Siemens SIPART PS2 User manual

Manual Edition 07/2003
Electropneumatic positioner
for linear and rotary actuators
6DR55xx
sipart ps2

1
SIPART PS2 PA Manual
A5E00127926-03
SIPART PS2 PA
6DR55xx
Edition 07/2003
Manual
Electropneumatic Positioner for
Linear and Rotary Actuators

2SIPART PS2 PA Manual
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Copyright eSiemens AG 2002 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 Automation & Drives
Geschäftsgebiet Process Instrumentation and
Analytics
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 2002
Technical data subject to change without notice
Trademarks
SIMATICe,SIPARTe,SIRECe, SITRANSeare registered trademarks of the 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 7.............................................
0.1 General information 7...........................................
0.2 Classification of Safety-Related Notices 8.........................
0.3 Qualified Personnel 9...........................................
0.4 Use as intended 11..............................................
0.5 Technical Documentation 11......................................
0.6 Warranty Information 12..........................................
0.7 Delivery Notes 12...............................................
0.8 Standards and Regulations 12....................................
1 Introduction 13............................................................
1.1 General information about the positioner 13.........................
1.2 General information regarding PROFIBUS 17.......................
1.2.1 Transmission method 17.........................................
1.2.2 Topology 17....................................................
1.2.3 Properties of the PROFIBUS PA 18................................
1.2.4 Profile 19.......................................................
1.2.5 Interfacing 19...................................................
2 Design and Method of Operation 23........................................
2.1 Overview 23....................................................
2.2 Instrument Components 24.......................................
2.2.1 Motherboard 25.................................................
2.2.2 Electrical Connections 25.........................................
2.2.3 Pneumatic Connections 26.......................................
2.2.4 Mounting Kit 28.................................................
2.2.5 Purge air switching (not in the explosion-proof version) 28............
2.2.6 Restrictors 28...................................................
2.3 Method of Operation 29..........................................
2.4 State as supplied 30.............................................
2.5 Options modules 30.............................................
2.5.1 Options modules in normal and intrinsically safe versions 30..........
2.5.2 Options modules in explosion-proof version 34......................
2.5.3 Alarm module 36................................................
2.5.4 Jy-module 36...................................................
2.5.5 SIA module 37..................................................
2.5.6 Accessories 37.................................................
3 Preparing for Operation 39.................................................
3.1 Instrument identification (type key) 39..............................
3.2 Dimensional drawings 39.........................................
3.3 Assembly 41....................................................
3.3.1 Instructions for using positioners in a wet environment 42.............
3.3.2 Instructions for using positioners which are exposed to great accelerations
or vibrations 44.................................................
3.3.3 Mounting kit ”linear actuator” 6DR4004-8V and 6DR4004-8L 46.......

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3.3.4 Assembly procedure (see figure 3-7, page 48) 46....................
3.3.5 Mounting kit ”Rotary actuator” 6DR4004-8D 49......................
3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) 50...............
3.4 Electrical Connection 55..........................................
3.4.1 Connection variant: Options in positioner in non-intrinsically safe and explo-
sion-proof version 60............................................
3.4.2 Connection variant: Options in the positioner in intrinsically safe
version 61......................................................
3.4.3 Connection variant: Options in the positioner in type of protection
“n” version 63...................................................
3.5 Pneumatic Connection 65........................................
3.6 Commissioning 66...............................................
3.6.1 Preparations for linear actuators 67................................
3.6.2 Automatic initialization of linear actuator 68.........................
3.6.3 Manual initialization of linear actuator 70............................
3.6.4 Preparations for rotary actuator 73.................................
3.6.5 Automatic initialization of rotary actuator 73.........................
3.6.6 Manual initialization of rotary actuators 76..........................
3.6.7 Automatic initialization (structograms) 78...........................
3.7 Copying initialization data (positioner exchange) 82..................
4 Operation 83..............................................................
4.1 Display 83......................................................
4.2 Input keys 83...................................................
4.3 Operating modes 86.............................................
4.4 Parameters 88..................................................
4.5 Diagnosis 103...................................................
4.5.1 Diagnostic display 103............................................
4.5.2 Meaning of the diagnostic values 104...............................
4.5.3 Online-Diagnosis 108.............................................
4.6 Meanings of other display texts 111.................................
4.7 Optimization of the control data 115.................................
4.8 Fault correction 116..............................................
5 Functions/Operation
via PROFIBUS PA 119.......................................................
5.1 System integration 119............................................
5.2 Acyclic Data Transmission 119.....................................
5.2.1 SIMATIC PDM 119...............................................
5.2.1.1 Allocate address 120.............................................
5.2.1.2 Load to device 120...............................................
5.2.1.3 Load to PG/PC 120...............................................
5.2.1.4 Read maintenance information 120.................................
5.2.1.5 Set maintenance information 121...................................
5.2.1.6 Operation 122...................................................
5.2.1.7 Reset 125.......................................................
5.2.1.8 Initialization parameters 126.......................................
5.2.1.9 Self-calibration 126...............................................
5.2.1.10 Write protection 126..............................................
5.3 Cyclic data transmission 127.......................................
5.3.1 Configuration 127................................................
5.3.1.1 Configuring the user data 127......................................
5.3.2 User data via PROFIBUS 129......................................
5.3.2.1 Status 135......................................................

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5.3.2.2 Diagnostics 136..................................................
5.3.3 Diagnostics acc. to PROFIBUS DP (DDLM_Slave_Diag) 137...........
6 Service and Maintenance 139................................................
7 Technical Data 141.........................................................
8 Scope of Delivery 147.......................................................
8.1 Ordering Data 148................................................
8.2 Scope of delivery of options 149....................................
8.3 Scope of delivery of accessories 149................................
9 Index 151..................................................................
10 Appendix 153..............................................................
10.1 Device master data file (GSD) 153..................................
10.2 Literature and catalogs 156........................................
10.3 Certificates 157..................................................
10.3.1 EC Declaration of Conformity (EEx d) 157...........................
10.3.2 EC Declaration of Conformity 158..................................
10.3.3 EC Type-Examination Certificate PTB 99 ATEX 1101 (EEx d) 159......
10.3.4 EC Type-Examination Certificate TÜV 00 ATEX 1654 162.............
10.3.5 Statement of conformity TÜV 01 ATEX 1786 X 170...................
10.3.6 FM Approval Report (EEx d) 173...................................
10.3.7 FM Approval Report 175..........................................
10.3.8 CSA Certificate of Compliance 177.................................
10.3.9 Control Drawing A5E00065622D 179...............................
10.3.10 Control Drawing A5E00065622AA 189..............................

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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 housing.
SSIPART PS2 EEx n in a metal or plastic housing
SSIPART PS2 EEx d in a pressurized explosion proof metal housing
(EEx d)
This manual takes each of these possibilities into consideration. Any
differences between the devices are indicated specially.
Scope of delivery, see chapter 8, page 147.
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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8
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.
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 Classification of Safety-Related Notices
This manual contains notices which you should observe to ensure your
own personal safety, as well as to protect the product and connected
equipment. These notices are highlighted in the manual by a warning
triangle and are marked as follows according to the level of danger:
!DANGER
indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
!WARNING
indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

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 safety alert symbol indicates a potentially hazardous si-
tuation which, if not avoided, may result in property damage.
NOTICE
used without the safety alert symbol indicates a potential situation
which, if not avoided, may result in an undesireable result or state.
.NOTE
highlights important information on the product, using the product, or
part of the documentation that is of particular importance and that will
be of benefit to the user.
0.3 Qualified Personnel
The result of unqualified intervention in the instrument or
nonobservance of the warnings given in this manual or on product
labels can be severe personal injury and/or serious material damage.
Therefore only properly qualified personnel must make changes and
settings in the instrument.
For the purpose of the safety information in this manual and on the
product labels, qualified personnel are those who
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 instrument is designed for connection to functional and safety
extra low voltage.
The instrument is designed for connection to operate voltage or safety
extra--low voltage.
Electrical safety depends only on the power supply equipment.
Pneumatic actuators exert considerable positioning forces. The safety
precautions of the actuator used must therefore be scrupulously
observed during installation and commissioning in order to prevent
injuries.
We explicitly draw your attention to the necessity of observing safety
regulations regarding operation in zones subject to explosion hazard, if
applicable.
The specifications of the examination certificate valid in your country
must be observed. Laws and regulations valid in your country must be
observed for the electrical installation in explosions hazardous areas.
In Germany these are for example:
-- Working reliability regulations,
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079--14 (in the past VDE 0165, T1).
It should be checked whether the available power supply, insofar as
this is required, is compliant with the power supply specified on the
rating plate and specified in the examination certificate valid in your
country.
Take care to avoid electrostatic discharges within the hazardous area,
such as can arise if a dry cloth is used to clean the positioner in the
plastic housing.
Devices with the protection type ”flameproof enclosure” may only be
opened when the power is off.
!WARNING
Devices with the protection type ”intrinsically safe” lose their certifica-
tion as soon as they are operated with circuits that do not conform to
the specifications laid down in the EC type examination certificate valid
in your country.
The successful and safe operation of this equipment is dependent
upon its proper handling, installation, operation and maintenance.

Information for the Operator
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0.4 Use as intended
Use as intended for the purpose of this manual means that this product
must only be used for the applications described in the technical
description (see also Chapter 3 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:
SLeaflet “Operation -- Concise Overview”
explains in visualized form the principle of operation and
parameterization and automatic commissioning.
S“Operating Instructions”
contains the information required for assembly, connection and
commissioning.
The following list contains all the documents available for these
instruments:
Order no. Description
A5E00127924
A5E00127926
A5E00120716
A5E00120717
A5E00120711
A5E00120712
A5E00120713
A5E00120714
A5E00120715
Manual German
Manual English
Operating instructions German/English
Operating instructions French/Italian/Spanish
Leaflet German
Leaflet English
Leaflet French
Leaflet Spanish
Leaflet Italian
This document is also available in electronic form on the Internet
under the address www.siemens.com/fielddevices

Information for the Operator
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12
0.6 Warranty Information
We should like to point out that the content of this manual is not part of
and does not modify a previous or current agreement, undertaking or
legal relationship. Siemens is bound solely by the contract of sale,
which also contains the complete and exclusive warranty. The
contractual warranty conditions are neither extended nor restricted by
this document.
0.7 Delivery Notes
The scope of delivery is listed on the dispatch papers accompanying
the delivery in accordance with the valid contract of sale.
When you open the packaging please observe the information on the
packaging. Check that the delivery is complete and undamaged. If
possible, compare the order number on the rating plates with the
ordering data.
For the scope of delivery please see Chapter 8.
0.8 Standards and Regulations
As far as possible, the harmonized European standards were used to
specify and manufacture this equipment. If harmonized European
standards have not been applied, the standards and regulations of the
Federal Republic of Germany apply (see also Chapter 7 “Technical
Data”).
If this product is used outside the area of applicability of these
standards and regulations, please observe the standards and
regulations in force in the country where the product is operated.

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.
The positioner together with the PROFIBUS PA communications inter-
face are components in a digital process automation system. It commu-
nicates with the master as a slave via the PROFIBUS PS field bus. The
field bus is used not only for communication but also to supply the posi-
tioner with electrical power.
For example, the positioner can be used to control valves as follows:
Swith linear actuator (figure 1-1, page 15) or
Swith rotary actuator VDI/VDE 3845 (figure 1-2, page 15)
Different mounting types are available for linear actuators:
SNAMUR or IEC534
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.
Purpose
Versions
Housing
1

Introduction
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The housing is available in three versions:
SPlastic housing for single- and double-acting actuators
SMetal housing for single-acting actuators
SExplosion-proof metal housing for single and double-acting actua-
tors
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.
Explosion-proof type ”n” versions can be used in explosion hazard zone
2 areas.
The positioner can be expanded with various options modules (chapter
2.5, page 30). The following modules are available in all:
SJy-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 rotary 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
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 in plastic housing
2 Rotary actuator
3 Manometer block, double-acting
Figure 1-2 Positioner mounted on rotary actuator (double-acting)

Introduction
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1
2
3
4
1 Actuator
2 Positioner, single-acting in explosion proof metal housing
3 Lantern
4 Manometer block, single-acting
Figure 1-3 Explosion proof positioner mounted on linear actuator (single-acting)
1
2
3
1 Positioner double-acting in explosion proof metal housing
2 Rotary actuator
3 Manometer block, double-acting
Figure 1-4 Explosion proof positioner mounted on rotary actuator (double-acting)

Introduction
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1.2 General information regarding PROFIBUS
The PROFIBUS-PA(PA = Process Automation) is a variant of the PRO-
FIBUS DP (DP = Decentral Peripheral) which is widely used in
manufacturing engineering.
The PROFIBUS (Process Field Bus) is an open communication sys-
tem for automation engineering and thousands are used all over the
world. It is specified in the European standard EN 50170.
1.2.1 Transmission method
The PROFIBUS PA has a special transmission method and therefore
satisfies the requirements of process automation and manufacturing
engineering. This transmission method is defined in the international
standard IEC61158--2. The low transmission speed reduces the power
loss compared to the PROFIBUS-DP and therefore enables an intrinsi-
cally safe technique for use in hazardous areas.
1.2.2 Topology
The bus topology can, to a large extent, be freely selected so that line,
star and tree structures are possible, as well as mixtures of these. All
kinds of field devices such as transformers, actuators, analyzers, etc.
can be connected to the PROFIBUS PA
The main advantage is in:
Sthe saving of installation costs
Sthe possibility of more extensive diagnostics with an increase in the
availability of system parts
Sthe possibility of automatic tracing of system documentation
Sthe possibility of system optimization in operation
In an automation system, several PROFIBUS PA channels are usually
connected to the fast PROFIBUS-DP with coupling units. The process
control system is also linked to this.
Both bus systems use a uniform protocol layer. This makes the PROFI-
BUS PA a communication-compatible extension of the PROFIBUS DP
into the field.

Introduction
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Master
(class 1)
Master
(class 2)
PROFIBUS-DP
I
PROFIBUS PA
(Field devices, decentralized peripherals,
secondary controls, mains transfer to PROFIBUS-PA)
8x
Slaves
Figure 1-5 Typical PROFIBUS automation system
Figure 1-5 shows the section of a typical PROFIBUS automation sys-
tem. The control system consists of two masters with distributed tasks.
The class 1 master looks after the control and regulation functions,
while the class 2 master enables operating and monitoring functions. A
cyclic exchange of measuring and setting data takes place between
master 1 and the field devices. Parallel to this data, the status data of
the field devices is transmitted to and evaluated in the class 1master.
No field device parameters are set or other device information read
during cyclic operation.
The information necessary for establishing communication is available
to the control system from the stored, device-specific device master
data (GS*) files (available on the Internet at
http://www.ad.siemens.de/csi_e/gsd).
One or more class 2 masters can access the field devices acyclically in
addition to the cyclic mode. With this communication type further infor-
mation can be fetched from the devices or settings made in the de-
vices.
1.2.3 Properties of the PROFIBUS PA
The PROFIBUS PA enables bi-directional communication between a
bus master and the field devices via a shielded two-wire line. At the
same time the power is supplied to the two-wire field devices on the
same lines.