Siemens SIPART PS2 6DR5020 Series User manual

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1

SIMATICr,SIPARTr,SIRECr, SITRANSr
are registered trademarks of Siemens AG.
All other product or system names are (registered) trademarks of their respective owners and must be treated accordingly.
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 created by the granting of patents or registration of a design are reserved.
Technical data subject to change without notice

3
SIPART PS2 Manual
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Contents
0 Information for the Operator 5.............................................
0.1 General information 5...........................................
0.2 Meaning of safety instructions and warnings 6.....................
0.3 Qualified Personnel 7...........................................
0.4 Use as intended 8..............................................
0.5 Technical Documentation 8......................................
0.6 Warranty Information 9..........................................
0.7 Delivery Notes 9...............................................
0.8 Standards and Regulations 10....................................
1 Introduction 11............................................................
1.1 General information about the positioner 11.........................
2 Design and Method of Operation 15........................................
2.1 Overview 15....................................................
2.2 Instrument Components 16.......................................
2.2.1 Motherboard 17.................................................
2.2.2 Electrical Connections 17.........................................
2.2.3 Pneumatic Connections 18.......................................
2.2.4 Mounting Kit 21.................................................
2.2.5 Purge air switching (not in the explosion proof version) 21............
2.2.6 Restrictors 21...................................................
2.3 Method of Operation 22..........................................
2.4 State as supplied 25.............................................
2.5 Options modules 25.............................................
2.5.1 Options modules in normal and intrinsically safe versions 25..........
2.5.2 Options modules in explosion proof version 28......................
2.5.3 HART-function 29...............................................
2.5.4 Alarm module 30................................................
2.5.5 Jy-module 31...................................................
2.5.6 SIA module 31..................................................
2.5.7 Accessories 32.................................................
3 Preparing for Operation 33.................................................
3.1 Instrument identification (type key) 33..............................
3.2 Dimensional drawings 33.........................................
3.3 Assembly 35....................................................
3.3.1 Instructions for using positioners in a wet environment 36.............
3.3.2 Instructions for using positioners which are exposed to great accelerations
or vibrations 38.................................................
3.3.3 Mounting kit ”linear actuator” 6DR4004-8V and 6DR4004-8L 39.......
3.3.4 Assembly procedure (see figure 3-6, page 41) 39....................

4SIPART PS2 Manual
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3.3.5 Mounting kit ”Rotary actuator” 6DR4004-8D 42......................
3.3.6 Assembly procedure (see figure 3-7 and figure 3-8) 43...............
3.4 Electrical Connection 48..........................................
3.4.1 Connection variants 49...........................................
3.4.1.1 Connection variant: not intrinsically safe 49.........................
3.4.1.2 Connection variant: intrinsically safe 50............................
3.4.1.3 Connection variant: Options in positioner in non--intrinsically safe
and explosion proof version 52....................................
3.4.1.4 Connection variant: Options in the positioner in intrinsically safe
version 54......................................................
3.5 Pneumatic Connection 56........................................
3.6 Commissioning 57...............................................
3.6.1 Preparations for linear actuators 58................................
3.6.2 Automatic initialization of linear actuator 59.........................
3.6.3 Manual initialization of linear actuator 61............................
3.6.4 Preparations for rotary actuator 64.................................
3.6.5 Automatic initialization of rotary actuator 64.........................
3.6.6 Manual initialization of rotary actuators 66..........................
3.6.7 Automatic initialization (structograms) 67...........................
3.7 Copying initialization data (positioner exchange) 72..................
4 Operation 73.............................................................
4.1 Display 73......................................................
4.2 Input keys 73...................................................
4.3 Operating modes 76.............................................
4.4 Parameters 78..................................................
4.5 Diagnosis 90...................................................
4.5.1 Diagnostic display 90............................................
4.5.2 Meaning of the diagnostic values 91...............................
4.5.3 Online-Diagnosis 93.............................................
5 Service and Maintenance 99................................................
6 Technical Data 101.........................................................
7 Scope of Delivery 105.......................................................
7.1 Scope of delivery of standard controller 105..........................
7.2 Scope of delivery of options 106....................................
7.3 Scope of delivery of accessories 106................................
A Appendix 107..............................................................
A1 Index 107..........................................................
A2 Literature and Catalog 109...........................................
A3 Conformity 109.....................................................

Information for the Operator
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SIPART PS2 Manual
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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:
-SIPART PS2 without Ex-protection in a metal-- or plastic housing.
-SIPART PS2 with EEx ia/ib-protection in a metal-- or plastic
housing.
-SIPART PS2 EEx d in a pressurized explosion proof metal 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 105.
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.
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 instrumen-
tation 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.
0

Information for the Operator
SIPART PS2 Manual
A5E00074631-01
6
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 installa-
tion, 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 Meaning of safety instructions and warnings
Safety information and warnings are intended to avert danger from the
life and health of users and maintenance personnel and to prevent
material damage. They are highlighted in this manual by the headings
defined here. They are also marked by warning symbols next to where
they appear. The headings used have the following meaning for the
purposes of this manual and the product labels:
!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.
!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 with the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury.

Information for the Operator
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NOTICE
NOTICE used without the safety alert symbol indicates a potential
situation which, if not avoided, may result in an undesireable result or
state.
.NOTE
indicates a reference to a possible advantage when this
recommendation is followed.
0.3 Qualified Personnel
The result of unqualified intervention in the instrument or
nonobservance of the warnings given in this manual or on product
labels can be severe personal injury and/or serious material damage.
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
Sif they are configuration personnel, are familiar with the safety
concepts of automation technology
Sif they are operating personnel, have been instructed in the handling
of automation equipment and know the content of this manual
relating to operation
Sif they are commissioning and/or service personnel, are trained to
repair such automation equipment and authorized to energize,
de-energize, clear ground and tag circuits and equipment according to
safety engineering standards.
Sand instructed additionally in first aid
Sand, in the case of ex-proof equipment, are trained, instructed or
authorized to perform work on electrical circuits of equipment
subject to explosion hazard.

Information for the Operator
SIPART PS2 Manual
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8
!WARNING
The instrument must only be installed and commissioned by qualified
personnel.
The instrument is designed for connection to functional and safety
extra low voltage.
Electrical safety depends only on the power supply equipment.
Pneumatic actuators exert considerable positioning forces. The safety
precautions of the actuator used must therefore be scrupulously
observed during installation and commissioning in order to prevent
injuries.
We explicitly draw your attention to the necessity of observing safety
regulations regarding operation in zones subject to explosion hazard, if
applicable.
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, manufac-
tured, tested and documented observing the relevant safety standards.
If the handling rules and safety information for configuration, installa-
tion, 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
In addition to this manual, the following documentation is also supplied
with the instrument:
-Leaflet “Operation -- Concise Overview”
explains in visualized form the principle of operation and
parameterization and automatic commissioning.
-“Operating Instructions”
contains the information required for assembly, connection and
commissioning.

Information for the Operator
9
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The following list contains all the documents available for these
instruments:
Title Language Order No.
Operating Instructions German/English
French/Italian/Spanish
A5E00074600
A5E00074601
Manual German
English
A5E00074630
A5E00074631
Leaflet German
English
French
Italien
Spanish
A5E00074610
A5E00074611
A5E00074612
A5E00074613
A5E00074614
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 7.

Information for the Operator
SIPART PS2 Manual
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10
0.8 Standards and Regulations
As far as possible, the harmonized European standards were used to
specify and manufacture this equipment. If harmonized European
standards have not been applied, the standards and regulations of the
Federal Republic of Germany apply (see also the Technical Data in
Chapter 6, page 101).
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.

Introduction
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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.
For example, the positioner can be used to control valves as follows:
-with linear actuator (figure 1-1, page 13) or
-with rotary actuator VDI/VDE 3845 (figure 1-2, page 13)
Different mounting types are available for linear actuators:
-NAMUR or IEC 534
-integrated mounting to ARCA
-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:
-double--acting and
-single--acting
For following applications:
-potentially explosive or
-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:
-Plastic housing for single and double--acting actuators
-Metal housing for single--acting actuators
-Explosion proof metal housing for single and double--acting
actuators
Purpose
Versions
Housing
1

Introduction
12 SIPART PS2 Manual
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The device is designed with IP65/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 positioner can be expanded with various options modules (chapter
2.5, page 25). The following modules are available in all:
-Jy-module: Two--wire current output 4 to 20 mA for position feed-
back
-Alarm module: 3 digital outputs and 1 digital input
-SIA module: one digital output for fault messages, two digital out-
puts for limit value alarms
-Manometer block: 2 or 3 manometers for single and double
action positioners
-Add--on flange (NAMUR) for safety valve block
-Add--on sets for linear and rotary actuator
Only environmentally friendly materials have been used in the
construction of the positioner.
The technical manual is printed on chlorine--free bleached paper.
Degree of
protection
Explosion
Protection
Options
Accessories
Environmental
Protection

Introduction
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1
2
3
4
1 Actuator
2 Positioner, single action in metal housing
3 Lantern
4 Manometer block, single action
5Valve
5
Figure 1-1 Positioner mounted on linear actuator (single action)
1
2
3
1 Positioner double action in plastic housing
2 Rotary actuator
3 Manometer block, double action
Figure 1-2 Positioner mounted on rotary actuator (double action)

Introduction
14 SIPART PS2 Manual
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1
2
3
4
1 Actuator
2 Positioner, single action in metal housing
3 Lantern
4 Manometer block, single action
Figure 1-3 Explosion proof positioner mounted on linear actuator (single action)
1
2
3
1 Positioner double action in plastic housing
2 Rotary actuator
3 Manometer block, double action
Figure 1-4 Explosion proof positioner mounted on rotary actuator (double action)

Design and Functional Principle
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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
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 predicative five--point switch by the output
variable ±Dy 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 pa-
rameterization) is effected by three keys and a display with the housing
cover removed.
The standard controller has one digital input (DI1). This can be configu-
red individually and can be used for blocking the operating levels for
example.
With the Jy-option module, the current actuator position can be output
as a two wire signal Jy=4to20mA.
In addition the actuator can be monitored for two programmable limit
values which respond on exceeding or dropping below the stroke or
angle of rotation.
The limit value alarms are output by the alarm option module which can
monitor and report the function of the positioner and the actuator addi-
tionally through a fault message output. The value of the control diffe-
rence dependent on the floating 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 implemen-
ted as semiconductor outputs and are error self--reporting, i.e. the out-
Introduction
2

Design and Functional Principle
16 SIPART PS2 Manual
A5E00074631-01
puts respond even when the power supply fails or the electronics are
defective.
The actuator can also be blocked or driven to its final positions depen-
ding 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.
2.2 Instrument Components
O
90
O
33
314
90°
33°
4
2
1
15
56
6.1 6.2
789101
1
12
13
4...20 mA
0/4...20 mA
3/4 W2W
DI1
1 Input: Supply air 7 Silencer
2 Output: Actuating pressure Y1 8 Transmission ratio selector
3 Display 9 Adjusting wheel slip clutch
4 Output: Actuating pressure Y2 *) 10 Terminals options modules
5 Operating keys 12 Dummy plug
6 Restrictor 13 Screw--type cable gland
6.1 Restrictor Y1 14 Terminal plate on cover
6.2 Restrictor Y2 *) 15 Purging air switch
*) in double--acting actuators
Figure 2-1 View of the positioner in normal version (cover open)

Design and Functional Principle
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8
9
6.2
6.1
10
37
----
++
1
10
138238 9
2121
45
1 Input: Supply air 7 Transmission ratio selector
2 Output: Actuating pressure Y1 (only possible with positioner open)
3 Display 8 Adjusting wheel slip clutch
4 Output: Actuating pressure Y2 *) 9 Terminals standard controller
5 Operating keys 10 Terminals options modules
6.1 Restrictor Y1 12 Safety catch
6.2 Restrictor Y2 *)
*) in double--acting actuators
Figure 2-2 View of the explosion proof version of the positioner
2.2.1 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.
2.2.2 Electrical Connections
The terminals of the standard controller, the Jy- and alarm-option mo-
dule 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 pre-
vents incorrect installation.

Design and Functional Principle
18 SIPART PS2 Manual
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2.2.3 Pneumatic Connections
The pneumatic connections are on the right hand side of the positioner
(figure 2-3 and figure 2-4).
1
2
3
4
5
1 Actuating pressure Y1 in single-- and double--acting actuators
2 Feedback shaft
3 Supply air Pz
4 Actuating pressure Y2 in double--acting actuators
5 Exhaust air output E with silencer on the bottom of the instrument
Figure 2-3 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 2-4 Pneumatic connection in explosion proof version
In addition, there are pneumatic connections on the back of the positio-
ner for integrated installation in single--acting linear actuators.
-Actuating pressure Y1
-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 33, figure 3-3, page 34 and figure 3-4, page 35).

Design and Functional Principle
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The exhaust air output E can be provided for supplying dry instrument
air to the tapping chamber and spring chamber to prevent corrosion.
Figure 2-5, page 20 shows the pneumatic connection variants for the
different actuator types, the positioning action and the safety position
after power failure.

Design and Functional Principle
20 SIPART PS2 Manual
A5E00074631-01
up
down
up
down
up
down
up
down
Safety position after power failure
electrical pneumatic
Down Down
Up Up
Down
Up
Y1
Y1
Y2
Y1
Y1
Y2
Y1
Y1
Y2
Y1
Y1
Y2
Open
Closed
Closed Closed
Open Open
Closed
Open
Last position
(before power
failure)
Actuator type
Positioning
pressure
Connection
In rotary actuators the
direction of rotation
counterclockwise looking
onto the actuating shaft of
the valve is usually defined
as ”Open”.
Open
Closed
up down
Open
Closed
OpenClosed
OpenClosed
Last position
(before power
failure)
Figure 2-5 Pneumatic connection positioning