Siemens PS2 6DR53xx, PS2 6DR50xx, PS2 6DR52xx, PS2 6DR51xx User Manual
SIPART PS2
6DR50xx
6DR51xx
6DR52xx
6DR53xx
Edition 10/2006
Manual
Electropneumatic Positioner for
Linear and Part-Turn Actuators
SIPART PS2 Manual
A5E00074630- -06
1
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 Automatisierungs-- und Antriebstechnik
Geschäftsgebiet Prozessinstrumentierung-- und
Analytik
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.
Trademarks
SIMATIC, SIPART, SIREC, SITRANS are registered trademarks of Siemens AG.
Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners.
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Contents
0 Information for the Operator 5.............................................
0.1 General information 5...........................................
0.2 Classification of Safety Related Notices 6.........................
0.3 Qualified Personnel 7...........................................
0.4 Use as intended 9..............................................
0.5 Technical Documentation 9......................................
0.6 Warranty Information 9..........................................
0.7 Delivery Notes 10...............................................
0.8 Standards and Regulations 10....................................
1 Introduction 11............................................................
1.1 General information about the positioner 1 1.........................
2 Design and Method of Operation 15........................................
2.1 Overview 15....................................................
2.2 Design name plate 17............................................
2.3 Instrument Components 17.......................................
2.3.1 Motherboard 18.................................................
2.3.2 Electrical Connections 18.........................................
2.3.3 Pneumatic Connections 19.......................................
2.3.4 Mounting Kit 22.................................................
2.3.5 Purge air switching (not in the explosion proof version) 22............
2.3.6 Restrictors 22...................................................
2.4 Method of Operation 23..........................................
2.5 HART-function 26...............................................
2.6 State as supplied 26.............................................
2.7 Installation of options modules 27.................................
2.7.1 Installation of options modules in normal and intrinsically
safe versions 27................................................
2.7.2 Installation of options modules in explosion proof version 29..........
2.7.3 Iy-module 31...................................................
2.7.4 Alarm module 32................................................
2.7.5 SIA module 33..................................................
2.7.6 Mechanical limit switch module 35.................................
2.7.7 EMC filter module 38............................................
2.7.8 Accessories 39.................................................
3 Preparing for Operation 41.................................................
3.1 Instrument identification (type key) 41..............................
3.2 Dimensional drawings 41.........................................
3.3 Assembly 43....................................................
3.3.1 Instructions for using positioners in a wet environment 44.............
3.3.2 Instructions for using positioners which are exposed to strong
accelerations or vibrations 46.....................................
3.3.3 Mounting kit “linear actuator” 6DR4004-8V and 6DR4004-8L 49.......
3.3.4 Assembly procedure (see figure 3-7, page 51) 50....................
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3.3.5 Mounting kit “part-turn actuator” 6DR4004-8D 52....................
3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) 53...............
3.4 Electrical Connection 57..........................................
3.4.1 Connection in non-intrinsically safe and explosion proof version 59.....
3.4.2 Connection in intrinsically safe version 62...........................
3.4.3 Connection in type of protection “n” version 68......................
3.5 Pneumatic Connection 71........................................
3.6 Commissioning 72...............................................
3.6.1 Preparations for linear actuators 73................................
3.6.2 Automatic initialization of linear actuator 74.........................
3.6.3 Manual initialization of linear actuator 76............................
3.6.4 Preparations for part-turn actuator 79..............................
3.6.5 Automatic initialization of part-turn actuator 79......................
3.6.6 Manual initialization of part-turn actuators 81........................
3.6.7 Automatic initialization (structograms) 82...........................
3.7 Copying initialization data (positioner exchange) 87..................
4 Operation 89..............................................................
4.1 Display 89......................................................
4.2 Input keys 89...................................................
4.3 Operating modes 92.............................................
4.4 Parameters 95..................................................
4.5 Diagnostics 122..................................................
4.5.1 Diagnostic display 122............................................
4.5.2 Meaning of the diagnostic values 123...............................
4.5.3 Online diagnostics 131............................................
4.5.4 Fault correction 136..............................................
4.6 Meaning of the other display text 139...............................
4.7 Optimizing the controller data 143..................................
5 Service and Maintenance 145................................................
6 Technical Data 147.........................................................
7 Scope of Delivery 153.......................................................
7.1 Scope of delivery of standard controller 154..........................
7.2 Scope of delivery of options 154....................................
7.3 Scope of delivery of accessories 155................................
7.4 List of Spare Parts 156............................................
8 Index 158..................................................................
9 Appendix 160..............................................................
9.1 Literature and catalogs 160........................................
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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 hous-
ing.
S SIPART PS2 EEx d in a pressurized explosion proof housing
This manual takes each of these possibilities into consideration.
Any differences between the devices are indicated specially.
Scope of delivery, see chapter 7, page 153.
0
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 immenently hazardous situation which, if not avoided, will
result in death or serious inury .
WARNING
indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury .
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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 the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.
NOTICE
indicates a potential situation which, if not avoided, may result in an
undesirable result or state.
.
NOTE
highlights important information on the product, using the product,
or part of the documentation that is of particular importance and that
will be of benefit to the user.
0.3 Qualified Personnel
The result of unqualified intervention in the instrument or 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
7
Information for the Operator
WARNING
!
The instrument must only be installed and commissioned by qualified
personnel.
The device may be used solely for the purposes described in this
manual.
The instrument is designed for connection to functional and safety
extra low voltage.
Electrical safety depends only on the power supply equipment.
Pneumatic actuators exert considerable positioning forces. The safety
precautions of the actuator used must therefore be scrupulously
observed during installation and commissioning in order to prevent
injuries.
We explicitly draw your attention to the necessity of observing safety
regulations regarding operation in zones subject to explosion hazard,
if applicable.
The specifications of the examination certificate valid in your country
must be observed. Laws and regulations valid in your country must be
observed for the electrical installation in explosions hazardous areas.
In Germany these are for example:
-- Working reliability regulations
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079-14 (in the past VDE 0165, T1).
It should be checked whether the available power supply, insofar as
this is required, is compliant with the power supply specified on the
rating plate and specified in the examination certificate valid in your
country.
Take care to avoid electrostatic discharges within the hazardous area,
such as can arise if a dry cloth is used to clean the positioner in the
plastic housing.
Devices with the protection type “flameproof enclosure” may only be
opened when the power is off.
WARNING
!
Devices with the protection type “intrinsically safe” lose their certification as soon as they are operated with circuits that do not conform to
the specifications laid down in the examination certificate valid in your
country.
The successful and safe operation of this equipment is dependent
upon its proper handling, installation, operation and maintenance.
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WARNING
!
The device may not be operated while the leaflets are in the housing.
0.4 Use as intended
Use as intended for the purpose of this manual means that this product
must only be used for the applications described in the technical description (see also Chapter 3 of this manual).
The product described in this manual has been developed, manufactured, tested and documented observing the relevant safety standards.
If the handling rules and safety information for configuration, installation, use as intended and maintenance are observed, there is normally
no danger with regard to material damage or for the health of personnel. Extra low voltages that are connected must be fed in by safe isolation.
Information for the Operator
0.5 Technical Documentation
The operating instructions are a constituent part of the enclosed CD
“sipartp ps2 POSITIONERS” (order number A5E00214567) and is
available on the Internet at:
www.siemens.com/sipartps2
Click on “More Info” and --> “Instructions and Manuals”.
On the enclosed CD, you will find an extract of the catalog FI 01 “Field
devices for process automation” with the current order data. The entire
FI 01 catalog is also available at the above Web address.
0.6 Warranty Information
We should like to point out that the content of this manual is not part of
and does not modify a previous or current agreement, undertaking or
legal relationship. Siemens is bound solely by the contract of sale,
which also contains the complete and exclusive warranty. The contractual warranty conditions are neither extended nor restricted by this
document.
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Information for the Operator
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 7, page 153.
0.8 Standards and Regulations
As far as possible, the harmonized European standards were used to
specify and manufacture this equipment. If harmonized European standards have not been applied, the standards and regulations of the Federal Republic of Germany apply (see also the Technical Data in Chapter 6, page 147).
If this product is used outside the area of applicability of these standards and regulations, please observe the standards and regulations in
force in the country where the product is operated.
10
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Introduction
Introduction
1.1 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.
Purpose
For example, the positioner can be used to control valves as follows:
S with linear actuator (figure 1-1, page 13) or
S with part-turn actuator VDI/VDE 3845 (figure 1-2, page 13)
Different mounting types are available for linear actuators:
S NAMUR or IEC 534
S integrated mounting to ARCA
1
Versions
Housing
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.
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
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Introduction
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.
The version with the type of protection “n” can be used in hazardous
areas of zone 2.
The SIPART PS2 positioners in the variations 6DR501*, 6DR511*,
6DR521* and 6DR531* (i.e. with 0/4 up to 20 mA control signal in the
single-acting design) are also suitable for positioning on fittings with
pneumatic actuators, which satisfy the special requirements for safety
devices up to SIL 2 to IEC 61508/ IEC 61511-1. For this, the SIL safety
instructions (see “SIPAR T PS2 SIL safety manual” A5E00442120) must
be followed.
The positioner can be expanded with various options modules (chapter 2.7, page 27). The following modules are available in all:
S
-module: Two-wire current output 4 to 20 mA for position feedback
Iy
S Alarm module: 3 digital outputs and 1 digital input
Accessories
Environmental
Protection
S SIA module: one digital output for fault messages, two digital out-
puts for limit value alarms
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 1-1 Positioner mounted on linear actuator (single-acting)
4
5
1
2
1 Positioner double-acting in plastic housing
2 Part-turn actuator
3 Manometer block, double-acting
Figure 1-2 Positioner mounted on part-turn actuator (double-acting)
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3
13
Introduction
1
2
4
3
1 Actuator
2 Positioner, single-acting in explosion proof housing
3 Lantern
4 Manometer block, single-acting
Figure 1-3 Explosion proof version of the positioner mounted on linear actuator (single-acting)
1
3
2
1 Positioner double-acting in explosion proof housing
2 Part-turn actuator
3 Manometer block, double-acting
Figure 1-4 Explosion proof version of the positioner mounted on part-turn actuator (double-acting)
Table 1-1
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Design and Functional Principle
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 actuator is detected by a
servo potentiometer and fed back as actual value x. The setpoint and
actual value are output simultaneously on the display.
The setpoint w is formed by a current fed to the positioner which at
the same time serves to supply the positioner in two-wire operation.
In 3/4-wire operation the supply comes from a 24 V voltage input.
The positioner operates as a predictive five-point switch by the output
variable ±∆y of which the integrated actuating valves are controlled with
pulse length modulation.
2
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 digital input (DI1). This can be configured individually and can be used for blocking the operating modes for
example.
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.
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 digital outputs are implemented as
semiconductor outputs and are error self-reporting, i.e. the outputs re-
-option module, the current actuator position can be output
y
=4to20mA.
y
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Design and Functional Principle
spond even when the power supply fails or the electronics are defective.
The actuator can also be blocked or driven to its final positions depending on the configuration for example by an external event via a digital
input (DI2) on the alarm module.
If you require electrically independent limit value messages from the
standard controller, you will have to use the SIA module with the slot
initiators instead of the alarm module.
Communication with the controller is possible via the optional HART
interface.
To be able to use the positioner with a variety of different part-turn and
linear actuators, it has a friction clutch and switchable gearing.
The switchable gearing allows you to adjust the positioner for small and
large lifts. You can switch using the yellow switch (8, Fig. 2-11, page 28)
between 33_ (as delivered) and 90_.
The friction clutch (8, Fig. 2-1 1, page 28) allows you to set the working
range, particularly for linear actuators, after installation. You thus do not
have to ensure symmetrical mounting during the installation.
As it is not allowed to open the housing of an explosion-proof version in
a potentially explosive atmosphere, the shaft has an externally fitted,
additional friction clutch (8, Fig. 2-12, page 31).
NOTICE
for the explosion-proof version:
Only adjust the outer friction clutch (8, Fig. 2-12, page 31). The internal
friction clutch (8, Fig. 2-1 1 page 28) is fixed and, for the explosionproof version, must not be adjusted.
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2.2 Name plate design
Design and Functional Principle
(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 2-1 Design name plate, example with protection class EEx ia/ib
2.3 Instrument Components
(7)(1)
314
90°
DI1
O
33
O
90
13
3/4 W2W
4...20 mA
0/4...20 mA
33°
12
6.1 6.2
7891011
1 Input: Supply air 7 Silencer
2 Output: Actuating pressure Y1 8 Transmission ratio selector
3 Display 9 Adjusting wheel for frichtion clutch
4 Output: Actuating pressure Y2
5 Operating keys 12 Dummy plug
6 Restrictor 13 Screw-type cable gland
6.1 Restrictor Y1 14 Terminal plate on cover
6.2 Restrictor Y2
*)
in double-acting actuators
*)
*)
10 Terminals options modules
15 Purging air switch
56
15
2
1
4
Figure 2-2 View of the positioner in normal version (cover open)
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Design and Functional Principle
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 Adjusting wheel for friction clutch
4 Output: Actuating pressure Y2
5 Operating keys 10 Terminals options 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 2-3 View of the explosion proof version of the positioner
2.3.1 Motherboard
The motherboard contains all the electronic elements such as the CPU,
memory, A/D converter. It also contains the display and the operating
keys.
In addition, the terminal strips for connecting the options modules are
also on the motherboard.
2.3.2 Electrical Connections
The terminals of the standard controller, the Iy- and alarm-option module are arranged at the left-hand front edges and offset against each
other in staircase form.
A module cover protects the modules from being pulled out and prevents incorrect installation.
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2.3.3 Pneumatic Connections
The pneumatic connections are on the right hand side of the positioner
(figure 2-4 and figure 2-5).
1
2
3
4
5
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
z
Design and Functional Principle
Figure 2-4 Pneumatic connection in normal version
1
2
3
4
5
6
7
1 Restrictor Y2 *) 5 Actuating pressure Y1
2 Restrictor Y1 6 Exhaust air output E
3 Actuating pressure Y2 *) 7 Housing ventilation (2x)
4 Supply air PZ
*)
in double-acting actuators
Figure 2-5 Pneumatic connection in explosion proof version
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In addition, there are pneumatic connections on the back of the positioner for integrated installation in single-acting linear actuators.
S Actuating pressure Y1
S Exhaust air output E (not in explosion proof version)
In the ex-factory state, these connections are sealed by screws
(see figure 3-1, page 41, figure 3-3, page 42 and figure 3-4, page 43).
19
Design and Functional Principle
The exhaust air output E can be provided for supplying dry instrument
air to the tapping chamber and spring chamber to prevent corrosion.
Figure 2-6, page 21 shows the pneumatic connection variants for the
different actuator types, the positioning action and the safety position
after power failure.
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Design and Functional Principle
Positioning
pressure
Connection
Y1
Y1
Y2
Y1
Y1
Y2
Closed
Closed
Actuator type
Open
Open
OpenClosed
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 2-6 Pneumatic connection positioning
Last position
(before power
failure)
up down
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Design and Functional Principle
2.3.4 Mounting Kit
The positioner can be mounted on almost all actuators with the appropriate mounting kit.
2.3.5 Purge air s witch in g (not in the explosion proof version)
The purge air switch is accessible above the pneumatic terminal strip
with the housing open (figure 2-7). In the IN position the inside of the
housing is purged with very small amounts of clean, dry instrument air.
In the OUT position the purge air is fed directly to the outside air.
Figure 2-7 Purge air switch on the valve block, view of the positioner onto pneumatic connection side
with cover open
2.3.6 Restrictors
In order to achieve travel times of > 1.5 s in small actuators, the air rate
can be reduced with the restrictors Y1 and Y2 (figure 2-8, in explosion
proof version, see figure 2-5, page 19). By turning to the right the air
rate is reduced up to shutting off. To set the restrictors it is advisable to
close them and then open them slowly (see initialization RUN3).
In the case of double-acting valves make sure that both chokes are set
approximately equal.
Hexagon socket 2.5 mm
Y1 Y2
Figure 2-8 Restrictors
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2.4 Method of Operation
The electropneumatic positioner SIPAR T PS2 forms a control circuit
with the pneumatic actuator in which the actual value x is the position
of the actuator bar in linear actuators or the position of the actuator
shaft in part-turn actuators and the command variable w is the
actuating current of a controller or a manual control station of 4 to
20 mA.
The stroke or part-turn movement of the actuator is transferred by the
appropriate mounting accessories, the feedback shaft and a play-free
switchable gearwheel to a high quality conductive plastic potentiometer
and to the analog input of the microcontroller. The current position can
also be preset for the positioner via an external sensor. The detection
of the stroke or rotation andle is performed by a non-contacting position sensor (Non Contacting Position Sensor) directly at the actuator.
This may correct the angle error of the stroke tap, compares the
potemtiometer voltage as actual value x with the setpoint w fed in at
the terminals 3 and 7 and calculates the manipulated variable
increments 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.
Design and Functional Principle
The pneumatic actuators are available in single and double-acting
versions. Only one pressure chamber is aerated or deaerated in the
single-acting version. The resulting pressure operates against a spring.
In the double-acting version, two pressure chambers are counteractive.
In this case the one volume is deaerated when the other volume is
aerated. See the block diagram figure 2-10, page 25.
The control algorithm is an adaptive predictive five-point switch
(see figure 2-9, page 24).
The valves are controlled with continuous contact at large control errors
(fast step zone). At medium control errors the valve is controlled by
pulse length modulated pulses (short step zone).
No actuating pulses are output in the small control error zone (adaptive
dead zone). The dead zone adaptation and the continuous adaptation
of the minimum pulse lengths in automatic operation cause the best
possible control accuracy to be achieved at the lowest switching frequency. The start parameters are determined during the initialization
phase and stored in a non-volatile memory. These are basically the real
travel with the mechanical limit stops, the travel times, the size of the
dead zone etc.
In addition the number of fault messages, changes in direction and the
number of strokes are determined and stored every 15 minutes during
operation. These parameters can be read out and documented by the
communication programs such as PDM and AMS. Conclusions as to
the wear on the fitting can be drawn (diagnostic function) especially by
comparing the old value with the currently determined values.
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23
Design and Functional Principle
Figure 2-10, page 25 shows the block diagrams for single- and doubleacting actuators with the linear actuator as an example.
.
Figure 2-9 Method of operation five-point switch
NOTE
The exhaust air valve is always open when there is no current.
24
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Design and Functional Principle
1
BE1
I
I
y
0
+
x
W+
W-
3 V
W
+U
_
W
x
0
6
BE2
7
+5 V
A
A
2
+24 V
D
D
HART
_
Micro-
controller
A1 A2
II
A1 A2
3
_
y
y
+
+
U
U
I
5
4
Zuluft
Supply air
p
Z
Exhaust air
Abluft
p
1
p
p
p
2
Abluft
Exhaust
air
1
2
stroke
9
p
2
p
1
stroke
8
p
1
1 Motherboard with microcontroller and input circuit
2 Control panel with LC-display and momentary action switch
3 Piezo-valve unit, always built-in
4 Valve unit with double-acting positioner always built-in
5 Iy-module for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital input
7 SIA-module (Slot Initiator-Alarm-module)
8 Spring-loaded pneumatic actuator (single-acting)
9 Spring-loaded pneumatic actuator (double-acting)
Figure 2-10 Block diagram of the electro-pneumatic positioner, functional diagram
.
NOTE
Alarm module (6) and SIA module (7) can only be used alternatively.
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25
Design and Functional Principle
2.5 HART-function
Function
.
The positioner is also available with built-in HART-functions. The HART
protocol allows you to communicate with your instrument with a handheld communicatorR, PC or programming unit. This enables you to
configure your instrument comfortably, save configurations, call diagnostic data, display online measured values and much more. Communication takes place as frequency modulation over the existing signal
lines for the command variable from 4 to 20 mA.
The SPART PS2 is integrated in the following parameterization tools:
S Handheld communicatorR
S PDM (Process Device Manager)
S AMS (Asset Management System)
S Cornerstone (without diagnostic values/-functions)
NOTE
Operation on the positioner has priority over the settings via the HART
interface.
Communication is aborted by a power failure at the positioner.
2.6 State as supplied
There are no mechanical mounting accessories on the controller in the
state as supplied. These must be ordered and installed according to
the “operating instructions” depending on the application.
The respective connections for single or double-acting versions are
prepared at the factory as ordered.
The pneumatic connections on the rear are sealed.
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Design and Functional Principle
2.7 Installation of options modules
2.7.1 Installation of options modules in normal and intrinsically safe versions
The following option modules are available for the positioner in the
standard and the intrinsically safe version:
-module
-- l
y
-- Alarm module
-- SIA-module
-- Mechanical limit switch module
-- EMC filter module
The installation of the options modules is described below:
Installation
.
Open positioner
.
The option modules are secured by a assembly covering ((1), see
figure 2-11, page 28) and mechanically fixed.
NOTE
To install the option modules the housing of the positioner needs to be
opened. As soon as the positioner is opened, the IP66 degree of
protection is not guaranteed.
To open the positioner, the four screws of the housing cover must be
loosened with a Phillips screwdriver.
Disconnect or isolate the power supply cables.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.
NOTE
To prevent premature wearing of the fixture by the self-tapping screws
(1.1), the following method of mounting the module cover (1) has
proven effective.
SIPART PS2 Manual
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1. Turn the screws counterclockwise until you feel them snap into the
thread
2. Tighten both screws carefully in clockwise direction
27
Design and Functional Principle
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 2-11 Installation of Options Modules
12 Actuating disc bearings
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Design and Functional Principle
2.7.2 Installation of options modules in explosion proof version
The following option modules are available for the positioner in the explosion-proof version:
-module
--
Iy
-- Alarm module
Installation
.
The options modules are protected and mechanically fixed by a module
cover ((1), see figure 2-12, page 31).
NOTE
The housing must be opened to install the options modules. The
degree of protection IP66/NEMA4x is not guaranteed as long as the
positioner is open.
WARNING
!
In areas in which the atmosphere may be potentially explosive, the
explosion-proof positioner may only be supplied with electrical auxiliary
power when the housing is closed and when built-in, approved 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
SIPART PS2 Manual
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See figure 2-12, page 31. Disconnect or isolate the power supply
cables first.
To open the positioner, the safety catch (12) must be opened and the
screw-on cover unscrewed.
After loosening the four fixing screws (13.1) the complete rack (13) can
be removed. The actuator may have to be turned so that the clutch can
be easily disengaged.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.
29
Design and Functional Principle
.
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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