Siemens SIPART PS2 User manual

SIPART PS2 4/20 mA (6DR50...6DR51...6DR52...6DR53...)
Electropneumatic positioners
08/2017Edition
Troubleshooting Guide

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SIPART PS2
Smart Valve Positioner
PS2 Troubleshooting Guide
Service Manual
03/2017
A5E36661550
-AA
Introduction
1
Valve Symptom Guide
2
Troubleshooting Procedures
3
Wiring
4
Appendix A
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E36661550
Ⓟ
08/2017 Subject to change
Copyright © Siemens AG 2017.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 3
Table of contents
1 Introduction............................................................................................................................................. 5
1.1 Purpose of this documentation .................................................................................................5
1.2 Requirements for special applications ......................................................................................5
1.3 Improper commissioning in hazardous areas ...........................................................................5
1.4 Loss of explosion protection .....................................................................................................6
1.5 Opening device in energized state ...........................................................................................6
1.6 Water in compressed air line ....................................................................................................6
1.7 Loss of degree of protection .....................................................................................................7
1.8 Commissioning and operation with error message ..................................................................7
1.9 Basic safety instructions ...........................................................................................................7
1.10 Customer and Product Support ................................................................................................8
1.11 Device Overview .......................................................................................................................8
2 Valve Symptom Guide .......................................................................................................................... 13
3 Troubleshooting Procedures ................................................................................................................. 15
3.1 Actuator Blow-By (double-acting only)....................................................................................15
3.2 Actuator End-Stops.................................................................................................................15
3.3 Air Leak...................................................................................................................................16
3.4 Alarm Parameters ...................................................................................................................17
3.5 Booster(s) Not Properly Tuned ...............................................................................................18
3.6 Change in Valve Stroke ..........................................................................................................20
3.7 Change in Tuning Parameters................................................................................................22
3.8 Deadband Too Large..............................................................................................................23
3.9 Deadband Too Small ..............................................................................................................24
3.10 Erratic Feedback.....................................................................................................................25
3.11 Erratic Input Signal..................................................................................................................26
3.12 High Vibration .........................................................................................................................27
3.13 Initialization Incomplete...........................................................................................................27
3.14 Insufficient Supply Air .............................................................................................................28
3.15 Loose or Worn Linkage...........................................................................................................29
3.16 Manual Mode ..........................................................................................................................31
3.17 Mechanical Blockage..............................................................................................................31

Table of contents
PS2 Troubleshooting Guide
4Service Manual, 03/2017, A5E36661550-AA
3.18 Parameter 1.YFCT................................................................................................................. 31
3.19 Parameter 6.SCUR ................................................................................................................ 33
3.20 Re-Initialization Positioner ..................................................................................................... 33
3.21 Reversing the Action.............................................................................................................. 34
3.22 Setpoint Ramping................................................................................................................... 35
3.23 Stays at 20 mA Position......................................................................................................... 35
3.24 Stiction ................................................................................................................................... 36
3.25 Supply Air Too High ............................................................................................................... 36
3.26 Too Much Restriction ............................................................................................................. 37
3.27 Tubing Lines Configuration .................................................................................................... 38
3.28 Unit Not Initialized .................................................................................................................. 38
3.29 Valve Block Failure ................................................................................................................ 38
3.30 Valve Does Not Go Fully Closed/Open ................................................................................. 42
4 Wiring ................................................................................................................................................... 43
4.1 2-Wire Connection, with terminals 6 through 10.................................................................... 43
4.2 2-Wire Connection, terminals 2 through 10 ........................................................................... 44
4.3 Power Specifications.............................................................................................................. 44
4.4 4 to 20 mA Feedback Module (Iy Module)............................................................................. 46
A Appendix A ........................................................................................................................................... 49
A.1 Transmission Ratio/Slide Bar................................................................................................. 49
A.2 Initialization Procedure........................................................................................................... 50
A.3 NOINI (P-Manual Mode) Troubleshooting ............................................................................. 58
A.4 SIPART PS2 Valve Positioner Fail-Safe Positions................................................................ 62
A.5 Leaflet "Operation - a concise overview" Firmware 4.00....................................................... 67
A.6 Leaflet "Operation - a concise overview" Firmware 5.00....................................................... 69

PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 5
Introduction
1
1.1
Purpose of this documentation
The purpose of this document is to aid with troubleshooting, installation and commissioning
of valve assemblies equipped with the SIPART PS2 valve positioner. Many valve related
issues can be discovered using the numerous SIPART PS2 features. This guide is intended
to direct a qualified technician to a specific troubleshooting procedure so the root-cause
failure of a valve assembly can be revealed. Since numerous symptoms can arise, the
attached
Valve Symptom Guide (Page 13) will guide you to the appropriate troubleshooting
steps. The Appendix section contains useful documents that are referenced in many of the
following troubleshooting procedures. The "NOINI (P-Manual Mode) Troubleshooting"
document, found in Appendix A, can be considered a "catch-all" procedure that should
uncover all issues that will prevent successful PS2 initialization. For mechanical installation
of positioner to actuator, refer to the specific mounting kit instructions.
1.2
Requirements for special applications
Due to the large number of possible applications, each detail of the described device
versions for each possible scenario during commissioning, operation, maintenance or
operation in systems cannot be considered in the instructions. If you need additional
information not covered by these instructions, contact your local Siemens office or company
representative.
Submit a Tech Support Request Online: http://www.usa.siemens.com/support-request
Siemens Valve Instrumentation Website: www.siemens.com/positioner
1.3
Improper commissioning in hazardous areas
WARNING
Improper commissioning in hazardous areas
Device failure or risk of explosion in hazardous areas.
•Do not commission the device until it has been mounted completely and connected in
accordance with the information in Chapter "Technical data" in Operating Instructions
A5E00074631.
•Before commissioning take the effect on other devices in the system into account.

Introduction
1.4 Loss of explosion protection
PS2 Troubleshooting Guide
6Service Manual, 03/2017, A5E36661550-AA
1.4
Loss of explosion protection
WARNING
Loss of explosion protection
Danger of explosion in hazardous areas if the device is open or not properly closed.
•Close the device as described in Chapter "Technical data" in Operating Instructions
A5E00074631.
1.5
Opening device in energized state
WARNING
Opening device in energized state
Danger of explosion in areas subject to explosion hazard.
•Only open the device in a de-energized state.
•Check prior to commissioning that the cover, cover locks, and cable inlets are
assembled in accordance with the directives.
Exception
: Devices having the type of protection "Intrinsic safety Ex i" may also be opened
in energized state in hazardous areas.
1.6
Water in compressed air line
WARNING
Water in compressed air line
Device damage and possibly loss of type of protection. The factory setting for the purging
air selector is "IN". In the "IN" position, water from the compressed air line may enter the
device from the pneumatics during initial commissioning.
•Before commissioning, make sure no water is present in the compressed air line.
If you cannot be sure that there is no water in the compressed air line:
•Set the purging air selector to "OUT". In this way, you prevent water from the
compressed air line from penetrating the device.
•Only set the purging air selector to "IN" again when all water has been discharged from
the compressed air line.

Introduction
1.7 Loss of degree of protection
PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 7
1.7
Loss of degree of protection
Note
Loss of degree of protection
Damage to device if the enclosure is o
pen or not properly closed. The degree of protection
specified on the nameplate or in Chapter "Technical data" in Operating Instructions
A5E00074631 is no longer guaranteed.
•
Make sure that the device is securely closed.
1.8
Commissioning and operation with error message
WARNING
Commissioning and operation with pending error
If an error message appears, correct operation in the process is no longer guaranteed.
•Check the gravity of the error.
•Correct the error.
•If the error still exists:
–Take the device out of operation.
–
Prevent renewed commissioning.
1.9
Basic safety instructions
Qualified personnel for hazardous area applications
Persons who install, connect, commission, operate, and service the device in a hazardous
area must have the following specific qualifications:
●They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures,
aggressive, and hazardous media.
●They are authorized, trained, or instructed in carrying out work on electrical circuits for
hazardous systems.
●They are trained or instructed in maintenance and use of appropriate safety equipment
according to the pertinent safety regulations.

Introduction
1.10 Customer and Product Support
PS2 Troubleshooting Guide
8Service Manual, 03/2017, A5E36661550-AA
1.10
Customer and Product Support
Customer/Product Support
For support and the location of your local Siemens representative, refer to the table below for
the URL of the Process Instrumentation portion of the Siemens public Internet site. Once at
the site, click
Support
in the right column and then
Product Support
. Next select the type of
support desired: sales, technical (see the table below), documentation, or software.
Online Support Request
http://www.siemens.com/automation/support-request
Technical Support 1-800-333-7421; 8 a.m. to 4:45 p.m. eastern standard time, Monday
through Friday (except holidays)
Customer Service &
Returns
1-800-365-8766 (warranty and non-warranty)
Public Internet Site
http://www.usa.siemens.com/pi
Technical Publications in
PDF
Click the above link to go to the Siemens Internet site and then click
Pro-
cess Instrumentation
. In the column to the right, click
Support>Manuals
. In
the column to the left, select the product line (e.g. Pressure or Tempera-
ture or Controllers) to open navigation and search panes.
1.11
Device Overview
How to gain access to the configuration buttons and mechanical settings
Markrolon (Gray Plastic) Housing
●Loosen the four screws on the outside cover.

Introduction
1.11 Device Overview
PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 9
①
Input: Supply air PZ
⑩
Transmission ratio selector
2)
②
Output: Actuating pressure Y1
⑪
Friction clutch adjustment wheel
③
Display
⑫
Basic electronics
④
Output: Actuating pressure Y2
1)
⑬
Connecting terminals of option modules
⑤
Buttons
⑭
Dummy plug
⑥
Restrictor Y1 for single-acting actuators
⑮
Cable gland
⑦
Restrictor Y1 for double-acting actuators
⑯
Wiring diagram on module cover
⑧
Restrictor Y2 for double-acting actuators
⑰
Purging air selector
⑨
Exhaust air outlet with a sound absorber
1) for double-acting actuators
2) only possible when positioner is open
Figure 1-1 View of basic positioner with cover open
Buttons
①
Display
②
Operating mode button
③
Decrement button
④
Increment button

Introduction
1.11 Device Overview
PS2 Troubleshooting Guide
10 Service Manual, 03/2017, A5E36661550-AA
Flameproof Enclosure
●Loosen the screw below the display and flip open the cover to access the push buttons.
①
Input: Supply air PZ
⑧
Restrictor Y2
1)
②
Output: Actuating pressure Y1
⑨
Friction clutch adjustment wheel
③
Display
⑩
Connecting terminals of option modules
④
Output: Actuating pressure Y2
1)
⑪
Connecting terminals of basic electronics
⑤
Buttons
⑫
Safety catch
⑥
Transmission ratio selector
2)
⑬
Ground terminal
⑦
Restrictor Y1
1)
for double-acting actuators
2)
only possible when positioner is open
Figure 1-2 View of the positioner in the flameproof enclosure, cover opened
Note
The friction clutch is black in color.
See also
Initialization Procedure (Page 50)

Introduction
1.11 Device Overview
PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 11
The chart below shows the PS2's operating modes and functions
Operating Mode
Function
Flashing "noini"
(P Manual)
No Initialization - Unit needs to be calibrated
•See Initialization Procedure (Page 50)
Initialization Mode Automatic Commissioning
•Parameter 4 in Configuration menu
Configuration
Contains all setup parameters including positioner features
MAN## Manual Mode – Manually move valve with and
•Does not follow command signal
AUT##
Automatic Mode - Unit follows command signal
Diagnostics Contains:
•Read-only/Resettable maintenance data
•Tuning parameters
•Leak and current detection
Operating
Mode
Representation in the
display
Pos.
Legend
P manual mode
①Potentiometer setting [%]
②Blinking indicator for the non-
initialized status.
Initialization
mode
①
Potentiometer setting [%]
②
Display of the current status of
initialization or a fault message.
③Indicator for ongoing initialization
or a fault message.
Configuring
①
Parameter value
②
Parameter name
③
Parameter number
Manual mode
(MAN)
①
Position [%]
②
Setpoint [%]
③
Fault message

Introduction
1.11 Device Overview
PS2 Troubleshooting Guide
12 Service Manual, 03/2017, A5E36661550-AA
Operating
Mode
Representation in the
display
Pos.
Legend
Automatic
(AUT)
①
Position [%]
②
Setpoint [%]
③Fault message
Diagnostics
①Diagnostic value
②
Diagnostic name
③Diagnostic number

PS2 Troubleshooting Guide
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Valve Symptom Guide
2
Possible Causes
Symptoms
Actuator Blow-By (double-acting only) (Page 15)
•
•
•
•
•
•
•
Actuator End-Stops (Page 15)
•
•
Air Leak (Page 16)
•
•
•
•
•
•
•
•
•
Alarm Parameters (Page 17)
•
Booster(s) Not Properly Tuned (Page 18)
•
•
•
•
Change in Valve Stroke (Page 20)
•
•
Change in Tuning Parameters (Page 22)
•
•
•
•
Deadband Too Large (Page 23)
•
•
•
Deadband Too Small (Page 24)
•
Erratic Feedback (Page 25)
•
•
•
Erratic Input Signal (Page 26)
•
High Vibration (Page 27)
•
•
•
Initialization Incomplete (Page 27)
•
Insufficient Supply Air (Page 28)
•
•
•
•
•
•
•
Loose or Worn Linkage (Page 29)
•
•
•
•
•
•
•
•
•
•
Manual Mode (Page 31)
•
Mechanical Blockage (Page 31)
•
•
•
Parameter 1.YFCT (Page 31)
•
•
•
•
•
Parameter 6.SCUR (Page 33)
•
Re-Initialization Positioner (Page 33)
•
Reversing the Action (Page 34)
•
Setpoint Ramping (Page 35)
•
Stays at 20 mA Position (Page 35)
•
Stiction (Page 36)
•
•
•
•
•
•
•
•
•
•
Supply Air Too High (Page 36)
•
•
Too Much Restriction (Page 37)
•
Tubing Lines Configuration (Page 38)
•
Unit Not Initialized (Page 38)
•
Valve Block Failure (Page 38)
•
•
•
•
•
•
Valve Does Not Go Fully Closed/Open (Page 42)
•
Wiring (Page 43)
•
•

PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 15
Troubleshooting Procedures
3
3.1
Actuator Blow-By (double-acting only)
This issue is found only with double acting applications that are utilizing both Y1 and Y2
output ports.
●One output increases air pressure while the other exhausts air pressure
●This creates the necessary differential pressure in the actuator to move the valve.
●The two air chambers in the actuator must be isolated from each other; otherwise the
differential pressure cannot increase.
●The actuator has an internal leak, and requires servicing if:
–When trying to move the valve to a new position, air is continuously blowing out from
the exhaust port.
–When trying to move the valve to a new position, the two output pressures gauges, Y1
& Y2, are relatively equal in pressure value.
3.2
Actuator End-Stops
Actuator end-stops are adjustable, and must be set correctly for each valve application. If not
set correctly the actuator will drive the valve too far into the valve seat, or over rotate the
valve in the opening position. This can damage the valve and cause poor process
performance.
To identify improper end-stop settings:
●Review actuator/valve manual and determine proper end-stops settings for valve.
●Put PS2 in manual mode:
–From Auto press button once.
–Use and/or to change valve position
●Using and/or buttons move valve to both end-stop positions, and determine if
valve is seating properly.
●If necessary make adjustments to actuator end-stops, refer to actuator’s service manual
for details.
●Re-initialize PS2, see Initialization Procedure (Page 50) (see Appendix A).

Troubleshooting Procedures
3.3 Air Leak
PS2 Troubleshooting Guide
16 Service Manual, 03/2017, A5E36661550-AA
3.3
Air Leak
Note
For firmware 5.00.00 or greater only:
Verify parameter "PNEUM" is set correct
ly:
•
"Std" = Standard Valve Block or
•
"FIP" = Fail In Place Valve Block ("F10" at the end of the model code indicates FIP
option.)
Perform a leak test. Any number greater than 1.0 % will need to be corrected to prevent
premature wear of pneumatic valve block.
●From Manual or "noini" mode, drive the valve to a mid-stroke position using the and/or
buttons.
●Press and hold all three buttons down for at least 2 seconds.
–PS2 will now be in Diagnostic mode, with diagnostic number in lower left hand corner
of display.
●Press button to advance through the diagnostic menu.
●Go to diagnostic: "LEAK".Press and hold button for at least 5 seconds.
–Display will flash between "test" and actual position.
–After one minute, the screen will display the leak rate in percent of travel from original
positon.
●To return to Automatic mode, press and hold the button for 5 seconds.
–The unit will now be in Manual mode.
Press button one time to return to Automatic mode.
●If leak is detected, check pneumatic fittings, air lines and actuator.
–Use some form of leak detection or soap and water around the pneumatic connections
taking care not to wet the internals of the unit.
–Identify leak and use appropriate method(s) for leak correction.

Troubleshooting Procedures
3.4 Alarm Parameters
PS2 Troubleshooting Guide
Service Manual, 03/2017, A5E36661550-AA 17
3.4
Alarm Parameters
If the unit is always going in to alarm, verify configuration settings.
●Parameter "AFCT" (Default is OFF)
–From AUT or MAN mode, press button for 5 seconds. Now observe the number in
the lower left hand corner.
–Continue to press the button until Parameter "AFCT" is reached.
–This parameter should be set to "OFF".
Use and/or to change option.
●Parameters " TIM" & " LIM"
Note
These paramet
ers should never be set to zero.
–Continue to press the button until Parameter " TIM" is reached.
If unit does not display "Auto", then use the button to go downward until "Auto" is
reached.
Repeat same steps with Parameter " LIM"
●Parameter "XDIAG"
–Continue to press the button until "XDIAG" is reached.
–This parameter should be set to "OFF".
Use and/or to change option.
–To return to Automatic mode, press and hold the button for 5 seconds.
–The unit will now be in Manual mode.
–Press the button one time to return to Automatic mode.

Troubleshooting Procedures
3.5 Booster(s) Not Properly Tuned
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18 Service Manual, 03/2017, A5E36661550-AA
3.5
Booster(s) Not Properly Tuned
Pneumatic volume boosters should always be equipped with a bypass needle valve. This
needle valve can be external or integral to the booster housing. Needle valve adjustments
are necessary to achieve proper valve response.
●If PS2 is in Auto and currently operating the valve:
–Rotate the needle valve counter-clockwise to slowdown response and reduce
overshoots.
–Rotate the needle valve clockwise to increase valve response
–Re-initialize PS2 after any needle valve adjustments; see Initialization Procedure
(Page 50)(see Appendix).
●A volume booster must be setup BEFORE initializing a valve positioner. The P-manual
mode ("NOINI" flashing), see display example below, can be used to perform this setup.
The P-manual mode will appear once proper electrical power is applied to a new PS2
valve positioner.
●If PS2 is currently initialized, activate "NOINI" mode:
–Press and hold button to enter configuration mode
–Configuration parameter number appears in lower left corner of display.
–Use button to reach parameter: "4 INITA".Press and hold button until "no"
appears on top of display.
–Press and hold button to exit configuration mode
–Display will be similar to the following (numerical value will vary).