Siemens SIPART PS2 User manual

Introduction and general
safety notes
1
Description
2
Installing
3
Connecting
4
Scope of delivery
5
Certificates
6
SIPART
Electropneumatic positioner
SIPART PS2 with mechanical limit
switch module
Operating Instructions (Compact)
04/2007
A5E01179056-01
Supplement to the equipment manuals
6DR5**0-*N*3*-**** in the plastic enclosure
6DR5**1-*N*3*-**** in the aluminum enclosure
6DR5**2-*N*3*-**** in the stainless steel enclosure
6DR5**0-*E*3*-**** in the plastic enclosure
6DR5**1-*E*3*-**** in the aluminum enclosure
6DR5**2-*E*3*-**** in the stainless steel enclosure

Safety Guidelines
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the 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.
Siemens AG
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Ordernumber: A5E01179056
Ⓟ 06/2007
Copyright © Siemens AG 2007.
Technical data subject to change

SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 3
Table of contents
1 Introduction and general safety notes........................................................................................................ 5
1.1 Purpose of this documentation ......................................................................................................5
1.2 General information .......................................................................................................................5
1.3 Correct usage.................................................................................................................................5
1.4 Laws and directives .......................................................................................................................5
1.5 Qualified Personnel........................................................................................................................6
1.6 The meaning of the pictograms .....................................................................................................6
2 Description................................................................................................................................................. 7
3 Installing .................................................................................................................................................... 9
3.1 Safety notes for installing the option modules ...............................................................................9
3.2 Set of signs for the non-intrinsically safe version.........................................................................10
3.3 Installing the mechanical limit switch module ..............................................................................10
3.4 Setting the limits of the mechanical limit switch module..............................................................14
4 Connecting .............................................................................................................................................. 15
4.1 Connection safety note ................................................................................................................15
4.2 Mechanical limit switch module wiring diagram, not Ex...............................................................17
4.3 Mechanical limit switch module wiring diagram, EEx i.................................................................18
4.4 Connecting the mechanical limit switch module ..........................................................................19
5 Scope of delivery ..................................................................................................................................... 21
6 Certificates............................................................................................................................................... 23

SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 5
Introduction and general safety notes 1
1.1 Purpose of this documentation
These instructions contain all the information you need for commissioning and using the
device.
It is aimed both at persons mechanically installing the device, connecting it electronically,
configuring the parameters and commissioning it as well as service and maintenance
engineers.
1.2 General information
This device left the factory free from safety problems. In order to maintain this status and to
ensure safe operation of the device, please observe the safety information and warnings
contained in these instructions.
1.3 Correct usage
The device may only be used for the purposes specified in these instructions.
Insofar as they are not expressly stated in these instructions, all changes to the device are
the sole responsibility of the user.
1.4 Laws and directives
The regulations of the test certification valid in your country are to be observed.
Electrical connection in hazardous zones with explosive atmospheres
The national directives and laws for hazardous areas valid in your country must be observed
for electrical connection. For example, in Germany these are:
● Operational safety regulations
● Directive for the installation of electrical systems in hazardous areas DIN EN 60079-14
(previously VDE 0165, T1)

Introduction and general safety notes
1.5 Qualified Personnel
SIPART PS2 with mechanical limit switch module
6 Operating Instructions (Compact), 04/2007, A5E01179056-01
1.5 Qualified Personnel
Qualified personnel are people who are familiar with the installation, mounting,
commissioning, and operation of the product. These people have the following qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
aggressive as well as hazardous media.
● For explosion-proof devices: 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 safety regulations.
● They should be trained in first aid.
1.6 The meaning of the pictograms
The pictograms on the warning labels are described below:
Notice Pay attention to the operating instructions
Warning hot surfaces. For ambient temperatures above 55°C there is a danger
of burns on contact.
Isolate the device from power using a circuit breaker.
Protect the device from shocks (otherwise the degree of protection IP66 is not
guaranteed).
Protective insulation; device in protection class II

SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 7
Description 2
The following are described in these Operating Instructions (Compact):
● Assembling, installing and connecting the mechanical limit switch module of both the non-
intrinsically safe and the intrinsically safe version.
● Subsequent installation of the mechanical limit switch module of both the non-intrinsically
safe and the intrinsically safe version.
For more information on the electropneumatic positioner, please see its Programming
Manual.

SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 9
Installing 3
3.1 Safety notes for installing the option modules
WARNING
Assembling the components
For the composition of the components it must be ensured that only positioners and option
modules that are certified for the relevant operating range are combined.
This condition applies in particular to the safe operation of the positioner in the areas of
zone 1, 2 and 22, in which the atmosphere can be potentially explosive. Make sure you
observe the device categories 2 and 3 of the device itself as well as the ones of its option
modules.
NOTICE
To observe before installation
Before you install option modules, you must open the housing of the positioner. Please note
that the degree of protection IP66/NEMA 4x is not guaranteed when the housing is open.

Installing
3.2 Set of signs for the non-intrinsically safe version
SIPART PS2 with mechanical limit switch module
10 Operating Instructions (Compact), 04/2007, A5E01179056-01
3.2 Set of signs for the non-intrinsically safe version
Warning labels
Fasten the included warning label on the side across from the type plate. There are different
warning labels depending on the housing material, as described below.
Figure 3-1 Warning label for a device with a plastic enclosure
Figure 3-2 Warning label for a device with an aluminum enclosure
Figure 3-3 Warning label for a device with a stainless steel enclosure
3.3 Installing the mechanical limit switch module
Preparing for installation
WARNING
Zone 2 and 22
It is not permissible to use the mechanical limit switch module in the zones 2 and 22.
To prepare the installation, proceed as follows:
1. Open the positioner.
2. To do this, loosen the four fixing screws of the housing cover with a Phillips screwdriver.
3. Disconnect the power supply cables or isolate them from power.
4. Remove the module cover.
5. To do this, remove the two screws with a screwdriver.

Installing
3.3 Installing the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 11
Overview of the installation of the option modules
The following drawing will assist you in installing the mechanical limit switch module:
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① Module cover ⑬ SIA module or mechanical limit switch module
② Fixing screws ⑭ Insulating cover
③ Fixing screws ⑮ Motherboard
④ Actuating disc bearing ⑯ Ribbon cable for alarm unit
⑤ Pneumatic block ⑰ Ribbon cable for Iy module
⑥ Transmission ratio selector ⑱ Type plate
⑦ Adjustment wheel for friction clutch Set of signs
⑧ Actuating disc for A2, terminals 51 and 52 ⑲ Warning label on the side across from the type plate
⑪ Iy module ⑳ Wiring diagram
⑫ Alarm unit

Installing
3.3 Installing the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
12 Operating Instructions (Compact), 04/2007, A5E01179056-01
Function
The module is used to signal two limits. The limits are signaled by means of electrical switch
contacts.
Equipment features
Figure 3-4 Mechanical limit switch module
The mechanical limit switch module contains:
● A binary output for the output of a group fault message.
● Two switches for signaling two limits that can be set mechanically. These two switches
are electrically independent from the rest of the electronic system.

Installing
3.3 Installing the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 13
Installing the mechanical limit switch module
To install the mechanical limit switch module, proceed as follows:
1. Remove all electrical connects in the motherboard.
2. Loosen both fixing screws on the motherboard.
3. Snap out the motherboard by carefully bending the four holders.
4. Insert the mechanical limit switch module from above until it reaches the upper circuit
board rail of the rack.
5. Push the mechanical limit switch module in the circuit board rail of the rack approx. 3 mm
toward the right.
6. Screw the special screw through the mechanical limit switch module into the axle of the
positioner. Tighten the special screw with a torque of 2 Nm.
NOTICE
A pin is pressed into the actuating disc bearing. Set this pin upright before it is touched
by the special screw. In order that the pins slot into the special screw, you must turn the
actuating disc bearing and the special screw simultaneously.
7. The insulating cover is locate above the mechanical limit switch module. Place the
insulating cover one on side under the mother board surface against the wall of the
container. The recesses in the insulating cover must slot into the corresponding webs on
the container wall.
8. Lay the insulating cover on the mechanical limit switch module by carefully bending the
container walls.
9. Snap the motherboard into the four holders.
10.Secure the motherboard with both fixing screws again.
11.Reestablish all electrical connections between the motherboard and the option modules.
Connect the motherboard and the option modules with the ribbon cables included with
the delivery. Connect the motherboard and the potentiometer with the potentiometer
cable.
12.Fix the module cover included with the delivery with both screws. Do not use the standard
module cover.
13.From the set of plates enclosed, select the plates that are already on the standard
version of the module cover. Stick the selected plates to the installed module cover as on
the standard version.
14.Reestablish all electrical connections.

Installing
3.4 Setting the limits of the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
14 Operating Instructions (Compact), 04/2007, A5E01179056-01
3.4 Setting the limits of the mechanical limit switch module
Setting limits L1 and L2
To set the limits, proceed as follows:
1. Drive the actuator to the first desired mechanical position.
2. Adjust the top actuating disc by hand until the output signal on terminals 41 and 42
changes. Set a high-low or low-high change as follows:
– Turn the actuating disc over the switching point out until you reach the next switching
point.
3. Drive the actuator to the second desired mechanical position.
4. Adjust the bottom actuating disc by hand until the output signal on terminals 51 and 52
changes. Set a high-low or low-high change as follows:
– Turn the actuating disc over the switching point out until you reach the next switching
point.
Note
To prevent the actuating discs from being accidentally moved during operation, the
actuating discs are designed to be relatively sluggish. You can achieve an easier and
more sensitive adjustment by temporarily reducing the friction. To do this, open and
close the actuator several times while at the same time holding the actuating discs
steady.

SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 15
Connecting 4
4.1 Connection safety note
DANGER
Low-voltage supply
When you supply the module in the non-intrinsically safe version with low voltage, you must
be sure to observe the following safety rules before starting work on the device:
1. Isolate the device from power. Use a circuit breaker positioned near the device to do
this.
2. Make sure that the device cannot be switched back on inadvertently.
3. Make sure the device is truly isolated from power.
WARNING
Assembling the components
For the composition of the components it must be ensured that only positioners and option
modules that are certified for the relevant operating range are combined.
This condition applies in particular to the safe operation of the positioner in the areas of
zone 1, 2 and 22, in which the atmosphere can be potentially explosive. Make sure you
observe the device categories 2 and 3 of the device itself as well as the ones of its option
modules.
WARNING
Protection against mechanical influences
In order to guarantee the degree of protection IP66/NEMA 4x, you must protect the module
against mechanical influences. This is achieved by selecting a suitable installation location
or by installing a suitable protection device. This required protection applies to the operation
of the module with the following voltages:
•> AC 16 V
•> DC 35 V, low voltage

Connecting
4.1 Connection safety note
SIPART PS2 with mechanical limit switch module
16 Operating Instructions (Compact), 04/2007, A5E01179056-01
NOTICE
Maximal values for terminals 41/42 and 51/52
The following maximum values concern only terminals 41, 42, 51, and 52:
•Maximum voltage:
– Not Ex: AC 250 V or DC 24 V
– Ex: 30 V DC
•Maximum current:
– Not Ex: 4 A AC/DC
– Ex: 100 mA DC
•Maximum performance:
– Ex: 750 mW
No safe separation between the terminals can be guaranteed.
NOTICE
Installing/connecting
Only qualified personnel is permitted to install and connect the mechanical limit switch
module.
NOTICE
To observe before connecting
Before you connect the mechanical limit switch module, observe the following conditions:
•Only qualified personnel is permitted to connect the mechanical limit switch module.
•Isolate all wires from power and make sure the device is truly isolated from power.
•Construct the cross-sectional area of the connection cables in such a way that it is
appropriate for the permitted current load.
•Selected the wires on the basis of the following rule: The temperature at which the wires
are permitted to be used must be 25°C above the maximum ambient temperature.
•Operate the Ex-version only in intrinsically safe circuits with approved switching
amplifiers.
NOTICE
Preparing the cables or stranded wires
1. Insulate the cables in such a way that the insulation is flush with the terminal when
plugging in the wires.
2. Fit ferrules to the ends of stranded wires.

Connecting
4.2 Mechanical limit switch module wiring diagram, not Ex
SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 17
4.2 Mechanical limit switch module wiring diagram, not Ex
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Connecting
4.3 Mechanical limit switch module wiring diagram, EEx i
SIPART PS2 with mechanical limit switch module
18 Operating Instructions (Compact), 04/2007, A5E01179056-01
4.3 Mechanical limit switch module wiring diagram, EEx i
WARNING
Electrical circuits
Only certified intrinsically safe electrical circuits can be connected as power supply, control,
and signal electrical circuits.
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Connecting
4.4 Connecting the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
Operating Instructions (Compact), 04/2007, A5E01179056-01 19
4.4 Connecting the mechanical limit switch module
Preparing to connect the mechanical limit switch module
NOTICE
Before you connect the mechanical limit switch module, observe the following conditions:
1. Only qualified personnel is permitted to connect the mechanical limit switch module.
2. Isolate all wires from power and make sure the device is truly isolated from power.
3. Construct the cross-sectional area of the connection cables in such a way that it is
appropriate for the permitted current load.
4. Selected the wires on the basis of the following rule: The temperature at which the wires
are permitted to be used must be 25°C above the maximum ambient temperature.
5. Operate the Ex-version only in intrinsically safe circuits with approved switching
amplifiers.
NOTICE
Prepare the cables or stranded wires as follows:
1. Insulate the cables in such a way that the insulation is flush with the terminal when
plugging in the wires.
2. Fit ferrules to the ends of stranded wires.
Connecting the mechanical limit switch module
How to connect the mechanical limit switch module:
1. Loosen the screw ⑱ on the transparent cover ⑲.
2. Pull the transparent cover ⑲ to the front stop.
3. Tighten each cable in the corresponding terminal.
4. Push the transparent cover ⑲ to the stop of the motherboard.
5. Tighten the screw ⑱ on the transparent cover ⑲.
6. Attach the wires of each switch in pairs on the lug of the circuit board. Use the cable ties
⑳ included with the delivery for this.

Connecting
4.4 Connecting the mechanical limit switch module
SIPART PS2 with mechanical limit switch module
20 Operating Instructions (Compact), 04/2007, A5E01179056-01
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Figure 4-3 Connecting the cables
⑱ Screw
⑲ Cover
⑳ Cable tie