Siemens SIPART PS2 6DR50xx User manual

1
SIPART PS2 Manual
A5E00074630--06
SIPART PS2
6DR50xx
6DR51xx
6DR52xx
6DR53xx
Edition 10/2006
Manual
Electropneumatic Positioner for
Linear and Part-Turn Actuators

2SIPART PS2 Manual
A5E00074630--06
Copyright eSiemens AG 2006 All rights reserved
The reproduction, transmission or use of this docu-
ment or its contents is not permitted without ex-
press written authority. Offenders will be liable for
damages. All rights, including rights created by pa-
tent grant or registration of a utility model or design,
are reserved.
Siemens AG
Bereich Automatisierungs-- und Antriebstechnik
Geschäftsgebiet Prozessinstrumentierung-- und
Analytik
D--76181 Karlsruhe
Disclaimer of Liability
We have checked the contents of this manual for
agreement with the hardware and software descri-
bed. 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 edi-
tions. Suggestions for improvement are welcomed.
eSiemens 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 trade-
marks 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 11.........................
2 Design and Method of Operation 15........................................
2.1 Overview 15....................................................
2.2 Design name plate 17............................................
2.3 Instrument Components 17.......................................
2.3.1 Motherboard 18.................................................
2.3.2 Electrical Connections 18.........................................
2.3.3 Pneumatic Connections 19.......................................
2.3.4 Mounting Kit 22.................................................
2.3.5 Purge air switching (not in the explosion proof version) 22............
2.3.6 Restrictors 22...................................................
2.4 Method of Operation 23..........................................
2.5 HART-function 26...............................................
2.6 State as supplied 26.............................................
2.7 Installation of options modules 27.................................
2.7.1 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........................................

Information for the Operator
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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:
SSIPART PS2 without Ex-protection in a metal- or plastic housing.
SSIPART PS2 with EEx ia/ib-protection in a metal- or plastic hous-
ing.
SSIPART 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.
0.1 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.
0

Information for the Operator
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This manual contains the information required for use as intended of
the product it describes. It is addressed to technically qualified person-
nel 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, op-
eration, 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 informa-
tion 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.

Information for the Operator
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!CAUTION
used with the safety alert symbol indicates a potentially hazardous si-
tuation 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 nonobser-
vance of the warnings given in this manual or on product labels can be
severe personal injury and/or serious material damage. Therefore only
properly qualified personnel must make changes and settings in the
instrument.
For the purpose of the safety information in this manual and on the
product labels, qualified personnel are those who
Sin the case of ex-proof equipment, are trained, instructed or
authorized to perform work on electrical circuits of equipment
subject to explosion hazard.
Sif they are configuration personnel, are familiar with the safety
concepts of automation technology
Sif they are operating personnel, have been instructed in the handling
of automation equipment and know the content of this manual
relating to operation
Sif they are commissioning and/or service personnel, are trained to
repair such automation equipment and authorized to energize,
de-energize, clear ground and tag circuits and equipment according
to safety engineering standards.
Sand instructed additionally in first aid

Information for the Operator
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!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 certifica-
tion 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.

Information for the Operator
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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 de-
scription (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 person-
nel. Extra low voltages that are connected must be fed in by safe isola-
tion.
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 con-
tractual warranty conditions are neither extended nor restricted by this
document.

Information for the Operator
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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 or-
dering 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 stan-
dards have not been applied, the standards and regulations of the Fed-
eral Republic of Germany apply (see also the Technical Data in Chap-
ter 6, page 147).
If this product is used outside the area of applicability of these stan-
dards 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:
Swith linear actuator (figure 1-1, page 13) or
Swith part-turn actuator VDI/VDE 3845 (figure 1-2, page 13)
Different mounting types are available for linear actuators:
SNAMUR or IEC 534
Sintegrated mounting to ARCA
Sintegrated 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:
Sdouble-acting and
Ssingle-acting
For following applications:
Spotentially explosive or
Snot potentially explosive applications.
The electronics with display, position feedback and valve block are inte-
grated in the housing.
The housing is available in three versions:
SPlastic housing for single and double-acting actuators
SMetal housing for single-acting actuators
SExplosion proof housing for single and double-acting actuators
Purpose
Versions
Housing
1

Introduction
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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 “SIPART PS2 SIL safety manual” A5E00442120) must
be followed.
The positioner can be expanded with various options modules (chap-
ter 2.7, page 27). The following modules are available in all:
SIy-module: Two-wire current output 4 to 20 mA for position feedback
SAlarm module: 3 digital outputs and 1 digital input
SSIA module: one digital output for fault messages, two digital out-
puts for limit value alarms
SManometer block: 2 or 3 manometers for single and double-acting
positioners
SConnection block (NAMUR) for safety valve block
SMounting kits for linear and part-turn actuator
For decentralized installation of the positioner and position sensor:
SExternal position detection system
SNon-Contacting Position Sensor (NCS)
Only environmentally friendly materials have been used in the construc-
tion of the positioner.
The technical manual is printed on chlorine-free bleached paper.
Degree of
protection
Explosion
Protection
SIL applications
Options
Accessories
Environmental
Protection

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

Introduction
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1
2
3
4
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
2
3
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

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 predictive five-point switch by the output
variable ±∆y of which the integrated actuating valves are controlled with
pulse length modulation.
These actuating signals cause fluctuations in pressure in the actuator
chamber(s) and thus adjustment of the actuator until the control error is
zero.
Operation (manual) and configuration (structuring, initialization and
parameterization) is effected by three keys and a display with the hous-
ing cover removed.
The standard controller has one digital input (DI1). This can be config-
ured individually and can be used for blocking the operating modes for
example.
With the Iy-option module, the current actuator position can be output
as a two wire signal Iy=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 differ-
ence dependent on the travel time is monitored in automatic mode. The
fault signal is always set when the control error cannot be leveled after
a certain time because for example the valve is blocked or the mains
pressure is insufficient. The three digital outputs are implemented as
semiconductor outputs and are error self-reporting, i.e. the outputs re-
Introduction
2

Design and Functional Principle
16 SIPART PS2 Manual
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spond even when the power supply fails or the electronics are defec-
tive.
The actuator can also be blocked or driven to its final positions depend-
ing on the configuration for example by an external event via a digital
input (DI2) on the alarm module.
If you require electrically independent limit value messages from the
standard controller, you will have to use the SIA module with the slot
initiators instead of the alarm module.
Communication with the controller is possible via the optional HART
interface.
To be able to use the positioner with a variety of different part-turn and
linear actuators, it has a friction clutch and switchable gearing.
The switchable gearing allows you to adjust the positioner for small and
large lifts. You can switch using the yellow switch (8, Fig. 2-11, page 28)
between 33_(as delivered) and 90_.
The friction clutch (8, Fig. 2-11, page 28) allows you to set the working
range, particularly for linear actuators, after installation. You thus do not
have to ensure symmetrical mounting during the installation.
As it is not allowed to open the housing of an explosion-proof version in
a potentially explosive atmosphere, the shaft has an externally fitted,
additional friction clutch (8, Fig. 2-12, page 31).
NOTICE
for the explosion-proof version:
Only adjust the outer friction clutch (8, Fig. 2-12, page 31). The internal
friction clutch (8, Fig. 2-11 page 28) is fixed and, for the explosion-
proof version, must not be adjusted.

Design and Functional Principle
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2.2 Name plate design
(7)(1)
(3)
(2)
(5) (6)
(4)
(8)
(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
O
90
O
33
314
90°
33°
4
2
1
15
56
6.1 6.2
7891011
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 for frichtion clutch
4 Output: Actuating pressure Y2 *) 10 Terminals options modules
5 Operating keys 12 Dummy plug
6 Restrictor 13 Screw-type cable gland
6.1 Restrictor Y1 14 Terminal plate on cover
6.2 Restrictor Y2 *) 15 Purging air switch
*) in double-acting actuators
Figure 2-2 View of the positioner in normal version (cover open)

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 for friction 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 2-3 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 mod-
ule 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
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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 Pz
4 Actuating pressure Y2 in double-acting actuators
5 Exhaust air output E with silencer on the bottom of the instrument
Figure 2-4 Pneumatic connection in normal version
1
2
3
4
5
6
7
1 Restrictor Y2 *) 5 Actuating pressure Y1
2 Restrictor Y1 6 Exhaust air output E
3 Actuating pressure Y2 *) 7 Housing ventilation (2x)
4 Supply air PZ
*) in double-acting actuators
Figure 2-5 Pneumatic connection in explosion proof version
In addition, there are pneumatic connections on the back of the posi-
tioner for integrated installation in single-acting linear actuators.
SActuating pressure Y1
SExhaust 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).

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