Siemens SIPART Series User manual

SIPART
Electropneumatic positioners
SIPART PS100
Operating Instructions
6DR71..
10/2018
A5E45863537-AA
Introduction and safety
information 1
Description 2
Installing and mounting 3
Connecting 4
Operation via display and
keys 5
Commissioning 6
Parameter assignment and
addressing 7
Troubleshooting 8
Service and maintenance 9
Technical specifications 10
Dimension drawings 11
Technical support A

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.
Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E45863537
Ⓟ 11/2018 Subject to change
Copyright © Siemens AG 2018.
All rights reserved

Table of contents
1 Introduction and safety information..............................................................................................................5
1.1 Product compatibility................................................................................................................5
1.2 Precondition for use.................................................................................................................5
1.3 Checking the consignment.......................................................................................................5
1.4 Security information.................................................................................................................5
2Description....................................................................................................................................................7
2.1 Overview of device components..............................................................................................7
3Installing and mounting.................................................................................................................................9
3.1 Freezing of the exhaust air outlets...........................................................................................9
3.2 Mounting to linear actuator.....................................................................................................10
3.3 Mounting to part-turn actuator................................................................................................13
4 Connecting.................................................................................................................................................17
4.1 Lever for position detection....................................................................................................17
4.2 Grounding..............................................................................................................................17
4.3 Electrical connection..............................................................................................................18
4.4 Pneumatic connection............................................................................................................18
4.4.1 Structure of pneumatic connection.........................................................................................18
4.4.2 Pneumatic connection............................................................................................................19
4.4.3 Response to failure of auxiliary power...................................................................................19
5 Operation via display and keys...................................................................................................................21
6 Commissioning...........................................................................................................................................23
6.1 Initialize in "NO INIT" operating mode....................................................................................24
7 Parameter assignment and addressing......................................................................................................25
7.1 Overview of the menu structure.............................................................................................25
7.2 QUICK START [01]................................................................................................................26
7.3 SETUP [20]............................................................................................................................27
7.4 MAINT/DIAGS [50].................................................................................................................29
8 Troubleshooting..........................................................................................................................................31
8.1 Device status symbols...........................................................................................................31
8.2 Info IDs, error messages and corrective measures...............................................................32
9 Service and maintenance...........................................................................................................................35
9.1 Cleaning the enclosure..........................................................................................................35
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9.2 Return procedure...................................................................................................................35
9.3 Disposal.................................................................................................................................36
10 Technical specifications..............................................................................................................................37
10.1 Input.......................................................................................................................................37
10.2 Output....................................................................................................................................37
10.3 Rated conditions....................................................................................................................38
10.4 Pneumatic data......................................................................................................................38
10.5 Construction...........................................................................................................................39
10.6 Controller................................................................................................................................40
11 Dimension drawings...................................................................................................................................41
A Technical support.......................................................................................................................................43
A.1 Technical support...................................................................................................................43
A.2 QR code label........................................................................................................................44
Table of contents
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4Operating Instructions, 10/2018, A5E45863537.-AA

Introduction and safety information 1
1.1 Product compatibility
Manual ed‐
ition
Comments Device revision Compatible version of device in‐
tegration package
10/2018 First edition FW: 1.00.00
Device revision 1
-
1.2 Precondition for use
This device left the factory in good working condition. In order to maintain this status and to
ensure safe operation of the device, observe these instructions and all the specifications
relevant to safety.
Observe the information and symbols on the device. Do not remove any information or symbols
from the device. Always keep the information and symbols in a completely legible state.
1.3 Checking the consignment
Check the device packaging for damage. Inform your supplier of any damage. Retain the
damaged parts for clarification.
Check the scope of delivery by comparing the shipping documents with your order for
correctness and completeness.
Do not take damaged or incomplete devices into operation under any circumstances.
Special conditions for storage and transportation of device listed in Section "Rated conditions
(Page 38)".
1.4 Security information
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines, and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be connected
to an enterprise network or the internet if and to the extent such a connection is necessary
and only when appropriate security measures (e.g. firewalls and/or network segmentation) are
in place.
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Operating Instructions, 10/2018, A5E45863537.-AA 5

For additional information on industrial security measures that may be implemented, please
visit:
https://www.siemens.com/industrialsecurity
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they are available
and that the latest product versions are used. Use of product versions that are no longer
supported, and failure to apply the latest updates may increase customer’s exposure to cyber
threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed under
https://www.siemens.com/industrialsecurity.
Introduction and safety information
1.4 Security information
SIPART PS100
6Operating Instructions, 10/2018, A5E45863537.-AA

Description 2
2.1 Overview of device components

①Wiring diagram on module cover ⑦Exhaust air outlet with a sound absorber
②Display ⑧Connecting terminals
③Output: Actuating pressure Y1 ⑨Grounding, thread M4
④Input: Supply air PZ ⑩Lower cable gland, thread M20x1.5
⑤Output: Actuating pressure Y2 1) ⑪Upper cable gland, thread M20x1.5
⑥Buttons
1) For double-acting actuators
Figure 2-1 View of positioner with cover open
See also
Structure of pneumatic connection (Page 18)
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Description
2.1 Overview of device components
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Installing and mounting 3
WARNING
High operating force with pneumatic actuators
Risk of injury when working on control valves due to the high operating force of the pneumatic
actuator.
● Please observe the corresponding safety instructions for the pneumatic actuator in use.
CAUTION
Please note the following before working on the control valve and when attaching the
positioner
Danger of injury.
● Prior to working on the control valve, you must move the control valve into a completely
pressureless state. Proceed as follows:
– Depressurize the actuator chambers.
– Switch off the supply air PZ.
– Lock the valve in its position.
● Make sure that the valve has reached the pressureless state.
● If you interrupt the pneumatic auxiliary power to the positioner, the pressureless position
may only be reached after a certain waiting time.
● When mounting, observe the following sequence imperatively to avoid injuries or
mechanical damage to the positioner/mounting kit:
– Mount the positioner mechanically.
– Connect the electrical auxiliary power supply.
– Connect the pneumatic auxiliary power supply.
– Commission the positioner.
3.1 Freezing of the exhaust air outlets
NOTICE
Freezing of the exhaust air outlets
The exhaust air outlets ② can ice up. The function of the device is impaired.
● Do not install the positioner with the base plate ① pointing up.
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Operating Instructions, 10/2018, A5E45863537.-AA 9


①Base plate
②Exhaust air outlets
Figure 3-1 Exhaust air outlets, base plate
3.2 Mounting to linear actuator
Requirements
Depending on the stroke height, you will need the following mounting kit:
● 3 to 35 mm mounting kit 6DR4004-8V
● 35 to 130 mm mounting kit 6DR4004-8V and additional 6DR4004-8L
Parts list 6DR4004-8L
Serial
no.
Quanti‐
ty
Name Note
①1 Lever For the range of stroke from 10 to 130 mm
Parts list 6DR4004-8V
The numbers in "serial no." column refer to the images in the description of the procedure.
Serial
no.
Quanti‐
ty
Name Note
①1 NAMUR mounting bracket
IEC 60534
Standardized connection point for mount with fin, column or plane surface
②1 Pick-up bracket Guides the pulley with the carrier pin and rotates the lever arm.
③2 Clamping piece Installs the pick-up bracket on the actuator spindle
④1 Carrier pin Installation with pulley ⑤ on lever ⑥
⑤1 Pulley Installation with carrier pin ④ on lever ⑥
⑥1 Lever For the range of stroke from 3 to 35 mm
⑦2 U–bolts Only for actuators with columns
Installing and mounting
3.2 Mounting to linear actuator
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Serial
no.
Quanti‐
ty
Name Note
⑧4 Hexagon bolt M8x20 DIN 933–A2
⑨2 Hexagon bolt M8x16 DIN 933-A2, torque, section "Technical specifications > Construc‐
tion (Page 39)"
⑩6 Spring lock washer A8 - DIN 127–A2
⑪6 Washer B8.4 - DIN 125–A2
⑫2 Washer B6.4 - DIN 125–A2
⑬1 Spring VD-115E 0.70 x 11.3 x 32.7 x 3.5
⑭1 Spring lock washer A6 - DIN 137A–A2
⑮1 Lock washer 3.2 - DIN 6799–A2
⑯3 Spring lock washer A6 - DIN 127–A2
⑰3 Socket cap screw M6x25 DIN 7984–A2
⑱1 Hexagon nut M6 - DIN 934–A4
⑲1 Square nut M6 - DIN 557–A4
⑳4 Hexagon nut M8 - DIN 934–A4
Procedure
1. Install the clamping pieces ③ on the actuator spindle. Use spring lock washers ⑯ and
socket cap screws ⑰ for this purpose.
2. Slide the pick-up bracket ② into the milled recesses of the clamping pieces ③.

Figure 3-2 Pick-up bracket
3. Tighten the screws ⑰ so that you can still shift the pick-up bracket ②.
Installing and mounting
3.2 Mounting to linear actuator
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Operating Instructions, 10/2018, A5E45863537.-AA 11

4. If you use a short lever, the carrier pin is already pre-mounted. If you use the long lever
6DR4004-8L, fasten the carrier pin ④ with the existing parts to the long lever.

Figure 3-3 Short lever

Figure 3-4 Long lever 6DR4004-8L with mounted carrier pin ④ and cylinder head screw ⑰
5. Position the carrier pin on the stroke value of the upper scale (90) of the lever ⑥. For
strokes greater than 35 mm, use the long lever, article number 6DR4004-8L.
6. Push the pre-installed lever ⑥ up to the endstop on the positioner shaft. Fasten the lever
⑥ with socket cap screw ⑰.
7. Install the mounting bracket ① at the rear side of the positioner. Use 2 hexagon bolts ⑨,
2 spring lock washers ⑩ and 2 flat washers ⑪ for this purpose.
Figure 3-5 Installation with mounting bracket
8. Select the row of holes. The selection of the row of holes depends on the yoke width of the
actuator. Select the row of holes in such a way that the carrier pin ④ meshes with the pick-
up bracket ② near the spindle. Ensure that the pick-up bracket ② does not touch the
clamping pieces ③.
Installing and mounting
3.2 Mounting to linear actuator
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12 Operating Instructions, 10/2018, A5E45863537.-AA

9. Keep the positioner and the fastening bracket on the actuator. Ensure that the carrier pin
④ is guided inside the pick-up bracket ②.
10.Fasten the positioner on the yoke.

Figure 3-6 Fastening to various yoke types
3.3 Mounting to part-turn actuator
Requirements
● An actuator-specific VDI/VDE 3845 mounting console
● Mounting kit 6DR4004-8D
Procedure
"Part-turn actuator" mounting kit 6DR4004–8D
Sr.
no. *)
Quan
tity
Name Note
①1 Coupling wheel Installation on positioner shaft
②1 Carrier Installing on the actuator shaft
③1 Multiple plate Display of the position, consisting of scale and pointer mark
8 Scale Different divisions
2 Pointer mark Reference point for scale
④ Mount Actuator-specific, VDI/VDE 3845
⑤4 Hexagon bolt M6x12 DIN 933, torque see the section "Technical specifications > Construction
(Page 39)"
⑥4 Lock washer S6
⑦1 Socket cap screw M6x16 DIN 84
⑧1 Washer 6.4 DIN 125
⑨1 Hex socket-head
screw
M4 for coupling wheel
⑩1 Square nut M4 for coupling wheel
1 Machinist's wrench For hexagon socket-head screw ⑨
*) The numbers refer to the images of the description of the installation steps below.
Installing and mounting
3.3 Mounting to part-turn actuator
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Operating Instructions, 10/2018, A5E45863537.-AA 13

1. Rest the actuator-specific VDI/VDE 3845 mount ④ on the rear side of the positioner.
2. Tighten the mount using the hexagon bolts ⑤ and lock washers ⑥.

Figure 3-7 Mount
3. Insert the square nut ⑩ into the coupling wheel. Insert the hex socket head screw ⑨ into
the square nut ⑩.

Figure 3-8 Coupling wheel
4. Push the coupling wheel ① or the stainless steel coupling up to the endstop on the
positioner shaft.
5. Move the coupling wheel or the stainless steel coupling back by approximately 1 mm.
6. Tighten the hexagon socket-head screw ⑨ using the machinist's wrench provided.
Maximum tightening torque = 1 Nm. If you are using the stainless steel coupling, omit the
next step.
Note
Coupling wheel
Instead of the polycarbonate coupling wheel ①, it is possible to use a stainless steel
coupling (article number TGX: 16300-1556).
7. Place the carrier ② on the actuator shaft.
Installing and mounting
3.3 Mounting to part-turn actuator
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8. Tighten the carrier ② using the cylinder head screw ⑦ and the washer ⑧.

Figure 3-9 Carrier
9. Place the positioner and the mount on the actuator carefully. One of the two pins ⑫ of the
coupling wheel ① must fit in the carrier ② when you do this.

Figure 3-10 Orientation of mount
When using the stainless steel coupling (article number TGX: 16300-1556): Place the
positioner and the mount on the actuator carefully. Place the stainless steel coupling on
the actuator shaft.
Installing and mounting
3.3 Mounting to part-turn actuator
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Operating Instructions, 10/2018, A5E45863537.-AA 15

10.Align the positioner/mount at the center of the actuator.
11.Tighten the positioner/mount unit.

Figure 3-11 Positioner with mount attached to the part-turn actuator
Installing and mounting
3.3 Mounting to part-turn actuator
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16 Operating Instructions, 10/2018, A5E45863537.-AA

Connecting 4
4.1 Lever for position detection
WARNING
Lever for position detection
Danger of crushing and shearing with mounting kits which use a lever for position detection.
During commissioning and ongoing operation, severing or squeezing of limbs could occur as
a result of the lever. Risk of injury when working on control valves due to the high operating
force of the pneumatic actuator.
● Do not reach into the range of motion of the lever following mounting of the positioner and
mounting kit.
Two-wire mode
NOTICE
Connection of voltage source to current input
Device damage if a voltage source is connected to the current input Iw (terminals 6 and 7).
● Never connect the current input Iw to a low-resistance voltage source, otherwise the
positioner may be destroyed.
● Always use a high-impedance power source.
● Observe the static destruction limit specified in the "Input (Page 37)".
4.2 Grounding
The positioner is grounded via the mounting kit or via grounding with thread M4 on the
enclosure, ⑨ in Overview of device components (Page 7).
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4.3 Electrical connection
,,8
①Switching amplifier ⑤Analog output of position feedback
②Power source 12 to 30 V DC ⑥Analog input current input 4 to 20 mA
③Signal source 4 to 20 mA ⑦Digital input (floating contact)
④Digital output
Figure 4-1 Wiring diagram
4.4 Pneumatic connection
4.4.1 Structure of pneumatic connection

①Output: Actuating pressure Y2 *)
②Input: Supply air PZ
③Output: Actuating pressure Y1
④Exhaust air outlet with sound absorber, thread G¼
*) for double-acting actuators
Figure 4-2 Pneumatic connection, example
Connecting
4.4 Pneumatic connection
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18 Operating Instructions, 10/2018, A5E45863537.-AA

See also
Overview of device components (Page 7)
4.4.2 Pneumatic connection
WARNING
Pneumatic auxiliary power
Owing to safety reasons, the pneumatic auxiliary power supply must be fed after installation
only if the positioner is switched to the "NO INIT" mode when an electrical signal is available.
Note
Specifications regarding air quality
Observe the specifications regarding the air quality, see section "Technical specifications >
Pneumatic data (Page 38)".
Note
Leakage
Besides continuous air consumption, a leakage can cause the positioner to try to compensate
the position deviation. This will result in premature wear in the entire control device.
● Check with "LECKAGE TEST" [04] if there is leakage.
● If there is leakage, check the pneumatic connections for leaks.
4.4.3 Response to failure of auxiliary power
Overview
The following overview diagram shows the pneumatic connection versions for different actuator
types, regulating action and safety position after an auxiliary power supply failure.
CAUTION
Before working on the control valve
Note that, before working on the control valve, you must first move it to the safety position.
Make sure that the control valve has reached the safety position. If you only interrupt the
pneumatic auxiliary power supply to the positioner, the safety position may in some cases
only be attained after a certain delay period.
Connecting
4.4 Pneumatic connection
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Operating Instructions, 10/2018, A5E45863537.-AA 19

The difference between a failure of auxiliary pneumatic power and a failure of electrical auxiliary
power:
● Failure of electrical auxiliary power means the failure of the signal source at the analog
input 4 to 20 mA.
● Failure of auxiliary pneumatic power means the supply air PZ is interrupted.
Actuator type Response to failure of auxiliary power: The actuator moves into safety position
Failure of electrical auxiliary power Failure of pneumatic auxiliary power
Single-acting Y1 = vented Y1 = vented
Double-acting Y1 = pressurized
Y2 = vented
Y1 = closed
Y2 = closed
Connecting
4.4 Pneumatic connection
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20 Operating Instructions, 10/2018, A5E45863537.-AA