents is not permitted without
express written authority. Offenders will be liable for
damages. All rights, including rights created by
patent grant or registration of a utility model or
design, are reserved.
Siemens AG
Bereich Automation & Drives
Geschäftsgebiet Process Instrumentation and
Analytics
D--76181 Karlsruhe
We have checked the contents of this manual for
agreement with the hardware and software
described. Since deviations cannot be precluded
entirely, we cannot guarantee full agreement.
However, the data in this manual are reviewed
regularly and any necessary corrections included in
subsequent editions. Suggestions for improvement
are welcomed.
e Siemens AG 2006
Technical data subject to change without notice
Trademarks
SIMATICe,SIPARTe,SIRECe, SITRANSe are registered trademarks of the Siemens AG
Third parties using for their own purposes any other names in this document which refer to
trademarks might infringe upon the rights of the trademark owners.
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Contents
0 Information for the operator 7.............................................
0.1 General information 7...........................................
0.2 Classification of safety--related notices 8..........................
0.3 Qualified personnel 9...........................................
0.4 Use as intended 11..............................................
0.5 Technical documentation 1 1......................................
0.6 Warranty information 12..........................................
0.7 Delivery notes 12................................................
0.8 Standards and regulations 12.....................................
1 Introduction 13............................................................
1.1 General information about the positioner 13.........................
1.2 General information regarding PROFIBUS 17.......................
1.2.1 Transmission method 17.........................................
1.2.2 Topology 17....................................................
1.2.3 Properties of the PROFIBUS PA 18................................
1.2.4 Profile 19.......................................................
1.2.5 Interfacing 19...................................................
2 Design and method of operation 23.........................................
2.1 Overview 23....................................................
2.2 Design Rating Plate 25...........................................
2.3 Instrument components 25.......................................
2.3.1 Motherboard 26.................................................
2.3.2 Electrical connections 26.........................................
2.3.3 Pneumatic connections 27........................................
2.3.4 Mounting kit 29.................................................
2.3.5 Purge air switching (not in the explosion--proof version) 29............
2.3.6 Restrictors 29...................................................
2.4 Method of operation 30..........................................
2.5 State as supplied 31.............................................
2.6 Option modules 31..............................................
2.6.1 Installation of options modules in normal and intrinsically
safe versions 31................................................
2.6.2 Installation of options modules in explosion proof version 34..........
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2.6.3 Iy module 36....................................................
2.6.4 Alarm module 37................................................
2.6.5 SIA module 38..................................................
2.6.6 Mechanical limit switch module 39.................................
2.6.7 EMC filter module 43............................................
2.6.8 Accessories 43.................................................
3 Preparing for operation 45.................................................
3.1 Instrument identification (type key) 45..............................
3.2 Dimensional drawings 45.........................................
3.3 Assembly 47....................................................
3.3.1 Instructions for using positioners in a wet environment 48.............
3.3.2 Instructions for using positioners which are exposed to great
accelerations or vibrations 50.....................................
3.3.3 Mounting kit ”linear actuator” 6DR4004--8V and 6DR4004--8L 53......
3.3.4 Assembly procedure (see figure 26, page 55) 53....................
3.3.5 Mounting kit ”part--turn actuator” 6DR4004--8D 56...................
3.3.6 Assembly procedure (see figure 27 and figure 28) 57.................
3.4 Electrical connection 62..........................................
3.4.1 Connection variant: options in positioner in non--intrinsically safe
and explosion--proof version 67...................................
3.4.2 Connection variant: options in the positioner in intrinsically safe
version 69......................................................
3.4.3 Connection variant: options in the positioner in type of protection
”n” version 71...................................................
3.5 Pneumatic connection 73.........................................
3.6 Commissioning 74...............................................
3.6.1 Preparations for linear actuators 75................................
3.6.2 Automatic initialization of linear actuator 76.........................
3.6.3 Manual initialization of linear actuator 78............................
3.6.4 Preparations for part--turn actuator 81..............................
3.6.5 Automatic initialization of part--turn actuator 81......................
3.6.6 Manual initialization of part--turn actuators 83.......................
3.6.7 Automatic initialization (structograms) 85...........................
3.7 Copying initialization data (positioner exchange) 89..................
4 Operation 91..............................................................
4.1 Display 91......................................................
4.2 Input keys 91...................................................
4.3 Operating modes 94.............................................
4.4 Parameters 97..................................................
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4.5 Diagnosis 113...................................................
4.5.1 Diagnostic display 1 13............................................
4.5.2 Meaning of the diagnostic values 1 14...............................
4.5.3 Online--diagnosis 118.............................................
4.6 Meanings of other display texts 122.................................
4.7 Optimization of the control data 126.................................
4.8 Fault correction 127..............................................
5 Functions/operation via PROFIBUS PA 131...................................
5.1 System integration 131............................................
5.2 Acyclic data transmission 131......................................
5.2.1 SIMATIC PDM 131...............................................
5.2.1.1 Allocate address 132.............................................
5.2.1.2 Load to device 132...............................................
5.2.1.3 Load to PG/PC 132...............................................
5.2.1.4 Read maintenance information 132.................................
5.2.1.5 Set maintenance information 133...................................
5.2.1.6 Operation 134...................................................
5.2.1.7 Reset 137.......................................................
5.2.1.8 Initialization parameters 138.......................................
5.2.1.9 Self--calibration 138...............................................
5.2.1.10 Write protection 139..............................................
5.3 Cyclic data transmission 139.......................................
5.3.1 Configuration 139................................................
5.3.1.1 Configuring the user data 139......................................
5.3.2 User data via PROFIBUS 141......................................
5.3.2.1 Status 148......................................................
5.3.2.2 Diagnostics 149..................................................
5.3.3 Diagnostics acc. to PROFIBUS DP (DDLM_Slave_Diag) 150...........
5.3.4 Condensed Status 152............................................
6 Service and maintenance 159...............................................
7 Technical data 161..........................................................
8 Scope of delivery 167.......................................................
8.1 Ordering data 168................................................
8.2 Scope of delivery of options 169....................................
8.3 Scope of delivery of accessories 169................................
8.4 List of Spare Parts 170............................................
9 Index 171..................................................................
10 Appendix 173..............................................................
10.1 Literature and catalogs 173........................................
10.2 Certificates 174..................................................
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Information for the operator
Information for the operator
Dear customer ,
Please read this manual before starting work!
It contains important information and data which, when observed,
ensure full availability of the equipment and save service costs. This
simplifies handling of this control instrument considerably and provides
accurate measuring results.
You have purchased an instrument which can be installed in various
configurations:
S SIPART PS2 without Ex--protection in a metal or plastic housing.
S SIPART PS2 with EEx ia/ib--protection in a metal or plastic housing.
S SIPART PS2 EEx n in a metal or plastic housing
S SIPART PS2 EEx d in flameproof enclosure (EEx d)
This manual takes each of these possibilities into consideration. Any
differences between the devices are indicated specially.
Scope of delivery, see chapter 8, page 167.
0
0.1 General information
The product described in this manual left the factory in a perfectly safe
and tested condition. To maintain this condition and to achieve perfect
and reliable operation of this product, it must only be used in the way
described by the manufacturer. Successful and safe operation of this
equipment is dependent on proper handling, installation, operation and
maintenance.
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Information for the operator
This manual contains the information required for use as intended of
the product it describes. It is addressed to technically qualified
personnel specially trained or having relevant knowledge of
instrumentation and control technology, hereafter called automation
technology.
Familiarity with and proper technical observance of the safety notes
and warnings contained in this manual are essential for safe installation
and commissioning and for safety in operation and maintenance of the
product described. Only qualified personnel as defined in Chapter 0.3
has the necessary specialist knowledge to interpret the general safety
notes and warnings given in this document in specific cases and to
take the necessary action.
The documentation supplied with the instrument is listed in Chapter
0.5.
This manual is not a permanent part of the scope of supply. For
reasons of clarity, it does not contain every detail about every version
of the product described and cannot take every eventuality in
installation, operation, maintenance and use in systems into account. If
you require further information or if problems occur that have not been
dealt with in sufficient detail in this document, please request the
required information from your local Siemens office or the office
responsible for you.
Functionality, commissioning and operation are described in this
manual.
Please pay special attention to the Warning and Note texts. These are
separated from the remaining text by horizontal lines and specially
marked with symbols (see Chapter 0.2).
0.2 Classification of safety--related notices
This manual contains notices which you should observe to ensure your
own personal safety, as well as to protect the product and connected
equipment. These notices are highlighted in the manual by a warning
triangle and are marked as follows according to the level of danger:
DANGER
!
!
indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
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Information for the operator
CAUTION
!
used with the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury.
CAUTION
used without safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.
NOTICE
used without the safety alert symbol indicates a potential situation
which, if not avoided, may result in an undesireable result or state.
.
NOTE
highlights important information on the product, using the product, or
part of the documentation that is of particular importance and that will
be of benefit to the user.
0.3 Qualified personnel
The result of unqualified intervention in the instrument or
nonobservance of the warnings given in this manual or on product
labels can be severe personal injury and/or serious material damage.
Therefore only properly qualified personnel must make changes and
settings in the instrument.
For the purpose of the safety information in this manual and on the
product labels, qualified personnel are those who
S in the case of ex--proof equipment, are trained, instructed or
authorized to perform work on electrical circuits of equipment
subject to explosion hazard.
S if they are configuration personnel, are familiar with the safety
concepts of automation technology
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S if they are operating personnel, have been instructed in the handling
of automation equipment and know the content of this manual
relating to operation
S if they are commissioning and/or service personnel, are trained to
repair such automation equipment and authorized to energize,
de--energize, clear ground and tag circuits and equipment according
to safety engineering standards.
S and instructed additionally in first aid
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Information for the operator
WARNING
!
The instrument must only be installed and commissioned by qualified
personnel.
The instrument is designed for connection to functional and safety
extra low voltage.
The instrument is designed for connection to operate voltage or safety
extra--low voltage.
Electrical safety depends only on the power supply equipment.
Pneumatic actuators exert considerable positioning forces. The safety
precautions of the actuator used must therefore be scrupulously
observed during installation and commissioning in order to prevent
injuries.
We explicitly draw your attention to the necessity of observing safety
regulations regarding operation in zones subject to explosion hazard, if
applicable.
The specifications of the examination certificate valid in your country
must be observed. Laws and regulations valid in your country must be
observed for the electrical installation in explosions hazardous areas.
In Germany these are for example:
-- Working reliability regulations,
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079--14 (in the past VDE 0165, T1).
It should be checked whether the available power supply , insofar as
this is required, is compliant with the power supply specified on the
rating plate and specified in the examination certificate valid in your
country.
Take care to avoid electrostatic discharges within the hazardous area,
such as can arise if a dry cloth is used to clean the positioner in the
plastic housing.
Devices with the protection type ”flameproof enclosure” may only be
opened when the power is off.
WARNING
!
Devices with the protection type ”intrinsically safe” lose their
certification as soon as they are operated with circuits that do not
conform to the specifications laid down in the EC type examination
certificate valid in your country.
The successful and safe operation of this equipment is dependent
upon its proper handling, installation, operation and maintenance.
10
WARNING
!
The device may not be operated as long as the quick start guides are
inside the housing.
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0.4 Use as intended
Use as intended for the purpose of this manual means that this product
must only be used for the applications described in the technical
description (see also Chapter 3 page 45 of this manual).
The product described in this manual has been developed,
manufactured, tested and documented observing the relevant safety
standards. If the handling rules and safety information for configuration,
installation, use as intended and maintenance are observed, there is
normally no danger with regard to material damage or for the health of
personnel. Extra low voltages that are connected must be fed in by
safe isolation.
0.5 Technical documentation
The instructions are a constituent part of the enclosed CD ”sipartp ps2
POSITIONERS” (order number A5E00214567). The manual and further documentations are available on the Internet at:
Information for the operator
.siemens.com/sipartps2
www
Click on ”More Info” and ”--> Instructions and Manuals”.
On the enclosed CD, you will find an extract of the catalog FI 01 ”Field
devices for process automation” with the current order data. The entire
FI 01 catalog is also available at the above Web address.
If you need more information or have particular problems which are not
covered sufficiently by the operating instructions, contact your local
Siemens office. You will find your local Siemens office on the Internet
under:
.siemens.com/processinstrumentation
www
Click on ”Contact” and select your closest town.
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Information for the operator
0.6 Warranty information
We should like to point out that the content of this manual is not part of
and does not modify a previous or current agreement, undertaking or
legal relationship. Siemens is bound solely by the contract of sale,
which also contains the complete and exclusive warranty . The
contractual warranty conditions are neither extended nor restricted by
this document.
0.7 Delivery notes
The scope of delivery is listed on the dispatch papers accompanying
the delivery in accordance with the valid contract of sale.
When you open the packaging please observe the information on the
packaging. Check that the delivery is complete and undamaged. If
possible, compare the order number on the rating plates with the
ordering data.
For the scope of delivery please see Chapter 8, page 167.
0.8 Standards and regulations
As far as possible, the harmonized European standards were used to
specify and manufacture this equipment. If harmonized European
standards have not been applied, the standards and regulations of the
Federal Republic of Germany apply (see also Chapter 7 page 161
”Technical Data”).
If this product is used outside the area of applicability of these
standards and regulations, please observe the standards and
regulations in force in the country where the product is operated.
12
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Introduction
Introduction
1.1 General information about the positioner
The positioner is used to adjust and control pneumatic actuators. The
controller operates electropneumatically with compressed air as an
energy supply.
The positioner together with the PROFIBUS PA communications
interface are components in a digital process automation system. It
communicates with the master as a slave via the PROFIBUS PS field
bus. The field bus is used not only for communication but also to supply
the positioner with electrical power.
Purpose
For example, the positioner can be used to control valves as follows:
S with linear actuator (figure 1, page 15) or
1
Versions
Housing
S with part--turn actuator VDI/VDE 3845 (figure 2, page 15)
Different mounting types are available for linear actuators:
S NAMUR or IEC534
S integrated mounting to ARCA
S integrated mounting to SAMSON (non explosion proof version)
This means the positioner can be installed and operated on all common
actuator systems.
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.
The electronics with display, position feedback and valve block are
integrated in the housing.
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Introduction
The housing is available in three versions:
S Plastic housing for single-- and double--acting actuators
S Metal housing for single--acting actuators
S Explosion proof housing for single and double--acting actuators
Degree of
protection
Explosion
Protection
SIL applications
Options
The device is designed with IP66/NEMA4x degree of protection.
The intrinsically safe version can be used in hazardous areas in zone 1
or zone 2.
The explosion proof version can be used in hazardous areas in zone 1
or zone 2.
Explosion proof type ”n” versions can be used in explosion hazard zone
2 areas.
The positioners (version 6DR551* for single acting actuators) are also
suitable for positioning on fittings with pneumatic actuators, which satisfy the special requirements for safety devices up to SIL 2 to
IEC 61508 part 1--7 and IEC 61511 part 1--3. For this the SIL safety
instructions in the ”SIL Safety Manual (PA/FF)” order number
A5E00489773 must be followed.
The positioner can be expanded with various options modules (chapter
2.6, page 31). The following modules are available in all:
S I
module: Two--wire current output 4 to 20 mA for position feedback
y
S Alarm module: three digital outputs and 1 binary input
Accessories
Environmental
Protection
S SIA module: one binary output for fault messages, two binary
outputs for limit value alarms
S Mechnical limit switch module: one binary output for the output of a
group error message, two switches for signalling two limit values
that can be set mechanically.
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)
Only environmentally friendly materials have been used in the
construction of the positioner.
The technical manual is printed on chlorine--free bleached paper.
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Introduction
1
2
3
1 Actuator
2 Positioner, single--acting in metal housing
3 Lantern
4 Manometer block, single--acting
5Valve
Figure 1 Positioner mounted on linear actuator (single--acting)
4
5
1
2
1 Positioner in plastic housing
2 Part--turn actuator
3 Manometer block, double- -acting
Figure 2 Positioner mounted on part--turn actuator (double--acting)
3
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Introduction
1
2
4
3
1 Actuator
2 Positioner, single--acting in explosion proof housing
3 Lantern
4 Manometer block, single--acting
Figure 3 Explosion proof positioner mounted on linear actuator (single--acting)
1
3
2
1 Positioner double--acting in explosion proof housing
2 Part--turn actuator
3 Manometer block, double- -acting
Figure 4 Explosion proof positioner mounted on part--turn actuator (double--acting)
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1.2 General information regarding PROFIBUS
The PROFIBUS PA (PA = Process Automation) is a variant of the
PROFIBUS--DP (DP = Decentral Peripheral) which is widely used in
manufacturing engineering.
The PROFIBUS (Process Field Bus) is an open communication
system for automation engineering and thousands are used all over the
world. It is specified in the European standard EN 50170.
1.2.1 Transmission method
The PROFIBUS PA has a special transmission method and therefore
satisfies the requirements of process automation and manufacturing
engineering. This transmission method is defined in the international
standard IEC61158--2. The low transmission speed reduces the power
loss compared to the PROFIBUS--DP and therefore enables an
intrinsically safe technique for use in hazardous areas.
1.2.2 Topology
The bus topology can, to a large extent, be freely selected so that line,
star and tree structures are possible, as well as mixtures of these. All
kinds of field devices such as transformers, actuators, analyzers, etc.
can be connected to the PROFIBUS PA
Introduction
The main advantage is in:
S the saving of installation costs
S the possibility of more extensive diagnostics with an increase in the
availability of system parts
S the possibility of automatic tracing of system documentation
S the possibility of system optimization in operation
In an automation system, several PROFIBUS PA channels are usually
connected to the fast PROFIBUS--DP with coupling units. The process
control system is also linked to this.
Both bus systems use a uniform protocol layer. This makes the
PROFIBUS PA a communication--compatible extension of the
PROFIBUS--DP into the field.
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Introduction
Master
(class 1)
PROFIBUS-DP
Slaves
(Field devices, decentralized peripherals,
secondary controls, mains transfer to PROFIBUS PA)
Figure 5 Typical PROFIBUS automation system
Figure 5 shows the section of a typical PROFIBUS automation system.
The control system consists of two masters with distributed tasks.
The class 1 master looks after the control and regulation functions,
while the class 2 master enables operating and monitoring functions. A
cyclic exchange of measuring and setting data takes place between
master 1 and the field devices. Parallel to this data, the status data of
the field devices is transmitted to and evaluated in the class 1master.
No field device parameters are set or other device information read
during cyclic operation.
Master
(class 2)
I
PROFIBUS PA
8x
The information necessary for establishing communication is available
to the control system from the stored, device--specific device master
data (GS*) files. The files are available on the Internet at:
.siemens.com/sipartps2
www
Click on “More Info” and “--> Instructions and Manuals”.
One or more class 2 masters can access the field devices acyclically in
addition to the cyclic mode. With this communication type further
information can be fetched from the devices or settings made in the
devices.
1.2.3 Properties of the PROFIBUS PA
The PROFIBUS PA enables bi--directional communication between a
bus master and the field devices via a shielded two--wire line. At the
same time the power is supplied to the two--wire field devices on the
same lines.
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1.2.4 Profile
Introduction
Supplementary to the EN standard 50170, the PNO (PROFIBUS
Userorganisation) has defined the functionality of the individual field
device types in a so--called profile description. This profile defines
minimum functional requirements and optional extensions. The
device--internal Device Management supplies all the basic information
necessary for finding the profile parameters to the control system
configuration tool. With this, a parametering tool can operate all
profile--conforming devices regardless of type and manufacturer.
Depending on the size of the system and thus the number of field
devices and the required timing, the system must be implemented with
one or more PROFIBUS PA channels. A PROFIBUS PA channel
consists of the components shown in Figure 6.
Control room Field
PROFIBUS-DP
Coupler
PLS, PC
Power
supply
T Terminating resistor
FD Field device
PC Personal computer
PLS Process control system
Figure 6 PROFIBUS PA architecture
1.2.5 Interfacing
The central process control system PLS or, in the case of low
requirements, a PC, is responsible for the control.
As a rule the signal conversion DP/PA, bus feeding and bus termination
functions are combined in a coupling module. Depending on the
number of PROFIBUS PA field devices to be operated in the
automation system and the required timing, a DP/PA coupler or, in the
case of higher requirements, a more powerful DP/PA link is used.
PROFIBUS-PA
T
FD
FD
T
additional
cable
termination
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Introduction
An additional terminating resistor T must be fitted at the far end of the
bus for transmission--technical reasons. When using the recommended
bus cable, the theoretically possible line length (sum of all line sections)
is a maximum of 1900 mm. In addition, the voltage drop over the lines
supplying the field devices must be taken into account in the planning.
However, the current requirements of the individual users and voltage
drop on the cable must also be taken into account in the planning. The
individual field devices FD can be connected almost anywhere in the
bus system. Further information can be found in the ”PROFIBUS
PPNO Guide A”.
DP/PA--coupler or DP/PA--link are supplied by a power supply unit with
SELV (Safety Extra Low Voltage). This power supply must have
adequate reserves for bridging brief power failures.
The maximum number of devices that can be connected to a bus
channel depends on their current consumption and the respective
conditions of use. When operating in a safe area, the couplers/links can
feed up to 400 mA into the bus.
In zones subject to explosion hazard, intrinsic safety is only ensured if
the maximum power fed into the bus does not exceed certain voltage
and current values. See chapter 7 ”Technical Data” (page 161) device
in intrinsically safe version.
WARNING
!
To power the intrinsically safe PROFIBUS only certified power supply
units (DP/P A couplers or links) must be used. See the EC--Type
Examination Certificate ”for use in Potentially Explosive Atmospheres”.
When explosion proof versions of positioners are used in areas where
the atmosphere is potentially explosive, they may be supplied with
auxiliary electrical power only within the enclosed housing.
The openings for the electronic connections must be executed with
EEx--d--certified cable glands or sealed with EEx--d--certified plugs, or
the ”Conduit Tube System” must be used to provide an explosion
barrier at a maximum distance of 46 cm (18 inches) from the housing.
The number of devices which can be connected to a bus channel can
be determined from the maximum current consumption of the devices
connected (according to standards ≥ 10 mA per device) and the
available current. A current reserve should be planned for safety
reasons, otherwise there is a risk that a defective device could overload
the bus with its increased current consumption and the power supply
and communication with all unaffected users could collapse. The power
reserve quantity depends on the current increase in the event of an
error specified by the manufacturer.
20
Every device has its own address to distinguish between the connected
process devices.
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Introduction
Before operation make sure that the positioner addresses of two or
more field devices are set on the bus. So that the addresses are
unique, each address must only be assigned once. In principle, an
address range from 1 to 125 is possible. In its as--supplied state,
address 126 is set. The lower addresses are usually assigned to the
masters in PROFIBUS systems. We therefore recommend starting
address assignment for the positioners with 30.
The address setting is made either on the positioner using operating
keys or via the bus with the SIMATIC PDM software. In the latter case,
a new positioner is always connected to the bus and the new address
set via software. After that, the next positioner is connected to the bus
and the same procedure followed.
We recommend that you write the set address on the positioner with a
permanent felt--tip pen.
For more detailed information about the components, assembly
guidelines and configuration, see the technical description of the field
technology package /2/.
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Introduction
22
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Design and method of operation
Design and method of operation
The following chapter describes the mechanical and electrical design,
the instrument components and method of operation of the positioner.
2.1 Overview
Introduction
The electropneumatic positioner forms a control system in connection
with an actuator. The current position of the positioner is detected by a
servo potentiometer and fed back as actual value x. In addition a
separate sensor can be fitted to the positioner for purposes of position
detection. The setpoint and actual value are output simultaneously on
the display.
The setpoint is set by the control system and passed to the positioner
by the PROFIBUS P A digitally.
2
The PROFIBUS PA variant of the positioner differs from previous
versions in the bus interface. The basic functions of the positioner
including operation and display are virtually unchanged.
The positioner operates as a predictive five--point switch by the output
variable ±∆y of which the integrated actuating valves are controlled with
pulse length modulation.
These actuating signals cause fluctuations in pressure in the actuator
chamber(s) and thus adjustment of the actuator until the control error is
zero.
Operation (manual) and configuration (structuring, initialization and
parameterization) is effected by three keys and a display with the
housing cover removed.
The standard controller has one binary input (BI1). This can be
configured individually and can be used for blocking the operating
modes for example. A further input (Shut down) has the function of
moving the actuator to a pre--set safety position (end stop).
With the I
as a two wire signal I
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.
-option module, the current actuator position can be output
y
=4to20mA.
y
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Design and method of operation
The limit value alarms are output by the alarm option module which can
monitor and report the function of the positioner and the actuator
additionally through a fault message output. The value of the control
difference dependent on the travel time is monitored in automatic
mode. The fault signal is always set when the control error cannot be
leveled after a certain time because for example the valve is blocked or
the mains pressure is insufficient. The three binary outputs are
implemented as semiconductor outputs and are error self--reporting,
i.e. the outputs respond even when the power supply fails or the
electronics are defective.
Theactuatorcanalsobeblockedordriventoitsfinalpositions
depending on the configuration for example by an external event via a
binary input (BI2) on the alarm module.
If you require electrically independent limit value messages from the
standard controller, you will have to use the SIA module with the slot
initiators instead of the alarm module.
To be able to use the positioner with a variety of different part-turn and
linear actuators, it has a friction clutch and switchable gearing.
The switchable gearing allows you to adjust the positioner for small and
large lifts. You can switch using the yellow switch (9, Fig. 8, page 25)
between 33_ (as delivered) and 90_.
The friction clutch (8, Fig. 8, page 25) allows you to set the working
range, particularly for linear actuators, after installation. You thus do not
have to ensure symmetrical mounting during the installation.
As it is not allowed to open the housing of an explosion proof version in
a potentially explosive atmosphere, the shaft has an externally fitted,
additional friction clutch (8, Fig. 9, page 26).
NOTICE
for the explosion proof version:
Only adjust the outer friction clutch (8, Fig. 9, page 26). The internal
friction clutch (9, Fig. 8 page 25) is fixed and, for the explosion proof
version, must not be adjusted.
24
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Page 27
2.2 Design Rating Plate
Design and method of operation
(2)
(8)
(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 7 Design rating plate, example with protection class EEx ia/ib
2.3 Instrument components
(7)(1)
8
1 Input: Supply air 8 Transmission ratio selector
2 Output: Actuating pressure Y1 9 Adjustment wheel for friction clutch
3 Display 10 Motherboard
4 Output: Actuating pressure Y2
5 Operating keys 12 Ground cable (only for plastic housing)
6 Restrictor 13 Bus cable
6.1 Restrictor Y1 14 Terminal plate on cover
6.2 Restrictor Y2
7 Silencer
*)
in double--acting actuators
*)
*)
11 Terminals option modules
15 Purging air switch
7
Figure 8 View of the positioner (cover open); plastic housing
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Design and method of operation
9
1
10
3
---++
10
1 Input: Supply air 7 Transmission ratio selector
2 Output: Actuating pressure Y1 (only possible with positioner open)
3 Display 8 Adjustment wheel for friction clutch
4 Output: Actuating pressure Y2
5 Operating keys 10 Terminals option modules
6.1 Restrictor Y1 12 Safety catch
6.2 Restrictor Y2
*)
in double--acting actuators
*)
*)
2121
6.1
138238 9
6.2
45
9 Terminals standard controller
7
8
Figure 9 View of the explosion proof version of the positioner
2.3.1 Motherboard
The motherboard contains all the electronic elements such as the CPU,
memory, A/D converter. It also contains the display and the operating
keys.
In addition, the terminal strips for connecting the option modules are
also on the motherboard.
2.3.2 Electrical conn ectio n s
The terminals of the standard controller, the Iy--, SIA-- and alarm--option
module are arranged at the left--hand front edges and offset against
each other in staircase form.
A module cover protects the modules from being pulled out and
prevents incorrect installation.
26
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Page 29
2.3.3 Pneumatic connections
The pneumatic connections are on the right hand side of the positioner
(figure 10 and figure 11).
1
2
3
4
5
1 Actuating pressure Y1 in single-- and double--acting actuators
2 Feedback shaft
3 Supply air P
4 Actuating pressure Y2 in double- -acting actuators
5 Exhaust air output E with silencer on the bottom of the instrument
Figure 10 Pneumatic connection in normal version
z
Design and method of operation
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 11 Pneumatic connection in explosion proof version
In addition, there are pneumatic connections on the back of the
positioner for integrated installation in single--acting linear actuators.
S Actuating pressure Y1
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S Exhaust air output E (not in explosion proof version)
In the ex--factory state, these connections are sealed by screws (see
figure 20, page 45, figure 22, page 46 and figure 23, page 47).
27
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Design and method of operation
The exhaust air output E can be provided for supplying dry instrument
air to the tapping chamber and spring chamber to prevent corrosion.
Figure 12, page 28 shows the pneumatic connection variants for the
different actuator types, the positioning acting and the safety position
after power failure.
Positioning
pressure
Connection
Y1
Y1
Y2
Y1
Y1
Y2
Closed
Closed
Actuator type
Open
Open
OpenClos ed
OpenClosed
Safety position after power failure”
electrical pneumatic
Closed Closed
Open Open
Open
Last position
(before power
failure)
Closed
In part--turn actuators the
direction of rotation
counterclockwise looking
onto the actuating shaft of
the valve is usually defined
as
”Open”.
Open
Closed
Y1
up
Down Down
down
Y1
up
down
Up Up
Y2
Y1
up
down
Up
Y1
Y2
up
down
Down
Figure 12 Pneumatic connection positioning
Last position
(before power
failure)
up down
28
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Design and method of operation
2.3.4 Mounting kit
The positioner can be mounted on almost all actuators with the
appropriate mounting kit.
2.3.5 Purge air switching (not in the explosion proof version)
The purge air switch is accessible above the pneumatic terminal strip
with the housing open (figure 13). In the IN position the inside of the
housing is purged with very small amounts of clean, dry instrument air.
In the OUT position the purge air is fed directly to the outside air (for
more information: see Chapter 3.3, page 47).
Figure 13 Purge air switch on the valve block, view of the positioner onto pneumatic connection side
with cover open
2.3.6 Restrictors
In order to achieve travel times of > 1.5 s in small actuators, the air rate
can be reduced with the restrictors Y1 and Y2 (figure 14, in explosion
proof version, see figure 11, page 27). By turning to the right the air
rate is reduced up to shutting off. To set the restrictors it is advisable to
close them and then open them slowly (see initialization RUN3).
In the case of double-acting valves make sure that both chokes are set
approximately equal.
Hexagon socket 2.5 mm
Y1 Y2
Figure 14 Restrictors
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Design and method of operation
2.4 Method of operation
The electropneumatic positioner forms a control circuit with the
pneumatic actuator in which the actual value x is the position of the
actuator bar in linear actuators or the position of the actuator shaft in
part--turn actuators and the command variable w is supplied digitally via
the PROFIBUS.
The stroke or part--turn movement of the actuator is transferred by the
appropriate mounting accessories, the feedback shaft and a play--free
switchable gearwheel to a high quality conductive plastic potentiometer
and to the analog input of the microcontroller . The current position of
the positioner can also be set using an external sensor. Determining
the stroke distance or the angle of rotation is done by an external
position detection system (e.g. non--contacting position sensor or a
potentiometer) directly on the actuator.
The positioner may correct the angle error of the stroke tap, compares
the actual value x with the setpoint w and calculates the manipulated
variable increments Δy. Depending on the size and direction of the
control error (x- -w) the piezo--controlled supply air or exhaust air valve
is opened. The volume of the actuator integrates the positioning
increments to actuating pressure y open which moves the actuator bar
or actuator shaft approximately proportionally. These positioning
increments change the actuating pressure until the control error
becomes zero.
The pneumatic actuators are available in single and double--acting
versions. Only one pressure chamber is aerated or deaerated in the
single--acting version. The resulting pressure operates against a spring.
In the double--acting version, two pressure chambers are
counteractive. In this case the one volume is deaerated when the other
volume is aerated.
The control algorithm is an adaptive predictive five--point switch (see
figure 15, page 31). The valves are controlled with continuous contact
at large control errors (fast step zone). At medium control errors the
valve is controlled by pulse length modulated pulses (short step zone).
No actuating pulses are output in the small control error zone (adaptive
dead zone). The dead zone adaptation and the continuous adaptation
of the minimum pulse lengths in automatic operation cause the best
possible control accuracy to be achieved at the lowest switching
frequency. The start parameters are determined during the initialization
phase and stored in a non--volatile memory. These are basically the
real actuating path with the mechanical limit stops, the travel times, the
size of the dead zone etc.
In addition the number of fault messages, changes in direction and the
number of strokes are determined and stored every 15 minutes during
operation. These parameters can be read out and documented by the
communication programs such as AMS. Conclusions as to the wear on
the fitting can be drawn (diagnostic function) especially by comparing
the old value with the currently determined values.
30
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Design and method of operation
.
Figure 15 Method of operation five--point switch
NOTE
The exhaust air valve is always open when there is no current.
2.5 State as supplied
There are no mechanical mounting accessories on the controller in the
state as supplied. These must be ordered and installed according to
the ”operating instructions” depending on the application.
The respective connections for single or double--acting versions are
prepared at the factory as ordered.
The pneumatic connections on the rear are sealed.
The input for the safety shut down is not activated.
2.6 Option modules
2.6.1 Installation of options modules in normal and intrinsically safe versions
The following option modules are available for the positioner in the
standard and the intrinsically safe version:
module
-- I
y
-- Alarm module
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-- SIA module
-- Mechanical limit switch module
-- EMC filter module
31
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Design and method of operation
Installation
.
Opening the
instrument
.
The option modules are secured by a assembly covering ((1), see figure 16, page 33) and mechanically fixed.
NOTE
The housing must be opened to install the options modules. The
degree of protection IP66 is not guaranteed as long as the positioner is
open.
To open the positioner, the four screws of the housing cover must be
loosened with a Phillips screwdriver.
Disconnect or isolate the power supply cables.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.
NOTE
To prevent premature wearing of the fixture by the self--tapping screws
(1.1), the following method of mounting the module cover (1) has
proven effective.
1. Turn the screws counterclockwise until you feel them snap into the
thread
2. Tighten both screws carefully in clockwise direction
32
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Design and method of operation
6
1
1.1
5
2.1
1.1
2.1
2
12
10
4
7
11
3
7.2 7.3
7.1 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)
3I
-module with ribbon cable (6) 8 Adjusting wheel for friction clutch
y
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
Figure 16 Installation of options modules in normal and intrinsically safe version
12 Actuating disc bearings
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Design and method of operation
2.6.2 Installation of options modules in explosion proof version
The following option modules are available for the positioner in the
explosion proof version:
module
-- I
y
-- Alarm module
Installation
.
The options modules are protected and mechanically fixed by a module
cover ((1), see figure 17, page 36).
NOTE
The housing must be opened to install the options modules. The
degree of protection IP66/NEMA4x is not guaranteed as long as the
positioner is open.
WARNING
!
In areas in which the atmosphere may be potentially explosive, the
explosion proof positioner may only be supplied with electrical auxiliary
power when the housing is closed and when built--in, approved
electronics are used.
The feed--though openings for the electronic connections must be
sealed with EEX-d certified cable glands or EEx-d certified plugs or an
ignition lock must be mounted at a maximum distance of 46 cm
(18 inches) when using the “conduit”--system.
Open the positioner
34
See figure 17, page 36. Disconnect or isolate the power supply cables
first.
To open the positioner, the safety catch (12) must be opened and the
screw--on cover unscrewed.
After loosening the four fixing screws (13.1) the complete rack (13) can
be removed. The actuator may have to be turned so that the clutch can
be easily disengaged.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.
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Design and method of operation
.
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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Design and method of operation
1.1
10
13.1
12
8
7
13.1
56
13
1
1.1
2
4
3
11
1 Module cover 7 Transmission ratio selector
1.1 Fixing screws 8 Adjusting wheel for friction clutch
2 PA module 10 Housing
3I
module with ribbon cable 11 Screw--on cover
y
4 Alarm module with ribbon cable 12 Safety catch
5 Ribbon cable for alarm module 13 Rack
6 Ribbon cable for I
module 13.1 Fixing screws
y
Figure 17 Installation of the options modules in the proof version
2.6.3 Iy module
Function
36
With the Iy-option module, the current actuator position can be output
as a two wire signal I
= 4 to 20 mA – potentially isolated from the
y
standard controller. The dynamic control of the I
error self--reporting.
module makes it also
y
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Design and method of operation
Installation
2.6.4 Alarm module
Function
The Iymodule (3) is pushed in to the bottom compartment of the module rack up to the stop and connected by the enclosed 6-wire ribbon
cable (6) to the motherboard (see figure 16, page 33).
The alarm module contains
S 3 digital outputs and
S 1 digital input
The digital outputs serve to output fault messages and alarms. The
configuration is described in chapter 4.4, page 98, with the parameters
44 to 54.
By an external signal applied at digital input (DI2) the actuator can be
blocked or driven to its limit positions for example depending on the
configuration. The configuration is described in chapter 4.4, page 98,
with the parameters 43.
The alarm module is available in two versions:
S explosion protected for connecting to switching amplifier
EN 60947- -5--6
Installation
S non--explosion protected for connection to voltage sources with a
maximum 35 V
The semiconductor outputs of the alarm module report an alarm (signal
state Low) by switching off with high resistance. They are conductive in
the High state (without alarm). The dynamic control makes them error
self--reporting.
The outputs are potentially isolated from the basic circuit and each
other.
The digital input is double.
S one potential isolated for voltage level
S one not potential isolated for floating contacts
These two inputs are designed as logic OR links.
The alarm module (4) is pushed in underneath the motherboard into the
module rack up to the stop and connected by the enclosed 8-wire ribbon cable (5) to the motherboard (see figure 16, page 33).
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Design and method of operation
2.6.5 SIA module
The SIA module contains three digital outputs.
Function
Installation
A collected fault message (see alarme module) is output via a digitaloutput. The floating digital output is implemented as a self error reporting semiconductor output.
The other two digital outputs are used for reporting two mechanically
adjustable limit values (L1, L2) by slot initiators. The two binary outputs
are electrically independent of the rest of the electronics.
(Slot Initiator Alarm module) Proceed as follows for installation:
1. Remove all the electrical connections from the motherboard (2).
2. Loosen the two fixing screws (2.1) of the motherboard.
3. Snap out the motherboard by carefully bending the four holders.
4. Insert the SIA-module (7) from above up to the top pcb rail of the
container.
5. Push the SIA module in the pcb rail of the container about 3 mm to
the right.
6. Screw the special screw (7.1) through the SIA module into the axle
of the positioner (Torque: 2 Nm):
CAUTION
The pin pressed into the actuating disc bearing (12) must be adjusted
to just before touching with the special screw. The actuating disc bearing and the special screw must then be turned simultaneously so that
the pins slot into the special screw.
7. Place the insulating cover (10) over the SIA module underneath
the surface of the motherboard at the container wall on one side.
The recesses in the insulating cover must slot into the corresponding lugs on the container wall. Place the insulating cover on the
SIA module by carefully bending the container walls.
8. Snap the motherboard into the four holders and screw it tight again
with the two fixing screws (2.1).
9. Make all the electrical connections between the motherboard and
the options with the ribbon cables provided and between the motherboard and potentiometers with the potentiometer cable.
10. Fix the enclosed module cover instead of the standard version with
the two screws (1.1).
38
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Page 41
1 1. Select the plates which already exist on the standard version of the
12. Make the electrical connections.
Setting the two limit values:
Design and method of operation
module cover from the set of plates enclosed. Stick the selected
plates according to the standard version to the mounted module
cover. In the case of the version which doesn’t feature explosion
protection, stick the warning sign (figure 2) onto the side of the
ground plate opposite the typeplate.
.
.
NOTE
Connect a suitable display instrument such as the Initiator--Tester type
2/Ex made by Peperl+Fuchs to the terminals 41 and 42 or terminals 51
and 52 of the SIA module to be able to see the switching state of the
slot initiators.
1. Drive the actuator to the first desired mechanical position.
2. Adjust the top actuating disc (7.2) by hand until the output signal
on terminals 41 and 42 changes.
3. Drive the actuator to the second desired mechanical position.
4. Adjust the bottom actuating disc (7.3) by hand until the output signal on terminals 51 and 52 changes.
NOTE
If you turn the actuating disc beyond the switching point up to the next
switching point, you can set a high-low or a low-high change.
To avoid the actuating discs being accidentally adjusted during operating, they are relatively sluggish. The following remedy might be of help
if you are having trouble with the adjustment: open and close the actuator several times while holding the actuating discs. T his temporarily
reduces the friction. This allows an easier and finer adjustment.
2.6.6 Mechanical limit switch module
The mechanical limit switch module contains the following:
S A binary output for the output of a group error message)
S Two switches for signaling two limit values that can be set mechani-
cally. These two switches are electrically independent from the rest
of the electronic system
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Design and method of operation
Installation
CAUTION
The following maximal values only refer to the clamps 41 and 42 as
well as the clamps 51 and 52.
Maximal voltage (not Ex) AC 250 V or DC 24 V
Maximal current (not Ex) AC/DC 4 A
Maximal voltage (Ex) DC 30 V
Maximal current (Ex) DC 100 mA
When you supply one circuit breaker with extra--low voltage (AC
< 16 V or DC < 35 V) and the other with low voltage, you ensure that
the cable insulation is doubled.
When operating the switch with low voltage, you must position the low
voltage circuits so that they are separated from the extra--low voltage
circuits.
Follow the instructions below for installation:
1. Remove all electrical connections on the motherboard (2).
2. Loosen carefully both fixing screws (2.1) for the motherboard.
3. Insert the limit switch module (7) from above until it reaches the
upper printed circuit board rail of the container.
4. Snap put the motherboard (2) by carefully bending the four holders.
5. Push the mechanical limit switch module (7) in the printed circuit
board rail of the container ca. 3 mm towards the right
6. Screw the special screw (7.1) through the mechanical limit switch
module into the axle of the positioner (torque: 2 Nm).
CAUTION
The pin pressed into the actuating disc bearing (12) must be adjusted just before it touches the special screw (7.1) In order that the
pin slot into the special screw, you must then turn the actuating
disc bearing and the special screw simultaneously
40
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Design and method of operation
7. Place the insulating cover (10) over the mechanical limit switch
module underneath the surface of the motherboard onto the container on the wall. The recesses in the insulating cover must slot
into the corresponding lugs on the container wall. Place the insulating cover on the mechanical limit switch module by carefully bending the container walls.
8. Snap the motherboard board into the four holders and screw it tight
again with the two fixing screws (2.1).
9. Make sure all electrical connections between the motherboard and
the options using the ribbon cables provided and between the motherboard and potentiometer using the potentiometer cable.
10. Fix the enclosed module cover (1) instead of the standard version
using the two screws (1.1).
.
.
NOTE
To prevent premature wearing of the fixture by the self--tapping screws
(1.1), the following method of mounting the module cover (1) has proven effective:
S Turn the screws counterclockwise until you feel them snap into the
thread.
S Tighten both screws carefully in a clockwise direction
NOTE
Before connecting up the limit contact module, ensure that:
S only qualified personnel connect and set the limit contact module.
S all cables are de--energized.
S the cables are stripped so that the insulation is flush with the termi-
nal when plugging in the wires.
S the ends of stranded wires have sleeves
S the connection cables are insulated according to the permitted cur-
rent load.
S the permissible working temperature of the cables exceeds the ma-
ximal ambient temperature by minimum 25 _C.
S the Ex--version is only allowed to be operated in intrinsically safe
circuits with approved switching amplifiers.
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Connection
1. Loosen the screw (1) on the cover (2).
2. Push the cover (2) till it reaches the front stop.
3. Screw each cable tight in the appropriate terminal.
4. Push the cover (2) till it stops at the motherboard.
5. T ighten the screw (1) of the cover (2).
6. Fix the cables of each switch in pairs on the mounting eye using
the cable binders provided (3).
41
Page 44
Design and method of operation
Figure 18 Cable connection
Setting the two limit values:
1. Drive the actuator to the first desired mechanical position.
2. Adjust the top actuating disc (7.2) by hand until the output signal
on terminals 41 and 42 changes.
.
3. Drive the actuator to the second desired mechanical position.
4. Adjust the bottom actuating disc (7.3) by hand until the output signal on terminals 51 and 52 changes.
NOTE
To avoid the actuating discs (7.2/7.3) being accidentally adjusted during operation, they are relatively sluggish. The following remedy might
be of help if you are having trouble with the adjustment: open and
close the actuator several times while holding the actuating discs. This
temporarily reduces the friction. This allows an easier and finer adjustment.
42
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Page 45
2.6.7 EMC filter module
The positioner can also be driven by an external position sensor (potentiometer or NCS) (see page 50 ”3.3.2 Instructions for using positioners which are exposed to strong accelerations or vibrations”). An EMC
filter module, order number C73451--A430--D23, is required for this.
2.6.8 Accessories
Design and method of operation
Y1
Y1
PZ
Figure 19 Manometer block (left for single-acting, right for double-acting actuators)
Manometer block
The manometer block for single-acting actuator contains two
manometers which are screwed to the lateral pneumatic connection of
the positioner with O-rings. The values for the input pressure (supply
air PZ) and output pressure (actuating pressure Y1) are displayed.
The manometer block for double-acting actuators contains three
manometers which are screwed to the lateral pneumatic connection of
the positioner with O-rings. The values for the input pressure (supply
air PZ) and output pressure (actuating pressure Y1 and Y2) are
displayed.
PZ
Y2
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Design and method of operation
44
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Page 47
Preparing for operation
Preparing for operation
This chapter describes all the preparations necessary for operating the
positioner.
3.1 Instrument identification (type key)
The order number of the positioner is printed on the rating plate and on
the packaging. Compare this with the order number in chapter 8.1,
page 168
Installation of any modules required is described in chapter 2.6,
page 31 of this technical manual.
3.2 Dimensional drawings
3
60
50x4xM6
h9
7
9 deep
1
3729
48
M20 x 1.5 or NPT adapter
15
14,5
95
2
Y1
65
80
13,5
96,6
23
88,5
E
58
33
M8, 9 deep
182
8
7
38,5
Y1
PZ
Y2
All air connections
G 1/4 or 1/4” NPT
29,5
72
29,5
11, 2
Figure 20 Dimensional drawing version plastic housing 6DR5xx0
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Preparing for operation
14
25
12
10
5
3x
G1/4or
1/4” NPT
9,5
90
79,5
2xM6
29,5
58,75
82
Thread depth 5.5
50
5,3
20,5
M4
3,5
9,5
9
5
Figure 21 Dimensional drawing terminal strip for plastic housing
50x4xM6
9 deep
2
Y1
65
E
M8, 9 deep
23
58
182
13,5
96,6
88,5
8
7
38,5
7
34,5
M20 x 1.5 or NPT--adapter
h9
1
14,5
84
29
27,5
All air connections
G 1/4 or 1/4” NPT
15
12
6,5
Y1
29,5
29,5
11, 2
59
14
PZ
Figure 22 Dimensional drawing version metal housing 6DR5xx1
46
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Preparing for operation
M8, 14 deep (4x)
43
65
M6, 11 deep (4x)
129,5
23
7,75
50
60
∅
3,5
All air connections
1/
G
or1/4”NPT
4
25
34
4,5
M6, 8 deep (2x)
M20, M25 or
1/
”NPT (2x)
2
10,25
19,25
1)
7,5
25,7
1)
Connection 238/Y2 only in
E
12
87,2
14,3
33,5
7
33,5
double--acting version
158,5
82,5
∅ 136.5
235,3
∅ 8h9
Figure 23 Dimensional drawing for positioner with metal housing in explosion proof version 6DR5xx5
3.3 Assembly
General
WARNING
!
To avoid injury or mechanical damage to the positioner/mounting kit,
the following order must be observed for assembly:
1. Mechanical fitting of positioner this chapter
2. Connection of electric power supply see chapter 3.4, p. 62
3. Connection of pneumatic power supply see chapter 3.5, p. 73
4. Put into operation see chapter 3.6, p. 74
Please also observe the warning on page 10 and 62!
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Preparing for operation
.
!
NOTE
The positioner will be equipped at the factory and delivered complete
with the necessary options at the customer’s request. Options modules
may only be retrofitted by our service technicians.
The positioner must be assembled -- especially in a moist environment
-- in such a way as to rule out freezing of the positioner axle at low
ambient temperature.
The operating keys must be covered to prevent liquid getting in.
WARNING
In the combination of components it must be ensured that only
positioners and options modules are combined which are approved for
the respective area of application. This applies especially for safe
operation of the positioner in areas in which the atmosphere is
potentially explosive (zone 1 and 2). The instrument categories (2 and
3) of the instrument itself and those of its options must be observed.
In addition, you must always make sure that no water gets into an open
housing or screw--type gland. This may be the case for example when
the positioner cannot be finally assembled and connected immediately.
It generally applies that the positioner may only be operated with dry
compressed air. Therefore use the normal water traps. An additional
drying unit may even be necessary in extreme cases. This is
particularly important when operating the positioner at low ambient
temperatures. Please set the purge air switch (on the valve block
above the pneumatic terminals) additionally to the ”OUT” position.
Use a sufficiently rugged console (e.g. plate thickness > 4 mm with
reinforcements) for part--turn actuators and the mounting kit ”linear
actuator” or integrated connection for linear actuators.
3.3.1 Instructions for using positioners in a wet environment
This information gives you important instructions for the assembly and
operation of the positioner in a wet environment (frequent, heavy rain
and/or prolonged tropical condensation) in which the IP66 degree of
protection is no longer sufficient and especially when there is a danger
that water may freeze.
To prevent water getting into the instrument in normal operation (e.g.
through the exhaust air openings) or the display being poorly legible,
please avoid the unfavorable installation positions illustrated in
figure 24.
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Figure 24 Favorable and unfavorable installation positions
If conditions oblige you to operate the positioner in a unfavorable
installation position, you can take additional precautionary measures to
prevent penetration by water.
Preparing for operation
Procedure
.
NOTE
Never clean the positioner with a high pressure water jet because the
IP66 degree of protection is inadequate protection for this.
The necessary additional measures to prevent penetration by water
depend on the installation position chosen and you may additionally
require:
S screw--type gland with sealing ring (e.g. FESTO: CK --1 / 4--PK--6)
S plastic hose approx. 20 to 30 cm (e.g. FESTO PUN-- 8X1,25 SW)
S cable straps (number and length depends on local conditions)
S Connect the pipes in such a way that rain water which runs along the
pipes can drip off before it reaches the terminal strip of the positioner.
S Check the electrical connections for perfect firm contact.
S Check the seal in the housing cover for damage and contamination.
Clean and replace if necessary.
S Mount the positioner if possible so that the sinter bronze silencer faces
downwards on the underside of the housing (vertical installation
position). If this is not possible, the silencer should be replaced by a
suitable screw--type gland with a plastic hose.
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Preparing for operation
Assembly of the screw--type gland with plastic hose
S Unscrew the sinter bronze silencer from the exhaust air opening on
the underside of the housing.
S Screw the screw--type gland mentioned above into the exhaust air
opening.
S Mount the above mentioned plastic hose on the screw--type gland
and check the good fit.
S Fix the plastic hose with a cable strap to the fitting so that the
opening faces downwards.
S Make sure that the hose has no kinks and the exhaust air can flow
out unhindered.
3.3.2 Instructions for using positioners which are exposed to great accelerations or vibrations
NOTICE
for explosion proof versions:
Only adjust the outer friction clutch (8, Fig.17, page 36). The internal
friction clutch (8, Fig.16 page 33 ) is fixed and, for the explosion proof
version, must not be adjusted.
The electro--pneumatic positioner features a friction clutch and a switchable drive and is, therefore, universally applicable for part--turn and
linear actuators. That’s why it is not necessary to take a zero--point into
consideration when implementing part--turn actuators. Similarly, there is
no need to ensure that the extension is symmetrically attached when
implementing linear actuators. In both cases, the work space can be
adjusted afterwards via the friction clutch.
The switchable drive can be used to adjust the positioner for short or
long strokes.
Large accelerating forces can occur on fittings subject to heavy mechanical wear and tear, such as openings which could break off, valves
subject to heavy vibrations as well as beating blast pipes. In some cases, these forces can far exceed the specifications. In extreme cases,
these forces could even cause the friction clutch to shift.
For these cases, the positioner is equipped with a position--securing
device for holding the friction clutch in place. Furthermore, it is also
possible to lock the transmission ratio selector into position, thus preventing it from shifting due to the influences stated above.
50
Both setting options are designated accordingly by icons on additional
signs (see Fig. 25 page 51).
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Preparing for operation
Procedure
After you have mounted the positioner and commissioned it completely,
you can set the friction clutch torque as follows:
S Plug a conventional 4 mm wide screwdriver into a slot in the yellow
wheel.
S Then turn the yellow wheel to the left with the screwdriver until it
snaps in audibly. This increases the torque of the friction clutch.
S A fixed friction clutch is recognizable from an approx. 1 mm wide
gap between the yellow and black wheel.
S If you have to make a zero point setting, e.g. after changing the
drive, please reduce the torque first by turning the yellow wheel to
the right stop. After the zero point setting, you can fix the friction
clutch as described above.
To lock the transmission ratio selector, takt the unit as factory set and
do as follows:
S Using a conventional flat headed screwdriver (approx. 4 mm wide)
turn the yellow wheel underneath the clamps to the left or right
according to your chosen setting (either 33_ or 90_) until it snaps in
audibly.
S In order to set the transmission ratio selector any locks in place
must first be released. Hence the yellow wheel must first be put into
the original factory set position in order to reset the transmission
ratio selector if necessary, e.g. after replacing the actuator.
90_
(1)
90
33
33_
(1) Transmission ratio switch interlock
(2) Open
(3) Friction clutch
(4) Close
Figure 25 Adjustable retaining device for the friction clutch
(2)
(3)
(4)
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Preparing for operation
External position
detection
Applications in which the measures described above are inadequate
are also conceivable. This applies for instance with continuous and
heavy vibration, increased or too low ambient temperatures and in the
case of nuclear radiation.
The separate attachment of position displacement sensor and
controller unit can help here. A universal component is available which
is suitable both for linear and part--turn actuators.
You require the following:
S The position detection system (order no. C73451--A430--D78). This
consists of a SIPART PS2 housing with integrated friction clutch,
built--in potentiometer and various dummy plugs and seals.
S or a Non--Contacting Position Sensor (e.g. 6DR4004--6N)
S The controller unit, any positioner version.
S The EMC filter module, this is a set together with cable clips and
M--20 screw- -type cable gland and has the order number
C73451--A430--D23. The EMC filter module must be installed in the
positioner. The installation instructions enclosed with the EMC filter
module explain how to assemble the components.
S A 3- -wire cable for connecting the components.
This EMC filter module always has to be used for the controller unit
whenever the external position detection unit C73451-A430-D78 is to
be replaced by a random drive--mounted potentiometer (resistance value 10 kOhm) or if a NCS sensor is to be installed.
WARNING
!
The explosion proof version may not be run together with the external
position detection syst em.
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3.3.3 Mounting kit ”linear actuator” 6DR4004--8V and 6DR4004--8L
The scope of delivery of the mounting kit” linear actuator IEC 534
(3 mm to 35 mm)” are contained (ser. no. see figure 26, page 55):
Ser. no. pieces Designation Note
1 1 NAMUR mounting kit bracket
IEC534
2 1 Pick--up bracket Guides the roller with carrier pin and turns lever
3 2 Clamping assembly Mounting of pick--up bracket on actuator spindle
4 1 Carrier pin Assembly with roll (5) on lever (6)
6 1 Lever NAMUR Forstrokerange3mmto35mm
7 2 U bolt Only for actuators with columns
8 4 Hexagon head screw M8 x 20 DIN 933--A2
9 2 Hexagon head screw M8 x 16 DIN 933--A2
10 6 Lock washer A8 -- DIN 127--A2
11 6 Flat washer B 8,4 -- DIN 125--A2
12 2 Flat washer B 6,4 -- DIN 125--A2
14 1 Spring washer A6 -- DIN 137A--A2
15 1 Lock washer 3.2 -- DIN 6799--A2
16 3 Spring washer A6 -- DIN 127--A2
17 3 Socket cap screw M6 x 25 DIN 7984--A2
18 1 Hexagon nut M6 -- DIN 934--A4
19 1 Square nut M6 -- DIN 557--A4
21 4 Hexagon nut M8 -- DIN 934--A4
Standardized connection for mounting console with
ledge, column or plane surface
arm
For stroke ranges> 35 mm to 130 mm (special
delivery), lever 6DR4004--8L is required
additionally
3.3.4 Assembly p rocedu re (see figure 26, page 55)
1. Mount clamping assembly (3) with hexagon socket cap screws
(17) and lock washer (16) on the actuator spindle.
2. Insert the pick--up bracket (2) into the recesses of the clamping
assembly. Set the necessary length and tighten the screws so that
the pick--up bracket can still be shifted.
3. Insert the premounted pin in the lever (6) and assemble with nut
(18), spring washer (14) and washer (12).
4. The value of the stroke range specified on the actuator or if this
does not exist as a scaling value, the next greatest scaling value is
set. The center of the pin must be in line with the scaling value.
The same value can be set later under parameter 3.YWAY in
commissioning to display the way in mm after initialization.
5. Assemble the hexagon socket cap screw (17), spring washer (16),
washer (12) and square nut (19) on the lever .
6. Push the premounted lever onto the positioner axle up to the stop
and fix with the hexagon socket cap screw (17).
7. Fit the mounting bracket (1) with two hexagon head screws (9),
lock washer (10) and flat washer (1 1) on the rear of the positioner.
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Preparing for operation
8. Selection of the row of holes depends on the width of the actuator
yoke. The roll (5) should engage in the pick--up bracket (2) as
close as possible to the spindle but may not touch the clamping
assembly.
9. Hold the positioner with the mounting bracket on the actuator so
that the pin (4) is guided within the pick--up bracket (2).
10. Tighten the pick--up bracket.
1 1. Position the mounting parts according to the type of actuator.
-- Actuator with ledge: Hexagon head screw (8), flat washer (11)
and lock washer (10).
-- Actuator with plane surface: Four hexagon head screws (8), flat
washer (11) and lock washer (10).
-- Actuator with columns: Two U bolts (7), four hexagon nuts (21)
with flat washer (11) and lock washer (10).
12. Secure positioner onto the yoke using the previously positioned
mounting parts.
.
NOTE
Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke center as possible. You can use the
lever scale as orientation. If no symmetrical mounting is possible it
must be guaranteed that the horizontal lever position is passed
through within the stroke range.
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Preparing for operation
2
16
17
1)
3
Without explosion proof version
11
10
9
1
17
16
12
19
2)
18
14
12
6
4
3)
Explosion proof version:
11
10
9
1
4)
11
10
9
11
10
9
Figure 26 Assembly procedure (linear actuator)
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Preparing for operation
1
10
8
Mounting on yoke
11
with ledge
5)
11
Mounting on yoke
with plane surface
11
Mounting on yoke
with columns
10
8
10
7
21
as required
Figure 26 Assembly procedure (linear actuator) continued
3.3.5 Mounting kit ”part--turn actuator” 6DR4004--8D
The scope of delivery of the mounting kit ”part--turn actuator” contains (ser. no. see figures 27
and 28):
Ser. no. Pieces Designation Note
2 1 Coupling wheel Mounting on position feedback shaft of the
SIPART PS2
3 1 Carrier Mounting on end of actuator shaft
4 1 Multiple plate Indication of actuator position, comprising 4.1
and 4.2
4.1 8 Scales Different divisions
4.2 1 Pointer mark Reference point for scale
14 4 Hexagon head screw DIN 933 -- M6 x 12
15 4 Lock washer S6
16 1 Fillister head screw DIN84--M6x12
17 1 Washer
DIN 125 -- 6.4
18 1 Hexagon socket head screw Premounted with coupling wheel
19 1 Allen key For item 18
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3.3.6 Assembly p rocedu re (see figure 27 and figure 28)
1. Attach VDI/VDE 3845 mounting console ((9), actuator--specific,
scope of delivery actuator manufacturer) onto rear of positioner
and secure using hexagon head screws (14) and lock washers
(15).
2. Adhere pointer (4.2) onto mounting console in the center of the
centering hole.
3. Push the coupling wheel (2) onto positioner axle, pull back by
about 1 mm and tighten the hexagon socket head screw (18) with
the Allen key provided.
4. Place the carrier (3) onto the end of the actuator and secure using
Fillister head screw (16) and washer (17).
5. Carefully place positioner with mounting console onto the actuator
such that the pin of the coupling wheel engages in the driver.
6. Align the positioner/mounting console assembly in the center of the
actuator and screw tight.
(Screws not included in delivery; they are part of the actuator
mounting console!)
Preparing for operation
7. Following startup as described in Chapter 3.6, page 74: Drive the
actuator to the end position and adhere scale (4.1) on the coupling
wheel (2) according to direction of rotation and part--turn actuator.
The scale is self--adhesive!
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Preparing for operation
9
1)
3
15
14
2
18
2)
16
17
3)
2
3
4)
Figure 27 Assembly procedure (part--turn actuator)
2
4.1
0%20 40 60 80 100%
5)
58
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Preparing for operation
15
14
9
1)
16
17
3
2)
18
2
3)
2
4.1
2
0%20 40 60 80 100%
3
4)
5)
Figure 28 Assembly procedure for explosion proof version (part--turn actuator)
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Preparing for operation
CUT A -- B
4.2 14,15
Positioner
part--turn actuators
2 Clutch wheel 10 Feedback shaft
3 Driver 14 Hexagon--head screw M6×12
4 Multiple--purpose plate 15 Retaining washer S6
4.1 Scale 16 Round--head screw M6×12
4.2 Pointer mark 17 Washer
9 VDI/VDE 3845 mounting bracket 18 Socket--head cap screw
Figure 29 Mounted positioner for part--turn actuators
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fastening level
positioner
Preparing for operation
4mm
M6
4
part- -turn actuator
4 35
F05--Lkr.-- 4 50
+0,1
25
4
12
6,5
Figure 30 Attachment of part--turn actuator, mounting console (scope of delivery actuator manufacturer),
dimensions
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Preparing for operation
3.4 Electrical connection
.
!
NOTE
Any necessary options modules must be installed before electrical
connection (see chapter 2.6, page 31).
N.B.: The transmission ratio selector can only be set when the
positioner is open. Therefore check this setting before closing the
positioner.
WARNING
The specifications of the examination certificate valid in your country
must be observed.
Electrical connection in hazardous areas
Laws and regulations valid in your country must be observed for the
electrical installation in explosions hazardous areas. In Germany these
are for example:
-- Working reliability regulations,
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079--14 (in the past VDE 0165, T1).
-- The certificate of conformity
If the intrinsically safe version is operated with a higher operating
voltage by mistake, the positioner must no longer be used for
intrinsically safe application.
The explosion proof positioner may only be supplied with electrical
power in areas in which the atmosphere may be potentially explosive
when the housing is closed.
The feed--though openings in the explosion proof version for the
electronic connections must be sealed with EEX--d certified cable
glands or EEx--d certified plugs or an ignition lock must be mounted at
a maximum distance of 46 cm (18 inches) when using the
”conduit”--system.
The plastic housing is metal lined to increase the electromagnetic
compatibility (EMC) against high frequency radiation. This screen is
connected electrically to the threaded bushes shown in figure 31, page
63.
The specified noise immunity and noise emission are only ensured if
the bus shield is fully effective.
This includes connecting the shields with the metallic connections of
the positioner with PROFIBUS PA, but also routing the shield to the
terminal boxes, distributors, DP/PA coupler or DP/PA link.
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Preparing for operation
CAUTION
!
To discharge impulses under fault conditions, the positioner must be
connected via a low resistance to an equipotential bonding (ground
potential). For this the positioner in plastic housing is provided with an
additional cable. Connect this cable using the cable clip to the
PROFIBUS cable shield and to the equipotential bonding.
Devices in metal housings have a corresponding terminal on the
outside of the housing, which also must be connected to equipotential
bonding.
Provide for suitable potential equibonding between the hazardous and
non--hazardous areas for applications in areas where there is a risk of
explosions.
Figure 31 Base plate
Fitting the bus cable
Normal, intrinsically safe and zone 2
versions.
1. Isolate the bus cable as shown in figure
32, page 64.
2. Open the positioner housing by undoing
the four cover screws.
3. Insert the prepared bus cable through the
cable gland.
4. Secure the shield with the cable clip and
the two screws to the housing.
Shield
Explosion proof version
1. Isolate the bus cable as shown in figure
32, page 64.
2. To open the positioner, the cover catch
(12) must be undone and the screw cover
unscrewed.
3. Insert the prepared bus cable through the
Ex--d--certified cable gland *)
4. Secure the shield with the cable clip and
the two screws to the housing.
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Preparing for operation
5. Tighten the cable gland. 5. Tighten the Ex--d--certified cable gland. *)
6. Connect the red and green wires as
shown in figure 33, page 65 to terminals 3
and 7 of the motherboard (the polarity is
immaterial).
for positioner in normal version
and in explosion proof version
10
6. Connect the red and green wires as
shown in figure 35, page 66 to terminals 6
and 7 of the motherboard (the polarity is
immaterial).
*) if the Conduit Tube System is being used, refer to the
relevant instructions.
a
5
Buscable 6XV1 830--5AH10
or 6XV1 830--5BH10
a = 80 in normal version (without Ex and without Ex i)
a = 120 in explosion proof version (Ex d)
Figure 32 Preparation of bus cable
For error--free communication the bus must be terminated at both ends
with a bus terminator. At the end nearest the control system, this is
already assured by the terminator contained within the coupling or link.
At the far end of the bus this must be achieved by fitting an additional
terminator.
So as to avoid potential differences between individual equipment parts
and thus the risk of functional impairment, a suitable potential bonding
is to be provided. Information regarding dimensions and types can be
found in DIN VDE 0100 parts 410 and 540.
.
NOTE
Use standard M20 x 1.5 cable gland nuts to ensure leakage (IP- protection of the housing) and for the necessary tensile strength use
only cables with a cable diameter ≥ 8 mm, or for smaller diameters
use a suitable sealing insert.
For the NPT version, the positioner will be delivered with an adapter.
Make sure that when fitting a part into the adapter, that the maximum
permissible torque of 10 Nm is not exceeded.
Cable shield
64
NOTE for use in zone 2:
Non--sparking equipment for Zone 2 may not be connected or
disconnected under power in normal operation.
However, during installation or repair work the positioner may be
connected or disconnected even under power (see also certificate for
zone 2).
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for positioner in normal version:
1 Bus cable
2 Cable clip
3BasicPCB
4 Module cover
5Plate
6 Terminal block
7 Ground potential
8 Cable glands
Preparing for operation
Figure 33 Bus cable connection
for positioner in explosion proof version
Base plate
Cable shield
Cable clip
Figure 34 Bus cable connection for positioner in explosion proof version
Bus cable
EEx d certified cable inlets
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Preparing for operation
Non--hazardous area
Approved associated apparatus
or barrier
+
≤ 30 V
--
EEx
PROFIBUS PA
EEx
DP/PA coupling
Figure 35 Electric connection of basic device with in intrinsically safe version
Non--hazardous area
≤ 24 V
+
--
≤ 30 V
Hazardous area zone 1
81
Input: Safe position
82
6
7
8
+
9
10
81
82
3V
Hazardous area
Input: Safe position
Positioner
Binary input 1
≤ 32 V
10
6
7
8
+
9
3V
PROFIBUS PA
DP/PA coupling
Figure 36 Electric connection for positioner in explosion proof version or in type of explosion protection ”n”
version
Safety position
The positioner is equipped with an additional input (terminal 81 [+] and
Positioner
Binary input 1
terminal 82 [--]) for driving to the safety position. After activating this
function this input must be supplied with uninterrupt +24 V, to allow
normal positioning operation.
If this power supply is switched off or drops out, the air exhaust valve is
automatically opened and the drive will move to the pre- -arranged
safety position, so that the drive cannot be activated using the keys on
the control unit or by means of the master switch. The communication
with the Master is still possible.
This function is activated by the coding bridge on the motherboard.
This is accessible after removing the module cover and must be moved
from the right position (as delivered) to the left position.
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3.4.1 Connection variant: options in positioner in non--intrinsically safe
and explosion proof version
Current output
+
U
Figure 37 I
≤35 V
H
+
module 6DR4004--8J, non Ex
y--
Binary inputs and outputs
+13 V
+
≤30 V
+4.5 V
+
≤35 V
616261
62
Alarm module
6DR4004--8A
11
12
+
21
22
1K
31
32
E
J
Iy--module:
6DR4004--8J
3V
≥1
Fault
message
Binary input 2
+
≤35 V
+
≤35 V
Figure 38 Alarm module 6DR4004--8A, non Ex
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42
51
52
1K
Limit A1
1K
Limit A2
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Preparing for operation
SIA module
SIA module:
6DR4004--8G
+
<35V
+
8.2 V
+
8.2 V
Figure 39 SIA module 6DR4004--8G, non Ex
31
32
41
42
51
52
Mechnical limit switch module
+
<35V
=
31
32
1K21
10K
Limit switch module
6DR4004-8K
1K21
10K
Fault
message
Limit A1
Limit A2
Fault message
+
max. AC 250 V
DC 24 V
Figure 40 Mechanical limit switch module 6DR4004--8K, non Ex
AC/DC 4 A
+
max. AC 250 V
DC 24 V
AC/DC 4 A
41
42
51
52
Limit A1
Limit A2
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Preparing for operation
3.4.2 Connection variant: options in the positioner in intrinsically safe version
Current output
Non--hazardous area
EEx
U
J
U
H
≤30 V
+
Intrinsically safe power sources
Figure 41 I
module 6DR4004--6J, EEx i
y
Binary inputs and outputs
Hazardous area zone 1 or zone 2
+
616261
62
+
E
J
Iymodule:
6DR4004--6J
Hazardous area zone 1 or zone 2Non--hazardous area
Alarm module
6DR4004--6A
+
≤25.2 V
EEx
EEx
EEx
EEx
+
8.2 V
+
8.2 V
+
8.2 V
Intrinsically
safe
Switching
amplifier to
EN 50227
Figure 42 Alarm module 6DR4004--6A, EEx i
11
12
21
22
31
32
41
42
51
52
2K1
10K
2K1
10K
2K1
10K
≥1
Binary
input 2
3V
+
Fault
message
Limit A1
Limit A2
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Preparing for operation
SIA module
Non--hazardous area
EEx
+
8.2 V
Intrinsically
safe
Switching
amplifier to
EN 50227
+
8.2 V
EEx
+
8.2 V
EEx
Figure 43 SIA module 6DR4004--8G, EEx i
Mechnical limit switch module
Hazardous area zone 1 or zone 2
SIA module:
6DR4004--6G
2K1
31
32
41
42
51
52
10K
2K1
10K
2K1
10K
Fault
message
Limit A1
Limit A2
Non-hazardous area
Hazardous area zone 1 or zone 2
Intrinsically safe
Switching amplifier to
Mechanical limit switch module
6DR4004-6K
EN 60947--5--6
+
EEx
max. DC 8.2 V
31
32
10K
+
41
42
= I
U
max
max
DC 30 V
100 mA
+
51
52
=
U
I
max
max
DC 30 V
100 mA
Figure 44 Mechnical limit switch module 6DR4004--6K, EEx i
2K1
Fault
message
Limit A1
Limit A2
70
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Preparing for operation
3.4.3 Connection variant: options in the positioner in type of protection ”n” version
Current output
Non--hazardous area
+
U
H
≤ 30 V
Figure 45 I
module 6DR4004--6J, EEx n
y
Binary inputs and outputs
+
+
≤ 25,2 V
Hazardous area zone 2
+
616261
62
E
J
Iymodule
6DR4004--6J
Hazardous area zone 2Non--hazardous area
Alarm module
6DR4004--6A
11
12
≥1
BI2
+
8.2 V
+
8.2 V
+
8.2 V
Switching amplifier to EN60947--5--6
Figure 46 Alarm module 6DR4004--6A, EEx n
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21
22
31
32
41
42
51
52
10K
10K
10K
2K1
2K1
2K1
3V
+
Alarm
Limit A1
Limit A2
71
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Preparing for operation
SIA module
Non--hazardous area
+
8.2 V
+
8.2 V
+
Switching amplifier to EN60947--5--6
8.2 V
Figure 47 SIA module 6DR4004--6G, EEx n
Hazardous area zone 2
SIA module
6DR4004--6G
2K1
31
10K
32
41
42
51
52
Fault message
Limit A1
Limit A2
72
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3.5 Pneumatic connection
WARNING
!
For reasons of safety, the pneumatic power may only be supplied after
assembly when the positioner is switched to operating mode P manual
operation with electrical signal applied (as--delivered state, see
figure 57, page 94).
Preparing for operation
.
NOTE
Note the air quality! Oil--free industrial air, solid content < 30 μm, pressure
dew point 20 K below the lowest ambient temperature (chapter 7
”Technical Data”, page 161).
S Connect a manometer block for supply air and actuating pressure if
necessary.
S Connection by female thread G 1/4 DIN 45141 or 1/4” NPT:
P
Z
Y1 actuating pressure 1 for single-- and double--acting
Y2 actuating pressure 2 for double--acting actuators
E exhaust air outlet (remove silencer if necessary)
see figure 10 and 11, page 27.
Supply air 1.4 to 7 bar
actuators
S Safety position when the electric power supply fails:
single--acting: Y1 deaerated
double--acting: Y1 Max. actuating pressure
(supply air pressure)
Y2 deaerated
S Connect actuating pressure Y1 or Y2 (only in double--acting
actuators) according to the desired safety position.
.
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S Connect supply air to P
NOTE
In order for spring- -loaded pneumatic actuators to be able to reliably
exploit the maximum possible actuating path, the supply pressure must
be sufficiently greater than the maximum required final pressure of the
actuator.
After installing the device, check the pneumatic connections of the entire
assembly for leakage. Any leakage would cause not only continuous
consumption of compressed air but also would cause the positioner to
continually endeavor to compensate for the variance in position, leading
in time to premature wear of the whole control mechanism.
.
Z
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Preparing for operation
3.6 Commissioning
Once the positioner has been fitted to a pneumatic actuator, it must be
provided with electrical and pneumatic auxiliary power.
The electrical auxiliary power can be provided via a bus interface or
separate power source with 15 to 30 V DC. Then you can then adapt
the positioner to the respective actuator by parameterizing and
initializing it and setting the bus address. Communication with a master
is not necessary for this.
If the positioner has not been initialized it will be in the ”P Manual
Mode” operating mode (which can also if necessary be attained by
”PRST”) -- ”NOINI” will flash.
This initialization can be effected in three different ways:
S Automatic initialization
Initialization takes place automatically. Hereby the positioner
determines the direction of action, the stem path and the angle of
rotation, the adjusting times of the actuator one after the other and
adapts the control parameters to the dynamic behavior of the
actuator.
.
S Manual initialization
The stem travel or angle of rotation of the actuator can be set
manually, the other parameters are determined as in automatic
initialization. This function is useful in actuators with soft limit stops.
S Copying initialization data (positioner exchange)
The initialization data of a positioner can be read out and copied to
another positioner. This enables a defective device to be changed
without having to interrupt an ongoing process by initialization.
Only a few parameters need to be set in the positioner prior to
initialization. The others are defaulted so that they do not normally
need to be adjusted. You will have no problems with commissioning if
you observe the following points.
The possible operating modes and parameters, together with the
adjustment capabilities and their effects are described in chapter 4
page 91 ”Operation”.
NOTE
N.B.: The operating pressure should be at least one bar greater than is
necessary for closing/opening the valve during initialization. Jedoch
darf der Betriebsdruck nicht größer sein als der maximal zulässige Betriebsdruck des Antriebs.
74
N.B.: The transmission ratio selector can only be set when the
positioner is open. Therefore check this setting before closing the
housing.
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3.6.1 Preparations for linear actuators
1. Assemble the positioner with the appropriate mounting kit (see
chapter 3.3.3, page 39).
Preparing for operation
.
NOTE
Particularly important is the position of the transmission ratio selector
(7, figure 8, page 25) in the positioner:
Stroke Lever Position of the transmission ratio
selector
5to20mm short 33° (i.e. down)
25 to 35 mm short 90° (i.e. up)
40 to 130 mm long 90° (i.e. up)
2. Push the carrier pin (4, figure 26 (page 55) 2) onto the lever (6,
figure 26, 2) to the scale position corresponding to the rated stroke
or next highest position and screw the carrier pin tight with the nut
(18, figure 26, 2).
3. Connect the actuator and the positioner with the pneumatic lines
and supply pneumatic power to the positioner (figure 10 and 11,
page 27 ).
4. Connect the positioner to the PROFIBUS line (figure 35, page 66
and figure 36, page 66).
5. The positioner is now in the operating mode ”P--manual
operation” The current potentiometer voltage (P) is displayed in
percent in the top line of the display, e.g.: ”P12.3”, and ”NOINI”
flashes in the bottom line:
.
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6. Check the free running of the mechanics in the whole actuating
range by moving the actuator with the keys
to the respective end position.
NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.
7. Now move the actuator to the horizontal position of the lever. A
value between P48.0 and P52.0 should be visible in the display. If
this is not the case, adjust the friction clutch (8, figure 16, page 33)
until ”P50.0” is displayed with a horizontal lever . The more
accurately you hit this value, the more exactly the positioner can
determine the path.
and and driving
75
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Preparing for operation
NOTICE
for the explosion proof version:
Only adjust the outer friction clutch (8, Fig. 9, page 26). The internal
friction clutch (9, Fig. 8 page 25) is fixed and, for the explosion proof
version, must not be adjusted.
3.6.2 Automatic initialization of linear actuator
If you can move the actuator correctly, leave it standing in a central
position and start automatic initialization:
.
1. Press the operation mode key
you to the Configuration operating mode.
Display:
2. Switch to the second parameter by pressing the operation mode
key
Display:
NOTE
It is vital that this value corresponds to the setting of the transmission
ratio selector (8, figure 8, page 25) (33° or 90°).
briefly.
for longer than 5 s. This brings
or
76
3. Switch on to the following display with the operation mode key :
You only need to set this parameter if you want to have the total
stroke in mm displayed at the end of the initialization phase. To do
this, select the same value in the display to which you have set the
carrier pin to the scale on the lever.
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Preparing for operation
4. Switch on to the following display with the operation mode key :
5. Start initialization by pressing the key for longer than 5 s.
Display:
During the initialization phase ”RUN1”to”RUN5” appear one after
another in the bottom display (see also structograms figures 49,
page 85 to figure 52, page 88).
.
NOTE
The initialization process may last up to 15 minutes depending on the
actuator.
The initialization is complete when the following display appears:
The following display appears after pressing the operation mode key
briefly:
To e x i t t h e Configuration mode, press the operation mode key for
longer than 5 s. The software version is displayed after about 5 s. The
instrument is in manual operation after releasing the operation mode
key.
.
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NOTE
You can abort an ongoing initialization at any time by pressing the
operation mode key. Your previous settings are retained. All the
parameters are reset to the factory setting only after performing a
”Preset”.
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Preparing for operation
3.6.3 Manual initialization of linear actuator
The positioner can be initialized with this function without the actuator
being driven hard against the limit stop. The start and end positions of
the stem path are set manually. The other initialization steps
(optimization of the control parameters) run automatically as in
automatic initialization.
Manual initializ-tion procedure in
linear actuator
.
1. Make preparations as described in chapter 3.6.1, page 75 for
linear actuator. In particular, make sure by manuallydriving the whole
stem path that the displayed potentiometer setting moves
in the permissible range between P5.0 and P95.0.
Press the operation mode key
you to the Configuration mode.
Display:
3. Switch to the second parameter by pressing the operation mode
key
NOTE
It is vital that this value corresponds to the setting of the transmission
ratio selector (33_ or 90°).
briefly. One of the following displays appears:
for longer than 5 s. This brings
or
78
4. Switch on to the following display with the operation mode key:
You only need to set this parameter if you want to have the total
stroke in mm displayed at the end of the initialization phase. To do
this, select the same value in the display to which you have set
the carrier pin to the scale on the lever or the next highest position
in intermediate positions.
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Preparing for operation
5. Switch on to the following display by pressing the operation
mode key twice:
6. Start initialization by pressing the increment key for longer
than5s.
Display:
7. After 5 s the display changes to:
.
(The display of the potentiometer setting is shown here and below
as an example only).
Now move the actuator to the position which you want to define as
the first of the two end positions with the increment
decrement
accepts the current position as end position 1 and switches on to
the next position.
NOTE
If the message ”RANGE” appears in the bottom line, the selected end
position is outside the permissible measuring range. There are several
ways to correct the error:
S Adjust the friction clutch until ”OK” appears and press the operation
mode key again or
S move to another end position with the increment and decrement key
or
S abort initialization by pressing the operation mode key. You then have
to change to P manual operation and correct the stem path and the
displacement detection according to step 1.
key. Then press the operation mode key .This
and
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Preparing for operation
8. If step 7 was successful, the following display appears:
Now move the actuator to the position which you want to define as
the second end position with the increment
decrement key. Then press the operation mode key .This
enters the current position as end position 2.
and
.
NOTE
If the message ”RANGE” appears in the bottom line, the selected end
position is outside the permissible measuring range. There are several
ways to correct the error:
S move to another end position with the increment and decrement key
or
S abort initialization by pressing the operation mode key. You then have
to change to P manual operation and correct the displacement path
and the displacement detection according to step 1.
If the message ”Set Middl” appears, the lever arm must be driven to
horizontal position using the increment and decrement key and then
the operation mode key pressed. This sets the reference point of the
sine correction in linear actuators.
9. The rest of the initialization now runs automatically. ”RUN1” to
”RUN5” appear one after another in the bottom line of the display.
The following display appears on successful completion of
initialization:
80
The first line additionally contains the determined stroke in millimeters if
the set lever length was specified with parameter 3 YWAY.
5 INITM appears in the bottom line again after pressing the operation
mode key
operating mode.
To exit the Configuration mode, press the operation mode key
longer than 5 seconds. The software version is displayed after about
5 seconds. The instrument is in manual operation after releasing the
operation mode key.
briefly. This brings you back to the Configuration
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Page 83
3.6.4 Preparations for part--turn actuator
Preparing for operation
.
NOTE
Very important: Switch the transmission ratio selector in the
positioner (8, figure 8, page 25) to position 90° (normal angle for
part--turn actuator).
1. Mount the positioner with the appropriate mounting kit (see chapter
3.3.5, page 56).
2. Connect the actuator and the positioner with the pneumatic lines
and supply pneumatic power to the positioner (figure 10 and 11,
page 27).
3. Connect the positioner to the PROFIBUS line (Figure 35, page 66
and Figure 36, page 66).
4. The positioner is now in the operating mode ”P-manual
operation” The current potentiometer voltage (P) is displayed in %
in the top line of the display, e.g.: ”P12.3”, and ”NOINI” flashes in
the bottom line:
5. Check the free running of the mechanics in the whole actuating
range by moving the actuator with the keys
to the respective end position.
and and driving
.
NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.
3.6.5 Automatic initialization of part--turn actu ator
If you can move the actuator correctly through the actuating range,
leave it standing in a central position and start automatic initialization:
1. Press the operation mode key
brings you to the Configuration mode.
Display
for longer than 5 seconds. This
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Preparing for operation
2. Set the parameter with the key to ”turn”
Display:
3. Switch to the second parameter by pressing the operation mode
key
Display:
4. Switch on to the following display with the operation mode key :
briefly. This has set automatically to 90°.
.
5. Start initialization by pressing the key for longer than
5 seconds.
Display:
During the initialization phase ”RUN1”to”RUN5” appear one after
another in the bottom display (see also structograms in figure 49,
page 85 to figure 52, page 88).
NOTE
The initialization process may last up to 15 minutes depending on the
actuator.
The initialization is complete when the following display
appears:
82
The top value indicates the total angle of rotation of the actuator
(example 93.5°).
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Preparing for operation
The following display appears after pressing the operation mode key
briefly:
To e x i t t h e Configuration mode, press the operation mode key for
longer than 5 seconds. The software version is displayed after about
5 seconds. The instrument is in manual operation after releasing the
operation mode key.
.
NOTE
You can abort an ongoing initialization at any time by pressing the
operation mode key. Your previous settings are retained. All the
parameters are set to the factory setting only after performing a
”Preset”.
3.6.6 Manual initialization of part--turn actuators
The positioner can be initialized with this function without the actuator
being driven hard against the limit stop. The start and end positions of
the displacement path are set manually. The other initialization steps
(optimization of the control parameters) run automatically as in
automatic initialization.
Manual initializa-tion procedure in
part--turn actuators
1. Make preparations as described in chapter 3.6.4, page 81 for
part--turn actuators. In particular, make sure by manually driving
the whole displacement path that the displayed potentiometer
setting moves in the permissible range between P5.0 and P95.0.
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2. Press the operation mode key
brings you to the Configuration mode.
Display:
3. Set the parameter YFCT to ”turn” with the decrement key.
Display:
for longer than 5 seconds. This
83
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Preparing for operation
4. Switch to the second parameter by pressing the operation mode
key
Display:
briefly.
.
NOTE
Make sure that the transmission ratio selector is in position 90 °!
5. Switch on to the following display by pressing the operation mode
key
The following steps are identical with the steps 6) to 9) for
initialization of linear actuators.
After successful initialization the determined part--turn range
appears in the top display.
”5.INITM” appears in the bottom line again after pressing the
operation mode key
Configuration operating mode.
To exit the Configuration mode, press the operation mode key
for longer than 5 seconds. The software version is displayed after
about 5 seconds. The instrument is in manual operation after
releasing the operation mode key.
twice:
briefly. This brings you back to the
84
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3.6.7 Automatic initialization (structograms)
Preparing for operation
Linear actuator
Up Down
Figure 48 Direction of action of the actuators
The initialization procedure should be taken from the following
structogram (figure 49 to figure 52). The terms Open/Closed and
up/down in the structogram refer to the direction of action of the
actuators as illustrated in figure 48.
configure
start: press
>5s
1
Part--turn actuator
Closed
Open
move the actuator
into the travel range
with:
piezo valve 1 opens
RUN 1
dy > 4 % ?
yes
no
piezo valve 2 opens
dy > 4 % ?
yes
Figure 49 Automatic initialization, part 1
continue with:
no
t>60s?
yes
no
2
t>60s?
no
yes
manual intervention
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Preparing for operation
2
actuator
tolerance band
4% < dw < 10%
RUN 2
actuator moves
up--dw > 25 % ?
moves
into closed
position
?
yes
into open
position
hard stop
up < 97 % ?
yes
span
no
no
no
continue with:
turn friction clutch
until 0 appears
in the bottom line
of the display
continue with:
check
mechanics
1
yes
3
continue with:
Figure 50 Automatic initialization part 2 (in part--turn actuators)
86
manual intervention
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Preparing for operation
2
set lever vertical to stem with:arm
continue with:
actuator
tolerance band
RUN 2
actuator moves
moves
into closed
position
4% < dw
?
yes
into open
position
hard stop
up < 97 % ?
yes
no
no
continue with:
continue with:
correct height
adjustment or
turn friction clutch
until 0 appears
in the bottom line
of the display
set the next lowest travel
value on the lever and
check the setting of the
transmission ratio selector
no
yes
has friction
clutch
been
moved?
continue with:
1
span
up--dw > 25 % ?
yes
was the
vertical position
(to stem) of the lever
driven through
?
yes
3
no
continue with:
no
Figure 51 Automatic initialization part 2 (in linear actuators)
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set the next highest travel
value on the lever and
check the setting of the
transmission ratio selector
manual intervention
1
87
Page 90
Preparing for operation
3
determine travel times
display travel times
flashes
alternating
RUN 3RUN 4RUN 5
yes
within
5s?
no
yes
within
5s?
no
determine minimum
positioning increments
if leakage test of
actuator is desired
if setting of travel
times is desired
flashes
alternating
actuator comes to standstill
after
1 minute
continue with:
continue with:
or
set restrictor(s) to
change the travel
times
display of travel
times in s
display of leakage
in % / min
optimizing of transient behavior and
determining of prediction horizon
or
continue with:
configure
Figure 52 Automatic initialization, part 3
88
display of stroke in mm
or angle of rotation in degrees,
is also the identification for
complete initialization
manual intervention
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Preparing for operation
3.7 Copying initialization data (positioner exchange)
With this function you have the possibility of starting up a positioner
without running the initialization routine. This allows for example a
positioner to be changed on a running system in which automatic or
manual initialization cannot be performed without disturbing the
process.
NOTICE
Initialization (automatic or manual) should be performed as soon as
possible afterwards because only then can the positioner be optimally
adapted to the mechanical and dynamic properties of the actuator.
Data are transmitted from the positioner to be replaced to the
replacement instrument via the HART®--communication interface.
The following steps must be performed to exchange a positioner:
1. Read in and save instrument parameters and initialization data
(determined in initialization) of the instrument to be replaced with
PDM (Process Device Manager) or HART®--Communicator. This
step is unnecessary if the instrument has been parameterized with
PDM and the data have already been stored.
2. Fix the actuator in its momentary position (mechanical or
pneumatic).
3. Read and note the current position actual value of the positioner to
be changed. If the electronics are defective, determine the current
position by measuring on the actuator or valve.
4. Disassemble the positioner. Mount the lever arm of the positioner
on the replacement instrument. Mount the replacement instrument
on the fitting. Move the transmission ratio selector to the same
position as the defective instrument. Copy the instrument data and
initialization data from the PDM or handheld.
5. If the displayed actual value does not match the noted value of the
defective positioner, set the correct value with the friction clutch.
6. The positioner is now ready to operate.
The accuracy and dynamic behavior may be restricted in relation
to correct initialization. The position of the hard stops and the
related maintenance data may show deviations in particular.
Therefore initialization must be performed at the earliest
opportunity.
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Preparing for operation
90
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Operation
Operation
4.1 Display
.
4
The following chapter describes the operation of the positioner.
The LC display has two lines whereby the lines have different
segmentation. The elements of the top line consist of 7, those of the
bottom line of 14 segments. The display depends on the selected
operating mode (see chapter 4.3, page 94)
NOTE
If the positioner is operated in ranges with temperatures below --10 °C
the liquid crystal display becomes sluggish and the display refresh rate
is reduced considerably.
4.2 Input keys
.
Figure 54 shows you the various display options.
The meaning of further display capabilities is detailed in chapter 4.6
page 122.
The positioner is operated by three keys (figure 55, page 93) the
function of which depends on the selected operating mode. In the
explosion proof version of the positioner the input keys are underneath
a key cover which can be lifted up after loosening the cover screw.
NOTE
The input keys of the explosion proof version must be covered to
prevent liquid getting in. The IP66/NEMA4x degree of protection is not
guaranteed when the housing is open or the key cover is open.
The housing cover must be removed to operate the keys in the normal
and intrinsically safe versions of the positioners.
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Operation
Figure 54 Meaning of the various display options
92
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1
23 4
1 Display
2 Operation mode key
3 Decrement key
4 Increment key
Figure 55 Display and input keys of the positioner
Explanations of the input keys
S The operation mode key (manual key) serves to switch over the
operating mode and pass on parameters.
Operation
.
Firmware version
NOTE
By pressing and holding the operation mode key and additionally
pressing the decrement key , you can select the parameters in reverse
order.
S The decrement key serves to select parameter values in
configuration and to move the actuator in manual operation.
S The increment key serves to select parameter values in
configuration and to move the actuator in manual operation.
The current firmware state is displayed when you exit the configuration
menu.
Figure 56 Firmware version
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Operation
4.3 Operating modes
The positioner can be operated in five operating modes.
1. P--manual mode (ex--factory state)
2. Configuration and initialization
3. Manual mode (MAN)
4. Automatic (AUT)
5. Diagnostic display
Figure 57 gives you an overview of the possible operating modes and
the change between them.
Figure 57 Change between the operating modes
94
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Operation
P--manual mode
(ex--factory state)
Configuration and
initialization
.
The display of the positioner shows you the current potentiometer
setting in the top line and ”NOINI” flashes in the second line. You can
move the actuator with the decrement and increment key . In order
to adapt the positioner to your actuator, you have to change to the
Configuration menu. See also chapter 3.6, page 74 ”Commissioning”.
Manual and automatic mode or output of alarms and position feedback
are possible after successful initialization.
To go to the Configuration menu, press the operation mode key
at least 5 seconds. In the Configuration menu you can adapt the
positioner individually to your actuator and start initialization. Only a few
parameters need to be set in the positioner prior to initialization. The
others are defaulted so that they do not normally need to be adjusted.
You can block the Configuration menu against manipulation by an
appropriately parameterized and activated binary input. Which
parameters you need to set and all other parameters are explained in
chapter 4.4, page 97 Parameterization.
The configuration mode can be reported by outputting a
parameterizable fault message, a position feedback or output of limit
values A1 and A2 is not possible in configuration mode.
NOTE
If the electric power supply fails during configuration, the positioner
switches back to the first parameter after recovering the power supply,
values which have already been parameterized are retained. When
doing this, please note that the new value will only be saved when
leaving the configuration menu or when another parameter is selected.
for
Without a power failure you re-enter the configuration menu at the
point you exited it when you call the Configuration menu again.
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Operation
to
Figure 58 Overview: Configuration
Manual mode
(MAN)
.
In this operating mode you can move the actuator with the decrement
) and increment keys ( ) and the current position is held
(
regardless of the setpoint current and any leakages.
NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.
at the same time
at the same time
at the same time
at the same time
.
Automatic (AUT)
Diagnostic display
The manual mode can be reported by outputting a parameterizable
fault message, a position feedback or output of limit values A1 and A2
is only possible in automatic mode.
NOTE
The positioner switches over to automatic mode automatically after an
electrical power failure.
The automatic mode is the normal mode. In this mode the positioner
compares the setpoint current with the current position and moves the
actuator until the control deviation reaches the parameterizable dead
zone. Error messages are output if this is not possible for various
reasons.
In this operating mode you can have the current operating data (such
as number of strokes, number of changes in direction, number of faults
messages, etc.) displayed (see table 1, page 114).
From the automatic or manual mode you go to the diagnostic display
by simultaneously pressing all three keys for at least two seconds.
See chapter 4.5, page 113 for further information.
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Operation
.
4.4 Parameters
NOTE
The respective operating mode (MAN or AUT) of the positioner is
retained when you switch to the diagnostic display, i.e. in automatic
operation the specified setpoint is still used for controlling and in
manual operation the position last reached is retained.
All the parameters of the positioner are listed in this chapter. Figure 59
shows an overview of the parameters.
The parameter name is shown once in plain text and once as it
appears in the display. The function of the parameter is described
briefly in the ”Function” column. In addition, the possible parameter
values, the physical unit and the factory setting of the parameters are
shown.
The configuration block diagram (figures 60 page 99) shows the
effects of the parameters.
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Operation
■
SIPART PS2 PA configurations (PROFIBUS version)
Parametername
1. YFCT Type of actuator:
2. YAGL
3. YWAY
4. INITA Initialization (automatic
5. INITM Initialization (manual
6. SDIR Setpoint direction rising
7. TSI Setpoint ramp OPEN Auto
8. TSD Setpoint ramp CLOSED 0 to 400 s
9. SFCT Setpoint function
10. SL0
30. SL20
31. DEBA Controller dead zone Auto
32. YA Start of manipulated variable
33. YE End of manipulated variable
34. YNRM Manipulated variable scaling
35. YCLS "Tight shut-off" with man. var.
36. YCDO
37. YCUP Value for "tight shut-off", up 0.0 to 100.0 %
38. BIN1 4)Function of binary input 1
Function Parameter values Dimen-
part-turn/linear
- Part-turn actuator
- Linear actuator
- Linear actuator without
sine-wave correction
- Part-turn actuator with
NCS
- Part-turn actuator with
NCS, reverse direction
- Linear actuator with NCS
1)
Rated angle of feedback 90 °
2)
Travel range 5 to 130 mm
(0.20 to 5.12 inch)
-None
- Short lever 33°
- Short lever 90°
- Long lever 90°
turn
WAY
LWAY
ncST
-ncST
ncSL
33 °
OFF
5/10/15/20
25/30/35
40/50/60/70/90/
110/130
no
commissioning)
###.#
Strt
FINISH
no
commissioning)
###.#
Strt
FINISH
riSE
Setpoint direction falling
FAL L
0 to 400 s
-Linear
- Equal percentage
- Equal percentage, reversed
- Freely adjustable
3)
Setpoint interpolation points
.
with free characteristic
.
0 %, 5 %, 10 % ... 100 %
Lin
1-25, 1-33, 1-50
n1-25, n1-33,
n1-50
FrEE
0.0 to 100.0 %
0.1 to 10.0 %
0.0 to 100.0 %
limit
limit
mech. travel/flow
-None
- Only up
- Only down
- Up and down
Value for "tight shut-off", down
None
0.0 to 100.0 %
MPOS
FLOW
no
uP:
do
uP do
0.0 to 100.0 %
OFF
NO
Only signal
Block configuring
Block config. and manual
Drive valve to ye
Drive valve to ya
Block movement
NC
Only signal
Drive valve to ye
Drive valve to ya
Block movement
Figure 59 Parameter table of the positioner
on
bLoc1
bLoc2
uP
doWn
StoP
-on
-uP
-doWn
-StoP
sion
Degrees
mm
Parametername
39. BIN2
Function Parameter values Dimen-
4)
Function of binary input 2
None
NO
Only signal
Drive valve to ye
Drive valve to ya
Block movement
OFF
on
uP
doWn
StoP
sion
NC
Only signal
Drive valve to ye
Drive valve to ya
Block movement
40. AFCT5)Alarm function
41. A1
42. A2
43. FCT
44. TIM Monitoring time for setting of
None
min : max: normal
min : min: normal
max : max: normal
inverted
inverted
inverted
Response threshold for alarm 1
Response threshold for alarm 2
5)
Function of alarm output
Fault:
normal
inverted
Fault + not Automatic:
normal
inverted
Fault + not Automatic + BI:
normal
inverted
(+ means logical OR
operation)
fault signal "Control devia-
-on
-uP
-doWn
-StoP
oFF
Mi:MA
Mi:MA
Mi:Mi
Mi:Mi
MA:MA
MA:MA
0.0 to 100.0 %
0.0 to 100.0 %
-
nA
- nA
nAb
- nAb
Auto
0 to 100
s
tion"
45. LIM Response threshold of fault
signal "Control deviation"
Auto
0.0 to 100.0 %
46. STRK Limit for travel integral 0 to 1.00E9
47. DCHG Limit for change in direction OFF
1 to 1.00E9
48. ZERO Limit for zero limit monitoring OFF
%
%
49. OPEN Limit for open limit monitor-
50. DEBA Limit for dead zone monitor-
ing
ing
0.0 to 100.0
OFF
0.0 to 100.0 %
OFF
0.0 to 10.0
51. PRST Preset (factory setting) no
Strt
oCAY
52. FSTY Safety setting:
53. FSTI Monitoring time for setting of
Parameterized safety
setpoint
Last setpoint
Open exhaust air valve
FSVL
FSSP
FSAC
0 to 100 s
safety position
54. FSVL Safety setpoint 0 to 100.0 %
55. STNR Station number 0 to 126
56. IDENT Device mode (Ident No.)
1
) Parameter only visible with "turn" or "WAY"; if "turn" is selected,
33 ° cannot be set.
2
) Parameter not visible if 1. YFCT = "turn", "LWAY" or "-ncST"
has been selected.
3
) Interpolation points only appear if 9.SFCT=FrEE has been selected.
4
) NC means: action with opened switch or Low level.
NO means: action with closed switch or High level.
5
) Normal means: High level without fault.
- Multi-vendor
- Full functionality
0
1
Inverted means: Low level without fault.
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