SIPART PS2 with PROFIBUS PA

SIPART PS2 with PROFIBUS PA
SIPART
Electropneumatic positioners
SIPART PS2 with PROFIBUS PA (6DR55..)
Operating Instructions
Edition
02/2016
Answers for industry.
Introduction
1
Safety information
2
SIPART
Description
3
Electropneumatic positioner
SIPART PS2 with PROFIBUS PA
Installing/mounting
4
Connect
5
Operation
6
Commissioning
7
Functional safety
8
Parameter assignment
9
Operating Instructions
6DR55..
02/2016
A5E00127926-AB
Functions/operations using
PROFIBUS PA
10
Alarm, fault and system
messages
11
Service and maintenance
12
Technical data
13
Dimension drawings
14
Spare parts / accessories /
scope of delivery
15
Appendix
A
Abbreviations
B
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
Order number: A5E00127926
Ⓟ 11/2015 Subject to change
Copyright © Siemens AG 2016.
All rights reserved
Table of contents
1
2
3
Introduction.................................................................................................................................................13
1.1
Purpose of this documentation...............................................................................................13
1.2
History....................................................................................................................................13
1.3
Purpose..................................................................................................................................14
1.4
Checking the consignment.....................................................................................................14
1.5
Transportation and storage....................................................................................................15
1.6
Product information................................................................................................................15
1.7
Notes on warranty..................................................................................................................15
Safety information.......................................................................................................................................17
2.1
Precondition for use...............................................................................................................17
2.2
Warning symbols on the device.............................................................................................17
2.3
Laws and directives................................................................................................................17
2.4
Conformity with European directives......................................................................................17
2.5
Improper device modifications...............................................................................................18
2.6
Requirements for special applications...................................................................................18
2.7
Use in hazardous areas.........................................................................................................19
Description..................................................................................................................................................21
3.1
Function.................................................................................................................................21
3.2
3.2.1
3.2.2
3.2.3
Structure.................................................................................................................................21
Design overview.....................................................................................................................21
Nameplate layout...................................................................................................................24
Explanation of Ex information................................................................................................25
3.3
3.3.1
3.3.2
3.3.3
Device components................................................................................................................26
Overview of device components............................................................................................26
Overview of device components (Ex).....................................................................................27
Basic electronics....................................................................................................................28
3.4
3.4.1
3.4.2
Functional principle................................................................................................................28
PROFIBUS system configuration...........................................................................................30
SIMATIC PDM........................................................................................................................31
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
PROFIBUS PA.......................................................................................................................31
Overview................................................................................................................................31
Transmission technology.......................................................................................................31
Bus topology..........................................................................................................................32
Properties...............................................................................................................................33
Profile.....................................................................................................................................33
Connection.............................................................................................................................33
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
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Table of contents
3.5.7
3.5.8
4
5
Installing/mounting......................................................................................................................................37
4.1
4.1.1
Basic safety instructions.........................................................................................................37
Proper mounting.....................................................................................................................40
4.2
Mounting the linear actuator...................................................................................................40
4.3
Mounting the part-turn actuator..............................................................................................45
4.4
Using the positioner in a humid environment.........................................................................50
4.5
4.5.1
4.5.2
Position controllers subjected to fast acceleration or strong vibration...................................51
Introduction locking the setting...............................................................................................51
Procedure locking the setting.................................................................................................52
4.6
External position detection.....................................................................................................53
4.7
4.7.1
4.7.1.1
4.7.1.2
4.7.1.3
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
Installing the optional modules...............................................................................................54
General information about the installation of option modules................................................54
Unsuitable device for the hazardous area..............................................................................54
Installing optional modules in the standard and intrinsically safe version..............................54
Installing the optional modules in the "flameproof enclosure" version...................................58
Position feedback module......................................................................................................62
Alarm module.........................................................................................................................63
Slit initiator alarm module.......................................................................................................64
Mechanical limit switch module..............................................................................................67
Internal NCS module 6DR4004-5L/-5LE................................................................................70
EMC filter module...................................................................................................................73
Accessories............................................................................................................................76
Connect......................................................................................................................................................77
5.1
5.1.1
5.1.2
5.1.3
Basic safety instructions.........................................................................................................77
Improvement of interference immunity...................................................................................80
Interference immunity.............................................................................................................81
Safety shutdown.....................................................................................................................81
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.5.1
5.2.5.2
5.2.5.3
5.2.5.4
5.2.6
5.2.6.1
5.2.6.2
Electrical wiring......................................................................................................................82
Bus cable...............................................................................................................................82
Wiring diagram for basic electronics......................................................................................85
Wiring NCS sensor to EMC filter module...............................................................................86
Connecting the external position detection system to the EMC filter module........................87
Option modules......................................................................................................................90
Alarm modules 6DR4004-6A and -8A....................................................................................90
Position feedback modules 6DR4004-6J and -8J..................................................................91
SIA modules 6DR4004-6G and -8G.......................................................................................91
Mechanical limit switch modules 6DR4004-6K and -8K.........................................................92
Option device version M12 connector....................................................................................93
M12 connector in the basic device.........................................................................................94
M12 connector for connection of the outputs of the alarm module 6DR4004-6A / -8A (Z D55)....................................................................................................................................94
M12 connector for connecting the outputs of the position feedback module 6DR4004-6J /
8J (-Z D53).............................................................................................................................95
M12 connector for connecting the external position detection system (-Z D54)....................95
M12 connector for connecting the outputs of the SIA module 6DR4004-6G /-8G (-Z D56)......95
5.2.6.3
5.2.6.4
5.2.6.5
6
Number of connectable devices.............................................................................................35
Assigning the device addresses.............................................................................................35
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Table of contents
6
7
8
9
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
Pneumatic connection............................................................................................................96
Pneumatic connection for 6DR55.0/1/2/3..............................................................................96
Integrated pneumatic connection...........................................................................................96
Pneumatic connection for 6DR55.5-0E..................................................................................97
Reaction to failure of auxiliary powers...................................................................................98
Pneumatic connection..........................................................................................................101
5.4
Restrictors............................................................................................................................102
Operation..................................................................................................................................................103
6.1
6.1.1
6.1.2
6.1.3
Operating elements..............................................................................................................103
Display.................................................................................................................................103
Buttons.................................................................................................................................104
Firmware version .................................................................................................................105
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Operating modes..................................................................................................................106
Overview of operating modes..............................................................................................106
Changing the operating mode..............................................................................................107
Overview of configuration.....................................................................................................108
Description of operating modes...........................................................................................108
Optimization of controller data.............................................................................................110
Commissioning.........................................................................................................................................113
7.1
Basic safety instructions.......................................................................................................113
7.2
Overview..............................................................................................................................115
7.3
Sequence of automatic initialization.....................................................................................116
7.4
Purge air switching...............................................................................................................122
7.5
7.5.1
7.5.2
7.5.3
Commissioning linear actuators...........................................................................................123
Preparing linear actuators for commissioning......................................................................123
Automatic initialization of linear actuators............................................................................124
Manual initialization of linear actuators................................................................................127
7.6
7.6.1
7.6.2
7.6.3
Commissioning part-turn actuators......................................................................................130
Preparing part-turn actuators for commissioning.................................................................130
Automatic initialization of part-turn actuators.......................................................................131
Manual initialization of part-turn actuators...........................................................................133
7.7
Device replacement.............................................................................................................136
Functional safety......................................................................................................................................139
8.1
Range of applications for functional safety..........................................................................139
8.2
Safety function.....................................................................................................................139
8.3
Safety Integrity Level (SIL)...................................................................................................140
8.4
Settings................................................................................................................................142
8.5
Safety characteristics...........................................................................................................143
8.6
Maintenance/check..............................................................................................................143
Parameter assignment.............................................................................................................................145
9.1
Introduction to parameter assignment section.....................................................................145
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
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Table of contents
8
9.2
9.2.1
9.2.2
9.2.3
Tabular overview of the parameters.....................................................................................146
Overview of initialization parameters 1 to 5.........................................................................146
Overview of application parameters 6 to 55.........................................................................147
Overview of advanced diagnostics parameters A to P.........................................................150
9.3
9.3.1
9.3.1.1
9.3.1.2
9.3.1.3
9.3.1.4
9.3.1.5
9.3.2
9.3.2.1
9.3.2.2
9.3.2.3
9.3.2.4
9.3.2.5
9.3.2.6
9.3.2.7
9.3.2.8
9.3.2.9
9.3.2.10
9.3.2.11
9.3.2.12
9.3.2.13
9.3.2.14
9.3.2.15
9.3.2.16
9.3.2.17
9.3.2.18
9.3.2.19
9.3.2.20
9.3.2.21
9.3.2.22
9.3.2.23
9.3.2.24
9.3.2.25
9.3.3
9.3.3.1
9.3.3.2
9.3.3.3
9.3.3.4
9.3.3.5
9.3.3.6
9.3.3.7
9.3.3.8
9.3.3.9
9.3.3.10
9.3.3.11
9.3.3.12
Description of parameters....................................................................................................154
Initialization parameters 1 to 5.............................................................................................154
'1.YFCT' Type of actuator....................................................................................................154
'2.YAGL' Rated angle of rotation of feedback......................................................................155
'3.YWAY' Range of stroke....................................................................................................156
'4.INITA' Initialization (automatically)...................................................................................156
'5.INITM' Initialization (manual)............................................................................................157
Application parameters 6 to 55............................................................................................157
'6.SDIR' Setpoint direction...................................................................................................157
'7.TSUP' Setpoint ramp UP / '8.TSDO' Setpoint ramp DOWN.............................................158
'9.SFCT' Setpoint function....................................................................................................158
'10.SL0' ... '30.SL20' Setpoint turning point..........................................................................159
'31.DEBA' Deadband of controller........................................................................................160
'32.YA' Manipulated variable limiting Start / '33.YE' Manipulated variable limiting End.......160
'34.YNRM' Manipulated variable standardization.................................................................160
'35.YDIR' Direction of action of manipulated variable for display and position feedback.....162
'36.YCLS' Tight closing with manipulated variable...............................................................162
'37.YCDO' Lower value for tight closing / '38.YCUP' Upper value for tight closing..............163
'39.BIN1' / '40.BIN2' Function of binary inputs.....................................................................163
'41.AFCT' Alarm function.....................................................................................................164
'42.A1' / '43.A2' Alarm response threshold...........................................................................166
'44.\\FCT' Function fault message........................................................................................166
'45.\\TIM' Monitoring time for setting of fault messages.......................................................167
'46.\\LIM' Response threshold for fault message.................................................................167
'47.\\STRK' Limit monitoring for the number of total strokes................................................168
'48.PRST' Preset..................................................................................................................168
'49.PNEUM' Fail in place......................................................................................................169
'50.XDIAG' Activation of extended diagnostics....................................................................170
'51.FSTY' Safety position.....................................................................................................171
'52.FSTI' Monitoring time to set the safety position..............................................................172
'53.FSVL' Safety setpoint.....................................................................................................172
'54.STNR' Station number....................................................................................................172
'55.IDENT' Device operating mode (ID No.)........................................................................173
Extended diagnostics parameters A to P.............................................................................173
Partial stroke test 'A.\\PST'...................................................................................................173
Monitoring of dynamic control valve behavior 'b.\\DEVI'......................................................179
Monitoring pneumatic leakage 'C.\\LEAK'............................................................................181
Monitoring the stiction (slipstick) 'd.\\STIC'...........................................................................183
Monitoring the deadband 'E.\\DEBA'....................................................................................185
Monitoring the lower endstop ''F.\\ZERO'.............................................................................186
Monitoring the upper endstop 'G.\\OPEN'............................................................................187
Monitoring the low limit temperature 'H.\\TMIN'...................................................................189
Monitoring the high limit temperature 'J.\\TMAX'..................................................................190
Monitoring the number of total strokes 'L.\\STRK'................................................................192
Monitoring the number of changes in direction 'O.\\DCHG'.................................................193
Monitoring the position average value 'P.\\PAVG'................................................................195
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Table of contents
10
Functions/operations using PROFIBUS PA.............................................................................................199
10.1
System integration...............................................................................................................199
10.2
10.2.1
10.2.2
10.2.2.1
10.2.2.2
10.2.2.3
10.2.2.4
10.2.2.5
10.2.2.6
10.2.2.7
10.2.2.8
10.2.2.9
10.2.2.10
10.2.2.11
10.2.2.12
10.2.2.13
10.2.2.14
10.2.2.15
10.2.2.16
10.2.2.17
10.2.2.18
10.2.2.19
10.2.2.20
10.2.2.21
10.2.3
10.2.3.1
10.2.3.2
10.2.4
10.2.4.1
10.2.4.2
10.2.4.3
10.2.4.4
10.2.4.5
10.2.4.6
10.2.4.7
Acyclic data transfer.............................................................................................................199
Acyclic data transfer using SIMATIC PDM...........................................................................199
'Device' menu.......................................................................................................................200
Load to device......................................................................................................................200
Load into PG/PC..................................................................................................................200
Assign address and TAG.....................................................................................................200
Value comparison................................................................................................................200
Object properties..................................................................................................................201
Calibration report..................................................................................................................202
Change log...........................................................................................................................203
Wizard..................................................................................................................................204
Partial stroke test (PST).......................................................................................................205
PST trace characteristic.......................................................................................................205
Offline leakage test..............................................................................................................206
Maintenance and diagnostics...............................................................................................206
Initialization parameters.......................................................................................................207
Initialization..........................................................................................................................207
Operation.............................................................................................................................208
Simulation............................................................................................................................210
Date and time in the device..................................................................................................211
Write protection....................................................................................................................211
Reset parameters in PDM....................................................................................................211
Reset parameters on the device..........................................................................................212
Reset the field device...........................................................................................................212
'View' menu..........................................................................................................................213
Process variables / diagnostics cockpit................................................................................213
Starting the lifelist.................................................................................................................214
'Diagnostics' menu...............................................................................................................214
Updating diagnostics............................................................................................................214
Device diagnostics...............................................................................................................216
Maintenance information......................................................................................................217
Trend characteristic..............................................................................................................218
Histograms...........................................................................................................................218
Alarm logbook......................................................................................................................218
Characteristic curve.............................................................................................................219
10.3
10.3.1
10.3.2
10.3.2.1
10.3.2.2
10.3.3
10.3.3.1
10.3.3.2
10.3.3.3
10.3.3.4
10.3.3.5
10.3.3.6
Cyclic data transfer..............................................................................................................219
Configuration........................................................................................................................219
Useful data through PROFIBUS..........................................................................................222
Possible combinations of the useful data.............................................................................223
Diagnostics...........................................................................................................................227
Adjustable status (condensed status)..................................................................................228
Diagnostics messages in case of deactivated condensed status........................................232
Diagnostics messages in case of activated condensed status............................................234
Definition of the status..........................................................................................................236
Sub-status for deactivated condensed status......................................................................236
Sub-status for activated condensed status..........................................................................237
List of diagnostics events with status and diagnostics message for deactivated
condensed status.................................................................................................................237
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
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Table of contents
10.3.3.7
11
Alarm, fault and system messages...........................................................................................................245
11.1
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
Output of system messages in the display...........................................................................245
System messages during operation.....................................................................................245
System messages before initialization.................................................................................246
System messages during initialization.................................................................................247
System messages when exiting the Configuration mode....................................................249
System messages during operation.....................................................................................250
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.4.1
11.2.4.2
11.2.4.3
11.2.4.4
11.2.4.5
11.2.4.6
11.2.4.7
11.2.4.8
11.2.4.9
11.2.4.10
11.2.4.11
11.2.4.12
11.2.4.13
11.2.4.14
11.2.4.15
11.2.4.16
11.2.4.17
11.2.4.18
11.2.4.19
Diagnostics...........................................................................................................................252
Display of diagnostics values...............................................................................................252
Saving the diagnostics values..............................................................................................253
Overview of diagnostics values............................................................................................253
Meaning of the diagnostic values.........................................................................................255
Diagnostic value '1.STRKS - Number of total strokes'.........................................................255
Diagnostic value '2.CHDIR - Number of changes in direction'.............................................255
Diagnostic value '3.\\CNT - Number of fault messages'.......................................................255
Diagnostic value '4.A1CNT - Number of alarms 1' / '5.A2CNT - Number of alarms 2'.........255
Diagnostic value '6.HOURS - Number of operating hours'..................................................256
Diagnostic value '7.HOURR - Resettable operating hours counter'.....................................256
Diagnostic value '8.WAY - Determined travel'......................................................................256
Diagnostic value '9.TUP - Travel time UP' / '10.TDOWN - Travel time DOWN'...................256
Diagnostic value '11.LEAK - Leakage test'..........................................................................257
Diagnostic value '12.PST - Monitoring of partial stroke test'................................................258
Diagnostic value '13.PRPST' - Time since last partial stroke test'.......................................259
Diagnostic value '14.NXPST - Time until next partial stroke test'........................................259
Diagnostic value '15.DEVI - General control valve fault'......................................................259
Diagnostic value '16.ONLK - Pneumatic leakage'................................................................259
Diagnostic value '17.STIC - Stiction (slipstick)'....................................................................260
Diagnostic value '18.ZERO - Lower endstop'.......................................................................260
Diagnostic value '19.OPEN - Upper endstop'......................................................................260
Diagnostic value '20.PAVG - Average value of position'......................................................261
Diagnostic value '21.P0 - Potentiometer value of lower endstop (0%)' / '22.P100 Potentiometer value of upper endstop (100%)'....................................................................261
Diagnostic value '23.IMPUP - Impulse length UP' / '24.IMPDN - Impulse length DOWN'....263
Diagnostic value '25.PAUTP - Pulse interval'.......................................................................263
Diagnostic value '26.DBUP - Deadband UP' / '27.DBDN - Deadband DOWN'....................263
Diagnostic value '28.SSUP - Slow step zone UP' / '29.SSDN - Slow step zone DOWN'.....263
Diagnostic value '30.TEMP - Current temperature'..............................................................264
Diagnostic value '31.TMIN - Minimum temperature' / '32.TMAX - Maximum temperature'....264
Diagnostic value '33.T1' ... '41.T9' - Number of operating hours in the temperature range
1 to 9....................................................................................................................................264
Diagnostic value '42.VENT1' / '43.VENT2' ..........................................................................264
Diagnostic value '44.VEN1R' / '45.VEN2R'..........................................................................265
Diagnostic value '46.STORE - Save maintenance data'......................................................266
Diagnostic value '47.PRUP - Prediction UP' / '48.PRDN - Prediction DOWN'.....................266
Diagnostic value '49.WT00' ... '56.WT95' - Number of operating hours in the travel range
WT00 to WT95.....................................................................................................................266
11.2.4.20
11.2.4.21
11.2.4.22
11.2.4.23
11.2.4.24
11.2.4.25
11.2.4.26
11.2.4.27
11.2.4.28
11.2.4.29
11.2.4.30
11.2.4.31
11.3
11.3.1
10
List of diagnostics events with status and diagnostics message for activated condensed
status....................................................................................................................................240
Online diagnostics................................................................................................................267
Overview of online diagnostics.............................................................................................267
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Table of contents
12
11.3.2
11.3.3
11.3.4
11.3.4.1
11.3.4.2
11.3.4.3
11.3.4.4
11.3.4.5
11.3.4.6
11.3.4.7
11.3.4.8
11.3.4.9
11.3.4.10
11.3.4.11
11.3.4.12
11.3.4.13
11.3.4.14
11.3.4.15
Overview of error codes.......................................................................................................268
XDIAG parameter ................................................................................................................269
Meaning of error codes........................................................................................................270
1 Remaining control deviation..............................................................................................270
2 Device not in "Automatic" mode........................................................................................270
3 Binary input BIN1 or BIN2 active.......................................................................................270
4 Monitoring the number of total strokes..............................................................................270
5 Monitoring the number of changes in direction.................................................................271
6 Monitoring the lower endstop / 7 Monitoring the upper endstop.......................................271
8 Monitoring deadband........................................................................................................271
9 Partial stroke test..............................................................................................................271
10 Monitoring of dynamic control valve behavior.................................................................272
11 Monitoring the pneumatic leakage..................................................................................272
12 Monitoring of stiction (slipstick).......................................................................................272
13 Monitoring the lower limit temperature............................................................................272
14 Monitoring the upper limit temperature...........................................................................272
15 Monitoring the position average value............................................................................272
16 Monitoring the plausibility of values for the partial stroke test.........................................272
11.4
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
Fault correction....................................................................................................................273
Fault identification................................................................................................................273
Remedial measures table 1.................................................................................................273
Remedial measures table 2.................................................................................................274
Remedial measures table 3.................................................................................................275
Corrective measures Table 4...............................................................................................275
Remedial measures table 5.................................................................................................276
Service and maintenance.........................................................................................................................277
12.1
Basic safety instructions.......................................................................................................277
12.2
12.2.1
Cleaning of the screens.......................................................................................................278
Positioners with Makrolon enclosure 6DR5..0, aluminum enclosure 6DR5..3, and
flameproof aluminum enclosure 6DR5..5.............................................................................278
Positioners with stainless steel enclosure 6DR5..2, flameproof stainless steel enclosure
6DR5..6, and narrow aluminum enclosure 6DR5..1.............................................................279
12.2.2
13
12.3
Replacing the basic electronics with the "Fail in Place" function.........................................280
12.4
Repair/Upgrading.................................................................................................................280
12.5
Return procedure.................................................................................................................281
12.6
Disposal...............................................................................................................................281
Technical data..........................................................................................................................................283
13.1
Rated conditions..................................................................................................................283
13.2
Pneumatic data....................................................................................................................284
13.3
Construction.........................................................................................................................284
13.4
Controller..............................................................................................................................286
13.5
Certificates, approvals, explosion protection........................................................................287
13.6
Electrical specifications........................................................................................................288
13.7
Technical data for natural gas as actuator medium.............................................................290
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
11
Table of contents
13.8
13.8.1
13.8.2
13.8.3
13.8.4
13.8.5
13.8.6
13.8.7
13.8.8
13.8.8.1
13.8.8.2
13.8.8.3
14
15
A
B
Option modules....................................................................................................................291
Alarm module.......................................................................................................................291
Position feedback module....................................................................................................292
SIA module...........................................................................................................................293
Mechanical limit switch module............................................................................................294
EMC filter module.................................................................................................................295
NCS 6DR4004-.N.20 and 6DR4004-.N.30...........................................................................296
Internal NCS modules 6DR4004-5L and 6DR4004-5LE......................................................297
External position sensing system.........................................................................................297
Rated conditions for external position detection system......................................................297
Construction for external position detection system.............................................................298
Certificates, approvals, explosion protection for external position detection system...........298
Dimension drawings.................................................................................................................................301
14.1
Positioner in non-flameproof enclosure................................................................................301
14.2
Terminal strip for positioners with Makrolon enclosure 6DR5..0 and aluminum enclosure
6DR5..3................................................................................................................................302
14.3
Positioner with flameproof enclosure...................................................................................303
Spare parts / accessories / scope of delivery...........................................................................................305
15.1
Order data............................................................................................................................305
15.2
Overview..............................................................................................................................305
15.3
Spare parts...........................................................................................................................306
15.4
Scope of delivery of external position detection system......................................................307
15.5
Scope of delivery of mechanical limit switch module...........................................................308
15.6
Scope of delivery EMC filter module ...................................................................................308
15.7
Accessories..........................................................................................................................309
Appendix...................................................................................................................................................311
A.1
Operation with boosters.......................................................................................................311
A.2
Certificates...........................................................................................................................312
A.3
Technical support.................................................................................................................312
Abbreviations............................................................................................................................................313
B.1
Abbreviations for positioners................................................................................................313
B.2
Abbreviations for functional safety.......................................................................................314
Glossary...................................................................................................................................................317
Index.........................................................................................................................................................325
12
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
1
Introduction
1.1
Purpose of this documentation
These instructions contain all information required to commission and use the device. Read
the instructions carefully prior to installation and commissioning. In order to use the device
correctly, first review its principle of operation.
The instructions are aimed at persons mechanically installing the device, connecting it
electronically, configuring the parameters and commissioning it, as well as service and
maintenance engineers.
1.2
History
This history establishes the correlation between the current documentation and the valid
firmware of the device.
The documentation of this edition applies to the following firmware:
Edition
Firmware code
02/2016
FW 6.00.00 or higher
The most important changes in the documentation as compared to the respective previous
edition are given in the following table.
Edition
Note
02/2016
1. Section Installing/mounting (Page 37) > Simpler commissioning of part-turn actuators
using coupling wheel with two pins.
2. New parameters and values in section Parameter assignment (Page 145):
–
1.YFCT - Actuator > Initialization of actuators with inverted direction of action is
now possible. Linear actuator > Mounting with carrier pin on actuator stem using
'FWAY/-FWAY' parameter value is now possible.
–
48.PRST - Preset > Resetting of individual parameter groups is now possible.
–
49.PNEUM > Fail in place function can now be activated with appropriate pneumatic
system.
3. New functions for the diagnostics parameters > section Partial stroke test 'A.\\PST'
(Page 173):
–
A5.RPMD and A6.RPRT > Partial stroke test is now possible in ramp mode.
–
A7.FLBH > Response following failed PST can now be defined.
4. New functions for the diagnostics values in section Diagnostics (Page 252):
–
7.HOURR > Resettable operating hours counter added.
–
11.LEAK > Offline leakage test added.
–
21.P0 and 22.P100 > Modification of upper and lower endstops now possible
without initialization.
–
25.PAUTP > Adjustable pulse pause added.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
13
Introduction
1.4 Checking the consignment
1.3
Purpose
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic drives in the following industries.
● Chemicals
● Oil and gas
● Energy production
● Food and beverages
● Pulp and paper
● Water/waste water
● Pharmaceutical industry
● Offshore plants
Operate the device according to the specifications in section "Technical data (Page 283)".
For additional information, refer to the operating instructions for the device.
1.4
Checking the consignment
1. Check the packaging and the delivered items for visible damage.
2. Report any claims for damages immediately to the shipping company.
3. Retain damaged parts for clarification.
4. Check the scope of delivery by comparing your order to the shipping documents for
correctness and completeness.
WARNING
Using a damaged or incomplete device
Danger of explosion in hazardous areas.
● Do not use damaged or incomplete devices.
14
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Introduction
1.7 Notes on warranty
1.5
Transportation and storage
To guarantee sufficient protection during transport and storage, observe the following:
● Keep the original packaging for subsequent transportation.
● Devices/replacement parts should be returned in their original packaging.
● If the original packaging is no longer available, ensure that all shipments are properly
packaged to provide sufficient protection during transport. Siemens cannot assume liability
for any costs associated with transportation damages.
CAUTION
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
● Provide additional packaging as necessary.
Special conditions for storage and transportation of the device are listed in Technical data
(Page 283).
1.6
Product information
The programming manual is an integral part of the CD, which is either supplied or can be
ordered. The programming manual is also available on the Siemens homepage.
On the CD, you will also find the catalog extract with the ordering data, the Software Device
Install for SIMATIC PDM for additional installation, and the required software.
See also
SIPART PS2 product information (http://www.siemens.com/sipartps2)
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
1.7
Notes on warranty
The contents of this manual shall not become part of or modify any prior or existing agreement,
commitment or legal relationship. The sales contract contains all obligations on the part of
Siemens as well as the complete and solely applicable warranty conditions. Any statements
regarding device versions described in the manual do not create new warranties or modify the
existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right
to make technical changes in the course of further development.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
15
Introduction
1.7 Notes on warranty
16
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
2
Safety information
2.1
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.
2.2
Warning symbols on the device
Symbol
Meaning
Consult operating instructions
2.3
Laws and directives
Observe the test certification, provisions and laws applicable in your country during connection,
assembly and operation. These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)
● Canadian Electrical Code (CEC) (Canada)
Further provisions for hazardous area applications are for example:
● IEC 60079-14 (international)
● EN 60079-14 (EC)
2.4
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following European
guidelines:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
17
Safety information
2.6 Requirements for special applications
Electromagnetic Compatibili‐Directive of the European Parliament and of the Council on the
ty EMC
approximation of the laws of the Member States relating to elec‐
2004/108/EC
tromagnetic compatibility and repealing Directive 89/336/EEC.
Atmosphère explosible
Directive of the European Parliament and the Council on the ap‐
ATEX
proximation of the laws of the Member States concerning equip‐
94/9/EC
ment and protective systems intended for use in potentially ex‐
plosive atmospheres.
LVD 2006/95/EC
Directive of the European Parliament and of the Council of the
harmonisation of the laws of Member States relating to electrical
equipment designed for use within certain voltage limits.
The applied standards can be found in the EC conformity declaration of the device.
See also
Certificates (http://www.siemens.com/processinstrumentation/certificates)
2.5
Improper device modifications
WARNING
Improper device modifications
Danger to personnel, system and environment can result from modifications to the device,
particularly in hazardous areas.
● Only carry out modifications that are described in the instructions for the device. Failure
to observe this requirement cancels the manufacturer's warranty and the product
approvals.
2.6
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.
Note
Operation under special ambient conditions
We highly recommend that you contact your Siemens representative or our application
department before you operate the device under special ambient conditions as can be
encountered in nuclear power plants or when the device is used for research and development
purposes.
18
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Safety information
2.7 Use in hazardous areas
2.7
Use in hazardous areas
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.
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
● Only use equipment that is approved for use in the intended hazardous area and labelled
accordingly.
WARNING
Loss of safety of device with type of protection "Intrinsic safety Ex i"
If the device has already been operated in non-intrinsically safe circuits or the electrical
specifications have not been observed, the safety of the device is no longer ensured for use
in hazardous areas. There is a danger of explosion.
● Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe
circuit.
● Observe the specifications for the electrical data on the certificate and/or in Chapter
"Technical data".
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
19
Safety information
2.7 Use in hazardous areas
20
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.1
3
Function
● The electropneumatic positioner and an actuator form a control system. The current position
of the actuator is recorded by a servo potentiometer and the actual value x is fed back. The
setpoint and the actual value are also shown simultaneously on the display.
● The control system provides the setpoint w digitally to the positioner over the bus.
● The positioner works as a predictive five-point positioner, through whose output value ±Δy
the integrated valves can be controlled by pulse length modulation.
● These input signals change pressure in the actuator chamber(s) and displace the actuator
until the control deviation becomes zero.
● Using the three buttons and the display with the enclosure cover removed, operation
(manual mode) and configuration (structuring, initialization, and parameter assignment)
can be performed.
● By default, the basic unit has a binary input (BIN). This binary input can be individually
configured and used, for example, to block the control levels.
● It has a friction clutch and a switchable gear so that the positioner can be used with different
mechanical part-turn and linear actuators.
● In the case of positioners with the "Fail in Place" function, the current position of the actuator
is held if the electric and/or pneumatic auxiliary power fails. Does not function in conjunction
with SIL.
● Parameter "51.FSTY" must be set to "FSSP" in the case of the "Fail in Place" function if
the current position is to be held when switching on again following failure of the electric
auxiliary power.
3.2
Structure
3.2.1
Design overview
The following sections describe the mechanical and electrical structure, components, and
principle functionality of the positioner.
The positioner and the PROFIBUS PA communication interface function as components in a
digital process automation system. It functions as a slave and communicates with the master
through the PROFIBUS PA fieldbus. Apart from communication, the fieldbus also supplies
electrical auxiliary power to the positioner.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
21
Description
3.2 Structure
The positioner is used to move and control pneumatic actuators. The positioner works
electropneumatically, using compressed air as auxiliary power. The positioner is used to
control valves, for example, with:
● Linear actuator
● Part-turn actuator VDI/VDE 3845
Various add-on extensions are available for linear actuators:
● IEC 60534-6-1 (NAMUR)
● Integrated mounting ARCA, except with flameproof versions
● Integrated addition to SAMSON in non-flameproof aluminum enclosure
①
②
③
④
⑤
Pressure gauge block, single-acting
Valve
Yoke / actuator yoke
Single-acting positioner in non-flameproof aluminum enclosure
Actuator
Figure 3-1
22
Positioner attached to a single-acting linear actuator
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.2 Structure
①
②
③
Part-turn actuator
Pressure gauge block, double-acting
Double-acting positioner in Makrolon enclosure
Figure 3-2
Positioner attached to double-acting part-turn actuator
①
②
③
④
Single-acting positioner in flameproof aluminum enclosure
Pressure gauge block, single-acting
Yoke / actuator yoke
Actuator
Figure 3-3
Positioner in flameproof aluminum enclosure attached to linear actuator
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
23
Description
3.2 Structure
①
②
③
Part-turn actuator
Double-acting positioner in flameproof aluminum enclosure
Pressure gauge block, double-acting
Figure 3-4
3.2.2
Positioner in flameproof aluminum enclosure attached to part-turn actuator
Nameplate layout
Layout of the nameplate
①
②
③
④
⑤
⑥
⑦
Manufacturer
Protection class
Consult operating instructions
Conformity with country-specific directives
Built-in option module
QR code to the mobile website with device-spe‐
cific information on the product
Serial number
Figure 3-5
24
⑧
⑨
⑩
⑪
⑫
⑬
⑭
Auxiliary power (supply air PZ)
Software/hardware version
Place of manufacture
Auxiliary power
Ordering supplement (Order code)
Article number
Product name
Nameplate layout, example
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.2 Structure
Layout of Ex nameplate
F-Nr.: ARR P3-123456
0044
TÜV 11 ATEX 093266 X /
IECEx TUN 12.0001 X / TÜV 12.0940 X
S N°:
ATEX
Logo
FM Logo
Technical data and temperature classes see certificate / operating instructions
TÜV 12 ATEX 107540 X / IECEx TUN 12.0028 X / TÜV 11.0287 X
II 2 G Ex ia IIC T4 Gb
II 3 G Ex ic IIC T4 Gc
II 2 D Ex ia IIIC 110°C Db
II 2 D Ex tb IIIC T100°C Db
II 3 G Ex nA IIC T4 Gc
IS / 1 / AEx / Ex ib / IIC, Gb
IS / I, II, III / 1 / A-G
IS / 21 / AEx / Ex ib / IIIC, Db, T110°C
DIP / 21 / AEx / Ex tb / IIIC, Db, T100°C
DIP / II, III / 1 / E-G
NI / 2 / AEx / Ex nA, Ex ic / IIC, Gc
NI / I / 2 / A-D
-
3.2.3
-30 ≤ Ta ≤ +80°C(T4)
XP, CL.I, DIV.1, GP.ABCD
XP, CL.I, Zone1, GP.IIC
DIP, CL.II, DIV.1, GP.EFG, CL.III, DIV.1
APPROVED IP 66 / NEMA 4x
XP, CL.I, DIV.1, GP.CD
Ex d IIC
DIP, CL.II, DIV.1, GP.EFG, CL.III, DIV.1
2006.1773456
S-XPL/090873
Inmetro Logo
13-KB4BO-0105
-30≤ Ta ≤ +50(T6)/80(T4)°C
KCS logo
Nepsi Logo
Approvals
ATEX/IECEx marking for hazardous area
Figure 3-6
Install per control Drawing
A5E00065622D
-
Before commissioning permanently
remove indications of the protection
2001.1233781. type which are not being used.
①
②
--
N1A6101234567
II 2 G Ex d IIC T6/T4 Gb
13-KB4BO-0369
③
④
Technical data and temperature classes see
certificate / operating instructions
SEAL ALL CONDUITS WITHIN 18 INCHES
FM/CSA marking for hazardous area
Permitted ambient temperature for the hazardous
area of the corresponding temperature class
Ex nameplate layout, example
Explanation of Ex information
Explanation of Ex information
II 2 G
II 2 D
II 3 G
Technical data and temperature classes see certificate / operating instructions
TÜV 12 ATEX 107540 X / IECEx TUN 12.0028 X / TÜV 11.0287 X
Ex ia IIC T4 Gb
II 3 G Ex ic IIC T4 Gc
Ex ia IIIC 110°C Db
II 2 D Ex tb IIIC T100°C Db
Ex nA IIC T4 Gc
①
Category for operating range
④
②
③
Type of protection
⑤
Maximum surface temperature (tempera‐
ture class)
Device protection level
Group (gas, dust)
Figure 3-7
Explanation of Ex information
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
25
Description
3.3 Device components
3.3
Device components
3.3.1
Overview of device components
33 O
Jumper
82
Shut
Down
input
Positioner
6
BUS
7
8
9
10
r
Transmission ratio selector
Shut Down
enabled
Binary
input 1
O
-
Shut Down
disabled
81
90
+
24V
r
①
②
③
④
⑤
⑥
⑦
⑧
⑨
Buttons
⑩
⑪
⑫
⑬
⑭
⑮
⑯
⑰
Restrictor Y2 for double-acting actuators
⑱
Bus cable
Wiring diagram on module cover
Display
Purging air selector
Output: Actuating pressure Y1
Input: Supply air
Output: Actuating pressure Y2
Figure 3-8
26
Restrictor Y1 for single-acting actuators
Restrictor Y1 for double-acting actuators
Exhaust air outlet with a sound absorber
Transmission ratio selector
Friction clutch adjustment wheel
Basic electronics
Connecting terminals of option modules
Shield connection (only with a Makrolon en‐
closure)
Cable gland
View of the positioner (cover open; Makrolon enclosure)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.3 Device components
3.3.2
Overview of device components (Ex)
$
138
$$
9
1
10
+
238
-
$
①
②
③
④
⑤
⑥
⑦
Input: Supply air PZ
Output: Actuating pressure Y1
Display
Output: Actuating pressure Y2
1)
Buttons
Transmission ratio selector 2)
⑧
⑨
⑩
⑪
⑫
⑬
Restrictor Y2 1)
Friction clutch adjustment wheel
Connecting terminals of option modules
Connecting terminals of basic electronics
Safety catch
Ground terminal
Restrictor Y1
1)
for double-acting actuators
2)
only possible when positioner is open
Figure 3-9
View of positioner in flameproof enclosure, cover opened
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
27
Description
3.4 Functional principle
3.3.3
Basic electronics
Figure 3-10
Basic electronics, schematic representation
The basic electronics contains:
● CPU
● Memory
● Analog-to-digital converter
● Display
● Buttons
● Terminal strips to connect the option module to the basic electronics
3.4
Functional principle
Control loop
The electropneumatic positioner forms a control loop with the pneumatic actuator:
● The actual value x represents the position of the actuator spindle for linear actuators or the
position of the actuator shaft for part-turn actuators.
● The higher-level control loop provides the setpoint w.
The stroke or rotary movement of the actuator is transferred to a potentiometer using suitable
attachments, positioner shaft and a backlash-free, switchable gear drive, and then to the
analog input of the microcontroller.
The current position can also be forwarded to the positioner using an external sensor. A NonContacting Position Sensor (NCS) is used to record the stroke or rotary angle directly on the
actuator.
The microcontroller:
● Corrects the angle error of the shaft pick-up if necessary.
● Compares the potentiometer voltage as actual value x with setpoint w.
● Calculates the manipulated variable increments ±∆y.
The piezo-controlled inlet or exhaust air valve is opened depending on the magnitude and
direction of the control deviation (x-w). The actuator volume integrates the controller increment
for the actuating pressure y which is proportional to the drive rod or the drive shaft. This
controller increment change the actuating pressure until the control deviation becomes zero.
28
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.4 Functional principle
Pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is ventilated and depressurized. The pressure developed
works against a spring. In a double-acting version, two pressure chambers work against each
other. Ventilating the volume of one chamber simultaneously depressurizes the volume of the
other.
Control algorithm
The control algorithm is an adaptive, predictive five-point controller.
In case of large control deviations, the valves are controlled using permanent contact. This
takes place in the so-called fast step zone.
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In case of medium control deviations, valves are controlled using pulse-length modulated
pulses. This takes place in the so-called slow step zone.
3XOVHSDXVH
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3XOVHOHQJWK
,0383
Figure 3-11
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SHUPDQHQWFRQWDFW
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3$873
3XOVHOHQJWK
,03'1
Functional principle of five-point controller
Small control deviations do not send control pulses in the zone. This takes place in the socalled adaptive deadband. The deadband adaptation and the continuous adaptation of
minimum pulse lengths in "Automatic" mode ensure the best possible control accuracy with
the smallest number of operating cycles. The start parameters are determined during the
initialization phase and stored in the non-volatile memory. The most important start parameters
are:
● The real actuator travel with end positions
● Travel times
● The deadband size
The number of fault messages, changes in direction, and the number of total strokes are
continuously determined during operation and saved every 15 minutes. You can read and
document these parameters using communication programs such as SIMATIC PDM and AMS.
By comparing the old values with the current ones, you can draw conclusions about the wear
and tear of the valve. You can use the diagnostics function for this.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
29
Description
3.4 Functional principle
3.4.1
PROFIBUS system configuration
Overview
The positioner can be used in a number of system configurations.
Use with the SIMATIC PCS 7 Automation System is described below.
System communication
The Operator Station of the SIMATIC PCS 7 process control system allows easy and safe
control of the process by the operating personnel using OS Multi-Clients.
The Maintenance Station assists the maintenance engineer in guaranteeing high plant
availability, securing this long-term using optimization measures, and implementing the
maintenance measures using a minimum of personnel, materials, energy, costs etc.
The field devices are integrated over PROFIBUS PA with:
● PA Link to the gateway between PROFIBUS PA and PROFIBUS DP
● Control system, e.g. SIMATIC PCS 7 Automation System, which communicates over
PROFIBUS
● Engineering Station, SIMATIC PDM (Process Device Manager) which communicates over
Industrial Ethernet
Operator station
Engineering station
SIMATIC PDM clients
OS multi-clients
Maintenance station
Maintenance/
OS server
Industrial Ethernet
SIMATIC PCS 7
automation system
PROFIBUS DP
PA Link
PROFIBUS PA
Figure 3-12
30
Typical system configuration
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.5 PROFIBUS PA
3.4.2
SIMATIC PDM
SIMATIC PDM is a software package for configuring, parameter assignment, commissioning,
diagnostics and maintenance of this device and other process devices.
SIMATIC PDM offers simple monitoring of process values, alarms, and device status
information.
SIMATIC PDM allows the process device data to be:
● displayed
● set
● modified
● saved
● diagnosed
● checked for plausibility
● managed
● simulated
Additional information on SIMATIC PDM can be found at SIMATIC PDM instructions and
manuals (https://support.industry.siemens.com/cs/products?
dtp=Manual&pnid=16983&lc=en-WW).
3.5
PROFIBUS PA
3.5.1
Overview
The Process Fieldbus (PROFIBUS) is an open communications system for automation
technology and is specified in the international standard IEC 61158.
PROFIBUS Process Automation (PROFIBUS PA) is a variant of PROFIBUS Decentral
Peripherals (PROFIBUS DP), which is widely used in process technology.
3.5.2
Transmission technology
PROFIBUS PA uses a special transmission technology, enabling it to fulfill the requirements
of process automation and process technology. This transmission technology is defined in the
international standard IEC 61158-2. The low transmission rate reduces the power loss in
comparison to PROFIBUS DP, enabling an intrinsically safe technology for use in hazardous
zones with explosive atmospheres. The PROFIBUS PA and PROFIBUS DP protocols are
identical.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
31
Description
3.5 PROFIBUS PA
3.5.3
Bus topology
The bus topology is mainly able to be selected as desired. Therefore, line, star and tree
structures, and mixed forms are possible. All types of field devices such as transmitters, actors,
analysis devices, etc. can be connected to the PROFIBUS PA.
Advantages include:
● Savings on installation costs
● More extensive diagnostics, leading to increased availability of installation sections
● Automatic management of installation documentation
● Installation optimization on the fly during operation
In an automation system, there are generally multiple PROFIBUS PA lines connected to fast
PROFIBUS DP via coupler units. This is also connected to the process control system.
Both bus systems use the same protocol layer. This makes PROFIBUS PA a "communicationscompatible" extension of the PROFIBUS DP into the field.
&ODVVPDVWHU
&ODVVPDVWHU
352),%86'3
352),%863$
6ODYHV
)LHOGGHYLFHVGLVWULEXWHG,2ORZHUOHYHO
FRQWUROOHUVJDWHZD\WR352),%863$
Figure 3-13
Functional principle of the PROFIBUS automation system
The figure shows a section of a typical PROFIBUS automation system. The control system
consists of two masters with distributed tasks.
The class-1 master recognizes the control and regulation tasks. The class-2 master enables
the operating and monitoring functions. Between the class-1 master and the field devices there
is a periodic exchange of measurement and settings data. The status information from the field
devices is transmitted parallel to this data, and evaluated in the class-1 master. Assignment
of parameters for the field devices or the reading of additional device information is not
performed during periodic operation.
Besides periodic operation, one or more class-2 masters can access the field devices
asynchronously. Using this type of communication, additional information can be retrieved
from the devices or settings sent to them.
32
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.5 PROFIBUS PA
3.5.4
Properties
PROFIBUS PA allows bidirectional communication between a bus master and field devices.
At the same time, the shielded two-strand wiring provides auxiliary power to the two-wire field
devices.
3.5.5
Profile
As an extension to the EN 50170 standard, the PROFIBUS user organization (PNO) defined
the functionality of the individual field device types in a so-called profile description. This profile
determines minimum functional requirements and optional extensions. The device-internal
"Device Management" provides the configuration tool of the control system with all necessary
basic information to find profile parameters. One parameter assignment tool serves all profileconforming devices, regardless of type or manufacturer.
Depending on the size of the installation (and therefore the number of field devices) and the
time behavior required, you implement the system with one or more PROFIBUS PA strands.
One PROFIBUS PA strand consists of the components shown in the following figure.
)LHOG
&RQWUROURRP
352),%86'3
&RXSOHU
3&6
3&
352),%863$
7
7
)'
3RZHU
VXSSO\
)'
$GGLWLRQDO
WHUPLQDWRU
FD
Field device
PC
Personal Computer
T
Terminating resistor
PCS
Process control system
Figure 3-14
PROFIBUS PA strand
Reference
PNO PROFIBUS-PA interest group
3.5.6
Connection
Control is performed by the central process control system (PCS) or by a PC for lowerperformance requirements.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
33
Description
3.5 PROFIBUS PA
In general, the following functions are combined into one coupling assembly:
● DP/PA signal transfer
● Bus power
● Bus termination
Depending on the number of the PROFIBUS PA field devices to be operated in the automation
system and the time behavior required, a DP/PA coupler or a DP/PA link is used. For standard
requirements, you use a DP/PA coupler; for higher requirements, a more powerful DP/PA link.
For reasons related to transmission technology, the bus is also equipped on the far end with
a terminating resistance T. When using the recommended bus cable, the theoretical maximum
cable length is 1900 meters. The theoretical maximum cable length is the sum of all cable
segments. During planning, also take into account the voltage drop over the wires powering
the field devices.
However, the power requirements of the individual nodes and the voltage drop on the cable
must also be calculated during projection. The individual field devices (FD) can be connected
at nearly any point in the bus system.
DP/PA couplers or DP/PA links are supplied using a safety extra-low voltage (SELV) power
supply. This power supply must have sufficient reserves to bridge over temporary power
failures.
The maximum number of devices which can be connected to one bus strand depends on their
power consumption and the conditions of use. When operated in the safe zone, the couplers
or links supply the bus with up to 400 mA.
When operated in explosive atmospheres, intrinsic safety is only guaranteed if all devices,
components, etc. connected to the bus (e.g. bus terminator) fulfill the following requirements:
● They are certified as intrinsically safe equipment.
● They fulfill the requirements of the FISCO model (Fieldbus Intrinsic Safety Concept).
Power supply devices in particular (bus couplers) must be certified as so-called FISCO power
supplies. Observe the safety-relevant maximum values and other specifications of the EG type
test certificate.
Connect power supplies (bus couplers) which are not explosion protected and certified to
intermediate EX-certified zener barriers. Observe the specifications of the EG type test
certificate.
WARNING
For power supply to intrinsically safe PROFIBUS, use only power supplies, DP/PA couplers,
or DP/PA links certified as compliant with the FISCO model.
Switch through zener barriers if using non-EX-protected power supplies. See the
requirements of the EG type test certificate.
34
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Description
3.5 PROFIBUS PA
3.5.7
Number of connectable devices
The number of devices which can be connected to a bus strand can be calculated from the
sum of the maximum power consumption of the devices and the power available. By default,
assume 10 mA per device. For safety reasons, plan for a power reserve. Otherwise you run
the risk of a defective device overloading the bus with an increased power consumption. This
can interrupt the power supply and communication with the functioning nodes. The amount of
power reserved is based on the nominal power increase given by the manufacturer in case of
failure.
3.5.8
Assigning the device addresses
So that the connected process devices can be distinguished from one another, each device
has its own address.
Be sure that the device addresses are set before operating two or more field devices on the
bus. Each address may only be given once to make sure they are unique.
Principally, the address range is from 1 to 125. The address 126 is set for the delivery state.
Normally, masters in PROFIBUS systems receive lower addresses. Therefore, we recommend
starting at 30 when assigning addresses to the positioners. Either use the keys on the
positioner or the SIMATIC PDM software via the bus to set the addresses. In the last case, a
new positioner is always connected to the bus and the new address is set via the software.
The next positioner is then connected to the bus and processed the same way.
We recommend writing the set address on the field device with a wipe resistant pen.
See also
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
35
Description
3.5 PROFIBUS PA
36
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.1
4
Basic safety instructions
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
● Only use equipment that is approved for use in the intended hazardous area and labelled
accordingly.
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.
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.
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
● Only use original accessories or original spare parts.
● Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
37
Installing/mounting
4.1 Basic safety instructions
WARNING
It is possible to damage the cover gasket
If the cover gasket is not positioned correctly in the groove of the base plate, it could be
damaged when the cover is mounted and screwed tight.
● Therefore make sure that the gasket is seated correctly.
WARNING
Open cable inlet or incorrect cable gland
Danger of explosion in hazardous areas.
● Close the cable inlets for the electrical connections. Only use cable glands or plugs which
are approved for the relevant type of protection.
WARNING
Exceeded maximum ambient or process media temperature
Danger of explosion in hazardous areas.
Device damage.
● Make sure that the maximum permissible ambient and process media temperatures of
the device are not exceeded. Refer to the information in Chapter "Technical data
(Page 283)".
CAUTION
Unsuitable compressed air
Device damage. As a general rule, the positioner must only be operated with dry and clean
compressed air.
● Use the customary water separators and filters. An additional dryer is required in extreme
cases.
● Use dryers, especially if you operate the positioner at low ambient temperatures.
38
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.1 Basic safety instructions
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.
WARNING
Mechanical impact energy
In order to ensure the degree of protection of the housing (IP66), protect the housing versions
of the positioners listed here from mechanical impact energy:
● 6DR5..3; not greater than 2 Joule
● 6DR5..0; not greater than 1 Joule
● 6DR5..1 with inspection window; not greater than 1 Joule
NOTICE
Torque with NPT screwed gland
Device damage. The maximum torque of the cable gland must not be exceeded.
● To avoid damage to the device, the NPT adapter must be held in place while the NPT
gland is screwed into the NPT adapter. Refer to the section "Technical specifications >
Construction (Page 284)" for the torque value.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
39
Installing/mounting
4.2 Mounting the linear actuator
4.1.1
Proper mounting
NOTICE
Incorrect mounting
The device can be damaged, destroyed, or its functionality impaired through improper
mounting.
● Before installing ensure there is no visible damage to the device.
● Make sure that process connectors are clean, and suitable gaskets and glands are used.
● Mount the device using suitable tools. Refer to the information in Technical data
(Page 283) for installation torque requirements.
CAUTION
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection
specified on the nameplate or in Chapter "Technical data (Page 283)" is no longer guaranteed.
● Make sure that the device is securely closed.
4.2
Mounting the linear actuator
Requirements
There are linear actuators for standard mounting in accordance with IEC 60534 and for
integrated mounting. Use the reduced mounting kit 6DR4004-8VK for actuators with integrated
mounting. Integrated mounting is not possible with flameproof stainless steel enclosure
(6DR5..6).
This section describes how to connect the positioner to the actuator using the mounting kit
6DR4004-8V. You require different installation parts of this mounting kit depending on the
selected actuator type. All installation parts listed in the following table are included in the
product package of the mounting kit 6DR4004-8V. The mounting kit is suitable for a stroke of
3 to 35 mm. In the event of a larger range of stroke, you require the accessory "Lever for
40
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.2 Mounting the linear actuator
strokes greater than 35 to 130 mm", article number 6DR4004-8L, in addition to the mounting
set 6DR4004-8V. Keep the suitable installation parts ready:
Actuator type
Required installation compo‐
nents
Yoke with fin
● Hexagon bolt ⑧
● Washer ⑪
● Spring lock washer ⑩
Yoke with
plane surface
● Four hexagon bolts ⑧
● Washer ⑪
● Spring lock washer ⑩
Yoke with col‐
umns
● Two U–bolts ⑦
● Four hexagon nuts ⑳
● Washer ⑪
● Spring lock washer ⑩
Procedure
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. no.
Quantity
Name
Note
①
1
②
③
NAMUR mounting bracket
IEC 60534
Standardized connection point for mount with fin, column or plane
surface
1
Pick-up bracket
Guides the pulley with the carrier pin and rotates the lever arm.
2
Clamping piece
Installs the pick-up bracket on the actuator spindle
*)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
41
Installing/mounting
4.2 Mounting the linear actuator
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. no. *)
Quantity
Name
Note
④
⑤
⑥
1
Carrier pin
Installation with pulley ⑤ on lever ⑥
⑦
⑧
⑨
⑩
⑪
⑫
⑬
⑭
⑮
⑯
⑰
⑱
⑲
⑳
1
Pulley
Installation with carrier pin ④ on lever ⑥
1
Lever
For the range of stroke from 3 mm to 35 mm
The lever 6DR4004–8L is additionally required for ranges of stroke
> 35 mm to 130 mm (not included in the scope of delivery).
2
U–bolts
Only for actuators with columns
4
Hexagon bolt
M8x20 DIN 933–A2
2
Hexagon bolt
M8x16 DIN 933–A2, torque see the section "Technical specifica‐
tions > Construction (Page 284)"
6
Spring lock washer
A8 - DIN 127–A2
6
Washer
B8.4 - DIN 125–A2
2
Washer
B6.4 - DIN 125–A2
1
Spring
VD-115E 0.70 x 11.3 x 32.7 x 3.5
1
Spring lock washer
A6 - DIN 137A–A2
1
Lock washer
3.2 - DIN 6799–A2
3
Spring lock washer
A6 - DIN 127–A2
3
Socket cap screw
M6x25 DIN 7984–A2
1
Hexagon nut
M6 - DIN 934–A4
1
Square nut
M6 - DIN 557–A4
4
Hexagon nut
M8 - DIN 934–A4
*)
The serial numbers refer to the images of the description of the installation steps below.
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 4-1
Pick-up bracket
3. Set the necessary length.
42
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.2 Mounting the linear actuator
4. Tighten the screws ⑰ so that you can still shift the pick-up bracket ②.
5. Fix the pre-installed carrier pin ④ to the lever ⑥. Use the flat washer ⑫, spring lock washer
⑭ and hexagon nut ⑱ for this purpose.
Figure 4-2
Lever with carrier pin
6. Set the stroke value. Use the stroke value specified on the nameplate of the actuator for
this purpose. If none of the values on the lever scale matches the stroke value of the
actuator, select the next higher value on the scale. Position the pin center ④ on the
corresponding value of the scale. If you need the value of actuator travel after initialization
in mm: ensure that the configured stroke value matches the value of the "3.YWAY"
parameter.
7. Install the following components on the lever ⑥: Socket cap screw ⑰, spring lock washer
⑯, flat washer ⑫, square nut ⑲.
Figure 4-3
Components on the lever
8. Push the pre-installed lever ⑥ up to the endstop on the positioner shaft. Fasten the lever
⑥ with socket cap screw ⑰.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
43
Installing/mounting
4.2 Mounting the linear actuator
9. 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 4-4
Installation with mounting bracket
Figure 4-5
Installation with mounting bracket, flameproof enclosure
10.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 pickup bracket ② near the spindle. Ensure that the pick-up bracket ② does not touch the
clamping pieces ③.
11.Keep the positioner and the fastening bracket on the actuator. Ensure that the carrier pin
④ is guided inside the pick-up bracket ②.
44
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.3 Mounting the part-turn actuator
12.Tighten the pick-up bracket ②.
13.Fasten the positioner on the yoke. Use the installation parts suitable for the corresponding
actuator.
Note
Height adjustment of the positioner
When you fasten the positioner on the yoke, the following applies to its height adjustment:
1. Set the height of the positioner in such a way that the horizontal lever position is near
the center of the stroke.
2. Orient yourself by the lever scale of the actuator.
3. If symmetrical mounting is not possible, you must always ensure that the horizontal lever
position is maintained within the range of stroke.
4.3
Mounting the part-turn actuator
Requirements
You require an actuator-specific VDI/VDE 3845 mount to install the positioner on a part-turn
actuator. Because of the high weight of the version in the flameproof stainless steel enclosure
6DR5..6, you should select a particularly stable mount.
Procedure
"Part-turn actuator" mounting kit 6DR4004–8D
Sr.
Quan Name
no. *) tity
Note
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
*)
1
Coupling wheel
Installation on positioner shaft
1
Carrier
Installation on stump of actuator shaft
1
Multiple plate
Display of the position, consisting of scale ⑤ and pointer mark ⑥
8
Scale
Different divisions
2
Pointer mark
Reference arrow for scale
Mount
Actuator-specific, VDI/VDE 3845
Hexagon bolt
M6x12 DIN 933, torque see the section "Technical specifications > Construction
(Page 284)"
4
4
Lock washer
S6
1
Socket cap screw
M6x16 DIN 84
1
Washer
6.4 DIN 125
1
Hexagon sockethead screw
For coupling wheel
1
Machinist's wrench
For hexagon socket-head screw ⑪
The serial numbers refer to the images of the description of the installation steps below.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
45
Installing/mounting
4.3 Mounting the part-turn actuator
1. Rest the actuator-specific VDI/VDE 3845 mount ⑥ on the rear side of the positioner.
Tighten the mount using the hexagon bolts ⑦ and lock washers ⑧.
2. Stick the pointer mark ⑤ on the mount. Position the pointer mark ⑤ at the center of the
centering hole.
Pointer mark
Pointer mark, flameproof enclosure
3. Push the coupling wheel ① or the stainless steel coupling up to the endstop on the
positioner shaft. Then retract the coupling wheel or the stainless steel coupling by
approximately 1 mm. Tighten the hexagon socket-head screw ⑪ 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 plastic coupling wheel ①, it is possible to use a stainless steel coupling
(article number TGX: 16300-1556).
Coupling wheel
46
Coupling wheel, flameproof enclosure
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.3 Mounting the part-turn actuator
4. Place the carrier ② on the stump of the actuator shaft. Tighten the carrier ② using the
socket cap screw ⑨ and the washer ⑩.
Carrier
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
47
Installing/mounting
4.3 Mounting the part-turn actuator
5. Place the positioner and the mount on the actuator carefully.
One of the two pins of the coupling wheel ① must fit in the carrier ② when you do this.
You need not adjust the friction clutch if you use the pins ⑫ as described below. This
greatly simplifies commissioning. Each of the two pins ⑫ has a recess, see the following
figures.
For actuators which close in the clockwise direction, use the pin on which the recess has
a V shape (B).
For actuators which open in the clockwise direction, use the pin on which the recess has
a rectangular shape (A).
$
%
Orientation of mount
$
%
Orientation of mount, flameproof enclosure
6. 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 stump of the actuator's positioner shaft.
7. Align the positioner/mount at the center of the actuator.
8. Tighten the positioner/mount unit.
9. Initialize the positioner.
48
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.3 Mounting the part-turn actuator
10.After commissioning, drive the positioner to the end position.
11.Stick the scale ④ with the direction of rotation or the swivel range on the coupling wheel
①. The stickers with scale are self-adhesive.
Adhesive label with scale
Adhesive label with scale, flameproof enclosure
0
D
+
E
D E 6.5 (0.26)
Ø35 (1.38)
F05-Lkr.-Ø50 (1.97)
H = height of shaft butt
①
②
Fixing level of positioner on mount
Part-turn actuator
Figure 4-6
Dimensions of mount in accordance with VDI/VDE 3845 (depends on actuator)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
49
Installing/mounting
4.4 Using the positioner in a humid environment
See also
Preparing part-turn actuators for commissioning (Page 130)
4.4
Using the positioner in a humid environment
Introduction
The positioner enclosure provides IP66 protection with an intended installation position. It can
therefore be operated in a moist or wet environment in the mounting positions shown below.
Do not use other mounting positions since it would then be possible for liquids, fluff, fibers or
dusts to enter the device via the exhaust openings.
Favorable and unfavorable mounting positions
Avoid the unfavorable mounting positions:
● To prevent fluids seeping through during normal operation of the device, e.g. through
exhaust air openings.
● Otherwise the display becomes poorly legible.
Figure 4-7
Favorable and unfavorable mounting positions
Additional measures to prevent liquids from seeping through
Take additional measures to prevent liquids from seeping through if the conditions force you
to operate the positioner in an unfavorable mounting position.
Additional measures required to prevent liquids from seeping through depend on the selected
mounting position. You may also require:
● Gland with sealing ring, e.g. FESTO: CK - 1 / 4-PK-6
● Approximately 20 to 30 cm plastic hose, e.g. FESTO: PUN - 8 x 1.25 SW
● Cable tie; the number and the length depend on the local conditions.
50
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.5 Position controllers subjected to fast acceleration or strong vibration
Procedure
1. Install the casing such that rain water or condensate running along the pipes can be drained
before the terminal strip of the positioner.
2. Check the seals of electrical connections for perfect fitting.
3. Check the seal in the enclosure cover for damage and contaminations. Clean and/or replace
if required.
4. Install the positioner such that the sintered bronze attenuator at the bottom side of the
enclosure points downwards in the vertical mounting position. If this is not possible, replace
the attenuator with a suitable gland with a plastic hose.
Procedure for installing the plastic hose on the gland
1. Unscrew the sintered bronze attenuator from the exhaust air opening at the bottom side of
the enclosure.
2. Screw in the aforementioned gland into the exhaust air opening.
3. Install the aforementioned plastic hose into the gland and check whether it fits firmly.
4. Fasten the plastic hose with a cable tie onto the control valve such that the opening points
downwards.
5. Ensure that the plastic hose does not have any kinks and the exhaust air flows out without
any hindrance.
4.5
Position controllers subjected to fast acceleration or strong vibration
4.5.1
Introduction locking the setting
The electropneumatic positioner has an gear latch for the friction clutch and for the
transmission ratio selector.
Strong acceleration forces act on control valves that are subjected to heavy mechanical loads,
e.g. breakaway valves, strongly shaking or vibrating valves, as well as in case of "vapor
shocks". These forces may be much higher than the specified data. This may cause the friction
clutch to move in extreme cases.
The positioner is equipped with an gear latch for the friction clutch to counter these extreme
cases. The setting of the transmission ratio selector can also be locked.
The locking procedure is illustrated and described below.
Note
Use of external NCS sensor / internal NCS module
If you use the accessory part "NCS sensor for contactless position measurement" or a built-in
internal NCS module, the locking and fixing measures described in this section are not
necessary.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
51
Installing/mounting
4.5 Position controllers subjected to fast acceleration or strong vibration
4.5.2
Procedure locking the setting
Overview diagram
NOTICE
Wrong registration of the rotary or part-turn movement
A different setting of the transmission ratio selector and the gear latch results in a hysteresis
in position registration. The hysteresis in position registration can result in unstable control
behavior of the higher level control loop.
● Make sure the transmission ratio selector ⑤ and the gear latch ① are set to the same
value, either to 33° or to 90°.
90
°
33
°
90°
33°
①
②
③
④
⑤
Gear latch
Locking transmission ratio to 33°
Neutral position
Locking transmission ratio to 90°
⑥
⑦
⑧
⑨
Friction clutch
Friction clutch latch
Locking friction clutch
Release friction clutch
Transmission ratio selector
Figure 4-8
52
Locking friction clutch and transmission ratio
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Installing/mounting
4.6 External position detection
Requirements
● The positioner is mounted.
● You know whether the transmission ratio is to be set to 33° or 90°.
● The positioner has been commissioned successfully, i.e. initialization was completed with
"FINISH".
Procedure
NOTICE
The following is applicable for the "flameproof enclosure" version:
● A friction clutch is provided on the outside of the positioner shaft. Change the work area
using this friction clutch, legend number ⑨ in "Overview of device components (Ex)
(Page 27)".
● Do not open the flameproof enclosure of the positioner in explosion-prone atmospheres.
Fix the setting acquired by initialization as follows:
1. Make sure the gear latch ① is in neutral position ③. The neutral position is between 33°
and 90°.
2. Make sure the transmission ratio selector ⑤ is in the correct position.
3. Fix the transmission ratio with the gear latch ①. Turn the gear latch ① with a standard
approx. 4 mm wide screwdriver until the gear latch ① locks. Turning right locks the
transmission ratio to 33°②. Turning left locks the transmission ratio to 90°④. The
transmission ratio is locked.
Note
Changing the setting of the transmission ratio selector
The setting of the transmission ratio selector ⑤ can only be changed effectively if the gear
latch ① is in the neutral position ③.
4. To fix the friction clutch ⑥, insert a standard approx. 4 mm wide screwdriver in the friction
clutch gear latch ⑦ (does not apply to device version "Flameproof enclosure").
5. Use the screwdriver to turn the friction clutch gear latch ⑦ anticlockwise until it engages.
The friction clutch ⑥ is fixed (does not apply to device version "Flameproof enclosure").
4.6
External position detection
WARNING
External position detection system
Versions with flameproof enclosures may not be operated with an external position detection
system.
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The aforementioned measures are not adequate in some applications. For example,
continuous and strong vibrations, high or too low ambient temperatures and nuclear radiation.
The position detection system and the controller unit are mounted separately for these
applications. A universal component is available for this purpose. It is suitable for part-turn and
linear actuators. You will require the following:
● An external position detection system with the article number C73451-A430-D78
comprising a positioner enclosure with integrated friction clutch, built-in potentiometer as
well as various blanking plugs and seals.
● Or an NCS sensor for contact-free position detection 6DR4004-6N.../-8N...
● A positioner
● An EMC filter module with the article number C73451-A430–D23 is provided in a set along
with cable clamps and M20 cable glands.
The EMC filter module is used for the controller unit whenever an external position detection
system is used instead of the internal position sensor. An external position detection system
is, for example, a potentiometer with a 10 kΩ resistance or an NCS sensor.
4.7
Installing the optional modules
4.7.1
General information about the installation of option modules
4.7.1.1
Unsuitable device for the hazardous area
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
● Only use equipment that is approved for use in the intended hazardous area and labelled
accordingly.
4.7.1.2
Installing optional modules in the standard and intrinsically safe version
Introduction
The following option modules are available for the positioner in the standard and intrinsically
safe version:
● Position feedback module
● Alarm module
● SIA module
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● Mechanical limit switch module
● Internal NCS module
● EMC filter module
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Overview screen
①
②
③
④
⑤
⑥
⑦
⑧
56
Module cover
Fixing screws module cover
Fixing screws basic electronics
Ribbon cable/connector for fitted potentiometer
or external position detection system
Ribbon cable/connector for alarm module, SIA
module or mechanical limit switch module
Ribbon cable/connector for position feedback
module
Basic electronics
Alarm module
⑪
⑫
⑬
⑭
⑮
⑯
⑰
⑱
Adapter
Transmission ratio selector
Pneumatic block
Warning label on the side opposite the
nameplate
SIA module or mechanical limit switch
module
Insulating cover, yellow
Special screw
Friction clutch adjustment wheel
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⑨
⑩
Position feedback module
⑲
Wiring diagram on module cover
Nameplate
Figure 4-9
Installing the optional modules in the standard and intrinsically safe version
General procedure for optional modules in the standard and intrinsically safe version
1. Open the positioner. Unscrew the four fixing screws of the enclosure cover.
2. Disconnect the power supply lines or de-energize them.
3. Remove the module cover ①. To do this, unscrew the two fixing screws ②.
4. Install the optional modules as described in the corresponding sections for the individual
optional modules.
5. Now start with the assembly. Install the module cover ①. To this end, turn the fixing screws
② counter clockwise until they noticeably engage in the thread pitch. The module cover
protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using self-tapping screws, one screw for the base plate and
one screw for the valve.
● Proceed as described here in order to avoid premature wear of the base plate and valve.
Carefully tighten both fixing screws ② in a clockwise direction.
6. Continue to assemble the positioner by executing steps 3 to 1 in reverse order.
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4.7.1.3
Installing the optional modules in the "flameproof enclosure" version
Introduction
The following option modules are available for the positioner in the flameproof enclosure:
● Position feedback module
● Alarm module
● Internal NCS module
● EMC filter module
DANGER
Risk of explosion
You must fulfill the following conditions before supplying auxiliary power to the positioner in
potentially hazardous areas:
● The installed electronic unit has been approved.
● The enclosure of the positioner is closed.
● The duct openings for electronic connections must be closed. Only use the Ex d certified
cable entries or sealing plugs.
● You must install an ignition trap if you use a "conduit piping system". The maximum
distance between the ignition trap and the positioner enclosure is 46 cm or 18".
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Overview screen
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
Module cover
Fixing screws module cover
Fixing screws basic electronics
Ribbon cable/connector for fitted potentiometer or external
position detection system
⑬
⑭
⑮
⑯
Pneumatic block
Warning label on the side opposite the nameplate
Screw cap
Feedback lever bracket with pin
⑰
Pin (feedback lever bracket)
Adjustment wheel for external friction clutch
Feedback shaft
Alarm module
⑱
⑲
⑳
Position feedback module
21
Safety catch
Nameplate
22
Ring gear
Ribbon cable/connector for alarm module, SIA module or
mechanical limit switch module
Ribbon cable/connector for position feedback module
Basic electronics
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⑪
⑫
Adapter
23
Enclosure
Transmission ratio selector
Figure 4-10
Installing the optional modules in the "flameproof enclosure" version
General procedure for optional modules in the "flameproof enclosure" version
1. Disconnect the power supply lines or de-energize them.
2. Open the safety catch
21 .
3. Unscrew the screw cap ⑮.
4. Completely dismount the positioner from the actuator.
5. The positioner comes with a ring gear 22 and a pin (feedback lever bracket) ⑰ which
interlock and ensure backlash-free position feedback. To ensure backlash-free position
feedback make sure you remove the adapter ⑪ carefully. To this end, turn the feedback
shaft ⑲ on the positioner until the pin (feedback lever bracket) ⑯ below the adapter ⑪
shows in the direction of removal. You determine the position of the pin by looking into the
enclosure below the adapter. Now, the pin can be easily removed from the ring gear 22 .
Note
Damage to the ring gear
The ring gear consists of two washers fastened staggered to each other. This offset ensures
that path detection is backlash-free.
● Do not change this offset mechanically.
6. Unlatch the four fixing screws ⑳.
7. Completely remove the adapter ⑪ from the enclosure
23 .
NOTICE
Displaced O-rings
There are several O-rings between adapter ⑪ and enclosure 23 . These O-rings may come
off during removal.
● Carefully remove the adapter. Make sure the O-rings do not get lost during removal.
8. Remove the module cover ①. Unlatch both screws ② using a screwdriver.
9. Install the optional modules as described in the corresponding sections for the individual
optional modules.
10.Now start with the assembly. Install the module cover ①. To this end, turn the screws ②
counter clockwise until they noticeably engage in the thread pitch. The module cover
protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using a self-tapping screw for the valve.
● Proceed as described here in order to avoid premature wear of the valve.
Carefully tighten both fixing screws ② in a clockwise direction.
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11.Continue to assemble the positioner by executing steps 7 to 5 in reverse order. Check
whether the position of the O-rings is correct. Make sure no loose items in the enclosure
interfere with the assembly.
12.Now check carefully whether the feedback shaft ⑲ can be smoothly turned by 360°.
If you feel resistance, do not continue to turn but turn the feedback shaft ⑲ back again to
the point of removal, making sure to remember the previously performed steps.
13.Once you have completed all previous steps successfully, continue by performing steps 4
to 1 in reverse order.
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4.7.2
Position feedback module
Function
● The optional position feedback module indicates the current position as a two-wire signal
with the travel range Iy = 4 to 20 mA. The position feedback module is electrically isolated
from the basic device.
● The current position is indicated only after successful initialization.
● Operational faults are signaled by a fault current of 3.6 mA.
Device features
Figure 4-11
Position feedback module
The position feedback module is:
● Single channel
● Potentially separated from the basic device.
Requirements
You are familiar with the general procedure described in the section "General information about
the installation of option modules (Page 54)".
Procedure
1. Slide the position feedback module up to the endstop in the lower bay of the rack.
2. Connect the module to the basic electronics. For this purpose, use the 6-pin flat ribbon
cable provided.
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4.7.3
Alarm module
Function
The alarm module triggers fault messages and alarms via three binary outputs. The message
function is based on the change in the signal status:
● If the signal status is "HIGH", there is no alarm message and the binary inputs are
conductive.
● If the signal status is "LOW", the module reports an alarm by shutting down binary outputs
using a high-resistance.
● Operational faults are signaled at a high-resistance output. Set the following parameters
to activate and configure the output of alarms and fault messages:
– "AFCT" - Alarm function
– "A1" - Response threshold, alarm 1
– "A2" - Response threshold, alarm 2
– "FCT" - Function for fault message output
– "TIM" - Monitoring time
– "LIM" - Response threshold
Apart from binary outputs, the alarm module has a binary input BIN2. Depending on the
selected parameters, it is used to block the actuator or to move it to its end position. Configure
the suitable settings on parameter "BIN2".
Device features
Figure 4-12
Alarm module
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The alarm module has the following features:
● Available in two versions.
– Explosion-proof version for connecting to a switching amplifier in conformity with
EN 60947-5-6.
– Non-explosion-proof version for connecting to power sources having a maximum of 35 V.
● Three binary outputs. Binary inputs are potentially separated from the basic configuration
and from each other.
● The binary input BIN2 has two inputs. Both inputs are implemented as logical OR
combination.
– Input 1 at terminals 11/12: Is electrically isolated, and is triggered by an active signal.
– Input 2 at terminals 21/22: Is not electrically isolated, and is triggered by a passive NO
contact.
Procedure for installing the alarm module
1. You have performed the steps described in the section General information about the
installation of option modules (Page 54).
2. Slide the alarm module into the rack below the basic electronics . Ensure that you slide it
up to the endstop.
3. Connect the module to the basic electronics. For this purpose, use the 8-pin flat ribbon
cable provided.
4. Proceed with the corresponding steps in the section General information about the
installation of option modules (Page 54).
4.7.4
Slit initiator alarm module
Function
If the standard controller requires electrically independent limit value messages, the slotted
initiator alarm module with slotted initiators is used instead of the alarm module.
● A binary output is used to display a collective fault message. Compare with the function of
the alarm module. The floating binary output is implemented as an automatic fault indicating
semiconductor output.
● The other two binary outputs are used to signal the two limits L1 and L2 which can be
adjusted mechanically using slotted initiators. Both these binary outputs are electrically
independent from the remaining electronic unit.
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Device features
①
②
③
Actuating disk bearings
Special screw
Pin
Figure 4-13
④
⑤
⑥
Upper actuating disk for limit L1, terminals 41/42
Lower actuating disk for limit L2, terminals 51/52
Binary outputs
SIA module
The slotted initiator alarm module, SIA module for short, consists of three binary outputs ⑥.
Procedure for installing the slot initiator alarm module
1. You have performed the steps described in the section General information about the
installation of option modules (Page 54).
2. Disconnect all electrical connections of the basic electronics.
3. Loosen the two fixing screws of the basic electronics.
4. Remove the basic electronics.
5. Insert the SIA module from the top up to the upper printed circuit board guide of the rack.
6. Slide the SIA module in the printed circuit board of the rack approximately 3 mm to the right.
7. Screw in the special screw ② through the SIA module into the positioner shaft. Tighten the
special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align pin ③ before placing the adjustment screw ② into the actuating disk bearing ①.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that
the pin ③ is inserted into the special screw ②.
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8. Set the limits L1 and L2 as described in the section "Slit initiator alarm module (Page 64)".
9. An insulating cover (yellow) is required over the module. This insulating cover is supplied
with the module. Place the insulating cover on one side under the basic electronics seat of
the rack. The recesses of the insulating cover must fit in the corresponding webs of the
rack.
10.Place the basic electronics onto the four holders.
11.Fix the basic electronics using both the fixing screws.
12.Reestablish all electrical connections between the basic electronics and the option
modules. Connect the basic electronics and the option modules to the ribbon cables
provided. Connect the basic electronics and the potentiometer to the potentiometer cable.
13.Using both the screws, fasten the module cover provided. Do not use the standard module
cover.
14.Select the labels that are already present on the standard version of the module cover from
the label set provided. Affix the selected labels on the installed module cover as per the
standard version.
15.Proceed with the corresponding steps in the section General information about the
installation of option modules (Page 54).
See also
Installing optional modules in the standard and intrinsically safe version (Page 54)
Procedure: Determining the switch status of the slotted initiators
You will require a suitable display device to determine the switch status. For example, use the
initiator tester type 2 / Ex from Pepperl + Fuchs.
1. Connect the display device to the following terminals of the SIA module:
– 41 and 42
– 51 and 52
2. Read the switch status of slotted initiators.
Procedure: Setting the L1 and L2 limits
The consecutive numbers in the following text refer to the above image in this section. Proceed
as follows to set the limits:
1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 41 and 42
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc ④ beyond the switching point until you reach the next
switching point.
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3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 51 and 52
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc ⑤ beyond the switching point until you reach the next
switching point.
Note
Adjusting the actuating disk
The actuating disks ④ and ⑤ are relatively difficult to move. This design prevents their
unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing stiction temporarily.
● Move the actuator to and fro while simultaneously holding the actuating disks ④ and
⑤.
4.7.5
Mechanical limit switch module
Requirement
You are familiar with the procedure described in the section "Installing optional modules in the
standard and intrinsically safe version (Page 54)".
Procedure for installing the mechanical limit switch module
①
②
③
Actuating disk bearings
Special screw
④
⑤
Upper actuating disk for limit L1, terminals 41/42
Lower actuating disk for limit L2, terminals 51/52
Pin
Figure 4-14
Mechanical limit switch module
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1. Disconnect all electrical connections of the basic electronics.
2. Loosen the two fixing screws of the basic electronics.
3. Remove the basic electronics.
4. Insert the mechanical limit switch module from the top up to the upper printed circuit board
guide of the module rack.
5. Slide the mechanical limit switch module in the printed circuit board of the module rack
approximately 3 mm towards right.
6. Screw in the special screw ② through the mechanical limit switch module into the positioner
shaft. Tighten the special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align pin ③ before placing the adjustment screw ② into the actuating disk bearing ①.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that
the pin ③ is inserted into the special screw ②.
7. Set the limits L1 and L2 as described below.
8. An insulating cover is provided over the mechanical limit switch module. Place the insulating
cover on one side under the basic electronics seat on the walls of the rack. The recesses
of the insulating cover must fit in the corresponding webs of the container wall.
9. Place the insulating cover on the mechanical limit switch module by bending the walls of
the rack carefully.
10.Place the basic electronics onto the four holders.
11.Fix the basic electronics using both the fixing screws.
12.Reestablish all electrical connections between the basic electronics and the option
modules. Connect the basic electronics and the option modules to the ribbon cables
provided. Connect the basic electronics and the potentiometer to the potentiometer cable.
13.Using both the screws, fasten the module cover provided. Do not use the standard module
cover.
14.Select the labels that are already present on the standard version of the module cover from
the label set provided. Affix the selected labels on the installed module cover as per the
standard version.
15.Establish all electrical connections.
Note
Protective conductor connector
A protective conductor connector is not required for safety reasons and therefore is not
provided.
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Procedure: Setting the limits L1 and L2
1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 41 and 42
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 51 and 52
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
Note
Adjusting the actuating disk
The actuating disks ④ and ⑤ are relatively difficult to move. This design prevents their
unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing stiction temporarily.
● Move the actuator to and fro while simultaneously holding the actuating disks ④ and
⑤.
See also
Mechanical limit switch module (Page 67)
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4.7.6
Internal NCS module 6DR4004-5L/-5LE
Function
Wear-free, contact-free position detection
Device features
'
)
*
'
%
&
(B) Internal NCS module 6DR4004-5L.
(F)
Adjustment wheel for the magnet clamp
(C) Insulating cover, yellow
(G) Adjustment wheel for the friction clutch (without
function)
(D) Ribbon cable of the internal NCS mod‐
ule
Figure 4-15
Installing the internal NCS module
Requirement
● The slot required for the internal NCS module in the rack is free. The following option
modules use the same slot in the rack:
– Alarm module
– SIA module
– Mechanical limit switch module
– Internal NCS module
● The positioner is mounted, or is to be mounted, directly on the valve using the positioner
shaft.
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Procedure for installing the internal NCS module
1. You have performed the steps described in the section General information about the
installation of option modules (Page 54).
The legend numbers refer to the indicated section. The legend letters refer to the figures
in this section.
2. Unplug the ribbon cable connector ④ to the installed potentiometer from the basic
electronics ⑦.
3. Remove the basic electronics ⑦ from the positioner. To do this, remove the two screws
that fasten the basic electronics to the pneumatic block ⑬.
4. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here
you fasten the ribbon cable to the container using a cable tie.
$
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5. Screw the special screw (E) into the shaft of the positioner. Tighten the special screw (E)
with a torque of 2 Nm.
(
*
6. Press the adjustment wheel of the magnet clamp (F) firmly onto the special screw (E) of
the friction clutch until you clearly hear it click into place.
)
(
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7. Position the ribbon cable of the internal NCS module (D) upwards, as shown in the figure,
before you slide the internal NCS module into the rack.
8. Slide the internal NCS module (B) under the basic electronics into the rack until you hear
it click into place.
9. An insulating cover is required over the internal NCS module. This insulating cover is
supplied with the internal NCS module. Place the insulating cover (C) on one side under
the basic electronics seat of the rack.
10.Now position the insulating cover by pressing one end against the seat of the rack and
slowly lowering the other end.
11.Firmly press the other end until the insulating cover is underneath the contact surface of
the basic electronics. The recesses of the insulating cover must fit in the corresponding
webs of the rack.
12.Install the basic electronics back into the positioner.
13.Insert the ribbon cable connector of the internal NCS (D) module onto the positioner basic
electronics.
Note for installed position feedback module: Reestablish all electrical connections between
the basic electronics and the position feedback module.
14.Using both the screws, fasten the module cover provided. Do not use the standard module
cover of the positioner. The provided module cover has a larger recess to accommodate
the adjustment wheel of the magnet clamp (F).
15.Make sure that the ribbon cable is not trapped.
16.Select the labels that already exist on the standard version of the module cover from the
label set provided. Affix the selected labels on the installed module cover as per the
standard version.
17.Proceed with the corresponding steps in the section General information about the
installation of option modules (Page 54).
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4.7.7
EMC filter module
Function
You will require the EMC filter module if you use an external position sensor on the positioner,
e.g. a potentiometer or a non-contacting sensor. The EMC filter module forms the interface
between external position sensors and the basic electronics of the positioner. This module
protects the positioner from electromagnetic effects.
Device features
● EMC protection
● Connection to basic electronics
● Connecting terminals for an external potentiometer
Figure 4-16
EMC filter module
Requirement
● You have an EMC filter module, article number C73451‑A430‑D23.
● The module cover is removed.
● Any already installed optional module has been removed.
A description of how to remove the module cover and install the optional modules is provided
in the section "General information about the installation of option modules (Page 54)"
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Procedure for installing the EMC filter module
①
②
③
④
EMC filter module terminals
Positioner
Yellow wheel for locking the position detection
⑤
⑥
⑦
Basic electronics
Screw
EMC filter module C73451-A430-D23
Ribbon cable connector of fitted potentiometer,
or ribbon cable connector of EMC filter module
Figure 4-17
Installation EMC filter module
1. You have performed the steps described in the section "General information about the
installation of option modules (Page 54)".
2. Unplug the ribbon cable connector ④ to the fitted potentiometer from the basic electronics
⑤.
3. Remove the basic electronics ⑤ from the positioner. To this end, remove the two screws
that fix the basic electronics to the pneumatic block.
4. Loosen the screw ⑥ in the connection area of the positioner.
5. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here
you fasten the ribbon cable with the supplied cable tie at the container.
$
$
6. Secure the EMC filter module using the screw ⑥ loosened in the fourth step.
7. Fit the basic electronics ⑤ back into the positioner.
8. Insert the ribbon cable connector ④ of the EMC filter module onto the positioner basic
electronics.
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9. Fasten the module cover. Make sure that the ribbon cable is not trapped.
10.Proceed with the corresponding steps in the section "General information about the
installation of option modules (Page 54)".
See also
Scope of delivery EMC filter module (Page 308)
Scope of delivery of external position detection system (Page 307)
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Installing/mounting
4.7 Installing the optional modules
4.7.8
Accessories
Pressure gauge block
Pressure gauge blocks that are available as accessories are illustrated below. The gauges
display measured values for the actuating pressure and supply air. The image to the left shows
the pressure gauge block for single-acting actuators. The image to the right shows the pressure
gauge block for double-acting actuators.
Y1
Actuating pressure
PZ
Supply air
Y2
Actuating pressure
Fixing the pressure gauge block
The pressure gauge block is fixed onto the lateral pneumatic connection of the positioner using
the screws provided. Use the provided O-rings as sealing elements.
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5.1
Basic safety instructions
WARNING
Improper power supply
Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using direct
current instead of alternating current.
● Connect the device in accordance with the specified power supply and signal circuits. The
relevant specifications can be found in the certificates, in Chapter "Technical data
(Page 283)" or on the nameplate.
WARNING
With intrinsically device version (Ex i)
Risk of explosion in hazardous areas.
For intrinsically safe device versions only the certified circuits may be connected as auxiliary
power supply, control and signal circuits.
● Make sure that the power source of the used circuits is marked as intrinsically safe.
WARNING
Unsafe extra-low voltage
Danger of explosion in hazardous areas due to voltage flashover.
● Connect the device to an extra-low voltage with safe isolation (SELV).
WARNING
Connecting device in energized state
Danger of explosion in hazardous areas.
● Connect devices in hazardous areas only in a de-energized state.
Exceptions:
● Circuits of limited energy may also be connected in the energized state in hazardous areas.
● Exceptions for type of protection "Non-sparking nA" (Zone 2) are regulated in the relevant
certificate
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5.1 Basic safety instructions
WARNING
Lack of equipotential bonding
Danger of explosion through compensating currents or ignition currents through lack of
equipotential bonding.
● Ensure that the device is potentially equalized.
Exception: It may be permissible to omit connection of the equipotential bonding for devices
with type of protection "Intrinsic safety Ex i".
WARNING
Unprotected cable ends
Danger of explosion through unprotected cable ends in hazardous areas.
● Protect unused cable ends in accordance with IEC/EN 60079-14.
WARNING
Improper laying of shielded cables
Danger of explosion through compensating currents between hazardous area and the nonhazardous area.
● Only ground shielded cables that run into the hazardous area at one end.
● If grounding is required at both ends, use an equipotential bonding conductor.
WARNING
Unsuitable cables and/or cable glands
Danger of explosion in hazardous areas.
● Only use suitable cables and cable glands complying with the requirements specified in
Chapter "Technical data".
● Tighten the cable glands in accordance with the torques specified in Chapter "Technical
data".
● When replacing cable glands use only cable glands of the same type.
● After installation check that the cables are seated firmly.
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5.1 Basic safety instructions
WARNING
Incorrect selection of type of protection
Danger of explosion in areas subject to explosion hazard.
This device is approved for several types of protection.
1. Decide in favor of one type of protection.
2. Connect the device in accordance with the selected type of protection.
3. In order to avoid incorrect use at a later point, make the types of protection that are not
used permanently unrecognizable on the nameplate.
NOTICE
Condensation in the device
Damage to device through formation of condensation if the temperature difference between
transportation or storage and the mounting location exceeds 20 °C (36 °F).
● Before taking the device into operation let the device adapt for several hours in the new
environment.
NOTICE
Ambient temperature too high
Damage to cable sheath.
● At an ambient temperature ≥ 60 °C (140 °F), use heat-resistant cables suitable for an
ambient temperature at least 20 °C (36 °F) higher.
NOTICE
Standard cable gland/torque
Device damage.
● Owing the reasons pertaining to tightness (IP enclosure rating) and the required tensile
strength, only use the cables having a diameter ≥ 8 mm for standard M20x1.5 cable gland,
or use a suitable seal insert in case of smaller diameters.
● In the NPT version, the positioner is delivered with a coupling. When inserting a counter
piece in the coupling, ensure that the maximum permissible torque of 10 Nm is not
exceeded.
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5.1 Basic safety instructions
CAUTION
Maximum AC/DC switching voltage with UL approval E344532
The mechanical limit switch module 6DR4004-6K is approved for use for positioners with UL
approval. The maximum supply voltage in this case is 30 V AC/DC.
The mechanical limit switch module 6DR4004-8K is not approved for use for positioners with
UL approval.
If this information is ignored, the UL approval for the mechanical limit switch module for the
positioner becomes invalid.
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 voltage source, otherwise the positioner may be
destroyed.
● Always use a voltage source with a maximum output current of I = 20 mA.
5.1.1
Improvement of interference immunity
Note
Improvement of interference immunity
● Lay signal cables separate from cables with voltages > 60 V.
● Use cables with twisted wires.
● Avoid getting too close to large electrical process cells.
● Use shielded cables to guarantee the full specification.
● Take account of the conditions for communication specified in the technical data.
Electromagnetic compatibility
The Macrolon enclosure is metalized from inside to increase the electromagnetic compatibility
(EMC) with respect to high-frequency radiation. The shield is connected to the threaded bush
shown in the following picture such that it is electrically conductive.
Note that this protection is effective only if you connect at least one of these bushes to the
earthed control valves through electrically conductive (bare) attachments.
80
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5.1 Basic safety instructions
Shield
Figure 5-1
5.1.2
Base plate
Interference immunity
If the bus shield is fully effective, the interference immunity and the interference emission
conform to the specifications. The following measures ensure that the bus shield is fully
effective:
● The shields have been connected to the metallic connections of the positioner.
● The shields have been laid up to the terminal boxes, the distributor and the transceiver.
Note
Dissipation of glitch impulses/equipotential bonding
In order to dissipate glitch impulses, the positioner must be connected to an equipotential
bonding cable (earth potential) using a low resistance. The positioner in the Makrolon
enclosure is therefore equipped with an additional cable. Connect the this cable to the shield
of the bus cable and the equipotential bonding cable using a cable clamp.
Devices in the stainless steel or aluminum enclosure have a corresponding terminal on the
outer side of the enclosure. This terminal must also be connected to the equipotential
bonding cable.
For applications in hazardous areas, ensure an adequately suitable equipotential bonding
between the hazardous and non-hazardous areas.
5.1.3
Safety shutdown
The positioner is equipped with an additional input (terminal 81 [+] and terminal 82 [-]) to
approach the safety position. After activating this function, this input must be continuously
supplied with +24 V in order to retain the normal control function.
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5.2 Electrical wiring
If the 24-V signal is interrupted, the safety position is set as described in chapter "Pneumatic
connection (Page 101)".
Communication with the master is still possible. The "Jumper" on the basic electronics is used
to activate this function. It can be accessed after removing the module cover, and must be
switched from the right position (delivery state) to the left position.
5.2
Electrical wiring
5.2.1
Bus cable
The following image will help you in preparing the bus cable for the connection:
a
①
②
D
80 mm: Normal version of device
120 mm: Version with flameproof enclosure (6DR5..5)
Bus cables to be used:
SIMATIC NET, PB FC Process Cable, bus cable for IEC 61158-2
Cable shield
Figure 5-2
Preparation of bus cable
Devices without flameproof enclosure are:
● Normal version of devices
● Intrinsically safe versions
● Versions for zones 2 and 22
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5.2 Electrical wiring
Procedure for device versions without flameproof enclosure
33 O
Jumper
Shut
Down
input
Positioner
6
BUS
7
8
9
10
Binary
input 1
r
Transmission ratio selector
82
Shut Down
disabled
Shut Down
enabled
O
-
81
90
+
24V
r
①
②
③
④
⑤
⑥
Bus cable
Cable clamp
Basic electronics
Connection diagram on module cover
Jumper on basic electronics
⑦
⑧
⑨
⑩
⑪
Label
Terminal strip with screw-type terminals
Earth potential
Grounding cable
Cable glands
Module cover
Figure 5-3
Connection of bus cable and grounding cable for device version with Makrolon enclosure
1. Strip the bus cable ①.
2. Open the enclosure of the positioner by unlatching the four cover screws.
3. Insert the prepared bus cable (described in Bus cable (Page 82)) through the cable inlet.
4. Fasten the shield using the clamp ② and the two screws on the enclosure.
5. Tighten the cable inlet.
6. Connect the red and the green wires to terminals 6 and 7 of the basic electronics as shown
in the following picture. The polarity does not play any role here.
Note
Bus cable and grounding cable for device version with stainless steel/aluminum enclosure
In the case of the stainless steel or aluminum enclosure, use the grounding terminal
provided on the outside of the device.
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5.2 Electrical wiring
Procedure for device versions with flameproof enclosure "Ex d"
①
②
③
④
⑤
Basic electronics bus cable
Grounding terminal
Ex d certified cable inlet
Bus cable
Cable clamp/shield
Figure 5-4
Connection of bus cable for versions with flameproof enclosure
1. Strip the bus cable.
2. Open the safety catch and unscrew the screw cap to open the positioner.
3. Insert the prepared bus cable ④ (described in Bus cable (Page 82)) through the Ex dcertified cable inlet ③. Follow the corresponding guidelines if you are using a conduit piping
system.
4. Fasten the shield on the adapter using the clamp ⑤ and the two screws.
5. Tighten the Ex d-certified cable inlet ③.
6. Connect the red and the green wires to terminals 6 and 7 of the basic electronics as shown
in the following picture. The polarity does not play any role here.
If a bus connection is not present, connect a separate power source with the following values
to terminals 6/7:
● With intrinsically-safe devices: intrinsically-safe isolating power supply with 24 V DC
● With non-intrinsically-safe devices: 15 to 30 V DC
Then match the positioner to the respective actuator by configuring and initializing it. Finally
set the bus address.
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5.2 Electrical wiring
5.2.2
Wiring diagram for basic electronics
([G([W([Q$
([L
352),
%863$
352),
%863$
352),
%863$
Non-hazardous area
Hazardous area
Basic electronics
Figure 5-5
④
⑤
⑥
$
①
②
③
(
9
Input: Safety shutdown
Binary input 1
Signal source
Device version with PROFIBUS PA
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5.2 Electrical wiring
5.2.3
Wiring NCS sensor to EMC filter module
Requirement
You need the EMC filter module, article number C73451‑A430‑D23, for the electrical
connection of the accessory part "NCS sensor for contactless position measurement" to the
positioner. The positioner supplies auxiliary power to the NCS sensor via the EMC filter module.
Wiring diagram
①
②
③
④
⑤
⑥
Positioner (open state)
Vcc: Yellow
Vref: Green
Vpos: Black
Ground: Brown
EMC filter module C73451-A430-D23
Figure 5-6
86
⑦
⑧
⑨
⑩
⑪
⑫
Cable clamp
Screw F3x8
Cable gland
Four-pole NCS cable
Non Contacting Sensor (NCS)
Cable shielding lug
Example of connecting the NCS to the EMC filter module
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5.2 Electrical wiring
Procedure
The NCS sensor is equipped with a shielded four-pole cable. Wire this cable to the positioner
as follows:
1. Feed the four-pole NCS cable ⑩ through the union nut and the cable gland. Note: The
type of cable gland depends on the positioner version.
2. Tighten the cable gland ⑨.
3. Terminate the four-pole NCS cable ⑩ in the positioner in accordance with the wiring
diagram.
4. Place the cable clamp ⑦ onto the outer insulation of the four-pole NCS cable ⑩.
5. Use the screw ⑧ to bond the cable shielding lug ⑫ and the cable clamp ⑦ to the ground
terminal of the positioner.
6. Grounding:
The rear steel panel of the NCS sensor is inevitably bonded to the ground potential of the
system when mounting on the console. This ground connection is only functional if there
is a low-impedance connection to ground potential of the system. Ensure this state by
measuring the ground resistance. If necessary, ensure proper grounding by means of an
additional cable from the NCS sensor to ground potential.
5.2.4
Connecting the external position detection system to the EMC filter module
Requirement
You need the EMC filter module with article number C73451‑A430‑D23 for the electrical
connection of an external position detection system, article number C73451-A430-D78, to the
positioner.
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5.2 Electrical wiring
Wiring diagram
a
a
①
EMC filter module terminals
⑧
②
Positioner with integral EMC filter module
C73451-A430-D23
⑨
③
④
⑤
⑥
⑦
Yellow wheel for locking the position detec‐
tion
Ribbon cable connector of fitted potentiom‐
eter, or ribbon cable connector of EMC filter
module
Basic electronics
Screw
⑩
External position detection system C73451A430-D78
External position detection system termi‐
nals
External position detection system cable
gland
⑪
Cable
⑫
⑬
EMC filter module cable gland
Input signal for positioner
EMC filter module C73451-A430-D23
Figure 5-7
Connection to positioner
Preparing the positioner
1. You have performed the steps described in the section "General information about the
installation of option modules (Page 54)".
2. Unplug the ribbon cable connector ④ to the fitted potentiometer from the basic electronics
⑤.
3. Remove the basic electronics ⑤ from the positioner. To this end, remove the two screws
that fix the basic electronics to the pneumatic block.
4. Loosen screw ⑥ in the connection area of the positioner.
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5.2 Electrical wiring
5. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here
you fasten the ribbon cable with the supplied cable tie at the container.
$
$
6. Secure the EMC filter module using the screw ⑥ loosened in the third step.
7. Fit the basic electronics ⑤ back into the positioner.
8. Insert the ribbon cable connector ④ of the EMC filter module onto the positioner basic
electronics.
9. In non-hazardous environment:
– Stick the supplied nameplate over the nameplate on the external position detection
system ⑧.
– Replace the blue cable gland ⑩ by the supplied gray cable gland.
Refer to section "Scope of delivery of external position detection system (Page 307)", items
"Nameplate for device version without explosion protection" and "Gray cable gland".
Procedure for connecting an external position detection system
1. Connect the three terminals of the external position detection system ⑨ to the three
terminals of the EMC filter module ① using a cable as shown in the wiring diagram.
2. Tighten the cable glands ⑩ and ⑫.
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5.2 Electrical wiring
5.2.5
Option modules
5.2.5.1
Alarm modules 6DR4004-6A and -8A
([G([W
9
9
9
9
ุ
9
.
.
$
$
.
([L([Q$
([
([
([
([
①
②
③
④
Non-hazardous area
Hazardous area
Alarm module
Binary input 2
Figure 5-8
90
⑤
⑥
⑦
⑧
ุ
9
.
.
.
.
$
$
.
.
Fault message
Limit
Switching amplifier
Switching output
Alarm module
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5.2 Electrical wiring
5.2.5.2
Position feedback modules 6DR4004-6J and -8J
([G([W
([L([Q$
8$X[
8$X[
Ex 8$X[
U
③
④
Non-hazardous area
Hazardous area
Position feedback module
Feed splitter
Position feedback module
SIA modules 6DR4004-6G and -8G
([W
([L([Q$
([
([
([
Non-hazardous area
Hazardous area
SIA module
Figure 5-10
I
5.2.5.3
①
②
③
E
62
I
Figure 5-9
61
U
I
①
②
④
⑤
⑥
.
.
$
$
Fault message
Limit
Switching amplifier
SIA module
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5.2 Electrical wiring
5.2.5.4
Mechanical limit switch modules 6DR4004-6K and -8K
DANGER
Supply with hazardous voltage
When you supply the non-intrinsically safe version of the module with hazardous voltage, you
must read 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.
CAUTION
Maximum AC/DC switching voltage with UL approval E344532
The mechanical limit switch module 6DR4004-6K is approved for use for positioners with UL
approval. The maximum supply voltage in this case is 30 V AC/DC.
The mechanical limit switch module 6DR4004-8K is not approved for use for positioners with
UL approval.
If this information is ignored, the UL approval for the mechanical limit switch module for the
positioner becomes invalid.
([G([W
([L([Q$
([
([
Non-hazardous area
Hazardous area
Mechanical limit switch module
$
$
⑤
⑥
⑦
Limit
Switching amplifier
Switching output
Fault message
Figure 5-11
92
([
①
②
③
④
.
.
Mechanical limit switch module
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5.2 Electrical wiring
Procedure
1. Loosen the screw ① on the transparent cover ②.
2. Pull the transparent cover ② up to the front end stop.
3. Tighten every cable in the corresponding terminal.
4. Slide the transparent cover ② up to the end stop of the basic electronics.
5. Tighten the screw ① of the transparent cover ②.
6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the
provided cable ties ③ for this purpose.
①
②
③
Screw
Cover
Cable tie
Figure 5-12
5.2.6
Connecting the cables
Option device version M12 connector
This section describes which terminal of the devices and option modules listed below is
connected with the respective pole of the M12 connector.
Note
Technical specifications
Observe the specifications for the electrical data in the certificate and/or in section "Technical
data (Page 283)".
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5.2 Electrical wiring
View of the mating side pole pattern
Pole designation Wire color of M12
connector
1
Brown
4
Black
3
Blue
2
White
5.2.6.1
M12 connector in the basic device
You have a positioner 6DR55..-0.R.. or 6DR55..-0.S. In this case the M12 connector is
connected to the bus circuit of the basic electronics.
Table 5-1
Assignment diagram
Bus circuit terminal
5.2.6.2
Pole designation
7
1 - Brown
Shield support of housing
4 - Black
6
3 - Blue
M12 connector for connection of the outputs of the alarm module 6DR4004-6A / -8A (-Z
D55)
You have a positioner with order suffix -Z order code D55. This version of the positioner is
connected via an M12 connector to the current output of the position feedback module.
Table 5-2
Assignment diagram
Alarm output terminal
94
Pole designation
41 (+)
1 - Brown
52 (-)
4 - Black
42 (-)
3 - Blue
51 (+)
2 - White
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5.2 Electrical wiring
5.2.6.3
M12 connector for connecting the outputs of the position feedback module 6DR4004-6J /
8J (-Z D53)
You have a positioner with order suffix -Z order code D53. In this version of the positioner, an
M12 connector is used to electrically connect the current output of the position feedback
module.
Table 5-3
Assignment diagram
Current output terminal
5.2.6.4
Pole designation
61 (+)
1 - Brown
Shield support of housing
4 - Black
62 (-)
3 - Blue
M12 connector for connecting the external position detection system (-Z D54)
You have a positioner with order suffix -Z order code D54. In this version of the positioner the
M12 connector connects the external position detection system with the built-in EMC filter
module (C73451-A430-D23).
Table 5-4
Assignment diagram
Terminal
5.2.6.5
Pole designation
POT (X1/2)
3 - Blue
VCC (X1/4)
1 - Brown
GND (X1/1)
4 - Black
VREF (X1/3)
2 - White
M12 connector for connecting the outputs of the SIA module 6DR4004-6G /-8G (-Z D56)
You have a positioner with order suffix -Z order code D56. In this version of the positioner, an
M12 connector is used to electrically connect the outputs of the SIA module.
Table 5-5
Assignment diagram
Alarm output terminal
Pole designation
41 (+)
1 - Brown
52 (-)
4 - Black
42 (-)
3 - Blue
51 (+)
2 - White
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5.3 Pneumatic connection
5.3
Pneumatic connection
5.3.1
Pneumatic connection for 6DR55.0/1/2/3
Structure
The pneumatic connections are provided on the right side of the positioner.
①
②
③
④
⑤
Actuating pressure Y1 for single and double-acting actuators
Positioner shaft
Supply air PZ
Actuating pressure Y2 for double-acting actuators
Exhaust air outlet with a sound absorber
Figure 5-13
5.3.2
Pneumatic connection on the standard controller
Integrated pneumatic connection
Structure
The following pneumatic connections are provided at the rear side of the basic device for the
integrated attachment for single-acting linear actuators:
● Actuating pressure Y1
● Exhaust air outlet
These connections are sealed with screws when the device is delivered.
The exhaust air outlet is corrosion-resistant for the blanketing of the pick-up room and the
spring chamber with dry instrument air.
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5.3 Pneumatic connection
①
②
Actuating pressure Y1
Exhaust air outlet
Figure 5-14
5.3.3
Integrated pneumatic connection
Pneumatic connection for 6DR55.5-0E...
Structure
The pneumatic connections are provided on the right side of the positioner.
①
②
③
④
Restrictor Y2 *)
Restrictor Y1
Actuating pressure Y2
*)
⑤
⑥
⑦
Actuating pressure Y1
Exhaust air outlet
Enclosure ventilation (2x)
Supply air PZ
*) for double-acting actuators
Figure 5-15
Pneumatic connection in the flameproof enclosure
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5.3 Pneumatic connection
5.3.4
Reaction to failure of auxiliary powers
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.
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5.3 Pneumatic connection
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Connect
5.3 Pneumatic connection
Overview of positioning effect for fail in place version
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100
Pneumatic connections for positioning effect with fail in place version
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Connect
5.3 Pneumatic connection
5.3.5
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 "P-manual mode" when an electrical signal is available,
refer to the as-delivered condition.
Note
Specifications regarding air quality
Observe the specifications regarding the air quality, see section "Technical specifications >
Pneumatic data (Page 284)".
● If required, connect the pressure gauge block for supply air and actuating pressure.
● Connection via female thread G¼ or ¼" NPT:
– Y1: actuating pressure 1 for single and double-acting actuators
– Y2: actuating pressure 2 for double-acting actuators
– Exhaust air outlet with a sound absorber. Remove the sound absorber if required.
● For double-acting actuators, connect actuating pressure Y1 or Y2 depending on the desired
safety setting.
● Safety position in case of electrical auxiliary power supply failure:
– Positioner with single-acting pneumatic system: Y1 depressurized
– Positioner with double-acting pneumatic system: Y1 pressurized (maximum actuating
pressure), Y2 depressurized
– Positioner with Fail in Place pneumatic system: Hold Y1 and Y2 (current actuating
pressure)
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.
● After installing the pneumatic connections, check the tightness of the entire control valve.
See also
Reaction to failure of auxiliary powers (Page 98)
Changing the operating mode (Page 107)
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Connect
5.4 Restrictors
5.4
Restrictors
● Reduce the air output to achieve travel times of T > 1.5 s for small actuators. Use restrictors
Y1 ① and Y2 ② for this purpose.
● When turned clockwise, they reduce the air output and finally shut it off.
● In order to set the restrictors, we recommend closing them and then opening slowly.
● In case of double-acting valves, ensure that both restrictors have approximately the same
setting.
①
②
③
Restrictor Y1
Restrictor Y2, only in the version for double-acting actuators
Hexagon socket-head screw 2.5 mm
Figure 5-18
Restrictors
See also
Pneumatic connection for 6DR55.5-0E... (Page 97)
Sequence of automatic initialization (Page 116)
102
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Operation
6.1
Operating elements
6.1.1
Display
Introduction
Note
Repetition rate display
When operated in temperature ranges below -10°C, the liquid crystal display of the positioner
becomes sluggish and the repetition rate display reduces considerably.
The display has two lines. These two lines are segmented differently. Each element in the
upper line has 7 segments, whereas that in the lower line has 14 segments. Contents of the
display depend on the selected mode.
Display options as per the mode
An overview of mode-specific display options is given below.
Operating mode
Representation in the display
P manual mode
Initialization mode
Pos.
Legend
①
②
Potentiometer setting [%]
①
②
③
Blinking indicator for the non-initialized status.
Potentiometer setting [%]
Display of the current status of initialization or a fault
message.
Indicator for ongoing initialization or a fault message.
Configuring
①
②
③
Parameter value
Parameter name
Parameter number
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Operation
6.1 Operating elements
Operating mode
Representation in the display
Manual mode (MAN)
Pos.
Legend
①
②
③
Position [%]
Setpoint [%]
①
②
③
Setpoint [%]
①
②
③
Diagnostics name
Fault message
Automatic (AUT)
Position [%]
Fault message
Diagnostics
Diagnostics value
Diagnostics number
See also
System messages before initialization (Page 246)
Changing the operating mode (Page 107)
6.1.2
Buttons
①
②
③
④
Display
Operating mode button
Decrement button
Increment button
Figure 6-1
104
Display and buttons of the positioner
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Operation
6.1 Operating elements
● You can use three buttons to operate the positioner.
● The function of the buttons depends on the mode selected.
● In a positioner with a flameproof enclosure, the buttons are protected with a cover. The
button cover can be opened after unlatching the locking screw.
Note
Key cover
In positioners with flameproof enclosures, the button cover prevents liquids from seeping
through. The IP66/NEMA 4x degree of protection is not ensured when the enclosure or the
button cover is open.
You have to remove the enclosure cover to operate the buttons of the basic device or the
"intrinsically safe" version.
Note
Degree of protection
The IP66/NEMA 4x degree of protection is not ensured as long as the positioner is open.
Function of buttons:
● The
button is used to select the modes and to forward the parameters.
● The
button is used to select parameter values in "Configuration" mode. You can use
this button to move the actuator in "Manual" mode.
● The
button is also used to select parameter values in "Configuration" mode. You can
use this button to move the actuator in "Manual" mode.
Note
Order
Parameters are activated in the reverse order when the
simultaneously.
and
buttons are pressed
See also
Display (Page 103)
6.1.3
Firmware version
The current firmware version is displayed when you exit the configuration menu.
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Operation
6.2 Operating modes
Figure 6-2
Firmware version, e.g. version 6.00.00
6.2
Operating modes
6.2.1
Overview of operating modes
You have five operating modes at your disposal to operate the positioner:
1. P-manual mode (as-delivered condition)
2. Configuration and initialization mode
3. Manual mode (MAN)
4. Automatic (AUT)
5. Diagnostics
106
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Operation
6.2 Operating modes
6.2.2
Changing the operating mode
The following picture illustrates the available operating modes and switching between the
operating modes.
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Switching between the operating modes
See also
Display (Page 103)
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Operation
6.2 Operating modes
6.2.3
Overview of configuration
The following picture illustrates the handling of operating modes such as "Configuration" and
"Initialization mode":
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6.2.4
Overview of the "Configuration" operating mode
Description of operating modes
P manual mode
Note
Delivery state
The "P manual mode" is preset for the positioner in the delivery state.
The display of the positioner shows the current potentiometer position in the upper line. "NOINI"
blinks in the second line of the display.
Move to the actuator with the
or
buttons.
Switch to "Configuration" mode to adapt the actuator to the positioner.
Alarms or position feedbacks can be triggered after initializing the positioner completely.
Configuration and initialization
To get to the "Configuration" mode, press the
108
button for at least 5 seconds.
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6.2 Operating modes
You can use the "Configuration" mode to adjust the positioner individually as per your actuator
and start commissioning or initialization.
The positioner reports the "Configuration" mode with a configurable fault message. A position
feedback or display of limits A1 and A2 is not possible.
Note
Failure of electrical auxiliary power
If electrical auxiliary power supply fails when configuring, the positioner responds as follows
when the power supply is reestablished:
● The positioner switches to the first parameter.
● Settings of the values already configured are retained.
In order to save the changed parameter values, exit the "Configuration" mode or switch to
another parameter. When "Configuration" mode is restarted, the output in the display switches
to the last activated parameter.
Manual mode (MAN)
or . The setting selected here is retained
In this mode, you move the actuator with
irrespective of the setpoint current and leakages, if any.
Note
Accelerating the actuator movement
Proceed as follows if you wish to accelerate the actuator movement:
1. Keep one of the two direction buttons pressed.
2. Press the remaining direction button simultaneously.
Note
Failure of power supply
When the power supply is reestablished after a failure, the positioner switches to the
"Automatic" mode.
Automatic (AUT)
Automatic is the standard mode. In this mode, the positioner compares the setpoint position
with the actual position. The positioner moves the actuator until the control deviation reaches
the configurable deadband. An error message is displayed if the deadband cannot be reached.
Diagnostics
Proceed as follows to call the "Diagnostics" mode from the "Automatic" or "Manual" modes:
Press the three buttons of the positioner at the same time for at least 2 seconds.
Current operating data can be called and displayed in this mode, e.g.:
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Operation
6.2 Operating modes
● Number of total strokes
● Number of changes in direction
● Number of fault messages
Note
Setting the mode
The "Automatic" and "Manual" modes remain set when switching to the "Diagnostics" mode.
The positioner responds as per the configured mode:
● The predefined setpoint is used as the control variable in "Automatic" mode.
● The last reached position is retained in "Manual" mode.
See also
Overview (Page 115)
Overview of advanced diagnostics parameters A to P (Page 150)
Overview of diagnostics values (Page 253)
6.2.5
Optimization of controller data
Note
Initializing
Initialize the positioner automatically before changing the parameter settings as per your
specific requirements.
The positioner determines the data for control quality automatically during the initialization
process.
The data determined is optimized for a short transient time in the case of minor overshoots.
The adjustment can be accelerated or the attenuation can be intensified by optimizing the data.
The following special cases are suitable for targeted data optimization:
● Small actuators with travel times < 1 s.
● Operation with boosters, described in section "Operation with boosters (Page 311)"
Procedure
1. Switch to "Diagnostics" mode.
2. Select the diagnostics parameters.
3. Press the three buttons of the positioner at the same time for at least 2 seconds.
4. Activate the setting function. Press the
110
or
button for at least 5 seconds.
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Operation
6.2 Operating modes
The modified diagnostics values are effective immediately. The effects on the controller results
can then be tested.
In order to optimize the controller data, change the values of the diagnostics parameters listed
below.
Diagnostics parameters '23.IMPUP' Impulse length UP / '24.IMPDN' Impulse length DOWN
You can use these diagnostics parameters to determine the smallest impulse lengths for each
actuating direction. The actuator is then moved with these lengths. The optimum value
depends in particular on the volume of the actuator. Small values lead to small controller
increments and frequent activation of the actuator. Large values are advantageous for large
actuator volumes.
Note
Controller increments
● There is no movement if the values are too small.
● Large controller increments also lead to large movements with small actuators.
Diagnostics parameters '28.SSUP' Slow step zone UP / '29.SSDN' Slow step zone DOWN
The slow step zone is the area of mean control deviation. For more information on the slow
step zone, refer to the section "Functional principle (Page 28)".
Select small values to achieve high speeds of shifting even with small control deviations. Select
large values to reduce overshoots particularly in case of large changes in the setpoint.
NOTICE
Overshoots or too low speeds of shifting
Too small values can result in overshoots.
● Enter a higher value.
Too large values result in too slow speeds of shifting near the adjusted status.
● Enter a smaller value.
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Operation
6.2 Operating modes
Diagnostics parameters '47.PRUP' Prediction UP / '48.PRDN' Prediction DOWN
These diagnostics parameters act as attenuation factors and are used to set the control
dynamics. Changes in the diagnostics values have the following results:
● Small values result in quick adjustments with overshoots.
● Large values result in slow adjustments without overshoots.
Note
Reference variable
It is advantageous to use a fixed reference variable to optimize the control data. Therefore,
change the deadband of the controller in the '34.DEBA' parameter from "Auto" to a fixed
value.
112
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Commissioning
7.1
7
Basic safety instructions
WARNING
Improper commissioning in hazardous areas
Device failure or danger 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 (Page 283)".
● Before commissioning take the effect on other devices in the system into account.
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 "Installing/mounting (Page 37)".
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.
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Commissioning
7.1 Basic safety instructions
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 that 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.
CAUTION
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection
specified on the nameplate or in Chapter "Technical data (Page 283)" is no longer guaranteed.
● Make sure that the device is securely closed.
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.
114
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Commissioning
7.2 Overview
When operating the positioner with natural gas, you must follow and adhere to the following
safety notes:
WARNING
Operation with natural gas
1. Only positioners and option modules which are connected to power supplies with type of
protection "Intrinsic safety, protection level [ia]" may be operated with natural gas.
2. Do not operate the positioner with natural gas in closed spaces.
3. Natural gas is continuously blown off in the servo-drive depending on the model. Special
care must therefore be taken during maintenance activities near the positioner. Always
ensure that the immediate surroundings of the positioner are adequately ventilated.
The maximum values for ventilation are listed in section "Technical data for natural gas
as actuator medium (Page 290)".
4. The mechanical limit switch module must not be used when operating the positioner with
natural gas.
5. Depressurize the devices operated with natural gas adequately during maintenance
activities. Open the cover in an explosion-free atmosphere and depressurize the device
for at least two minutes.
Note
Quality of natural gas
Only use natural gas which is clean, dry and free from additives.
7.2
Overview
Note
● During the initialization process, the operating pressure must be at least one bar more than
that required to close or open the valve. However, the operating pressure should not be
greater than the maximum permissible operating pressure for the actuator.
General information about commissioning
1. After installing the positioner on a pneumatic actuator, you must supply electric and
pneumatic auxiliary power to it.
2. The positioner is in the "P manual mode" before initialization. At the same time, "NOINI"
blinks in the lower line of the display.
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Commissioning
7.3 Sequence of automatic initialization
3. Position feedback: You can adjust the range of position detection using the friction clutch
if necessary.
4. Adjust the positioner as per the respective actuator with the help of the initialization process
and by setting the parameters. If required, use the "PRST" parameter to cancel the
adjustment of the positioner on the actuator. The positioner is again in the "P manual mode"
after this process.
Types of initialization
You can initialize the positioner as follows:
● Automatic initialization:
during automatic initialization, the positioner determines the following one after the other:
– The direction of action
– The actuator travel and angle of rotation
– The travel time of the actuator
The positioner also adjusts the control parameters as per the dynamic response of the actuator.
● Manual initialization:
the actuator travel and the angle of rotation of the actuator are set manually. The remaining
parameters are automatically determined. This function is useful for valves which are lined,
for example, with PTFE.
● Copying the initialization data when replacing a positioner:
the initialization data of a positioner can be read and copied into another positioner. A
defective device can thus be replaced without interrupting an ongoing process through
initialization.
You have to define a few parameters for the positioner before initialization. Owing to the preset
values, you cannot adjust further parameters for initialization.
You can use a suitably configured and activated binary input to protect the configured settings
against accidental adjustment.
See also
Overview of operating modes (Page 106)
7.3
Sequence of automatic initialization
Overview
The automatic initialization takes place in the following phases:
116
Automatic initialization phase
Description
Start
-
RUN1
Establishing the direction of action.
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Commissioning
7.3 Sequence of automatic initialization
Automatic initialization phase
Description
RUN2
Checking the actuator travel and trimming the lower and
upper endstops.
RUN3
Establishing and displaying the travel time (leakage test)
RUN4
Minimization of controller increments
RUN5
Optimization of the transient response
End
-
The following structured charts describe the sequence of initialization. The "Up/Down" names
indicate the direction of action of actuators.
Linear actuator
Open
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Part-turn actuator
Closed
Closed
Open
117
Commissioning
7.3 Sequence of automatic initialization
Sequence of RUN1
This structured chart describes the process to establish the direction of action.
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This structured chart describes the sequence for checking the actuator travel. It also contains
information about the sequence for trimming the lower and upper endstops.
118
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Operating Instructions, 02/2016, A5E00127926-AB
Commissioning
7.3 Sequence of automatic initialization
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Sequence of RUN2 for linear actuators
This structured chart describes the process to determine the actuator travel checks. It also
contains information about the sequence for trimming the lower and upper endstops.
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119
Commissioning
7.3 Sequence of automatic initialization
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Sequence of RUN3 to RUN5
This structured chart describes:
120
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Operating Instructions, 02/2016, A5E00127926-AB
Commissioning
7.3 Sequence of automatic initialization
● Establishing and displaying the travel time/leakage in RUN3
● Minimization of controller increments in RUN4
● Optimization of the transient response in RUN5
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Operating Instructions, 02/2016, A5E00127926-AB
121
Commissioning
7.4 Purge air switching
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7.4
Purge air switching
When the enclosure is open, the purge air switch above the pneumatic terminal strip on the
pneumatic block can be accessed.
● In the IN position, the enclosure is flushed from inside with a small volume of clean and dry
instrument air.
● In the OUT position, the purge air is directly directed towards outside.
①
②
Purging air selector
Pneumatic connections Y1, PZ and Y2
Figure 7-1
Purge air switch on the pneumatic block; view of the positioner on the pneumatic
connection side when the cover is open
The factory setting is the "IN" position.
122
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Commissioning
7.5 Commissioning linear actuators
7.5
Commissioning linear actuators
7.5.1
Preparing linear actuators for commissioning
Requirement
You have already installed the positioner using the suitable mounting kit.
Setting the transmission ratio selector
Note
Commissioning
The setting of the transmission ratio selector is extremely important to commission the
positioner.
Stroke [mm]
Position of the transmission ratio selector
5 ... 20
33°
25 ... 35
90°
40 ... 130
90°
Connecting the positioner
1. Connect a suitable current or voltage source. The positioner is now in the "P manual mode".
The current potentiometer voltage (P) in percent is shown in the upper line of the display,
e.g.: "P37.5", and "NOINI" flashes in the bottom line:
2. Connect the actuator and the positioner to the pneumatic lines.
3. Supply the pneumatic auxiliary power to the positioner.
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7.5 Commissioning linear actuators
Setting the actuator
1. Check whether the mechanical unit can be moved freely in the entire travel range. Move
the actuator to the respective end position for this purpose using the
or
button.
Note
End position
By simultaneously pressing the
and
buttons, you reach the end position faster.
2. Now move the actuator to the horizontal position of the lever.
3. A value between "P48.0" and "P52.0" is shown on the display.
4. If a value beyond this value range is shown on the display, you must move the friction clutch.
Move the friction clutch until a value between "P48.0" and "P52.0" is achieved. The closer
this value is to "P50.0", the more accurately the positioner determines the stroke travel.
Note
Device versions with flameproof enclosure
The inner friction clutch is fixed. Therefore, only move the outer friction clutch. This also
applies when using an internal NCS module.
The following applies to device versions without flameproof enclosure with internal NCS
module 6DR4004-5L.:
The inner friction clutch has no function. This means you should only adjust the adjustment
wheel of the magnet clamp, see section "Internal NCS module 6DR4004-5L/-5LE
(Page 70)". Requirement: The '1.YFCT' Type of actuator (Page 154) parameter is set.
See also
Device components (Page 26)
Installing the optional modules (Page 54)
External position detection (Page 53)
Mounting the linear actuator (Page 40)
7.5.2
Automatic initialization of linear actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The actuator spindle can be moved completely.
2. The actuator spindle is at a central position after moving.
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7.5 Commissioning linear actuators
Initializing the linear actuator automatically
Note
Interrupting initialization
An ongoing initialization can be interrupted at any time. To do this, press
configured until then are retained.
. The settings
All parameters are reset to factory settings only if you have explicitly activated the preset
settings in the "PRST" parameter.
1. Switch to the "Configuration" mode. To do this, press the
The display shows the following:
button for at least 5 seconds.
2. Call the "2.YAGL" parameter. To do this, briefly press the
on the display depending on the setting:
button. The following is shown
3. Check whether the value displayed in the "2.YAGL" parameter matches the setting of the
transmission ratio selector. If required, change the setting of the transmission ratio selector
to 33° or 90°.
4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of parameter
3 is optional. The display shows the determined total stroke only at the end of the
initialization phase.
– Briefly press the
button if you do not require any information about the total stroke in
mm. You are then directed to parameter 4.
– Call the "3.YWAY" parameter. To do this, briefly press the
the following:
button. The display shows
Note
Set the "3.YWAY" parameter
Proceed as follows to set parameter 3:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter with the buttons or to the read value.
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5. Call the "4.INITA" parameter. To do this, briefly press the
following:
6. Start the initialization process. To do this, press the
the display shows the following:
button. The display shows the
button for at least 5 seconds until
The positioner runs through five initialization steps during the automatic initialization
process. Displays for the initialization steps from "RUN 1" to "RUN 5" are shown in the lower
line on the display. The initialization process depends on the actuator used, and takes up
to 15 minutes.
7. The following display indicates that the automatic initialization is complete:
Aborting the automatic initialization process
1. Press the
button. The display shows the following:
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The software status is displayed.
After releasing the
button, the positioner is in "P manual mode". The positioner is not
initialized.
See also
Sequence of automatic initialization (Page 116)
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7.5 Commissioning linear actuators
7.5.3
Manual initialization of linear actuators
You can use this function to initialize the positioner without needing to move the actuator to
the lower and upper endstops. The lower and upper endstops of the actuator travel are set
manually. When the control parameters are optimized, the further initialization process runs
automatically.
Requirements
The following requirements must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on linear actuators.
2. The actuator spindle can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Initializing the linear actuator automatically
1. Switch to the "Configuration" mode. To do this, press the
until the display shows the following:
button for at least 5 seconds
2. Call the "2.YAGL" parameter. To do this, briefly press the
on the display depending on the setting:
button. The following is shown
3. Check whether the value displayed of the "2.YAGL" parameter matches with the setting of
the transmission ratio selector. If required, change the setting of the transmission ratio
selector to 33° or 90°.
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4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of the
"3.YWAY" parameter is optional. The display shows the determined total stroke only at the
end of the initialization phase.
– Briefly press the
button if you do not require any information about the total stroke in
mm. You are then directed to parameter 4.
– Call the "3.YWAY" parameter. To do this, briefly press the
the following:
button. The display shows
Note
Set the "3.YWAY" parameter
To set the "3.YWAY" parameter proceed as follows:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter to the read value with the
or
button.
5. Call the "5.INITM" parameter. To do this, press the
following:
button twice. The display shows the
6. Start the initialization process. To do this, press the
the display shows the following:
button for at least 5 seconds until
The current potentiometer position is output on the display after 5 seconds. Examples of
the displayed potentiometer positions are given below:
7. Determine the lower endstop of the actuator spindle.
8. Move the actuator to the desired position using the
128
or
button.
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9. Press the
following:
button. The current position of the actuator is applied. The display shows the
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
2. Press the
button.
3.
4.
5.
6.
Move the actuator to another position using the
or
Abort the manual initialization process by pressing the
Then return to "P manual mode" mode.
Correct the actuator travel and the position detection.
button.
button.
10.Determine the upper endstop of the actuator spindle. Move the actuator to the desired
position using the
or button.
11.Press the
button. The current position of the actuator is applied.
Note
Fault message "Set Middl"
The lever arm is not in the horizontal position if the "Set Middl" message is output on the
display. To correct the fault, set the reference point of the sine correction. Proceed as
follows:
1. Move the lever arm to the horizontal position using the
or
button.
2. Press the
button.
12.The initialization process is automatically resumed. Initialization steps "RUN1" to "RUN5"
are output in the bottom line of the display. The following is displayed when the initialization
has been completed successfully:
Note
Total stroke
If the "3.YWAY" parameter has been set, the display shows the total stroke in mm.
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7.6 Commissioning part-turn actuators
Aborting the manual initialization process
1. Press the
button. The display shows the "5.INITM" parameter. The positioner is in the
"Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds. The
software status is displayed. After releasing the
button, the positioner is in "P manual
mode". The positioner is not initialized.
7.6
Commissioning part-turn actuators
7.6.1
Preparing part-turn actuators for commissioning
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°.
● Set the transmission ratio selector in the positioner to 90°.
Requirements
The following conditions must be fulfilled before activating the initialization:
1. You have installed the positioner for the part-turn actuators using the suitable mounting kit.
2. You have connected the actuator and the positioner to the pneumatic lines.
3. Pneumatic auxiliary power is supplied to the positioner.
4. The positioner has been connected to a suitable current or voltage source.
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7.6 Commissioning part-turn actuators
Setting the actuator
1. The positioner is in the "P manual mode". The current potentiometer voltage P in percent
is shown on the upper line in the display. "NOINI" blinks in the lower line of the display.
Examples of corresponding displays are given below:
2. Check whether the mechanical unit can be moved freely in the entire travel range. Move
the drive to the respective end position for this purpose using the
or
button.
Note
End position
By simultaneously pressing the
and
buttons, you reach the end position faster.
3. After checking, move the actuator to a central position. This accelerates the initialization
process.
See also
External position detection (Page 53)
7.6.2
Automatic initialization of part-turn actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The travel range of the actuator can be passed through completely.
2. The actuator shaft is at a central position.
Initializing the part-turn actuator automatically
Note
Interrupting initialization
An ongoing initialization can be interrupted at any time. To do this, press
configured until then are retained.
. The settings
All parameters are reset to factory settings only if you have explicitly activated the preset
settings in the "PRST" parameter.
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7.6 Commissioning part-turn actuators
1. Switch to the "Configuration" mode. To do this, press the
until the display shows the following:
button for at least 5 seconds
2. Use the button to change from linear actuator to part-turn actuator until the display shows
the following:
3. Call the "2.YAGL" parameter. To do this, briefly press the
button. This parameter has
already been set to 90° automatically. The display shows the following:
4. Call the "4.INITA" parameter. To do this, briefly press the
following:
5. Start the initialization process. To do this, press the
the display shows the following:
button. The display shows the
button for at least 5 seconds until
The positioner runs through five initialization steps during the automatic initialization
process. Displays for the initialization steps from "RUN1" to "RUN5" are shown in the lower
line on the display. The initialization process depends on the actuator used, and takes up
to 15 minutes.
6. The following display indicates that the automatic initialization is complete. The total angle
of rotation of the actuator is shown on the upper line on the display:
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7.6 Commissioning part-turn actuators
Aborting the automatic initialization process
1. Press the
button. The display shows the following:
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The software status is displayed.
After releasing the
button, the positioner is in "P manual mode". The part-turn actuator
is not initialized.
See also
Sequence of automatic initialization (Page 116)
7.6.3
Manual initialization of part-turn actuators
You can use this function to initialize the positioner without needing to move the actuator to
the lower and upper endstops. The lower and upper endstops of the actuator travel are set
manually. When the control parameters are optimized, the further initialization process runs
automatically.
Requirements
The following requirements must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on part-turn actuators.
2. The actuator can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°. Accordingly set the transmission
ratio selector in the positioner to 90°.
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7.6 Commissioning part-turn actuators
Initializing the positioner manually
1. Switch to the "Configuration" mode. To do this, press the
until the display shows the following:
button for at least 5 seconds
2. Set the "YFCT" parameter to "turn". To do this, press
. The display shows the following:
3. Call the second parameter "YAGL". To do this, press
. The display shows the following:
4. Call the "INITM" parameter. To do this, press the
following:
5. Start the initialization process. Press the
shows the following:
button twice. The display shows the
button for at least 5 seconds until the display
6. The current potentiometer position is output on the display after 5 seconds:
7. Determine the lower endstop of the actuator.
8. Move the actuator to the desired position using the
134
or
button.
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7.6 Commissioning part-turn actuators
9. Press the
following:
button. The current position of the actuator is applied. The display shows the
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
2. Press the
button.
3.
4.
5.
6.
Move the actuator to another position using the
or
Abort the manual initialization process by pressing the
Then return to "P manual mode".
Correct the actuator travel and the position detection.
button.
button.
10.Determine the upper endstop of the actuator. Move the actuator to the desired position
using the
or
button.
11.Press the
button. The current position of the actuator is applied.
12.The initialization process is automatically resumed. Initialization steps "RUN1" to "RUN5"
are output in the bottom line of the display. The following display indicates that the
initialization has been completed successfully:
Aborting the manual initialization process
1. Press the
button. The display shows the "INITM" parameter. The positioner is in the
"Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
3. The software status is displayed.
4. After releasing the button, the positioner is in "P manual mode". "P manual mode" means
that the positioner has not been initialized.
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7.7 Device replacement
7.7
Device replacement
Introduction
Note
Initialization
The positioner can be replaced without having to interrupt ongoing processes. However,
copying and pasting of the initialization parameters only allows an approximate adjustment of
the positioner to your actuator. Following initialization, the positioner initially works with the
manually defined parameters.
● For this reason, an automatic or manual initialization should be carried out as soon as
possible.
Note
Deferred initialization
Initialize the new positioner as soon as possible. The following properties can be ensured only
after initializing:
● Optimum adjustment of the positioner as per the mechanical and dynamic properties of the
actuator.
● Non-deviating position of end stops
● Correctness of the maintenance data
There are two ways of replacing a positioner when the equipment is in operation, without having
to interrupt the process. The two options depend on whether your positioner has
communication.
First possibility - with communication
1. Read the initialization parameters from the previous positioner. Use the parameter
assignment tools suitable for this purpose.
2. Read the initialization parameters from Point 1 into the new positioner.
3. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
4. Determine the actual position value. To do this, read the actual position value from the
display of the previous positioner. Note down the read value.
5. Dismount the previous positioner from the actuator.
6. Attach the lever arm of the previous positioner to the new positioner.
7. Mount the new positioner on the actuator.
8. Set the transmission ratio selector of the new positioner to the same position as that of the
previous positioner.
9. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
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7.7 Device replacement
10.The new positioner is ready for operation when the displayed and noted values match.
11.Release the fixing of the actuator.
Second possibility - without communication
1. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
2. Determine the actual position value. To do this, read the actual position value on the display
of the previous positioner. Note down the read value.
Note
Electronics defect
If the positioner's electronics is defective, measure the actual position value with a ruler or
protractor at the actuator or valve. Convert the read value into %. Note down the converted
value.
3. Dismount the previous positioner from the actuator.
4. Attach the lever arm of the previous positioner to the new positioner.
5. To prevent interference with the ongoing process, initialize the new positioner on an
actuator with a similar stroke or swivel range. Attach the new positioner to this actuator.
Initialize the new positioner.
6. Then dismount the new, initialized positioner from this actuator.
7. Mount the new, initialized positioner on the fixed actuator.
8. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
9. Use the buttons on the positioner to enter the parameters which deviate from the factory
setting, such as type of actuator or tight closing.
10.Change to the measured value view using the
operating modes (Page 108)".
button, see section "Description of
11.Release the fixing of the actuator.
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7.7 Device replacement
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Functional safety
8.1
8
Range of applications for functional safety
The positioner is suitable for use on valves that satisfy the special requirements in terms of
functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511. The 6DR5.1.-0....-....Z C20 versions are available for this.
These are single-acting positioners for mounting on pneumatic actuators with spring return.
The positioner automatically depressurizes the valve actuator on demand or in case of faults,
which thus switches the valve to the specified safety position.
This positioner meets the following requirement:
● Functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511 for safe venting
See also
Functional safety in process instrumentation (http://www.siemens.com/SIL)
8.2
Safety function
Safety function on positioner
Depressurizing of the connected actuator is the safety function for the positioner. The built-in
spring brings the valve to the required safety position. Depending on the direction of action of
this spring, the valve is completely opened or closed.
This safety function can be triggered by:
● The signal at the input for the safety shutdown (terminals 81 and 82) is < 4.5 V.
This function is also referred to as "safety shutdown" in the device documentation.
● Failure of the auxiliary power supply via the bus connection.
The safety function is not affected by other device functions, particularly the microcontroller,
software and communication interface. With respect to this safety function, the positioner must
therefore be considered as a type A subsystem in accordance with EN 61508-2.
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Functional safety
8.3 Safety Integrity Level (SIL)
Situations in which it is not possible to depressurize the actuator on demand or in the case of
a fault represent a dangerous failure.
WARNING
Disregarding conditions for fulfilling the safety function
Disregarding conditions can result in a malfunction of the process system or application, for
example, process pressure too high, maximum level exceeded.
The mandatory settings and conditions are listed in sections Settings (Page 142) and Safety
characteristics (Page 143).
● These conditions must be met in order to fulfill the safety function.
The pneumatic block of the positioner pressurizes and depressurizes the actuator. The
pneumatic block contains two pilot valves. The characteristic service life of the pneumatic block
depends on the load. On average it is approx. 200 million switching cycles for each of the two
pilot valves with symmetrical load. The number of control procedures for the switching cycles
is called in the local display or via the communication function. For more details, see Diagnostic
value '42.VENT1' / '43.VENT2' (Page 264).
Safety-instrumented system in single-channel operation (SIL 2)
Transmitter
Automation system
0HDVXUHG
YDOXH
Figure 8-1
Final controlling element
6KXWGRZQVLJQDO
Safety-instrumented system in single-channel operation
The combination of transmitter, automation system and final controlling element forms a safetyinstrumented system that performs a safety function.
The transmitter generates a process-related measured value that is transferred to the
automation system. The automation system monitors this measured value. If the measured
value exceeds the range of the high or low limit, the automation system generates a shutdown
signal for the connected final controlling element, which switches the associated valve to the
specified safety position.
8.3
Safety Integrity Level (SIL)
The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from
SIL 1 to SIL 4. Every level corresponds to a probability range for the failure of a safety function.
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Functional safety
8.3 Safety Integrity Level (SIL)
Description
The following table shows the dependency of the SIL on the "average probability of dangerous
failures of a safety function of the entire safety-instrumented system" (PFDAVG). The table deals
with "Low demand mode", i.e. the safety function is required a maximum of once per year on
average.
Table 8-1
Safety Integrity Level
SIL
Interval
4
10-5 ≤ PFDAVG < 10-4
3
10-4 ≤ PFDAVG < 10-3
2
10-3 ≤ PFDAVG < 10-2
1
10-2 ≤ PFDAVG < 10-1
The "average probability of dangerous failures of the entire safety-instrumented system"
(PFDAVG) is normally split between the following three components:
7UDQVPLWWHU
$XWRPDWLRQ
V\VWHP
)LQDOFRQWUROOLQJ
HOHPHQW
3)'$9*3DUW
Figure 8-2
PFD distribution
The following table shows the achievable Safety Integrity Level (SIL) for the entire safetyinstrumented system for type A devices depending on the safe failure fraction (SFF) and the
hardware fault tolerance (HFT).
● Type A devices include analog transmitters and shut-off valves without complex
components, e.g. microprocessors (see also IEC 61508, Section 2).
● The specific values for your device are listed in the manufacturer's declaration (SIL
Declaration of Conformity, Functional Safety according to IEC 61508 and IEC 61511):
Certificates (http://www.siemens.com/processinstrumentation/certificates).
SFF
HFT for type A devices
0
1
2
< 60%
SIL 1
SIL 2
SIL 3
60 to 90 %
SIL 2
SIL 3
SIL 4
90 to 99 %
SIL 3
SIL 4
SIL 4
> 99%
SIL 3
SIL 4
SIL 4
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Functional safety
8.4 Settings
8.4
Settings
WARNING
Safety function: Positioning "Jumper" on the basic electronics
The safety function is not activated in the delivered state; the "Jumper" is in the "Normal"
position. "Normal" means: Without safety function, no depressurizing of the connected
actuator. To activate the safety function, proceed as follows:
● Insert the "Jumper" in the left position facing the terminals. This corresponds to the position
"Shut Down enabled" on the wiring diagram present on the module cover, see "Figure 3-8
View of the positioner (cover open; Makrolon enclosure) (Page 26)".
Or
● Remove the "Jumper" from the basic electronics.
Special parameter settings are not necessary.
Protection against configuration changes
You should attach the housing cover so that the device is protected against unwanted and
unauthorized changes/operation.
Checking the safety function
Prerequisite for checking the safety function
● Positioner is in operation.
● The actuator belonging to the positioner is not in the safety position.
Procedure
1. In order to test the safety shutdown, apply a LOW level, i.e. a voltage of maximum 4.5 V,
to the input for the safety shutdown.
2. Verify that the valve returns to the safety position.
3. In order to test the response of the actuator, apply a HIGH level, i.e. a voltage >13 V, to
the input for the safety shutdown.
4. Set the setpoint to 50% using a local operation (manual operation) or bus communication.
5. Reduce the inlet pressure (PZ) to a third of the maximum supply pressure.
6. Verify that the valve returns to the safety position.
7. Check the filters in the pneumatic connections for contamination and clean them if
necessary.
See also
Overview of device components (Page 26)
Safety function (Page 139)
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Functional safety
8.6 Maintenance/check
8.5
Safety characteristics
The safety characteristics necessary for use of the system are listed in the SIL declaration of
conformity. These values apply under the following conditions:
● The positioner is only used in applications with low demand rate for the "Low demand mode".
● "Jumper" on the basic electronic system was plugged into the left position facing the
terminals at position "Shut Down enabled" or removed completely.
● The positioner is blocked against unwanted and unauthorized changes/operation.
● The shut-off signal for the positioner is generated at the input for the safety shutdown
(terminals 81 and 82) by a safe system which meets at least SIL 2. The LOW level has a
maximum of 4.5 V at the input terminals.
● The connected actuator must be singe-acting and return the valve to the safe end position
by spring force in the following scenario:
– At a chamber pressure (Y1 connection) up to a third of the maximum available intake
pressure (Pz connection)
● The air outlet does not contain any additional cross-sectional contractions leading to an
increased dynamic pressure. In particular, a silencer is only allowed if icing or other
contamination is ruled out.
● The restrictor in the Y1 circuit may not be completely closed during operation.
● The auxiliary pneumatic power is free of oil, water and dirt in line with:
DIN/ISO 8573-1, maximum class 2
● The average temperature viewed over a long period is 40 °C.
● Fault rates are calculated on the basis of a mean time to repair (MTTR) of 8 hours.
● In case of a fault, the pneumatic outlet of the positioner is depressurized. A spring in the
pneumatic actuator must move the valve to the pre-defined, safe end position.
● A dangerous failure of the positioner is when the pressure outlet is not depressurized, or
the safety position is not reached, with a LOW level of maximum 4.5 V at the input for the
safety shutdown.
See also
Settings (Page 142)
8.6
Maintenance/check
Interval
We recommend that the functioning of the positioner is checked at regular intervals of one
year.
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143
Functional safety
8.6 Maintenance/check
Checking the safety function
Check the safety function as detailed in chapter "Settings (Page 142)"
Checking safety
Verify the safety function of the entire safety circuit on a regular basis in accordance with
IEC 61508/61511. The test intervals are determined in the course of calculations for each
safety circuit of a system (PFDAVG).
144
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Parameter assignment
9.1
9
Introduction to parameter assignment section
A positioner is responsible for controlling a valve and for monitoring the status of a valve. The
parameters described in this section are used to optimally adapt the positioner to the valve
and its application.
The parameters are divided into initialization parameters, application parameters, and the
extended diagnostics parameters.
● Initialization parameters 1 to 5 (Page 154): Describes die parameters which are relevant
for initial commissioning of the positioner on the valve. For example, you can start the
automatic initialization here.
● Application parameters 6 to 55 (Page 157): Describes die parameters with which the
positioner is adapted to the valve application, for example tight closing at the end stops.
● Extended diagnostics parameters A to P (Page 173): Describes the diagnostics functions
which are provided by the positioner. These include monitoring of leakages as well as the
partial stroke test. Following activation of these functions, the positioner continuously
monitors the status of the valve. If you enter thresholds in the parameters of the diagnostics
functions, the positioner actively signals high or low violation of these thresholds. The
current monitoring state for these thresholds is displayed as a diagnostic value. For
additional details on diagnostics and diagnostic values, refer to the section Diagnostics
(Page 252).
The following configuration schematic shows the principle of operation of the parameters. This
is followed by a tabular overview of the parameters. Finally, the individual parameters and their
functionality are described.
Furthermore, the positioners with HART, PA and FF communication interface in combination
with a host system, e.g. SIMATIC PDM or HART communicator etc., offer the following
advantages:
● Offline tests such as full stroke test, step response test, multi-step response test and valve
performance test.
● Diagnostics cockpit which provides an overview of the state of positioner and valve.
● Logbook with time stamp for documentation of all events such as the violation of thresholds.
● Wizards which provide prompting through the relevant parameters during commissioning,
the partial stroke test as well as the offline test.
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145
Parameter assignment
9.2 Tabular overview of the parameters
9.2
Tabular overview of the parameters
9.2.1
Overview of initialization parameters 1 to 5
Introduction
Parameters 1 to 5 are the same for all versions of the positioner. These parameters are used
to adjust the positioner to the actuator. Normally, setting these parameters is sufficient to be
able to operate the positioner on an actuator.
If you want to get to know all details of the positioner, gradually try out the effects of the
remaining parameters by systematic testing.
Note
Factory-set parameter values are printed in bold in the following table.
Overview
Parameter
Function
1.YFCT
Type of actuator
2.YAGL
Parameter values
Unit
Normal
Inverted
Part-turn actuator
turn
-turn
Linear actuator
WAY
-WAY
Linear actuator - carrier pin on actuator spindle
FWAY
-FWAY
Linear actuator - external linear potentiometer
LWAY
-LWAY
Part-turn actuator with NCS
ncSt
-ncSt
Linear actuator with NCS
ncSL
-ncSL
Linear actuator with NCS and lever
ncSLL
-ncLL
Rated angle of rotation of positioner shaft
1)
33°
Degrees
90°
3.YWAY2)
Range of stroke (optional setting) 3)
OFF
mm
5 | 10 | 15 | 20
(Short lever 33°, range of stroke 5 to 20
mm)
25 | 30 | 35
(Short lever 90°, range of stroke 25 to 35
mm)
40 | 50 | 60 | 70 | 90 | 110 | 130
(Long lever 90°, range of stroke 40 to 130
mm)
4.INITA
Initialization (automatic)
NOINI | no / ###.# | Strt
5.INITM
Initialization (manual)
NOINI | no / ###.# | Strt
146
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Parameter assignment
9.2 Tabular overview of the parameters
1)
Set the transmission ratio selector accordingly.
2)
Parameter only appears with "WAY", "-WAY", "ncSLL", and "-ncLL"
3)
If used, the value on the actuator must correspond to the set range of stroke on the lever arm.
Carrier must be set to the value of the actuator travel or, if this value is not scaled, to the next larger scale value.
See also
Commissioning (Page 113)
9.2.2
Overview of application parameters 6 to 55
Introduction
These parameters are used to configure the following additional functions of the positioner:
● Setpoint preparation
● Actual value preparation
● Binary signal processing
● Tight closing function
● Limit detection
Note
Factory-set parameter values are printed in bold in the following table.
Overview
Parameter
Function
6.SDIR
Setpoint direction
Parameter values
Rising
Falling
7.TSUP
Setpoint ramp up
8.TSDO
Setpoint ramp down
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Unit
riSE
FALL
Auto / 0 ... 400
s
0 ... 400
s
147
Parameter assignment
9.2 Tabular overview of the parameters
Parameter
Function
9.SFCT
Setpoint function
Parameter values
Linear
Equal percentage
Inverse equal percentage
Lin
1 : 25
1 - 25
1 : 33
1 - 33
1 : 50
1 - 50
25 : 1
n1 - 25
33 : 1
n1 - 33
50 : 1
n1 - 50
Freely adjustable
10.SL0 ...
30.SL20 1)
10.SL0
FrEE
Setpoint turning points with free characteristic
At
0%
11.SL1 ....
5 % ...
29.SL19
95 %
30.SL20
Unit
0 ... 100.0
%
Auto / 0.1 ... 10.0
%
100 %
31.DEBA
Deadband of closed-loop controller
32.YA
Start of the manipulated variable limit
0.0 ... 100.0
%
33.YE
End of the manipulated variable limit
0.0 ... 100.0
%
34.YNRM
Standardization of manipulated variable
35.YDIR
To mechanical travel
MPOS
On flow
FLoW
Direction of action of manipulated variable for display and position feedback
36.YCLS
Rising
riSE
Falling
FALL
Tight closing manipulated variables
None
no
Up only
uP
Down only
do
Up and down
uP do
37.YCDO
Low value for tight closing
0.0 ... 100.0
%
38.YCUP
Upper value for tight closing
0.0 ... 100.0
%
39.BIN1
Binary input 1 function
2)
Normally open contact
None
Message only
148
Normally closed con‐
tact
OFF
on
-on
Block configuration
bloc1
Block configuring and manual opera‐
tion
bloc2
Move valve to position YE
uP
-uP
Move valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Partial stroke test
PST
-PST
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.2 Tabular overview of the parameters
Parameter
Function
Parameter values
40.BIN2 2)
Binary input 2 function
Normally open contact
None
OFF
Message only
on
-on
Move valve to position YE
uP
-uP
Move valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Partial-Stroke-Test
41.AFCT 3)
Unit
Normally closed con‐
tact
Alarm function
PST
-PST
Normal
Inverted
none
OFF
A1 = Min, A2 = Max
A1 = Min, A2 = Min
A1 = Max, A2 = Max
42.A1
43.A2
44. FCT
3)
Trigger threshold, alarm 1
0.0 ... 10.0 ... 100
%
Trigger threshold, alarm 2
0.0 ... 90.0 ... 100
%
Fault message function
Normal
Inverted
Fault
Fault + not automatic 4)
Fault + not automatic + BIN4)
45. TIM
Monitoring period for setting the fault message
"Control deviation"
Auto / 0 ... 100
s
46. LIM
Response threshold of the fault message 'Con‐
trol deviation'
Auto / 0 ... 100
%
47. STRK
Limit monitoring for the number of total strokes
0 ... 1.00E9
48.PRST
Preset
49.PNEUM
50.XDIAG
Reset all parameters which can be re‐
set by Init, PArA and diAg .
ALL
Reset initialization parameters
1.YFCT to 5.INITM.
Init
Reset parameters 6.SDIR to 47.
STRK and 51.FSTY to 53.FSVL.
PArA
Reset parameters A to P of the exten‐
ded diagnostics function as well as
parameter 50.XDIAG.
diag
Fail in Place
Standard pneumatic block
Std
Fail in place pneumatic block
FIP
Activation of extended diagnostics
Off
OFF
Single stage message
On1
Two stage message
On2
Three stage message
On3
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149
Parameter assignment
9.2 Tabular overview of the parameters
Parameter
Function
51.FSTY
Safety setting
Parameter values
Parameterized safety setpoint
Unit
FSVL
Last setpoint
FSSP
Open vent valve
FSAC
52.FSTI
Monitoring period for setting the safety setting
0 ... 100
s
53.FSVL
Safety setpoint
0.0 ... 100.0
%
54.STNR
Station number
0 ... 126
55.IDENT
Device operating mode (ID No.)
Vendor-independent profile ID num‐
ber
9710
Device-specific ID number for full
functionality
8079
Automatic adaptation by the control
system
1)
2)
3)
4)
9.2.3
AdAPT
Setpoint turning points only appear when '9.SFCT = FrEE' is selected.
"Normally closed" means: Operation when a switch is open or Low level
"Normally open" means: Action on switch closed or High level
"Normal" means: High level, no fault message
"Inverted" means: Low level, no fault message
"+" means: Logical OR combination
Overview of advanced diagnostics parameters A to P
Introduction
These parameters are used to set the extended diagnostics functions of the positioner.
Note
Factory setting
Factory-set parameter values are printed in bold in the following table.
Note
Display
Parameters A to P and their sub-parameters are only displayed when the extended diagnostics
has been activated in parameter "'50.XDIAG' Activation of extended diagnostics (Page 170)"
with setting "On1", "On2" or "On3".
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.2 Tabular overview of the parameters
Overview parameter A
Parameter
Function
Parameter values
A. PST
Partial stroke test with the following parameters:
Unit
A1.STPOS
Start position
0.0 ... 100.0
%
A2.STTOL
Start tolerance
0.1 ... 2.0 ... 10.0
%
A3.STRKH
Stroke height
0.1 ... 10.0 ... 100.0
%
A4.STRKD
Stroke direction
uP / do / uP do
A5.RPMD
Ramp mode
OFF / On
A6.RPRT
Ramp rate
0.1 ... 1.0 ... 100.0
A7.FLBH
Behavior after failed PST
Auto / HOld / AirIn / AirOu
%/s
A8.INTRV
Test interval
OFF / 1 ... 365
Days
A9.PSTIN
Reference stroke time for partial stroke test
NOINI / (C)##.# / FdInI / rEAL
s
AA.FACT1
Factor 1
0.1 ... 1.5 ... 100.0
Ab.FACT2
Factor 2
0.1 ... 3.0 ... 100.0
AC.FACT3
Factor 3
0.1 ... 5.0 ... 100.0
Overview parameter b
Parameter
Function
b. DEVI
Monitoring of dynamic control valve behavior with the following parameters:
b1.TIM
Time constant
Parameter values
Unit
Auto / 1 ... 400
s
%
b2.LIMIT
Limit
0.1 ... 1.0 ... 100.0
b3.FACT1
Factor 1
0.1 ... 5.0 ... 100.0
b4.FACT2
Factor 2
0.1 ... 10.0 ... 100.0
b5.FACT3
Factor 3
0.1 ... 15.0 ... 100.0
Overview parameter C
Parameter
Function
C. LEAK
Monitoring of pneumatic leakage with the following parameters:
C1.LIMIT
Limit
Parameter values
0.1 ... 30.0 ... 100.0
C2.FACT1
Factor 1
0.1 ... 1.0 ... 100.0
C3.FACT2
Factor 2
0.1 ... 1.5 ... 100.0
C4.FACT3
Factor 3
0.1 ... 2.0 ... 100.0
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Operating Instructions, 02/2016, A5E00127926-AB
Unit
%
151
Parameter assignment
9.2 Tabular overview of the parameters
Overview parameter d
Parameter
Function
Parameter values
d. STIC
Monitoring of stiction (slipstick) with the following parameters:
d1.LIMIT
Limit
0.1 ... 1.0 ... 100.0
d2.FACT1
Factor 1
0.1 ... 2.0 ... 100.0
d3.FACT2
Factor 2
0.1 ... 5.0 ... 100.0
d4.FACT3
Factor 3
0.1 ... 10.0 ... 100.0
Unit
%
Overview parameter E
Parameter
E. DEBA
E1.LEVL3
Function
Parameter values
Unit
Monitoring of deadband with the following parameters:
Threshold
0.1 ... 2.0 ... 2.9
%
Parameter values
Unit
Overview parameter F
Parameter
Function
F. ZERO
Monitoring of lower endstop with the following parameters:
F1.LEVL1
Threshold 1
0.1 ... 1.0 ... 10.0
F2.LEVL2
Threshold 2
0.1 ... 2.0 ... 10.0
F3.LEVL3
Threshold 3
0.1 ... 4.0 ... 10.0
%
Overview parameter G
Parameter
Function
G. OPEN
Monitoring of upper endstop with the following parameters:
G1.LEVL1
Threshold 1
Parameter values
Unit
0.1 ... 1.0 ... 10.0
G2.LEVL2
Threshold 2
0.1 ... 2.0 ... 10.0
G3.LEVL3
Threshold 3
0.1 ... 4.0 ... 10.0
%
Overview parameter H
Parameter
Function
Parameter values
H. TMIN
Monitoring of lower limit temperature with the following parameters:
Unit
H1.TUNIT
Temperature unit
°C
°F
H2.LEVL1
Threshold 1
-40 ... -25 ... 90
-40 ... 194
H3.LEVL2
Threshold 2
-40 ... -30 ... 90
-40 ... 194
H4.LEVL3
Threshold 3
-40 ... 90
-40 ... 194
152
°C/°F
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.2 Tabular overview of the parameters
Overview parameter J
Parameter
Function
Parameter values
J. TMAX
Monitoring of upper limit temperature with the following parameters:
Unit
J1.TUNIT
Temperature unit
°C
°F
J2.LEVL1
Threshold 1
-40 ... 75 ... 90
-40 ... 194
J3.LEVL2
Threshold 2
-40 ... 80 ... 90
-40 ... 194
J4.LEVL3
Threshold 3
-40 ... 90
-40 ... 194
°C/°F
Overview parameter L
Parameter
L. STRK
L1. LIMIT
Function
Parameter values
Unit
Monitoring of number of total strokes with the following parameters:
Limit for number of total strokes
1 ... 1E6 ... 1E8
L2.FACT1
Factor 1
0.1 ... 1.0 ... 40.0
L3.FACT2
Factor 2
0.1 ... 2.0 ... 40.0
L4.FACT3
Factor 3
0.1 ... 5.0 ... 40.0
Overview parameter O
Parameter
Function
Parameter values
O. DCHG
Monitoring the number of changes in direction with the following parameters:
O1.LIMIT
Limit for number of changes in direction
1 ... 1E6 ... 1E8
O2.FACT1
Factor 1
0.1 ... 1.0 ... 40.0
O3.FACT2
Factor 2
0.1 ... 2.0 ... 40.0
O4.FACT3
Factor 3
0.1 ... 5.0 ... 40.0
Unit
Overview parameter P
Parameter
P. PAVG
P1.TBASE
Function
Parameter values
Unit
Monitoring the position average value with the following parameters:
Time basis of average value generation
0.5h / 8h / 5d / 60d / 2.5y
P2.STATE
Status of monitoring of position average value IdLE / rEF / ###.# / Strt
P3.LEVL1
Threshold 1
0.1 ... 2.0 ... 100.0
%
P4.LEVL2
Threshold 2
0.1 ... 5.0 ... 100.0
%
P5.LEVL3
Threshold 3
0.1 ... 10.0 ... 100.0
%
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153
Parameter assignment
9.3 Description of parameters
9.3
Description of parameters
9.3.1
Initialization parameters 1 to 5
9.3.1.1
'1.YFCT' Type of actuator
Requirement:
Possible settings:
Purpose:
Description:
Type of actuator as well as mounting type and direction of action
are known.
Actuator with normal direction of Actuator with inverted direction of
action
action
● turn
● -turn
● WAY
● -WAY
● FWAY
● -FWAY
● LWAY
● -LWAY
● ncSt
● -ncSt
● ncSL
● -ncSL
● ncSLL
● -ncLL
Use this parameter to adjust the positioner to the respective actua‐
tor.
● turn/-turn: Use this setting for a part-turn actuator with a directly
mounted positioner.
● WAY/-WAY: Use this setting for a linear actuator with a carrier
pin mounted on the lever.
● FWAY/-FWAY: Use this setting for a linear actuator with a carrier
pin mounted on the actuator spindle.
● LWAY/-LWAY: Use this setting for an external linear
potentiometer on a linear actuator.
● ncSt/-ncSt: Use this setting for an NCS sensor (6DR4004-.N.10
and -.N.40) on a part-time actuator.
● ncSL/-ncSL: Use this setting for an NCS sensor (6DR4004-.N.
20) on a linear actuator for strokes < 14 mm (0.55 inch).
● ncSLL/-ncLL: Use this setting for an NCS sensor (6DR4004-.N.
30) on a linear actuator for strokes > 14 mm (0.55 inch) and for
an internal NCS module. No limitations apply to the internal NCS
module.
In the case of actuators with inverted direction of action, use the
settings with the minus sign, e.g. -turn.
Meaning of actuator with normal direction of action:
● Part-turn actuator closes when the drive shaft, positioner shaft
or magnet of the NCS sensor rotates in the clockwise direction.
● Linear actuator closes when the actuator spindle rotates
downwards and the positioner shaft or magnet of the NCS sensor
rotates in the anti-clockwise direction.
154
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Parameter assignment
9.3 Description of parameters
Factory setting:
9.3.1.2
Meaning for actuator with inverted direction of action:
● Part-turn actuator closes when the drive shaft, positioner shaft
or magnet of the NCS sensor rotates in the anti-clockwise
direction.
● Linear actuator closes when the actuator spindle rotates
downwards and the positioner shaft or magnet of the NCS sensor
rotates in the clockwise direction.
Additional information:
● The '3.YWAY' Range of stroke (Page 156) parameter is
displayed only for 'WAY', '-WAY', 'ncSLL' or '-ncLL'.
● turn/-turn: The '2.YAGL' Rated angle of rotation of feedback
(Page 155) parameter is automatically set to 90° and cannot be
changed.
● WAY/-WAY: The positioner compensates the non-linearity
caused due to the transformation of the linear movement of the
linear actuator into the rotary movement of the positioner shaft.
For this purpose, the positioner is set in the factory in such a way
that it displays a value between 'P49.0' and 'P51.0' when the
lever on the positioner shaft is perpendicular to the linear
actuator spindle.
WAY
'2.YAGL' Rated angle of rotation of feedback
Requirement:
Possible settings:
Purpose:
Factory setting:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Transmission ratio selector and the value set in the '2.YAGL' pa‐
rameter match. Only then does the value shown on the display
match the actual position.
● 33°
● 90°
Use this parameter for a linear actuator. For a linear actuator, set
an angle of 33° or 90° depending on the range of stroke. The current
setting of the actuator is then measured more accurately. The fol‐
lowing is applicable:
● 33°: Strokes ≤ 20 mm
● 90°: Strokes 25 ... 35 mm
● 90°: Strokes > 40 ... 130 mm
Use the mounting kit:
● 6DR4004-8V for strokes up to 35 mm
● 6DR4004-8L for strokes greater than 35 up to 130 mm
'2.YAGL' can only be adjusted if '1.YFCT' is set to 'WAY'/'-WAY' or
'FWAY'/'-FWAY'.
With all other settings of '1.YFCT', an angle of 90° is automatically
set for '2.YAGL'.
33°
155
Parameter assignment
9.3 Description of parameters
See also
Sequence of automatic initialization (Page 116)
9.3.1.3
'3.YWAY' Range of stroke
Requirement:
Possible settings:
Purpose:
Factory setting:
9.3.1.4
156
● Positioner is mounted.
● Carrier pin is mounted on the lever in accordance with the
actuator's range of stroke as described in section Mounting the
linear actuator (Page 40), Figure 4-2 Lever with carrier pin
(Page 43).
● OFF
● 5.0 | 10.0 | 15.0 | 20.0 | 25.0 |30.0 | 35.0 | 40.0 |
50.0 | 60.0 | 70.0 | 90.0 | 110.0 | 130.0
Use this parameter to display the determined stroke value in mm
when initialization of a linear actuator has been completed.
If you select the 'OFF' setting, the real stroke is not displayed after
initialization.
From the possible settings shown above, select the value which
corresponds to the range of stroke of your actuator in mm.
If the range of stroke of the actuator does not correspond to a pos‐
sible setting, use the next higher value. Use the value specified on
the nameplate of the actuator for this purpose.
'3.YWAY' is only displayed if '1.YFCT' is set to 'WAY'/'-WAY' or
'ncSLL'/'-ncLL'.
OFF
'4.INITA' Initialization (automatically)
Possible settings:
● NOINI
Purpose:
● no / ###.#
● Strt
Use this parameter to start the automatic initialization process.
Factory setting:
1. Select the "Strt" setting.
button for at least 5 seconds.
2. Then press the
The sequence of the initialization process from "RUN1" to "RUN5"
is output in the bottom line of the display.
NOINI
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
9.3.1.5
'5.INITM' Initialization (manual)
Possible settings:
Purpose:
Description:
Factory setting:
● NOINI
● no / ###.#
● Strt
Use this parameter to start the manual initialization process.
1. Select the "Strt" setting.
2. Then press the
button for at least 5 seconds.
If the positioner has already been initialized and if the "4.INITA" and
"5.INITM" values are set, it is possible to reset the positioner to the
non-initialized status. To do this, press the
button for at least 5
seconds.
NOINI
9.3.2
Application parameters 6 to 55
9.3.2.1
'6.SDIR' Setpoint direction
Possible settings:
Purpose:
Factory setting:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
● riSE
● FALL
This parameter is used to set the setpoint direction. The setpoint
direction is used to reverse the direction of action of the setpoint.
● Rising (riSE): A higher value at the setpoint input results in
opening of the valve.
● Falling (FALL): A higher value at the setpoint input results in
closing of the valve.
The setpoint direction is primarily used for the split-range mode and
for single-acting actuators with the safety setting 'uP'.
riSE
157
Parameter assignment
9.3 Description of parameters
9.3.2.2
'7.TSUP' Setpoint ramp UP / '8.TSDO' Setpoint ramp DOWN
Possible settings:
Purpose:
Factory setting:
9.3.2.3
With "TSUP"
With "TSDO"
● Auto
● 0 ... 400
● 0 ... 400
The setpoint ramp is effective in "Automatic" mode and limits the
speed of change of the effective setpoint. This parameter is used to
set the value in seconds. When switching over from "Manual" mode
to "Automatic" mode, the setpoint ramp is used to adjust the effective
setpoint to the setpoint of the positioner.
This smooth switching from "Manual" mode to "Automatic" mode
prevents pressure excess in long pipelines.
The parameter "TSUP = Auto" means the slower of the two actuating
times determined during initialization is used for the setpoint ramp.
Parameter value "TSDO" then has no effect.
0
'9.SFCT' Setpoint function
Possible settings:
Purpose:
Factory setting:
● Lin
● 1 - 25
● 1 - 33
● 1 - 50
● n1 - 25
● n1 - 33
● n1 - 50
● FrEE
This parameter is used to linearize nonlinear valve characteristics.
Optional flow characteristics as shown in the figure in the description
of the "'10.SL0' ... '30.SL20' Setpoint turning point (Page 159)" pa‐
rameter are simulated for linear valve characteristics.
Lin
Seven valve characteristics are stored in the positioner and are selected using the "SFCT"
parameter:
Valve characteristics
Set with parameter value
Linear
1:25
1-25
Equal percentage
1:33
1-33
Equal percentage
1:50
1-50
Inverse equal percentage
25:1
n1-25
Inverse equal percentage
33:1
n1-33
Inverse equal percentage
50:1
n1-50
Freely adjustable
158
Lin
Equal percentage
FrEE
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
'10.SL0' ... '30.SL20' Setpoint turning point
0.0 ... 100.0
These parameters are used to assign a flow coefficient in units of
5% to each setpoint turning point. The setpoint turning points form
a polyline with 20 linear segments which models the valve charac‐
teristic; see figure below.
0, 5 ... 95, 100
Factory setting:
[
7LJKWFORVLQJ
([DPSOH
<&/6 83
<&83 6)&7 /LQ
6)&7 )U((
7LJKWFORVLQJ
([DPSOH
<&/6 '2
<&'2 6HWSRLQW
Z
6HWSRLQW
LQWHUSRODWLRQSRLQW
([DPSOH
6/ 7LJKWFORVLQJ
([DPSOH
<&/6 83
<&83 [
&RQWUROUDQJH
Adjustment range:
Purpose:
&RQWUROUDQJH
9.3.2.4
7LJKWFORVLQJ
([DPSOH
<&/6 '2
<&'2 6HWSRLQW
Z
6/2
Setpoint characteristic curves, standardization of manipulated variables, and tight closing
function
Input of the setpoint turning points is only possible if the "'9.SFCT' Setpoint function
(Page 158)" parameter is set to "FrEE". You can only enter one monotone rising characteristic
curve and two consecutive interpolation points must differ by at least 0.2%.
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159
Parameter assignment
9.3 Description of parameters
9.3.2.5
'31.DEBA' Deadband of controller
Possible settings:
Purpose:
Factory setting:
9.3.2.6
● Auto
● 0.1 ... 10.0
This parameter is used with the "Auto" setting to adjust the dead‐
band in automatic mode continually and adaptively to the require‐
ments of the control loop. If a regulator oscillation is detected, then
the deadband is incrementally enlarged. The reverse adaptation
takes place using a time criterion.
The deadband is set using the values 0.1 to 10.0. The value is given
in percent. Control oscillations can then be suppressed. The smaller
the deadband, the better the control accuracy.
Auto
'32.YA' Manipulated variable limiting Start / '33.YE' Manipulated variable limiting End
Adjustment range:
Purpose:
Factory setting:
0.0 ... 100.0
These parameters are used to limit the mechanical actuator travel
from stop to stop to the configured values. The value is given in
percent. This allows the mechanical travel range of the actuator to
be limited to the effective flow, preventing integral saturation of the
controlling closed-loop controller.
See the figure in the description of the '34.YNRM' Manipulated var‐
iable standardization (Page 160) parameter.
When 'YA': 0.0
When 'YE': 100.0
Note
'YE' must always be set larger than 'YA'.
9.3.2.7
'34.YNRM' Manipulated variable standardization
Possible settings:
Purpose:
160
● MPOS
● FLoW
Use the '32.YA' Manipulated variable limiting Start / '33.YE' Manip‐
ulated variable limiting End (Page 160) parameters to limit the ma‐
nipulated variable. This limitation causes two different scaling types
'MPOS' and 'FLoW' for the display and for the position feedback
through the current output.
The MPOS scale shows the mechanical positions from 0 to 100%
between the upper and lower endstops of the initialization. The po‐
sition is not influenced by the '32.YA' Manipulated variable limiting
Start / '33.YE' Manipulated variable limiting End (Page 160) param‐
eters. The 'YA' and 'YE' parameters are shown in the MPOS scale.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
The FLoW scale is the standardization from 0 to 100% in the range
between the 'YA' and 'YE' parameters. Over this range, the setpoint
w is also always 0 to 100%. This results in a more or less flow-pro‐
portional display and position feedback 'IY'. The flow-proportional
display and position feedback 'IY' also result when using valve char‐
acteristics.
In order to calculate the control deviation, the setpoint in the display
is also shown in the corresponding scale.
The following uses the example of an 80-mm linear actuator to illus‐
trate the dependence of the stroke on the scaling as well as on the
'YA' and 'YE' parameters; see the following figure.
MPOS
Factory setting:
PP
PP
PP
PP
PP
7UDYHOOLPLWORZ
Figure 9-1
6HWSRLQW
0HDVXULQJYDOXHGLVSOD\
6HWSRLQWGLVSOD\
0HFKDQVWURNH
PP DFWXDOYDOXH
7UDYHOOLPLWKLJK
YNRM = MPOS or YNRM = FLoW; default: YA = 0 % and YE = 100 %
6HWSRLQW
0HDVXULQJYDOXHGLVSOD\
6HWSRLQWGLVSOD\
PP
PP
PP
PP
PP
7UDYHOOLPLWORZ
Figure 9-2
0HFKDQVWURNH
PP DFWXDOYDOXH
7UDYHOOLPLWKLJK
Example: YNRM = MPOS with YA = 10 % and YE = 80 %
PP
PP
PP
7UDYHOOLPLWORZ
Figure 9-3
PP
0HDVXULQJYDOXHGLVSOD\
6HWSRLQWGLVSOD\
PP
6HWSRLQW
0HFKDQ6WURNH
PP DFWXDOYDOXH
7UDYHOOLPLWKLJK
Example: YNRM = FLoW with YA = 10 % and YE = 80 %
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161
Parameter assignment
9.3 Description of parameters
See also
'36.YCLS' Tight closing with manipulated variable (Page 162)
9.3.2.8
'35.YDIR' Direction of action of manipulated variable for display and position feedback
Possible settings:
Purpose:
Factory setting:
9.3.2.9
● riSE
● FALL
This parameter is used to set the direction of action of the display
and the position feedback IY. The direction can be rising or falling.
riSE
'36.YCLS' Tight closing with manipulated variable
Possible settings:
Purpose:
Factory setting:
● no
● uP
● do
● uP do
This parameter is used to move the valve into its seat with the max‐
imum force of the actuator (permanent contact of the piezo valves).
The tight closing function is activated on one side or for both end
positions. Parameter "36.YCLS" becomes effective when the effec‐
tive setpoint is at or below parameter "37.YCDO" or at or above
parameter "38.YCUP".
no
See the figure in the description of the "'34.YNRM' Manipulated variable standardization
(Page 160)" parameter and the figure in the description of the "'10.SL0' ... '30.SL20' Setpoint
turning point (Page 159)" parameter.
Note
Activated tight closing function
If the tight closing function is activated, then for parameter "46. LIM" the monitoring of control
deviation is turned off in the appropriate overflow direction. Parameter "YCDO: < 0 %" and
parameter "YCUP: > 100 %" are applicable in such a case. This functionality is especially
advantageous for valves with soft seats. For a long-term monitoring of the end stop positions,
we recommend activating the parameters "F. ZERO" and G. OPEN".
162
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
9.3.2.10
'37.YCDO' Lower value for tight closing / '38.YCUP' Upper value for tight closing
Adjustment range:
Purpose:
Factory setting:
0.0 ... 100.0
These parameters are used to set the values for "Lower value for
tight closing " (YCDO) and "Upper value for tight closing" (YCUP) in
%.
When "YCDO": 0.0
When "YCUP": 100.0
Note
The value in the parameter "YCDO" is always smaller than that in "YCUP". The tight closing
function has a fixed hysteresis of 1%. The parameters "YCDO" and "YCUP" are relative to the
mechanical stops. The parameters "YCDO" and "YCUP" are independent of the value set in
the "'6.SDIR' Setpoint direction (Page 157)" parameter.
9.3.2.11
'39.BIN1' / '40.BIN2' Function of binary inputs
Setting option
Purpose:
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Operating Instructions, 02/2016, A5E00127926-AB
● Binary input 1
Normally open
Normally closed
OFF
OFF
on
-on
bloc1
-uP
bloc2
-doWn
uP
-StoP
doWn
-PST
StoP
PST
● Binary input 2
Normally open
Normally closed
OFF
OFF
on
-on
uP
-uP
doWn
-doWn
StoP
-StoP
PST
-PST
These parameters determine the function of the binary inputs. The
possible functions are described below. The direction of action can
be adapted to a normally closed or normally open mode.
● BIN1 or BIN2 = On or -On
Binary messages from peripherals, e.g. from pressure or
temperature switches, are read over the communication
interface or fed through a logical OR combination with other
messages to trigger the error message output.
163
Parameter assignment
9.3 Description of parameters
Factory setting:
9.3.2.12
'41.AFCT' Alarm function
Possible settings:
Purpose:
Factory setting:
164
● BIN1 = bLoc1
Use this parameter value to interlock the "Configuration" mode
against adjustment. The lock is performed e.g. with a jumper
between terminals 9 and 10.
● BIN1 = bLoc2
If binary input 1 has been activated, the "Manual" as well as
"Configuration" modes are blocked.
● BIN1 or BIN2 =
contact uP or doWn closes, or
contact -uP or -doWn opens
If the binary input is activated, the actuator uses the value defined
by the "'32.YA' Manipulated variable limiting Start / '33.YE'
Manipulated variable limiting End (Page 160)" parameter for
controlling in "Automatic" mode.
● BIN1 or BIN2 contact closes = StoP or -StoP contact opens
In "Automatic" mode, the piezo valves are blocked when the
binary input is activated. The actuator remains at the last
position. Leakage measurements can be performed in this way
without using the initialization function.
● BIN1 or BIN2 = PSt or -PSt
Using binary inputs 1 or 2, a partial-stroke test can be triggered
by actuation of your choice of a normally closed or normally open
switch.
● BIN1 or BIN2 = OFF
No function
Special function of binary input 1: If binary input 1 is activated in
"P-manual mode" by means of a jumper between terminals 9 and
10, the firmware version will be displayed when the mode button
is pressed.
If one of the above functions is activated simultaneously with the
"BIN1" and "BIN2" parameters, then: "Blocking" takes priority over
"uP". "uP" takes priority over "doWn". "doWn" takes priority over
"PST".
OFF
See representation below
This parameter can be used to determine the value at which going
above or below a given offset or angle will result in a message. The
triggering of alarms (limits) is relative to the MPOS scale. Alarms
are signaled through the alarm module. In addition, alarms can also
be read via the communication interface.
The direction of action of the binary outputs can be adjusted from
"High active" to "Low active" for the next system.
OFF
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
Direction of action and hysteresis
Alarm module
/LPLW
Examples
$
A1 = 48
$
ZD\
0,1
0$;
0,1
0,1
0$;
0$;
0,1
0$;
A2
A2 = 52
AFCT = MIN / MAX
Way =45
Active
Way =50
Way =55
A1 = 48
A2 = 52
Active
AFCT = -MIN / -MAX
Way =45
Active
Way =50
Active
Way =55
Active
Active
0$;
A1 = 52
0,1
A1
0,1
0$;
A2 = 48
AFCT = MIN / MAX
Way =45
Active
Way =50
Active
Way =55
A1 = 52
A2 = 48
Active
Active
AFCT = -MIN / -MAX
Way =45
Active
Way =50
Way =55
Active
Note
If the extended diagnostic is activated using parameter "'50.XDIAG' Activation of extended
diagnostics (Page 170)" with setting "On3", then the alarms are not output through the alarm
module. Alarm A1 is output with setting "On2". However, notification via the communication
interface is possible at any time.
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165
Parameter assignment
9.3 Description of parameters
9.3.2.13
'42.A1' / '43.A2' Alarm response threshold
Adjustment range:
Purpose:
Factory setting:
9.3.2.14
0.0 ... 100.0
These parameters are used to specify when an alarm should be
displayed. The response thresholds of the alarms (in percent) refer
to the MPOS scale in the "'34.YNRM' Manipulated variable stand‐
ardization (Page 160)" parameter. The MPOS scale corresponds to
the mechanical travel.
Depending on the setting of the alarm function in the "'41.AFCT'
Alarm function (Page 164)" parameter, the alarm is triggered upon
an upward violation (Max) or downward violation (Min) of this re‐
sponse threshold.
With "A1": 10.0
With "A2": 90.0
'44.\\FCT' Function fault message
Requirement:
Possible settings:
Purpose:
At least one of the following modules is fitted
● Alarm module
● Slot initiator alarm module (SIA module)
● Mechanical limit switch module
Normal direction of action
Inverted direction of action
●
● ● nA
● - nA
● nAb
● - nAb
The fault message in the form of monitoring of control deviation over
time can also be triggered due to the following events:
● Power failure
● Processor fault
● Actuator fault
● Valve fault
● Compressed air failure
● Threshold 3 message of extended diagnostics.
See parameter '50.XDIAG' Activation of extended diagnostics
(Page 170).
The fault message cannot be switched off, but it can be suppressed
(factory setting) when you exit 'Automatic' mode. Set the ' FCT' pa‐
rameter to ' nA' to also generate a fault message here.
You also have an option to "or" the fault message with the status of
the binary inputs. To do this, first set the '39.BIN1' / '40.BIN2' Func‐
tion of binary inputs (Page 163) parameter to 'on' or '-on'. Subse‐
quently set the ' FCT' parameter to ' nAb'.
Select the '- ' setting if you want the fault message to be output with
inverted direction of action.
Factory setting:
166
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Parameter assignment
9.3 Description of parameters
9.3.2.15
'45.\\TIM' Monitoring time for setting of fault messages
Possible settings:
Purpose:
Factory setting:
● Auto
● 0 ... 100
The ' TIM' parameter is used to set the time in seconds within which
the positioner must have reached the regulated condition. The cor‐
responding response threshold is specified in the ' LIM' parameter.
When the configured time is exceeded, the fault message output is
set.
Auto
Note
Activated tight closing function
If the tight closing function is activated, then for the ' LIM' parameter the monitoring of control
deviation is turned off in the appropriate overflow direction. Then 'YCDO: < 0 %' and
'YCUP: > 100 %'. This functionality is especially advantageous for valves with soft seats. For
long-term monitoring of the endstop positions, we recommend activating the parameters
Monitoring the lower endstop ''F.\\ZERO' (Page 186) and Monitoring the upper endstop 'G.\
\OPEN' (Page 187).
9.3.2.16
'46.\\LIM' Response threshold for fault message
Possible settings:
Purpose:
Factory setting:
● Auto
● 0 ... 100
This parameter is used to set a value for the permissible size of the
control deviation to trigger a fault message. The value is given in
percent.
If the ' TIM' and ' LIM' parameters are set to 'Auto', then the fault
message is set if the slow step zone is not reached within a certain
period of time. Within 5 to 95% of the actuator travel, this time is twice
the initialization travel time, and ten times the initialization travel time
outside of 10 to 90%.
Auto
Note
Activated tight closing function
If the tight closing function is activated, then for the ' LIM' parameter the monitoring of control
deviation is turned off in the appropriate overflow direction. Then 'YCDO: < 0 %' and
'YCUP: > 100 %'. This functionality is especially advantageous for valves with soft seats. For
long-term monitoring of the endstop positions, we recommend activating the parameters
Monitoring the lower endstop ''F.\\ZERO' (Page 186) and Monitoring the upper endstop 'G.\
\OPEN' (Page 187).
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167
Parameter assignment
9.3 Description of parameters
9.3.2.17
'47.\\STRK' Limit monitoring for the number of total strokes
Possible settings:
Purpose:
Description:
Factory setting:
0 ... 1.00E9
Use this parameter to set a limit for the number of total strokes. This
parameter corresponds to the profile parameter 'TO‐
TAL_VALVE_TRAVEL_LIMIT' and was applied for compatibility rea‐
sons.
If the configured limit is exceeded, the 'CB_TOT_VALVE_TRAV' bit
is set in the profile parameter 'CHECK_BACK'.
This function enables preventive maintenance of the control valve.
1E9
See also
Monitoring the number of total strokes 'L.\\STRK' (Page 192)
'50.XDIAG' Activation of extended diagnostics (Page 170)
Diagnostic value '1.STRKS - Number of total strokes' (Page 255)
9.3.2.18
'48.PRST' Preset
Possible settings:
Purpose:
168
● ALL
● Init
● PArA
● diAg
Use this parameter to restore the factory settings for most parame‐
ters. The following parameter groups are available:
● ALL: Reset all parameters together which can be reset by 'Init',
'PArA' and 'diAg'.
● Init: Reset initialization parameters '1.YFCT' to '5.INITM'.
● PArA: Reset parameters '6.SDIR' to '47. STRK' and '51.FSTY'
Safety position (Page 171) to '53.FSVL' Safety setpoint
(Page 172).
● diAg: Reset parameters A to P of the extended diagnostics
function as well as parameter '50.XDIAG'.
An overview of the parameters and factory settings can be found in
section Tabular overview of the parameters (Page 146).
In order to select one of the parameter groups listed above, repeat‐
button until the desired setting is output in the dis‐
edly press the
button pressed until 'oCAY'
play. Start the function by keeping the
is output in the display. The values of the parameter group are now
the factory settings.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
Description:
Factory setting:
9.3.2.19
If you wish to use a previously initialized positioner on a different
control valve, set the parameters to the factory settings prior to a new
initialization. To do this, use the 'ALL' or 'Init' setting.
Restore the factory settings if you have changed several parameters
at once without being able to predict their effect and the undesired
reactions which may occur as a result. To do this, use the 'ALL' set‐
ting.
ALL
'49.PNEUM' Fail in place
Requirement:
Possible settings:
Purpose:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
You have a positioner with the "Fail in Place" function, article number
with order suffix -Z F01.
● Std
● FIP
You only require this parameter for servicing if the basic electronics
has been replaced.
If you order a positioner for Fail in Place applications, it is then
equipped with a special pneumatic block. The "PNEUM" parameter
is preset to "FIP".
When you replace the basic electronics, you have to set the pneu‐
matic type:
1. Set the "49.PNEUM" parameter from "Std" to "FIP".
2. Set the "'51.FSTY' Safety position (Page 171)" parameter to
"FSSP" so that the positioner retains the current position even
following switching on again.
169
Parameter assignment
9.3 Description of parameters
9.3.2.20
'50.XDIAG' Activation of extended diagnostics
Use this parameter to activate the extended diagnostics and simultaneously the online
diagnostics. At the factory, extended diagnostics are deactivated. 'XDIAG' parameter is set to
'OFF'. To activate extended diagnostics, there are three modes available:
● On1: Extended diagnostics is activated. Threshold 3 messages will be output via the error
message output. Single stage message (maintenance required).
● On2: Extended diagnostics is activated. Threshold 2 messages will be activated via alarm
output 2. Threshold 3 messages will also be output via the error message output. Two stage
message (maintenance demand).
● On3: Extended diagnostics is activated. Threshold 1 messages will be activated via alarm
output 1. Threshold 2 messages will be activated via alarm output 2. Threshold 3 messages
will also be output via the error message output. Three stage message (maintenance alarm).
Note
Activation of extended diagnostics
Please note that the parameters of extended diagnostics from 'A.\\PST' to 'P.\\PAVG' will
only be shown in the display following selection of one of the modes 'On1' to 'On3'.
In the factory settings, the 'A.\\PST' to 'P.\\PAVG' parameters are deactivated by default.
'XDIAG' parameter is set to 'OFF'. The corresponding parameters are only displayed after
you have activated the appropriate menu item with 'On'.
Note
Cancellation of messages
If a threshold is exceeded or fallen below, the positioner outputs a message in the form of
an error code and a column in the display. The message is cancelled if, for example:
● The counter is reset.
● The threshold is set to a new value.
● The device is re-initialized at the upper and lower endstops.
● Monitoring is deactivated.
With extended diagnostics, the threshold of the message is displayed using columns ① in
addition to the error code. These columns ① are shown on the display as follows:
Figure 9-4
170
Display of a threshold 1 message (maintenance required)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
Figure 9-5
Display of a threshold 2 message (maintenance demand)
Figure 9-6
Display of a threshold 3 message (maintenance alarm)
The factory setting is 'OFF'.
See also
Partial stroke test 'A.\\PST' (Page 173)
Monitoring the position average value 'P.\\PAVG' (Page 195)
Overview of error codes (Page 268)
9.3.2.21
'51.FSTY' Safety position
Possible settings:
Purpose:
Description:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
● FSVL
● FSSP
● FSAC
Use this parameter to move the actuator to a defined safety position
when communication fails.
Three settings are available:
● FSVL:
the actuator is controlled using the configured safety setpoint.
This value also becomes effective following failure of the auxiliary
power supply.
● FSSP:
the actuator is controlled using the last effective setpoint.
● FSAC:
the positioner responds in the same way as when the auxiliary
power supply fails, see section "Reaction to failure of auxiliary
powers (Page 98)".
171
Parameter assignment
9.3 Description of parameters
Fail in Place
Factory setting:
9.3.2.22
'52.FSTI' Monitoring time to set the safety position
Possible settings:
Purpose:
Factory setting:
9.3.2.23
Factory setting:
0.00 ... 100
Default value of the safety position.
Note that the safety setpoint of 0% set here always refers to the
mechanical position in which the actuator is depressurized. The me‐
chanical position is especially important if you have set the '6.SDIR'
Setpoint direction (Page 157) parameter to 'FALL' and expect 100%
mechanical position at 0% setpoint default. The 'FALL'' setting cor‐
responds a declining characteristic curve of the setpoint.
0.0
'54.STNR' Station number
Possible settings:
Purpose:
Factory setting:
172
0 ... 100
If communication fails, the positioner switches to the safety position
after the set value expires. This parameter is used to set the value
in seconds.
0
'53.FSVL' Safety setpoint
Possible settings:
Purpose:
Description:
9.3.2.24
The following must be observed when using the "Fail in Place" func‐
tion:
The "51.FSTY" parameter must be set to "FSSP" so that the posi‐
tioner retains the current position even following switching on again.
FSAC
0 ... 126
A separate station number must be set on each device in order to
address the devices on the bus separately.
126
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
9.3.2.25
'55.IDENT' Device operating mode (ID No.)
Possible settings:
Purpose:
Description:
Factory setting:
● 9710
● 8079
● AdAPT
The positioner identifies two device operating modes with respect to
the response to the DP master of class 1:
● [9710] Vendor-independent profile ID number.
Can be replaced by positioners of other manufacturers complying
with PROFIBUS PA profile 3.0.
● [8079] Device-specific ID number for full functionality.
Complete functional range of the positioner (condition at delivery).
● AdAPT Automatic adaptation by the control system.
A specific GSD file is allocated to every device operating mode. If
the configuration of your PROFIBUS PA path does not match the set
device operating mode, the device cannot accept the cyclic data ex‐
change. The station number and the device operating mode cannot
be modified during ongoing communication with a master of class 1.
You can recognize successful establishment of connection to a cyclic
master in that the positioner responds to the setpoint of the master.
Communication with an acyclic master is indicated by a flashing dec‐
imal point in the top line of the positioner's display.
1
See also
Cyclic data transfer (Page 219)
9.3.3
Extended diagnostics parameters A to P
9.3.3.1
Partial stroke test 'A.\\PST'
A. PST - Partial Stroke Test
Requirement:
Possible settings:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
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173
Parameter assignment
9.3 Description of parameters
Purpose:
Factory setting:
Use this parameter to activate and deactivate the partial stroke test.
To activate monitoring, set the parameter to 'On'. Sub-parameters
are displayed.
Trigger the partial stroke test using:
● Buttons on the device
● A binary input
● Communication
● A cyclic test interval
The current status of the partial stroke test displayed in Diagnostic
value '12.PST - Monitoring of partial stroke test' (Page 258).
Diagnostic value '13.PRPST' - Time since last partial stroke test'
(Page 259) and Diagnostic value '14.NXPST - Time until next partial
stroke test' (Page 259) provide further information on the partial
stroke test.
OFF
A1.STPOS - Start position
Adjustment range:
Purpose:
Factory setting:
0.0 ... 100.0
Use this sub-parameter to define the start position of the partial
stroke test in percent. Set the start position in a range from '0.0' to
'100.0'. The triggering of alarms (limits) is relative to the MPOS scale.
The actuator moves during the partial stroke test from the start po‐
sition to the target position. The target position is determined from
the interaction between start position (A1.STPOS), stroke height
(A3.STRKH) and stroke direction (A4.STRKD).
100.0
A2.STTOL - Start tolerance
Adjustment range:
Purpose:
Example:
Factory setting:
174
0.1 ... 10.0
Use this sub-parameter to define the start tolerance of the partial
stroke test in percent. Set the start tolerance relative to the start
position in a range from '0.1' to '10.0'.
You have set '50.0' as a start position and '2.0' as a start tolerance.
In this case, a partial stroke test is initiated during operation only
between a position of 48 and 52%.
2.0
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
A3.STRKH - Stroke height
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to define the stroke height of the partial
stroke test in percent. Set the stroke height in a range from '0.1' to
'100.0'.
10.0
A4.STRKD - Stroke direction
Possible settings:
Purpose:
Formula (uP):
Formula (do):
Formula (uP do)
Factory setting:
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Operating Instructions, 02/2016, A5E00127926-AB
● uP
● do
● uP do
Use this sub-parameter to set the stroke direction of the partial
stroke test.
uP: Actuator only moves upward
● The actuator moves from its start position to the upper target
position.
● After reaching the upper target position, the actuator moves back
to the start position.
Upper target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) + Stroke height (A3.STRKH)
do: Actuator only moves downward
● The actuator moves from its start position to the lower target
position.
● After reaching the lower target position, the actuator moves back
to the start position.
Lower target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) + Stroke height (A3.STRKH)
uP do: Actuator moves up and down
● The actuator first moves from its start position to the upper target
position.
● It then moves from the upper target position to the lower target
position.
● After reaching the lower target position, the actuator moves back
to the start position.
Target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) + Stroke height (A3.STRKH)
do
175
Parameter assignment
9.3 Description of parameters
A5.RPMD - Ramp mode
Setting options:
Purpose:
Factory setting:
● OFF
● On
Enable or disable ramp mode.
● OFF: The partial stroke test is executed in an uncontrolled
manner.
● On: The partial stroke test is executed in a controlled manner.
Control is at the ramp rate set in the 'A6.RPRT' parameter.
Use ramp mode to shorten or extend the time of the partial stroke
test. Extend the partial stroke test to give the higher-level control
loop a chance to react to the partial stroke test.
OFF
A6.RPRT - Ramp rate
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Change the ramp rate to shorten or extend the duration of the partial
stroke test. The ramp rate refers to the total stroke of the control valve
and is set in % stroke per second (%/s). Smaller values extend the
duration, larger values shorten the duration of the partial stroke test.
Example: Setting '10.0' means that the partial stroke test is run with
10% stroke per second.
1.0
A7.FLBH - Behavior after failed PST
Setting options:
Purpose:
Factory setting:
176
● Auto
● HOLd
● AirIn
● AirOu
Specify how the positioner is to respond if a partial stroke test fails.
Note: A partial stroke test fails if the limit threshold set in 'Factor 3
(AC.FACT3)' is exceeded.
● Auto: Switch to 'Automatic' mode. 'AUT' is displayed on the
device.
● HOLd: Hold current position.
● AirIn: Pressurize actuator with supply air PZ.
● AirOu: Depressurize actuator.
Auto
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Parameter assignment
9.3 Description of parameters
A8.INTRV - Test interval
Adjustment range:
Purpose:
Factory setting:
OFF, 1 ... 365
Use this sub-parameter to enter the interval time for the cyclic partial
stroke test in days. Set the test interval in a range from 1 to 365.
OFF
A9.PSTIN - Reference stroke time for partial stroke test
Indication on the display: ● NOINI
● (C)##.#
● FdInI
● rEAL
Purpose:
Status for reference stroke time in seconds
Description:
Use this sub-parameter to measure the reference stroke time for the
partial stroke test.
The reference stroke time corresponds to the controlled movement
from the start position to the target position.
If the positioner has already been initialized, the calculated average
travel time of the control valve is displayed as a reference value.
● NOINI: Positioner has not yet been initialized.
● (C)##.#: An average travel time of 1.2 seconds, for example, is
shown in the display as 'C 1.2', where 'C' stands for 'calculated'.
The average travel time can be used as a reference stroke time.
However, it merely represents a rough guideline value.
● FdInI: 'FdInI' is displayed if the start position cannot be
approached or the stroke target cannot be reached. 'FdInI'
stands for 'failed PST initialization'.
● rEAL: Set the sub-parameters 'A1.STPOS' to 'A5.RPMD'
according to your requirements. Then start measuring the
button for at least 5
reference stroke time by pressing the
seconds. The display shows 'rEAL' during these 5 seconds.
The device then moves to the configured start position
automatically and executes the desired stroke. The current
position in percent is continuously shown on the display. 'inPST'
for 'initialize partial stroke test' appears in the lower line of the
display.
Factory setting:
NOINI
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177
Parameter assignment
9.3 Description of parameters
AA.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1.
Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the reference stroke time and 'AA.FACT1'. Determining
the reference stroke time is described under 'A9.PSTIN'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
1.5
Ab.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
2.
Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the reference stroke time and 'Ab.FACT2'. Determining
the reference stroke time is described under 'A9.PSTIN'.
The threshold 2 message is displayed when threshold 2 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
3.0
AC.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
178
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
3.
Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the reference stroke time and 'AC.FACT3'. The process
to determine the reference stroke time is described under
'A9.PSTIN'.
The threshold 3 message is displayed when threshold 3 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
The positioner responds in accordance with the option set in the subparameter 'A7.FLBH - Behavior after failed PST'.
5.0
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Parameter assignment
9.3 Description of parameters
9.3.3.2
Monitoring of dynamic control valve behavior 'b.\\DEVI'
b. DEVI - Monitoring of dynamic control valve behavior
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
This parameter allows you to monitor the dynamic control valve be‐
havior. The actual position course is compared with the expected
position course for this purpose. This comparison helps in drawing
a conclusion about the correct operational response of the control
valve. Monitoring is performed in three steps. To activate monitoring,
set the parameter to 'On'. Sub-parameters are displayed. Appropri‐
ately set the sub-parameters.
The current value is displayed in Diagnostic value '15.DEVI - Gen‐
eral control valve fault' (Page 259). The positioner triggers a mes‐
sage if the current value exceeds one of the three thresholds.
OFF
b1.TIM - Time constant of low-pass filter
Possible settings:
Purpose:
Factory setting:
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Operating Instructions, 02/2016, A5E00127926-AB
● Auto
● 1 ... 400
Use this sub-parameter to define the attenuation effect of the lowpass filter. The unit is seconds. The time constant 'b1.TIM' is calcu‐
lated from the travel times 'uP' and 'doWn' determined during the
initialization. This time constant becomes effective when the
'b1.TIM' parameter is set to 'Auto'.
If the time constant is inadequate, the setting of 'b1.TIM' can be
changed manually. Set the time constant in a range from '1' to '400'.
In this case:
● Setting '1' indicates a very weak attenuation.
● Setting '400' indicates a strong attenuation.
The currently determined deviation is displayed in Diagnostic value
'15.DEVI - General control valve fault' (Page 259). The positioner
triggers a message if the current value exceeds one of the three
parameterizable thresholds.
Auto
179
Parameter assignment
9.3 Description of parameters
b2.LIMIT - Limit for dynamic control valve behavior
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set a base limit in percent. The base limit
defines the magnitude of the permissible deviation from the expec‐
ted position course. The limit serves as a reference variable for the
fault message factors.
Set the base limit in a range from '0.1' to '100.0'.
1.0
b3.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'b2.LIMIT' and 'b3.FACT1'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. This message is only output if threshold 2 or 3 is not exceeded
at the same time. The process to activate and display this message
is described in the 'XDIAG' parameter.
5.0
b4.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'b2.LIMIT' and 'b4.FACT2'.
The threshold 2 message is displayed when threshold 2 is excee‐
ded. This message is only output if threshold 3 is not exceeded at
the same time. The process to activate and display this message is
described in the 'XDIAG' parameter.
10.0
b5.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
180
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'b2.LIMIT' and 'b5.FACT3'.
The threshold 3 message is displayed when threshold 3 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
15.0
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Parameter assignment
9.3 Description of parameters
9.3.3.3
Monitoring pneumatic leakage 'C.\\LEAK'
C. LEAK - Monitoring pneumatic leakage
Note
Accuracy of results
Please note that this monitoring only delivers results in the case of single-acting, spring-loaded
actuators and a setpoint from 5 to 95%.
Note
Activated tight closing function
Please note that this monitoring only delivers results in the case of an activated tight closing
function and a setpoint with the following values:
Lower value for tight closing (YCDO) +5 % up to upper value for tight closing (YCUP) -5 %
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
Use this parameter to detect leakages in the actuator or in the pipe
installation. Monitoring is performed in three steps. To activate mon‐
itoring, set the parameter to 'On'. Sub-parameters are displayed.
Appropriately set the sub-parameters.
The current value is displayed in Diagnostic value '16.ONLK - Pneu‐
matic leakage' (Page 259). The positioner triggers a message if the
current value exceeds one of the three thresholds.
OFF
C1.LIMIT - Limit for leakage indicator
Adjustment range:
Purpose:
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Operating Instructions, 02/2016, A5E00127926-AB
0.1 ... 100.0
Use this sub-parameter to set the limit of the leakage indicator in
percent. Set the limit in a range from '0.1' to '100.0'. If no leakage
exists, monitoring of the pneumatic leakage is automatically calibra‐
ted in such a way during the initialization (see section Commission‐
ing (Page 113)) that the leakage indicator remains below the value
30. If a value above 30 is displayed, this means that a leakage exists.
'30.0' is therefore an advisable setting for the parameter. After a
certain time this limit can be varied slightly depending on the appli‐
cation.
181
Parameter assignment
9.3 Description of parameters
Factory setting:
To optimize the sensitivity of the monitoring of the pneumatic leak‐
age to your specific application, follow these steps:
1. After initializing the positioner automatically, use a calibration
device to initiate a ramp movement.
2. Conditions for the ramp movement:
– The ramp covers the normal operating range of the valve.
– The steepness of the ramp matches the dynamic
requirements of the corresponding application.
– The characteristic of the ramp corresponds to the
characteristic of the setpoint that actually occurs.
3. During the ramp movement, the Diagnostic value '16.ONLK Pneumatic leakage' (Page 259) provides information about the
actual values. Define the limit of the leakage indicator
accordingly.
The positioner triggers a message if the current value exceeds one
of the three thresholds. How to set the three thresholds is described
below.
30.0
C2.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'C1.LIMIT' and 'C2.FACT1'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
1.0
C3.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
182
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
2. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'C1.LIMIT' and 'C3.FACT2'.
The threshold 2 message is displayed when threshold 2 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
1.5
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Parameter assignment
9.3 Description of parameters
C4.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
9.3.3.4
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
3. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'C1.LIMIT' and 'C4.FACT3'.
The threshold 3 message is displayed when threshold 3 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
2.0
Monitoring the stiction (slipstick) 'd.\\STIC'
d. STIC - Monitoring the stiction (slipstick)
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
Use this parameter to continuously monitor the current stiction (slip‐
stick) of the control valve. If the parameter is activated, the positioner
detects the slipstick that may occur. Sudden changes in the valve
position, so-called slip jumps, indicate excessive stiction. Where slip
jumps are detected, the filtered step height is stored as a slipstick
value. If slip jumps no longer exist, the stiction (slipstick) is reduced
slowly. Monitoring is performed in three steps. To activate monitor‐
ing, set the parameter to 'On'. Sub-parameters are displayed. Ap‐
propriately set the sub-parameters.
The current value is displayed in Diagnostic value '17.STIC - Stiction
(slipstick)' (Page 260). The positioner triggers a message if the cur‐
rent value exceeds one of the thresholds.
OFF
Note
Incorrect interpretation in case of travel times below one second
If the travel times are less than one second, the positioner does not accurately differentiate
between a normal movement of the actuator and a sudden change. Therefore, increase the
travel time if required.
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183
Parameter assignment
9.3 Description of parameters
d1.LIMIT - limit for slipstick detection
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the base limit for slipstick detection
in percent. Set the base limit in a range from '0.1' to '100.0'.
1.0
d2.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the values entered for 'd1.LIMIT' and 'd2.FACT1'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
2.0
d3.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
2. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the values entered for 'd1.LIMIT' and 'd3.FACT2'.
The threshold 2 message is displayed when threshold 2 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
5.0
d4.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set the factor for formation of threshold
3. Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of the values entered for 'd1.LIMIT' and 'd4.FACT3'.
The threshold 3 message is displayed when threshold 3 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
10.0
See also
Diagnostic value '15.DEVI - General control valve fault' (Page 259)
184
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Parameter assignment
9.3 Description of parameters
9.3.3.5
Monitoring the deadband 'E.\\DEBA'
E. DEBA - Monitoring the deadband
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
The '31.DEBA' Deadband of controller (Page 160) parameter is set
to 'Auto'.
● OFF
● On
Use this parameter to continuously monitor the automatic adaptation
of the deadband. Monitoring is performed in three steps. To activate
monitoring, set the parameter to 'On'. The sub-parameter is dis‐
played. Appropriately set the sub-parameter.
The current value is displayed in Diagnostic value '26.DBUP - Dead‐
band UP' / '27.DBDN - Deadband DOWN' (Page 263). The position‐
er triggers a message if the current value exceeds the threshold.
OFF
E1.LEVL3 - Deadband threshold
Adjustment range:
Purpose:
Factory setting:
0.1 ... 2.9
Use this sub-parameter to set the threshold to the deadband in per‐
cent. Set the threshold in a range from '0.1' to '2.9'.
The threshold 3 fault message is displayed when the current dead‐
band exceeds the threshold during the test. The procedure to acti‐
vate and display this error message is described in the 'XDIAG' pa‐
rameter.
2.0
Note
Fault message display
The three-stage alarm display has not been implemented for monitoring of the deadband. The
positioner triggers only threshold 3 fault messages depending on the setting.
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185
Parameter assignment
9.3 Description of parameters
9.3.3.6
Monitoring the lower endstop ''F.\\ZERO'
F. ZERO - Monitoring the lower endstop
Note
Fault detection
Monitoring the lower endstop not only responds to faults in the valve. If the limit thresholds of
the lower endstop are exceeded due to misalignment of the position feedback, the
misalignment also triggers a diagnostics message.
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
The '36.YCLS' Tight closing with manipulated variable (Page 162)
parameter is set to 'do' or 'uP do'.
● OFF
● On
Use this parameter to activate continuous monitoring of the lower
endstop. The monitoring is executed whenever the valve is in the
'Lower tight closing' position. It checks whether the lower endstop
has changed compared to its value during initialization. Monitoring
is performed in three steps. Set the following sub-parameters ap‐
propriately. To activate monitoring, set the parameter to 'On'. Subparameters are displayed.
The current value is displayed in Diagnostic value '18.ZERO - Lower
endstop' (Page 260). The positioner triggers a message if the cur‐
rent value undershoots one of the three thresholds.
OFF
F1.LEVL1 - threshold 1
Adjustment range:
Purpose:
Factory setting:
186
0.1 ... 10.0
Use this sub-parameter to set threshold 1 for the lower endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the low‐
er endstop and the initialization value undershoots threshold 1. The
process to activate and display this message is described in the
'XDIAG' parameter.
1.0
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Parameter assignment
9.3 Description of parameters
F2.LEVL2 - threshold 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 10.0
Use this sub-parameter to set threshold 2 for the lower endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the low‐
er endstop and the initialization value undershoots threshold 2. The
process to activate and display this message is described in the
'XDIAG' parameter.
2.0
F3.LEVL3 - threshold 3
Adjustment range:
Purpose:
Factory setting:
9.3.3.7
0.1 ... 10.0
Use this sub-parameter to set threshold 3 for the lower endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the low‐
er endstop and the initialization value undershoots threshold 3. The
process to activate and display this message is described in the
'XDIAG' parameter.
4.0
Monitoring the upper endstop 'G.\\OPEN'
G. OPEN - Monitoring the upper endstop
Note
Fault detection
Monitoring the upper endstop not only responds to faults in the valve. If the limit thresholds of
the upper endstop are exceeded due to misalignment of the position feedback, the
misalignment also triggers a message.
Requirement:
Possible settings:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
The '36.YCLS' Tight closing with manipulated variable (Page 162)
parameter is set to 'uP' or 'uP do'.
● OFF
● On
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187
Parameter assignment
9.3 Description of parameters
Purpose:
Factory setting:
Use this parameter to activate continuous monitoring of the upper
endstop. The monitoring is executed whenever the valve is in the
'Upper tight closing' position. It checks whether the upper endstop
has changed compared to its value during initialization. Monitoring
is performed in three steps. Set the following sub-parameters ap‐
propriately. To activate monitoring, set the parameter to 'On'. Subparameters are displayed.
The value is displayed in Diagnostic value '19.OPEN - Upper end‐
stop' (Page 260). The positioner triggers a message if the current
value exceeds one of the three thresholds.
OFF
G1.LEVL1 - threshold 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 10.0
Use this sub-parameter to set threshold 1 for the upper endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the up‐
per endstop and the initialization value overshoots threshold 1. The
process to activate and display this message is described in the
'XDIAG' parameter.
1.0
G2.LEVL2 - threshold 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 10.0
Use this sub-parameter to set threshold 2 for the upper endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the up‐
per endstop and the initialization value overshoots threshold 2. The
process to activate and display this message is described in the
'XDIAG' parameter.
2.0
G3.LEVL3 - threshold 3
Adjustment range:
Purpose:
Factory setting:
188
0.1 ... 10.0
Use this sub-parameter to set threshold 3 for the upper endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a message if the difference between the up‐
per endstop and the initialization value overshoots threshold 3. The
process to activate and display this message is described in the
'XDIAG' parameter.
4.0
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
9.3.3.8
Monitoring the low limit temperature 'H.\\TMIN'
H. TMIN - Monitoring the low limit temperature
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
The current temperature inside the enclosure of the field device is
recorded by a sensor on the basic electronics. Use this parameter
to activate continuous monitoring of the low limit temperature inside
the enclosure. Monitoring is performed in three steps. To activate
monitoring, set the parameter to 'On'. Sub-parameters are dis‐
played. Appropriately set the sub-parameters.
The value is displayed in Diagnostic value '31.TMIN - Minimum tem‐
perature' / '32.TMAX - Maximum temperature' (Page 264). The po‐
sitioner triggers a message if the current value undershoots one of
the three thresholds.
OFF
H1.TUNIT - temperature unit
Possible settings:
Purpose:
Factory setting:
°C
°F
Use this sub-parameter to set the temperature unit '°C' or '°F'. The
selected temperature unit is then also applicable for all other tem‐
perature-based parameters.
°C
H2.LEVL1 - threshold 1
Adjustment range:
-40.0C ... 90.0C
Purpose:
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 1.
Factory setting:
The positioner triggers a message if the current temperature inside
the enclosure undershoots threshold 1. The process to activate and
display this message is described in the 'XDIAG' parameter.
-25.0C
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189
Parameter assignment
9.3 Description of parameters
H3.LEVL2 - threshold 2
Adjustment range:
Purpose:
Factory setting:
-40.0C ... 90.0C
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 2.
The positioner triggers a message if the current temperature inside
the enclosure undershoots threshold 2. The process to activate and
display this message is described in the 'XDIAG' parameter.
-30.0C
H4.LEVL3 - threshold 3
Adjustment range:
Purpose:
Factory setting:
9.3.3.9
-40.0C ... 90.0C
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 3.
The positioner triggers a message if the current temperature inside
the enclosure undershoots threshold 3. The process to activate and
display this message is described in the 'XDIAG' parameter.
-40.0C
Monitoring the high limit temperature 'J.\\TMAX'
J. TMAX - Monitoring the upper limit temperature
Requirement:
Possible settings:
Purpose:
Factory setting:
190
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
The current temperature inside the enclosure of the field device is
recorded by a sensor on the basic electronics. Use this parameter
to activate continuous monitoring of the high limit temperature inside
the enclosure. Monitoring is performed in three steps. To activate
monitoring, set the parameter to 'On'. Sub-parameters are dis‐
played. Appropriately set the sub-parameters.
The value is displayed in Diagnostic value '31.TMIN - Minimum tem‐
perature' / '32.TMAX - Maximum temperature' (Page 264). The po‐
sitioner triggers a message if the current value exceeds one of the
three thresholds.
OFF
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
J1.TUNIT - temperature unit
Possible settings:
Purpose:
Factory setting:
°C
°F
Use this sub-parameter to set the temperature unit '°C' or '°F'. The
selected temperature unit is then also applicable for all other tem‐
perature-based parameters.
°C
J2.LEVL1 - threshold 1
Adjustment range:
Purpose:
Factory setting:
-40.0C ... 90.0C
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 1.
The positioner triggers a message if the current temperature inside
the enclosure overshoots threshold 1. The process to activate and
display this message is described in the 'XDIAG' parameter.
75.0C
J3.LEVL2 - threshold 2
Adjustment range:
Purpose:
Factory setting:
-40.0C ... 90.0C
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 2.
The positioner triggers a message if the current temperature inside
the enclosure overshoots threshold 2. The process to activate and
display this message is described in the 'XDIAG' parameter.
80.0C
J4.LEVL3 - threshold 3
Adjustment range:
-40.0C ... 90.0C
Purpose:
-40.0F ... 194.0F
Use this sub-parameter to set the temperature for threshold 3.
Factory setting:
The positioner triggers a message if the current temperature inside
the enclosure undershoots threshold 3. The process to activate and
display this message is described in the 'XDIAG' parameter.
90.0C
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Parameter assignment
9.3 Description of parameters
9.3.3.10
Monitoring the number of total strokes 'L.\\STRK'
L. STRK - Monitoring the number of total strokes
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
Use this parameter to continuously monitor the total strokes covered
by the actuator. A total stroke corresponds to the path from the lower
endstop of the actuator to the upper endstop and back again, in other
words twice the travel. During operation, partial strokes of the ac‐
tuator are added together into total strokes. Monitoring is performed
in three steps. To activate monitoring, set the parameter to 'On'. Subparameters are displayed. Appropriately set the sub-parameters.
The current value is displayed in Diagnostic value '1.STRKS - Num‐
ber of total strokes' (Page 255). The positioner triggers a message
if the current value exceeds one of the three thresholds. This mes‐
sage is only output if threshold 2 or 3 is not exceeded at the same
time.
OFF
L1.LIMIT - Limit for number of total strokes
Adjustment range:
Purpose:
Factory setting:
1 ... 1.00E8
Use this sub-parameter to set the base limit for the number of total
strokes. Set the base limit in a range from '1' to '1.00E8'.
1.00E6
L2.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
192
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '40.0'. The threshold is the
product of 'L1.LIMIT' and 'L2.FACT1'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
1.0
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
L3.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '40.0'. The threshold is the
product of 'L1.LIMIT' and 'L3.FACT2'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
2.0
L4.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
9.3.3.11
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold
1. Set the factor in a range from '0.1' to '40.0'. The threshold is the
product of 'L1.LIMIT' and 'L4.FACT3'.
The threshold 1 message is displayed when threshold 1 is excee‐
ded. The process to activate and display this message is described
in the 'XDIAG' parameter.
5.0
Monitoring the number of changes in direction 'O.\\DCHG'
O. DCHG - Monitoring the number of changes in direction
Requirement:
Possible settings:
Purpose:
Factory setting:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
Use this parameter to continuously monitor the number of changes
in direction of the actuator beyond the deadband. Monitoring is per‐
formed in three steps. Set the following sub-parameters appropri‐
ately. To activate monitoring, set the parameter to 'On'. Sub-param‐
eters are displayed.
The current value is displayed in Diagnostic value '2.CHDIR - Num‐
ber of changes in direction' (Page 255). The positioner triggers a
message if the current value exceeds one of the three thresholds.
OFF
193
Parameter assignment
9.3 Description of parameters
O1.LIMIT - Limit for number of changes in direction
Adjustment range:
Purpose:
Factory setting:
1 ... 1.00E8
Use this sub-parameter to set the base limit for the changes of direction of the
actuator. Set the base limit in a range from '1' to '1.00E8'.
1.00E6
O2.FACT1 - Factor 1
Adjustment range:
Purpose:
Factory setting:
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold 1. Set the factor
in a range from '0.1' to '40.0'. The threshold is the product of 'O1.LIMIT' and
'O2.FACT1'.
The threshold 1 message is displayed when threshold 1 is exceeded. The process
to activate and display this message is described in the 'XDIAG' parameter.
1.0
O3.FACT2 - Factor 2
Adjustment range:
Purpose:
Factory setting:
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold 1. Set the factor
in a range from '0.1' to '40.0'. The threshold is the product of 'O1.LIMIT' and
'O3.FACT2'.
The threshold 1 message is displayed when threshold 1 is exceeded. The process
to activate and display this message is described in the 'XDIAG' parameter.
2.0
O4.FACT3 - Factor 3
Adjustment range:
Purpose:
Factory setting:
194
0.1 ... 40.0
Use this sub-parameter to set the factor for formation of threshold 1. Set the factor
in a range from '0.1' to '40.0'. The threshold is the product of 'O1.LIMIT' and
'O4.FACT3'.
The threshold 1 message is displayed when threshold 1 is exceeded. The process
to activate and display this message is described in the 'XDIAG' parameter.
5.0
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Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
9.3.3.12
Monitoring the position average value 'P.\\PAVG'
P. PAVG - Monitoring the position average value
Requirement:
Possible settings:
Purpose:
Factory setting:
The '50.XDIAG' Activation of extended diagnostics (Page 170) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● OFF
● On
Use this parameter to activate the test to calculate and monitor the
average value of position. During the test, the average values of
position and reference are always compared at the end of a time
interval.
The current value is displayed in Diagnostic value '20.PAVG - Aver‐
age value of position' (Page 261). The positioner triggers a message
if the current average value of position undershoots one of the three
thresholds.
OFF
P1.TBASE - Time basis of average value generation
Possible settings:
Purpose:
Factory setting:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
0.5h / 8h / 5d / 60d / 2.5y
Use this sub-parameter to set the time interval to calculate the aver‐
age value of position. The following values are available to define
the time intervals:
● 30 minutes
● 8 hours
● 5 days
● 60 days
● 2.5 years
After starting the calculation for average value of reference and ex‐
piry of the time interval, a position average over the interval period
is determined and compared with the average value of reference.
The test is then restarted.
0.5h
195
Parameter assignment
9.3 Description of parameters
P2.STATE - Status of monitoring position average value
Possible settings:
Purpose:
Factory setting:
IdLE / rEF / ###.# / Strt
Use this sub-parameter to start the calculation for average value of
position. If an average value of reference has never been deter‐
mined, the parameter value is 'IdLE'.
Then start the calculation by pressing the
button for 5 seconds.
The value in the display changes from 'IdLE' to 'rEF'. The average
value of reference is calculated.
When the time interval expires, the calculated average value of ref‐
erence is shown on the display.
IdLE
Note
Current average value of position
The respective current average value of position is displayed in the Diagnostic value '20.PAVG
- Average value of position' (Page 261). If no average value of position has been calculated,
'COMP' is displayed as the diagnostic value.
P3.LEVL1 - threshold 1
Possible settings:
Purpose:
Factory setting:
0.1 ... 100.0
Use this sub-parameter to set threshold 1 for the maximum deviation
of the current average value of position from the average value of
reference. The value is given in percent. Set the threshold in a range
from '0.1' to '100.0'.
The positioner triggers a message if the difference between the
average value of position and the average value of reference ex‐
ceeds threshold 1. The procedure to activate and display this mes‐
sage is described in the 'XDIAG' parameter.
2.0
P4.LEVL2 - threshold 2
Possible settings:
Purpose:
Factory setting:
196
0.1 ... 100.0
Use this sub-parameter to set threshold 2 for the maximum deviation
of the current average value of position from the average value of
reference. The value is given in percent. Set the threshold in a range
from '0.1' to '100.0'.
The positioner triggers an error message if the difference between
the average value of position and the average value of reference
exceeds threshold 2. The process to activate and display this mes‐
sage is described in the 'XDIAG' parameter.
The factory setting is '5.0'.
5.0
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Parameter assignment
9.3 Description of parameters
P5.LEVL3 - threshold 3
Possible settings:
Purpose:
Factory setting:
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
0.1 ... 100.0
Use this sub-parameter to set threshold 3 for the maximum deviation
of the current average value of position from the average value of
reference. The value is given in percent. Set the threshold in a range
from '0.1' to '100.0'.
The positioner triggers a message if the difference between the
average value of position and the average value of reference ex‐
ceeds threshold 3. The procedure to activate and display this mes‐
sage is described in the 'XDIAG' parameter.
10.0
197
Parameter assignment
9.3 Description of parameters
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Functions/operations using PROFIBUS PA
10.1
10
System integration
A control system (master) uses acyclic and cyclic data transfer to operate and monitor the
positioner. You must set an address of the positioner in advance so that it can communicate
with the master as a slave.
The PROFIBUS address is set to 126 in the as-delivered condition. You set the PROFIBUS
address on the device or use a configuration tool like SIMATIC PDM to set the address through
the bus.
10.2
Acyclic data transfer
10.2.1
Acyclic data transfer using SIMATIC PDM
SIMATIC PDM
The acyclic data transfer is mainly used to transfer parameters during commissioning and
maintenance, for batch processes or to display other measured variables that do not participate
in the cyclic transmission of useful data.
The data is transferred between a class 2 master and a field device using the so-called C2
connections. The device supports up to four C2 connections, so the multiple class 2 masters
can access the same positioner simultaneously.
SIMATIC PDM is preferably used for the acyclic data transfer. It is a software package for
project planning, parameterization, commissioning, diagnostics and maintenance of the
positioner and other field devices.
SIMATIC PDM enables access to process values, alarms, status and diagnostics information
of the device. You can use SIMATIC PDM to execute the following functions for field devices:
● Display
● Set
● Change
● Compare
● Check for plausibility
● Manage and simulate
Procedure for acyclic data transfer:
We recommend the following general procedure:
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10.2 Acyclic data transfer
1. First read the current settings from the device using the "Load to PG/PC" menu item.
2. Check the current settings.
3. Make any necessary settings.
4. Load the parameter settings into the device using the "Download to device" menu item.
5. Save the settings in the SIMATIC PDM as well.
The menu bar of SIMATIC PDM contains the "File", "Device", "View", "Diagnostics" and "Help"
menus. The "Device" and "View" menus, which also contain other sub-menus, are described
below in detail.
10.2.2
'Device' menu
10.2.2.1
Load to device
Use this sub-menu to load the parameters from the offline display of SIMATIC PDM into the
device. Call up the function using the following button:
Figure 10-1
10.2.2.2
Load to device
Load into PG/PC
Use this sub-menu to read the parameters from the device. These parameters are then
displayed in SIMATIC PDM. Call up the function using the following button:
Figure 10-2
10.2.2.3
Load to PG/PC
Assign address and TAG
Use this sub-menu to assign a new address and TAG. Note that this is only possible if the
slave is not yet integrated into the cyclic service.
10.2.2.4
Value comparison
Use this dialog box to start the comparison of device parameters. The parameter values of a
device which are always saved in the project form the basis for the comparison of values.
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10.2 Acyclic data transfer
The parameter values of a device which are saved in the project can be compared with the
following data types.
● Offline data: The parameter values of a device which are saved in the project.
● Online data: Parameter values currently saved in the device.
10.2.2.5
Object properties
"General" tab
In this "General" tab you can find information on the PDM object and enter optional additional
information.
In the "General" tab you can find:
● Object name
● Description
● Message
● Properties
"Device" tab
In this "Device" tab you display the device data.
The contents of the fields cannot be changed. The contents are derived from the Device
Description assigned to the object if these have been entered in it.
Certain entries are displayed as keys and not as plain text.
In the "Device" tab you can find:
● Device type
● Manufacturer
● Order No.
● Catalog path
● Device DDL
● EDD version
● Device version
"Diagnostics" tab
In this "Diagnostics" tab you can display information for device communication. The symbol
which is displayed on the device is formed in accordance with this information.
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10.2 Acyclic data transfer
In the "Diagnostics" tab you can find:
● Communication
● Last test
● Message text
"Communication" tab
In this "Communication" tab you can display the address of a device. If the device has been
configured in the process device network view, you can change the address.
In the "Communication" tab you can find:
● Redundancy
"Document manager" tab
In this "Document manager" tab, you can assign documents to a PDM object.
10.2.2.6
Calibration report
The "Calibration report" section contains information on the following topics:
"Test environment" tab
In this "Test environment" tab you can find:
● Data on the field device
● Data on the operator and test date of the calibration report
● Operator remarks concerning the test
● Comment field
● Settings for scheduling
"Diagnostics" tab
In this "Diagnostics" tab you can find:
● Information on display of the communication connection status
● Information on display of the device status
● Date of the last change
● Messages of the last test
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10.2 Acyclic data transfer
"Measuring range settings" tab
In this "Measuring range settings" tab you can find:
● Channel-specific Information (configurable: maximum 8 channels)
● Channel selection
● Configurable settings per channel:
– Measuring circuit unit
– Measuring range
– Output unit
– Permissible deviation in output range (setpoint/actual value)
– Comment fields
"Appendices" tab
Configure files which are to be linked to the report.
In the "Appendices" tab you can find:
● Possible file types:
– pdf
– doc; docx
– xls; xlsx
– txt
– jpg
"Comments" tab
Additional comments for various types of comment
In the "Comments" tab you can find:
● Wiring errors
● Unsuitable measuring point
● Device error
● Error comment
10.2.2.7
Change log
The change log is used to record the actions carried out on system objects using SIMATIC
PDM.
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10.2 Acyclic data transfer
Properties:
● The change log is part of the associated SIMATIC project.
● The change log is a circular log (first in - first out). Some fields in the change log are created
automatically. The information is entered in the language which is pre-selected in the
SIMATIC project.
Requirements for using the "Change log" function:
You require the license key for "SIMATIC PDM Extended" in order to use the "Change log"
function.
Entries in the change log:
Actions are shown in the dialog window "SIMATIC PDM change log" which have been executed
in the project or also on individual objects (devices). The displayed actions depend on the
object displayed in SIMATIC PDM.
You can restrict the displayed information by setting the filter. The drop-down list "Action" of
the filter shows the actions which can be displayed.
10.2.2.8
Wizard
This menu item is only available if the extended diagnostics has been previously activated in
the parameter list. In this menu you can display and execute the various diagnostics options:
The following diagnostics options can be activated and parameterized:
'Quick Start' wizard
Use the 'Wizard - Quick Start' button to start up the device.
'Partial Stroke Test' wizard
Use the 'Wizard - Partial Stroke Test' button to set a diagnostics function which moves and
monitors the stroke over a certain distance.
'Full Stroke Test' wizard
Use the 'Wizard - Full Stroke Test' button to set a diagnostics function which moves and
monitors the stroke over the complete distance.
'Step Response Test' wizard
Use the 'Wizard - Step Response Test' button to set a diagnostics function which moves and
monitors the stroke over an intentional distance.
'Multi-Step Response Test' wizard
Use the 'Wizard - Multi-Step Response Test' button to set a diagnostics function which
repeatedly moves and monitors the stroke over an intentional distance.
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10.2 Acyclic data transfer
'Valve Performance Test' wizard
Use the 'Wizard - Valve Performance Test' button to set a diagnostics function which
determines the characteristic values of the valve in accordance with IEC 61298-2.
10.2.2.9
Partial stroke test (PST)
Availability
This menu item is only available if previously activated in the parameter list using the 'Extended
diagnostics' menu. You can then activate and parameterize the partial stroke test.
Functions
Use the 'Partial stroke test' button to access the functions of the partial stroke test:
● Execute the partial stroke test.
● Cancel the partial stroke test.
● Deactivate diagnostics
Changes become effective as soon as the Transfer button is pressed.
10.2.2.10
PST trace characteristic
Availability
This menu item is only available if the extended diagnostics has been previously activated in
the parameter list. Use this menu item to call the following sub-menus:
● Read trace
● Export as *.csv file
● Import a .csv file
Read trace
When executing a partial stroke test, the temporal course of the actual value is scanned in the
background and saved in the RAM of the positioner with a maximum of 1000 data points. Use
this menu item to read in the saved data in SIMATIC PDM. The end of the reading process is
displayed in the SIMATIC PDM status bar.
Export as *.csv file
Use this menu item to save the currently read in temporal course of the partial stroke test in
the SIMATIC PDM as a csv file.
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10.2 Acyclic data transfer
10.2.2.11
Offline leakage test
Application
Use this menu item to open an online dialog in which you can recognize following execution
whether a leakage is present in the actuator or in the piping.
You will also obtain information about the statuses in the diagnostic field 'Leakage test status':
● Not executed (only '-' is shown in the positioner display)
● Running
● Stopped
● Complete
If you execute the test using the 'Start offline leakage test' button in the online dialog, the
leakage is measured at the position at which the positioner is currently present. The measured
leakage [%/min] is subsequently saved in the '11.LEAK' parameter.
A distinction must be made here between the extended diagnostics 'Monitoring pneumatic
leakage C.\\LEAK' and the 'Offline leakage test'. Monitoring is not activated by the 'Offline
leakage test'. A single offline test is executed to check for leakages and save the measured
leakage value [%/min] in the '11.LEAK' parameter.
10.2.2.12
Maintenance and diagnostics
Application
The sub-menu "Maintenance and diagnostics" is only available if the extended diagnostics has
been activated. You can then activate and parameterize the following extended diagnostics
parameters:
● Monitoring the dynamic control valve behavior ''b.\\DEVI'
● Monitoring the pneumatic leakage 'C._LEAK'
● Monitoring the stiction (slipstick) ''d.\\STIC'
● Monitoring the deadband ''E.\\DEBA'
● Monitoring the lower endstop ''F.\\ZERO'
● Monitoring the upper endstop 'G.\\OPEN'
● Monitoring the lower limit temperature ''H.\\TMIN'
● Monitoring the high limit temperature 'J.\\TMAX'
● Monitoring the number of total strokes ''L.\\STRK'
● Monitoring the number of changes in direction ''O.\\DCHG'
● Monitoring the position average value 'P.\\PAVG'
Changes become effective as soon as the Transfer button is pressed.
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10.2 Acyclic data transfer
10.2.2.13
Initialization parameters
Use
Not only you can display the initialization parameters in this menu, but also change them
specifically. Allow only specialists to change the initialization parameters.
You also need this function if you need to replace the electronic unit. However you cannot
initialize at the moment.
10.2.2.14
Initialization
Application
With SIMATIC PDM, you also have the option to initialize the positioner for the first time.
First initialization
WARNING
Start initialization
You are not located on-site at the positioner. In order to prevent personal injuries and material
damage, take in-house precautionary measures before starting the initialization process.
Note
Also ensure that you always start the initialization process from the acyclic master even if the
positioner is in automatic mode and contains setpoints of a cyclic master.
If required, you can interrupt the ongoing initialization by pressing the "Stop initialization"
button. You can also press the operating mode button or disconnect the power supply to
interrupt the initialization process on the device.
Proceed as follows to initialize the positioner using SIMATIC PDM for the first time:
1. Go to the "Device" menu and then to the "Initialization" sub-menu. A window containing an
overview of the initialization status then opens.
2. Press the "Start initialization" button. A warning is then displayed. Follow this warning
without fail to prevent personal injuries and damage to the system.
3. Acknowledge the warning.
The initialization process starts once you acknowledge the warning. You can monitor the
progress in the "Status (initialization)" field in the open window of the initialization menu. As
soon as the initialization is completed successfully, the positioner continues working in the
operating mode from which the initialization process was started. If a fault message appears,
an on-site correction is required.
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10.2 Acyclic data transfer
10.2.2.15
Operation
Open the 'Device > Operation' menu. An online dialog is opened with two tabs. Go to the
'Operation' tab.
Target mode
The following target modes (operating modes of function blocks) are possible:
● Automatic (AUT)
● Manual (MAN)
● Out of service (O/S)
Note that the target modes refer to the operating modes of function blocks of the PROFIBUS PA
block model, and should not be confused with the "Automatic" and "Manual" operating modes
of the positioner.
The above target modes are effective when the positioner is in automatic mode (AUT). If the
positioner is in manual mode (MAN), they are only effective after an on-site switchover to
automatic mode (AUT).
These target modes are saved in the positioner in the power failure-safe manner.
Automatic mode
As long as the positioner is not integrated into the cyclic service as a slave, SIMATIC PDM
can be used to send a setpoint to it in a cyclic manner.
Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Automatic".
3. Enter a value between 0 and 100% for the desired setpoint, quality as "Good" and the status
as "OK".
4. Transfer these settings to the positioner.
The positioner is controlled using the desired setpoint until a cyclic master starts
communication with a slave or you switch over the positioner to the "Manual" mode on-site.
Note
Note that the positioner responds with the "Poor" quality and the "Constant value" status after
sending the data.
If you exit this target mode and no other master sends a setpoint to the positioner, it is controlled
using the configured fail-safe value after the set monitoring time expires.
Manual mode
You can use SIMATIC PDM to send a setpoint to the positioner even when cyclic
communication is active. To do this, you need only set priority over the cyclic master
beforehand.
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Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Manual".
3. Enter a value between 0 and 100% as a starting value, "Good" as the quality and "OK" as
the status.
4. Transfer these settings to the positioner.
The positioner is now controlled using the desired starting value and reports this manual mode
through "MM" on the display.
Note that the starting value entered in the manual mode is directly written in the starting block
of the positioner without scaling.
You can switch the positioner to the manual mode on-site and move the actuator using buttons.
The setpoint is tracked as per the current actual value. The manual mode and the current
position are retained after switching back to the automatic mode.
After a power failure, the positioner is controlled in the manual mode depending on the direction
of action of the actuator using the value set in the "YA" or "YE" parameters.
Note
You must set the target mode to "Automatic" to reactivate the setpoints of the cyclic master.
Out of service (O/S)
You can use SIMATIC PDM to put the positioner out of service irrespective of the cyclic
communication.
CAUTION
Depressurize
In order to prevent physical injuries and material damage, you must ensure that the actuator
is depressurized when it is put out of service.
Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Out of service (O/S)".
3. Transfer these settings to the positioner.
The successful transmission is reported by "OS--" on the display of the positioner.
You can switch the positioner to the manual mode on-site and move the actuator using buttons
in this target mode also. "MAN--" is then shown on the display.
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The "Out of service (O/S)" mode is retained after switching back to the automatic mode. The
actuator remains depressurized after a power failure.
Note
You must set the target mode to "Automatic" to reactivate the setpoints of the cyclic master.
10.2.2.16
Simulation
Register
Use this sub-menu to access the "Simulation" online menu that is split into the following four
tabs:
● Simulation of actual value
● Simulation of device status
● Simulation of device diagnostics
Simulation of actual value
You can activate the actual value simulation in this tab and also define the actual value to be
simulated and its quality and status. The following feedback values are available:
● Setpoint
● Actual value
● Setpoint deviation
● Checkback
Changes become effective as soon as the Transfer button is pressed.
Simulation of device status
You can activate simulation of the device status in this tab and then select the diagnostics
messages to be simulated. This concerns the content of the "DIAGNOSTICS physical block
parameter" that generates different diagnostics messages depending on whether the
condensed status has been activated or deactivated. Changes become effective as soon as
the Transfer button is pressed.
Simulation of device diagnostics
In this tab you enable simulation of device diagnostics.
You can then select the desired diagnostics events in the simulation of device diagnostics,
and use device diagnostics and message text to obtain the feedback indicating that the
corresponding event has been triggered in the device. Changes become effective as soon as
the Transfer button is pressed.
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10.2.2.17
Date and time in the device
Application
Use this menu item to open an online dialog in which you can set the date and time in the
device.
10.2.2.18
Write protection
Application
Following completion of commissioning, you can set the write protection to prevent undesired
changes by an acyclic master.
However, you can change the parameters of the positioner on-site as before.
Enabling write protection
1. Call the "Write protection" sub-menu.
2. Set 'Write protection' in the sub-menu to 'On'.
If you still try to write, the PDM displays the 'Connection terminated' message.
Note
Write protection
1. If 'On' is displayed for 'Hardware write protection' in the online dialog 'Write protection', the
application parameter '39.BIN1' / '40.BIN2' Function of binary inputs (Page 163) 'bLoc1' or
'bLoc2' has been set on the positioner. Writing via SIMATIC PDM is thus also blocked. The
write protection directly activated in the positioner can only be canceled again directly on
the positioner.
2. In SIMATIC PDM, the write protection can only be changed via the online dialog 'Write
protection' in the 'Device' menu. You cannot change the write protection via the tree
topology in the parameter table 'Security'.
10.2.2.19
Reset parameters in PDM
Application
Use this menu item to open a dialog box to reset all SIMATIC PDM parameters to their factory
settings (default values).
SIMATIC PDM parameters are reset when you press the 'OK' button. You can then transfer
the parameters to the SIMATIC PDM memory using 'File->Save'.
Select 'Device->Load to device' to transfer the reset parameters to the positioner as well.
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10.2.2.20
Reset parameters on the device
Application
Use this menu item to open an online dialog to reset the parameters in the positioner to their
factory settings (default values).
The following parameters can be selected for resetting:
● Initialization parameters
● Device parameters (except 49.PNEUM, 54.STNR and 55.IDENT)
● Parameters of extended diagnostics
● Offline test parameters
The parameters are reset when you press the 'OK' button.
Select 'Device->Load to PG/PC' to transfer the reset parameters of the positioner to SIMATIC
PDM as well.
10.2.2.21
Reset the field device
Resetting to delivery state
If the positioner has been maladjusted such that it can no longer perform its control task, you
can use the 'Reset' function to restore the delivery state. This function resets all parameters
to their factory settings except for the PROFIBUS address.
Resetting is displayed in the online dialog by the diagnostics message 'Device status' as
"Restart (cold startup) carried out". You must then reset all parameters and execute an
initialization process.
Warm restart
With the warm restart you initiate a complete restart of the positioner. This interrupts and then
reestablishes communication.
This restart is displayed in the online dialog by the diagnostics message 'Device status' as
"New startup (warm startup) carried out". If no measured values are available, the automation
or control system reads in the "Uncertain, initial value, constant value" status.
Resetting the address (STRN) to 126
If no device in your system has the preset address 126, you can add your positioner to the
PROFIBUS path during ongoing operation of the automation or control system. You must
subsequently change the address of the newly connected device to a different value.
If you remove a positioner from the PROFIBUS path, you must reset its address to 126 using
this function 'Resetting the address (STRN) to 126' so that you can re-integrate a positioner
in this or another system depending on the requirement.
The address cannot be reset if a cyclic master is already communicating with the positioner.
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10.2.3
'View' menu
10.2.3.1
Process variables / diagnostics cockpit
"Cockpit overview" tab
This "Cockpit overview" tab contains:
● Bar graph displays of actual value and setpoint [stroke/%]
● Bar graph of absolute control deviation [control deviation/%]
● Bar graph of current temperature '30.TEMP' [temperature/°C]
● Information on the TAG, description, message and setpoint function '9.SFCT'
"Trend view (setpoint/actual value)" tab
This "Trend view (setpoint/actual value)" tab displays the setpoint/actual value as a bar and
as a trend.
Furthermore, menu items exist with which you can call the following sub-menus:
● Export as *.csv file
● Import a .csv file
● Connect axes
● Print
"Status" tab
In the "Status" tab you can find:
● Information about checkback, binary input 1 and binary input 2
● Information about limit status
There is an additional 'Detailed status' button in which you can obtain detailed device
diagnostics 1 and device diagnostics 2.
"More cockpit options" tab
You can find additional buttons in the "More cockpit options" tab:
● Min/Max temperature
● Trend charts 'Temperature' and 'Control deviation'
● Setpoint function
● Diagnostics system status
● Maintenance counter
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10.2.3.2
Starting the lifelist
Application
In this menu it is possible to identify active field devices without configuring. Use 'Lifelist' to
carry out a scan on one of the following PDM objects:
● PROFIBUS DP network
● PROFIBUS PA network
● HART modem network
● Foundation Fieldbus network
10.2.4
'Diagnostics' menu
10.2.4.1
Updating diagnostics
Use this sub-menu to update the diagnostics information in SIMATIC PDM that is visualized
using symbols. The symbols are shown before the device name. Call up the function using the
following button:
Figure 10-3
Updating diagnostics
The following table shows the symbols and the associated diagnostics information.
Meaning
Symbols
Deactivated
No device description (EDD) from the device catalog has yet been as‐
signed to the field device / Field device cannot be accessed.
Not validated
A device description from the device catalog has been assigned to the
field device.
Communication disrupted
Communication error; communication has been interrupted or no com‐
munication could take place with the device at the configured address.
The device cannot provide detailed diagnostics information.
Assignment error
The field device is incompatible with the configured field device or the
device has been configured incorrectly. The device cannot provide de‐
tailed diagnostics information.
Maintenance alarm
Maintenance is required immediately as there is a device fault.
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Meaning
Symbols
Maintenance demand
Maintenance is required to prevent a possible device fault from occur‐
ring. Additional diagnostics information is available.
Maintenance required
Maintenance must be scheduled.
No functional restriction has been diagnosed for the field device, service
is requested. Additional diagnostics information is available.
Manual mode
There is a communication connection with the field device. The device
is in manual mode.
Simulation mode
There is a communication connection with the field device. The device
is in manual mode.
For example, the device is in manual mode "Out of service".
Out of service
There is a communication connection with the field device. The device
is in manual mode.
For example, the device is in manual mode "Out of service".
Configuration error
Field device fault due to a parameter or configuration error in the hard‐
ware components. A maintenance alarm is triggered automatically.
Configuration warning
Field device warning due to invalid parameters for which substitute val‐
ues are used. A maintenance request is triggered automatically.
Configuration changed
The parameters set for the device do not match the parameter data
saved in the project. Communication with the device is possible to carry
out a value comparison or to change parameter settings.
Unknown diagnostics status
Unknown field device status due to invalid parameters for which substi‐
tute values are used. A maintenance request is triggered automatically.
Process value alarm
At least one process value has exceeded or fallen below a hardware
interrupt limit whose parameters were assigned in the device. Commu‐
nication with the device is possible.
Process value warning
At least one process value has exceeded or fallen below a process
warning limit whose parameters were assigned in the device. Commu‐
nication with the device is possible.
Process value tolerance
At least one process value has exceeded or fallen below a process
tolerance limit whose parameters were assigned in the device. Commu‐
nication with the device is possible.
No messages
No functional restrictions or diagnostics information known.
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Meaning
Symbols
No diagnostics check
No functional restrictions known. The field device does not support ad‐
ditional diagnostics information.
Test mode (background color of diagnostics icon)
The device is in local test mode. All the displayed information or diag‐
nostics may be simulated. The information transferred to the automation
systems (process values and status) may also be simulated.
10.2.4.2
Device diagnostics
"Diagnostics" tab
In this "Diagnostics" tab you can find:
● Communication
● Device status
● Last test
● Message text
"Messages" tab
In this "Messages" tab you can find:
● Device status
● Checkback
● Limit status (group signal of all three-stage diagnostics events, detailed diagnostics events
can be found under the "Device diagnostics" tab)
● Binary input 1
● Binary input 2
"Device diagnostics" tab
In this "Device diagnostics" tab you can find:
● Device diagnostics 1
● Device diagnostics 2
● Quality
● Status
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10.2.4.3
Maintenance information
"Current" tab
In this "Current" tab you can find information about the values of the positioner which were
determined during the last initialization. The following values are displayed:
● Manipulated variable zero point / upper endstop
● Travel time UP / DOWN
● Impulse length UP / DOWN
● Deadband UP / DOWN
● Slow step zone UP / DOWN
● Determined actuator travel
● Leakage
The 'Save maintenance information (last maintenance)' button requests you to enter a
maintenance date. The current values are saved in the positioners and in the "Last
maintenance" tab. The values can be used as reference values in the "Last maintenance" tab
for comparison purposes during subsequent reinitialization of the positioner.
Use the 'Reset maintenance information' button to reset the maintenance date to '01.01.2000'.
This date informs the positioner that no maintenance has been carried out yet.
"Last maintenance" tab
In this "Last maintenance" tab, you can find the values which have been saved from the
"Current" tab. These values include a save date.
"Maintenance counter" tab
In this "Maintenance counter" tab, you can find an overview of the number of:
● 100% strokes
● Changes of direction
● Fault messages
● Alarms
● Operating hours
● Switching cycles
Press the 'Reset maintenance counter' button to access a selection menu to reset all
maintenance counters at one go or individually.
"Temperature" tab
This "Temperature" tab displays the minimum, current and maximum temperatures
[Temperature/°C] as a bar graph and as a trend.
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10.2.4.4
Trend characteristic
Application
The temporal course of the corresponding measured variable over the selected interval is
shown in a trend characteristic. The trend characteristic provides an overview of the previous
development of the measured value and can be used as the basis to estimate the future course.
If sufficient measured values are available, trends over the last 30 minutes, eight hours, five
days, two months and 30 months can be processed.
You can use the menu item "Trend charts" to display trends of the following sub-menus:
● Actual value
● Control deviation
● Leakage
● Stiction (slipstick)
● Zero point
● Upper endstop
● Temperature
● Deadband
10.2.4.5
Histograms
Application
A class division over the entire measuring range of a variable is included in a histogram. The
time spent by the measured variable within different classes is also displayed.
You can use the position histogram to assess whether a control valve has been designed
practically and whether it was essentially in the expected operating point during its use so far.
You can use the menu item "Histograms" to display histograms of the following sub-menus:
● Position
● Control deviation
● Temperature
10.2.4.6
Alarm logbook
Application
You can use the menu item "Alarm logbook" to display information about the time stamp,
operating hours, interrupts and status.
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10.2.4.7
Characteristic curve
Characteristic curve
The characteristic curves of devices are displayed here if it has been set to "free (user-defined)".
If tight closing is active, the tight closing limits are also displayed irrespective of the setting of
the characteristic curve.
10.3
Cyclic data transfer
The cyclic data transfer is used to transfer the useful data relevant for the process automation
between the class 1 master (control or automation system) and the positioner.
10.3.1
Configuration
Configuring with the GSD
Information about input and output ranges as well as the consistency of the cyclically
transferred data is defined in the GSD file that is used by the device to check the configuration
telegram and to declare it as valid if required.
The useful data to be transferred in the cyclic operation is determined during the projecting
planning. The data volume to be transferred can thus be optimized. The GSD files of all
common devices are already stored in the Siemens control systems. GSD files can be imported
later. You can download the GSD files from:
www.siemens.de/sipartps2
Under "More Info", click on "→ Downloads".
Configuring the useful data
The useful data made available to the control system or the controller through PROFIBUS
depends on the selected desired configuration.
Note
Configuration tool
In case of STEP 7, the configuration tool used is HW config.
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Figure 10-4
①
②
③
④
⑤
⑥
Example of a small PROFIBUS DP/PA system
PC or PG (master class 2)
Power supply
PROFIBUS DP
PROFIBUS PA
Splitter
Bus terminator
⑦
⑧
⑨
⑩
PA devices
DP/PA coupler/link
CPU SIMATIC S7 (master class 1)
MPI cable (required for commissioning
and monitoring)
A small STEP 7 program that establishes cyclic exchange with the positioner using
PROFIBUS PA (positioner) is given below.
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Figure 10-5
STEP 7 sample program
In this example, all data in the input and output directions supported by the device are
transferred. The selected peripheral starting address is 256 (W#16#100).
Note
Only the older SIMATIC CPUs require the SFC14 and SFC16 modules for consistent reading
and writing.
Legend of the sample program
Byte
Function
Composition
Number of bytes
Byte 15
Input data
READBACK
5
Byte 10
Output data
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RCAS_OUT
5
CHECKBACK
3
POS_D
2
SP
5
RCAS_IN
5
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10.3.2
Useful data through PROFIBUS
Cyclic useful data
The positioner can exchange a combination of the following cyclic useful data through
PROFIBUS:
Name
Abbreviation
Direction from the posi‐ Length in
tioner's point of view
byte
Comprising:
German
English
Setpoint
Setpoint
SP
Input
5
Value/Status
Readback
Readback
RB
Output
5
Value/Status
Position discrete
Position discrete
POS_D
Output
2
Value/Status
Checkback
Checkback
CB
Output
3
Value
Remote Cascade Input
Remote Cascade Input
RCAS_IN
Input
5
Value/Status
Remote Cascade Out‐
put
Remote Cascade Out‐
put
RCAS_OUT
Output
5
Value/Status
Setpoint
The setpoint is divided into a floating point value (4 bytes) and the corresponding status (1
byte, see further below).
Actual value
The actual value indicates the valve position. The actual value is divided into a floating point
value (4 bytes) and the corresponding status (1 byte).
Position discrete
The discrete valve position is displayed as a value (1 byte) having the following meaning:
0 = not initialized
1 = valve closed
2 = valve open
3 = valve in the intermediate position: Even this value has a status (1 byte).
Checkback
The checkback is displayed in 3 bytes in a bit-coded format:
Bit
0
222
Meaning of "1"
Remarks
0
Device in the fail safe position
The position is determined by the "49.FSTY" parameter.
1
Request for on-site operation
Reports that a button has been pressed.
2
The device is operated on-site.
The device is parameterized on-site, e.g. using the
"1.YFCT" parameter or is not initialized.
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10.3 Cyclic data transfer
Bit
1
2
Meaning of "1"
Remarks
3
Emergency operation active
The device is in the manual mode. Representation on
the display: MAN or P
4
Deviation of the movement direction
Not required for the positioner.
5
End stop reached (valve completely open)
Not required for the positioner.
6
End stop reached (valve completely closed)
Not required for the positioner.
7
Run time overshoot
The device could not be adjusted. Monitoring time and
threshold in the "44.TIM" and "45.LIM" parameters ex‐
ceeded, e.g. due to the lack of compressed air
0
The valve is opened.
The "Ventilate actuator" command issued
1
The valve is closed.
The "Depressurize actuator" command issued
2
Parameters were changed.
Set temporarily after switching back from the "Configu‐
ration" mode if one or more parameters were changed.
3
Simulation mode
The simulation mode was released. Master class 2 can
overwrite the current actual value, e.g., to test the re‐
sponse of limits in the control system.
4
Not occupied in profile 3.
-
5
Fault in the closed-loop control.
Not required for the positioner.
6
Closed-loop control inactive
Not required for the positioner.
7
Self-monitoring active
Not required for the positioner.
0
Path integral exceeded
Set if the set limit for the path integral has exceeded
1
Additional input active
Binary 1 was activated.
2
Additional input active
Binary 2 was activated.
Remote cascade input
The remote cascade input is used as a setpoint in the remote cascade mode (actual mode =
remote cascade). The remote cascade input comprises the floating point value (4 bytes) and
the status (1 byte).
Remote cascade output
This output delivers the current setpoint in the AUTO and Remote cascade modes. The status
is specially used for the transfer from AUTO to Remote cascade.
In combination with the input variable parameter (primary value scale), not only you can define
the setpoints as a percentage of the valve position, but also in terms of physical variables such
as cubic meter per day or liter per minute. Even the actual values are adjusted as per this
scale.
10.3.2.1
Possible combinations of the useful data
Useful data and position in the address room
You can select a combination of values for the communication of cyclic useful data between
the master and the positioner:
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SP
Setpoint:
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
0
RCAS_OUT - floating point number
RCAS_OUT, RCAS_IN
Remote cascade output, remote cascade input:
Input (master view)
Starting address
1
2
3
4
RCAS_OUT - status
0
RCAS_IN - floating point number
Output (master view)
Starting address
1
2
3
4
RCAS_IN - status
0
READBACK - floating point number
READBACK, POS_D, SP
Actual value, discrete position, setpoint:
Input (master view)
Starting address
1
2
3
224
4
READBACK - status
5
POS_D
6
POS_D - status
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Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
0
CHECKBACK
Checkback, SP
Checkback, setpoint:
Input (master view)
Starting address
1
2
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
READBACK, CHECKBACK, POS_D, SP
Actual value, discrete position, checkback, setpoint:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
POS_D
6
POS_D - status
7
CHECKBACK
8
9
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Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
RCAS_OUT, CHECKBACK, RCAS_IN
Remote cascade output, checkback, remote cascade input:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
POS_D
6
POS_D - status
0
RCAS_IN - floating point number
Output (master view)
Starting address
1
2
3
4
226
RCAS_IN - status
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READBACK, RCAS_OUT, POS_D, CHECKBACK, SP, RCAS_IN
Actual value, remote cascade output, discrete position, checkback, setpoint, remote cascade
input:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
RCAS_OUT - floating point number
6
7
8
9
RCAS_OUT - status
10
POS_D
11
POS_D - status
12
CHECKBACK
13
14
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
5
RCAS_IN - floating point number
6
7
8
9
10.3.2.2
RCAS_IN - status
Diagnostics
Function
The positioner can report active information about its device status. These diagnoses are
important information that can be used by an automation system to initiate remedial measures.
Standard mechanisms of PROFIBUS-DP are used to transfer the diagnostics information and
report it actively to the class 1 master. PROFIBUS-DP has a protocol to transfer the information
that has higher priority than the useful data to the class 1 master.
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The contents of the "Device status" parameter from the physical block are reported along with
the information whether a status change (event received/event sent) has occurred.
Diagnostics as per PROFIBUS DP (DDLM_Slave_Diag)
The positioner delivers the diagnostics data in the following format:
Input (master view)
Starting address
0
Station_status_1
1
Station_status_2
2
Station_status_3
3
Diag_Master_Add
4
Ident_Number
5
Ident_Number
6
Header
7
Status_Type
8
Slot_Number
9
Specifier
10
Diagnostics (0)
11
Diagnostics (1)
12
Diagnostics (2)
13
Diagnostics (3)
Standard DP - diagnostics
Status coding as per DP/V1
Diagnostics object of the physical block
Specifier
The following specifiers are available:
1: Incoming event
2: Outgoing event
10.3.3
Adjustable status (condensed status)
Diagnostics messages are generated in the DIAGNOSTICS physical block parameter
depending on the diagnostics events in the device. At the same time, the statuses of three
PowerTags (FEEDBACK_VALUE, READBACK and POS_D) that are sent to the master by
the SIPART PS2 PA positioner are affected.
In the device, there is now an option to use diagnostics messages and predefined status
messages that are permanently associated with the triggering diagnostics events. The
condensed status must be deactivated for this purpose.
If the condensed status is activated, the diagnostics messages in a specific frame can be
allocated to a smaller number of collective diagnostics messages and selectable status
messages. This "routing" of diagnostics events is shown in the following picture.
228
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
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Figure 10-6
Routing of a diagnostics event
Note
Please note that the condensed status cannot be changed using the SIMATIC PDM when the
device is in a cyclic operation with a master class 1.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
229
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Figure 10-7
230
Activating the condensed status for the device parameterization - with an example of HW configuration with
SIMATIC S7
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Figure 10-8
Activating the condensed status for the device parameterization - with an example of SIMATIC PDM
SIPART PS2 with PROFIBUS PA
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231
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
10.3.3.1
Diagnostics messages in case of deactivated condensed status
The diagnostics messages of the DIAGNOSTICS physical block parameter in case of the
deactivated condensed status are shown in the following table:
Byte
Bit
0
0 ... 2
232
Name and meaning
Cause
Measure
Not used
-
-
3
DIA_TEMP_ELECTR
Electronic unit temperature too
high
The temperature measured at the
device electronic unit has excee‐
ded one or more set thresholds.
Check why the temperature is be‐
yond the specified range.
4
DIA_MEM_CHKSUM
Memory error
During operation, the memory is Replace the electronic unit.
constantly checked for the check‐
sum and write/read errors. This
message is generated in case of
an error.
5
Not used
-
6
DIA_NOT_INIT
Device not initialized
The initialization process re‐
Carry out the device initialization
quired for the device functioning process.
has not yet been carried out suc‐
cessfully.
7
DIA_INIT_ERR
Error in initialization
Values obtained during the initial‐ Carry out the device initialization
ization process cannot be used. process again. Check the rele‐
vant parameter settings.
-
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Operating Instructions, 02/2016, A5E00127926-AB
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byte
Bit
1
0
DIA_ZERO_ERR
The lower end stop is beyond the
Lower end stop beyond the toler‐ set tolerance.
ance
Name and meaning
Cause
1
DIA_SUPPLY
A run time overshoot was detec‐ Establish the compressed air sup‐
Error in the compressed air supply ted. In all probability, the energy ply and check the feed lines.
(compressed air) is not available.
2
Not used
-
-
3
DIA_WARMSTART
Warm restart executed (goes to
"0" after 10 s)
Power was fed to the device.
Check the cabling and the supply
unit.
SIMATIC PDM was used to trig‐
ger a warm restart.
Measure
Check the valve. Flow restrictors
and/or the seat ring are probably
worn out.
The internal watchdog has re‐
sponded.
4
DIA_COLDSTART
Restart executed
(goes to "0" after 10 s)
The device was reset to factory
settings.
-
5
DIA_MAINTENANCE
Maintenance required
To determine the cause, check in
DIAGNOSTICS_EXTENSION
and DIAGNOSTICS_EXTEN‐
SION_2 which diagnostics event
has triggered the message.
Depends on the triggering diag‐
nostics event.
6
DIA_CHARACT
Characteristic curve invalid
The parameterized characteristic
curve does not have the required
monotony, number of support
points, or the x values are not ar‐
ranged in 5% distances. The orig‐
inal characteristic curve is used
further.
Modify the configuration data
(change the GSD) such that it is
consistent with the identification
number set in the device.
7
IDENT_NUMBER_VIOLATION
Identification number changed
You have changed the PROFI‐
BUS identification number param‐
eter during the active cyclic oper‐
ation. The device reports the iden‐
tification number violation and dis‐
plays a failure warning. In case of
a warm restart, the device no lon‐
ger participates in the cyclic trans‐
fer of useful data without chang‐
ing the system configuration.
Modify the configuration data
(change the GSD) such that it is
consistent with the identification
number set in the device.
2
0 ... 7
Reserved
-
-
3
0 ... 6
Reserved
-
-
EXTENSION_AVAILABLE
Extension available
Further information about the trig‐ gering diagnostics event is avail‐
able in DIAGNOSTICS_EXTEN‐
SION and DIAGNOSTICS_EX‐
TENSION_2.
7
SIPART PS2 with PROFIBUS PA
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233
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
10.3.3.2
Diagnostics messages in case of activated condensed status
Thematic classification
Collective diagnosis messages of the DIAGNOSIS physical block parameter when the
condensed status is activated are given below. The Group column contains a thematic
classification of diagnostics messages. The same meaning is also used for status messages:
Maintenance:
M1
M12
M
MAINTENANCE REQUIRED
MAINTENANCE REQUIRED,
MAINTENANCE DEMAND
MAINTENANCE REQUIRED,
MAINTENANCE DEMAND,
MAINTENANCE ALARM
Process-dependent:
P
PROCESS RELATED
Function check:
F
FUNCTION CHECK
Collective diagnostics messages
Collective diagnostics messages in the case of the activated condensed status are shown in
the following table:
234
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Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byte
Bit
Name and meaning
Cause
Measures
Group
0
0
... 7
Reserved
-
-
-
1
0
... 2
Reserved
-
-
-
3
DIA_WARMSTART
Warm restart executed (goes to "0" after
10 s)
To determine the cause, check in
DIAGNOSIS_EXTENSION and
DIAGNOSIS_EXTENSION_2
which diagnosis event has trig‐
gered the message.
Check the wiring
and the supply volt‐
age.
4
DIA_COLDSTART
Restart executed
(goes to "0" after 10 s)
-
-
5
DIA_MAINTENANCE
Maintenance required
You have changed the PROFI‐
Depends on the
M1, M12,
BUS identification number pa‐
triggering diagnos‐ M
rameter during the active cyclic
tics event.
operation. The device reports the
identification number violation
and displays a failure warning. In
case of a restart, the device will
no longer participate in cyclic
user data exchange unless the
system configuration is changed.
6
Reserved
-
-
7
IDENT_NUMBER_VIOLATION
Identification number changed
To determine the cause, check in
DIAGNOSIS_EXTENSION and
DIAGNOSIS_EXTENSION_2
which diagnosis event has trig‐
gered the message.
Modify the configu‐ ration data
(change the GSD)
such that it is con‐
sistent with the
identification num‐
ber set in the de‐
vice.
0
DIA_MAINTENANCE_ALARM
Maintenance alarm
To determine the cause, check in
DIAGNOSIS_EXTENSION and
DIAGNOSIS_EXTENSION_2
which diagnosis event has trig‐
gered the message.
Depends on the
M
triggering diagnos‐
tics event.
1
DIA_MAINTENANCE_DEMANDED
Maintenance demand
To determine the cause, check in
DIAGNOSIS_EXTENSION and
DIAGNOSIS_EXTENSION_2
which diagnosis event has trig‐
gered the message.
Depends on the
M12, M
triggering diagnos‐
tics event.
2
DIA_FUNCTION_CHECK
Function check
The device is in on-site operation
or the FEEDBACK_VALUE is si‐
mulated
-
3
DIA_INV_PRO_COND
Invalid process conditions
To determine the cause, check in
DIAGNOSIS_EXTENSION and
DIAGNOSIS_EXTENSION_2
which diagnosis event has trig‐
gered the message.
Depends on the
P
triggering diagnos‐
tics event.
4
... 7
Reserved
-
-
2
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
-
-
F
-
235
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byte
Bit
3
Name and meaning
Cause
Measures
Group
0
... 6
Reserved
-
-
-
7
EXTENSION_AVAILABLE
Extension available
Further information about the trig‐ gering diagnosis event is availa‐
ble in DIAGNOSIS_EXTENSION
and DIAGNOSIS_EXTEN‐
SION_2.
-
10.3.3.3
Definition of the status
Status byte
The status is used to provide information about the quality of the input and output values. This
information is classified into four stages. Quality stages such as "Bad", "Uncertain", "Good"
and "Good (cascade)" are accompanied with further information. In this case, it deals with the
sub-status and the limit bits. The status byte has the following structure:
Status byte structure
7
6
5
4
Quality
3
2
1
Sub-status
0
Limit bits
Quality
00
01
10
11
Bad
Uncertain
Good
Good (cascade)
Limit bits
00
01
10
11
Good
Lower limit reached
Upper limit reached
Value is constant.
The meaning of the sub-status depends on whether the condensed status is activated or not.
The sub-status is therefore specified separately for both the cases.
10.3.3.4
Sub-status for deactivated condensed status
Bit
Name profile
German name
7
6
5
4
3
2
1
0
0
0
0
0
0
0
x
x
Bad, non specific
Schlecht
0
0
0
0
0
1
x
x
Bad, configuration error
Schlecht, Konfigurationsfehler
0
0
0
0
1
0
x
x
Bad, not connected
Schlecht, keine Verbindung
0
0
0
0
1
1
x
x
Bad, device failure
Schlecht, Gerätefehler
0
0
0
1
0
0
x
x
Bad, sensor failure
Schlecht, Sensorfehler
236
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Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Bit
Name profile
German name
7
6
5
4
3
2
1
0
0
0
0
1
1
1
x
x
Bad, out of service
Schlecht, Außer Betrieb
0
1
0
0
0
0
x
x
Uncertain, non specific
Unsicher
0
1
0
1
0
0
x
x
Uncertain, sensor conversion not accurate Unsicher, Wert ungenau
0
1
0
1
1
1
x
x
Uncertain, configuration error
Unsicher, Konfigurationsfehler
0
1
1
0
0
0
x
x
Uncertain, simulated value
Unsicher, Simulationswert
1
0
0
0
0
0
x
x
Good, ok
Gut, Ok
1
0
0
0
0
1
x
x
Good, update event
Gut, Aktiver Blockalarm
1
0
1
0
0
1
x
x
Good, maintenance required
Gut, Instandhaltungsbedarf
1
1
0
0
0
0
x
x
Good (Cascade), ok
Gut (Kaskade), Ok
1
1
0
0
0
1
x
x
Good (Cascade), initialisation acknowl‐
edged
Gut (Kaskade), Initialisierung bestätigt
1
1
0
0
1
0
x
x
Good (Cascade), initialisation request
Gut (Kaskade), Initialisierung angefordert
1
1
0
0
1
1
x
x
Good (Cascade), not invited
Gut (Kaskade), Nicht eingeladen
1
1
0
1
1
0
x
x
Good (Cascade), local override
Gut (Kaskade), Vor-Ort-Bedienung
1
1
1
0
0
0
x
x
Good (Cascade), initiate fail safe
Gut (Kaskade), Sicherheitsstellung anfah‐
ren
10.3.3.5
Sub-status for activated condensed status
Bits
Name
7
6
5
4
3
2
1
0
0
0
1
0
0
1
x
x
Bad, maintenance alarm
Schlecht, Instandhaltungsalarm
M
0
0
1
0
1
0
x
x
Bad, process related, no mainte‐
nance
Schlecht, Prozess-Störung, kein
Wartungsbedarf
P
0
0
1
1
1
1
x
x
Bad, function check /local override;
value not usable
Schlecht, Funktion überprüfen /
Handbetrieb
F
0
1
1
0
1
0
x
x
Uncertain, maintenance demand
Uncertain, maintenance demand
M
0
1
1
1
1
0
x
x
Uncertain, process related, no main‐ Unsicher, Prozess-Störung, kein
tenance
Wartungsbedarf
P
1
0
0
0
0
0
x
x
Good, ok
Gut, Ok
-
1
0
1
0
0
1
x
x
Good, maintenance required
Gut, Instandhaltungsbedarf
M1,
M12, M
1
0
1
0
1
0
x
x
Good, maintenance demand
Good, maintenance requirement
M12, M
1
0
1
1
1
1
x
x
Good, function check
Gut, Funktion überprüfen / Handbe‐
trieb
10.3.3.6
Profile
Group
German
F
List of diagnostics events with status and diagnostics message for deactivated
condensed status
A list of diagnostics events with status and diagnostics message for deactivated condensed
status is given in the following table. DIAGNOSTICS_EXTENSION and
DIAGNOSTICS_EXTENSION_2 are physical block parameters.
SIPART PS2 with PROFIBUS PA
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237
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
DIAGNOSTICS_EXTENSION physical block parameter
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
0
0
1
Run time error of the actuator
Bad, maintenance requirement DIA_SUPPLY
1
2
The device is not in the "Auto‐
matic mode"
Uncertain, simulation value
None
2
3
Binary 1 is active (only mes‐
sage)
Good, maintenance required
DIA_MAINTENANCE
3
4
Action triggered by binary input
1
Uncertain, simulation value
None
4
5
Binary 2 is active (only mes‐
sage)
Good, maintenance required
DIA_MAINTENANCE
5
6
Action triggered by binary input
2
Uncertain, simulation value
None
Reserved
-
-
7 ... 21
2
3
5
22
Limit for alarm A1 exceeded
Good, maintenance required
DIA_MAINTENANCE
6
23
Limit for alarm A2 exceeded
Good, maintenance required
DIA_MAINTENANCE
7
24
Error in the device electronic
unit
Bad, device error
DIA_MEM_CHKSUM
0
25
The device is not yet ready for
operation (not initialized)
Bad, configuration error
DIA_NOT_INIT
1
26
The device is not yet ready for
operation (initialization error)
Bad, configuration error
DIA_INIT_ERR
3
27
Reserved
-
-
3
28
Reserved
-
-
4
29
Device in the Manual mode (FB Depends on the set status
in the Manual mode)
5
30
Device in the Simulation mode
(FEEDBACK is simulated)
Depends on the simulated sta‐ None
tus
6
31
Device in the TRACE mode
-
None
7
32
Diagnostics simulation (diag‐
nostics events are simulated)
Depends on the simulated di‐
agnostics event
Depends on the simulated di‐
agnostics event
Reserved
-
-
33 ... 48
238
DIAGNOSTICS bit
None
SIPART PS2 with PROFIBUS PA
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Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
DIAGNOSTICS_EXTENSION_2 physical block parameter
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
0
1
2
DIAGNOSTICS bit
0
49
General control valve fault (lim‐ Good, maintenance required
it 1)
DIA_MAINTENANCE
1
50
General control valve fault (lim‐ Good, maintenance required
it 2)
DIA_MAINTENANCE
2
51
General control valve fault (lim‐ Good, maintenance required
it 3)
DIA_MAINTENANCE
3
52
Pneumatic leakage (limit 1)
Good, maintenance required
DIA_MAINTENANCE
4
53
Pneumatic leakage (limit 2)
Good, maintenance required
DIA_MAINTENANCE
5
54
Pneumatic leakage (limit 3)
Good, maintenance required
DIA_MAINTENANCE
6
55
Static friction (limit 1)
Good, maintenance required
DIA_MAINTENANCE
7
56
Static friction (limit 2)
Good, maintenance required
DIA_MAINTENANCE
0
57
Static friction (limit 3)
Good, maintenance required
DIA_MAINTENANCE
1
58
Lower end stop monitoring (lim‐ Good, maintenance required
it 1)
DIA_ZERO_ERR
2
59
Lower end stop monitoring (lim‐ Good, maintenance required
it 2)
DIA_ZERO_ERR
3
60
Lower end stop monitoring (lim‐ Good, maintenance required
it 3)
DIA_ZERO_ERR
4
61
Upper end stop monitoring (lim‐ Good, maintenance required
it 1)
DIA_ZERO_ERR
5
62
Upper end stop monitoring (lim‐ Good, maintenance required
it 2)
DIA_MAINTENANCE
6
63
Upper end stop monitoring (lim‐ Good, maintenance required
it 3)
DIA_MAINTENANCE
7
64
Limit 1 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
0
65
Limit 2 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
1
66
Limit 3 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
2
67
Limit 1 for changes of direction
exceeded
Good, maintenance required
DIA_MAINTENANCE
3
68
Limit 2 for changes of direction
exceeded
Good, maintenance required
DIA_MAINTENANCE
4
69
Limit 3 for changes of direction
exceeded
Good, maintenance required
DIA_MAINTENANCE
5
70
Limit 1 for position average ex‐ Good, maintenance required
ceeded
DIA_MAINTENANCE
6
71
Limit 2 for position average ex‐ Good, maintenance required
ceeded
DIA_MAINTENANCE
7
72
Limit 3 for position average ex‐ Good, maintenance required
ceeded
DIA_MAINTENANCE
SIPART PS2 with PROFIBUS PA
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239
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
3
0
73
PST reference time exceeded
(limit 1)
Good, maintenance required
DIA_MAINTENANCE
1
74
PST reference time exceeded
(limit 2)
Good, maintenance required
DIA_MAINTENANCE
2
75
PST reference time exceeded
(limit 3)
Good, maintenance required
DIA_MAINTENANCE
Reserved
-
-
76 ... 80
4
0
81
Permissible device tempera‐
ture exceeded (limit 1)
Good, maintenance required
DIA_TEMP_ELECTR
1
82
Permissible device tempera‐
ture exceeded (limit 2)
Good, maintenance required
DIA_TEMP_ELECTR
2
83
Permissible device tempera‐
ture exceeded (limit 3)
Good, maintenance required
DIA_TEMP_ELECTR
3
84
Permissible device tempera‐
ture undershot (limit 1)
Good, maintenance required
DIA_TEMP_ELECTR
4
85
Permissible device tempera‐
ture undershot (limit 2)
Good, maintenance required
DIA_TEMP_ELECTR
5
86
Permissible device tempera‐
ture undershot (limit 3)
Good, maintenance required
DIA_TEMP_ELECTR
6
87
Limit for dead zone monitoring
exceeded
Good, maintenance required
DIA_TEMP_ELECTR
Reserved
-
-
88 ... 96
10.3.3.7
DIAGNOSTICS bit
List of diagnostics events with status and diagnostics message for activated condensed
status
A list of diagnostics events with status and diagnostics message for activated condensed status
is given in the following table. DIAGNOSTICS_EXTENSION and
DIAGNOSTICS_EXTENSION_2 are physical block parameters.
Different status and diagnostics messages can be allocated to individual diagnostics events
as per the following tables. The frame in which an allocation is possible is defined by the group
in the selection column. The following principle is used: in case of three-stage diagnostics
events of the MAINTENANCE group, the effect of the higher lever events can be downgraded,
but that of the lower level events cannot be upgraded.
240
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Operating Instructions, 02/2016, A5E00127926-AB
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
DIAGNOSTICS_EXTENSION physical block parameter
Byt
e
Bit
No.
Diagnostics events
0
0
1
Run time error of the ac‐ Good, Ok
tuator
DIA_MAINTENANCE_ALARM
M
1
2
The device is not in the
"Automatic mode"
Good, check function /
manual mode
DIA_FUNCTION_CHECK
F
2
3
Binary 1 is active (only
message)
Good, Ok
DIA_MAINTENANCE_DEMAN‐
DED
M, F, P
3
4
Action triggered by bina‐ Good, Ok
ry input 1
DIA_FUNCTION_CHECK
M, F, P
4
5
Binary 2 is active (only
message)
DIA_MAINTENANCE_DEMAN‐
DED
M, F, P
5
6
Action triggered by bina‐ Good, Ok
ry input 2
DIA_FUNCTION_CHECK
M, F, P
Quality status code
7 ... 21 Reserved
2
3
Good, Ok
Group
DIAGNOSTICS bit
-
-
-
5
22
Limit for alarm A1 ex‐
ceeded
Good, maintenance re‐
quirement
DIA_MAINTENANCE
None, hard-co‐
ded
6
23
Limit for alarm A2 ex‐
ceeded
Good, maintenance re‐
quirement
DIA_MAINTENANCE
None, hard-co‐
ded
7
24
Error in the device elec‐ Bad, maintenance re‐
tronic unit
quirement
DIA_MAINTENANCE_ALARM
None, hard-co‐
ded
0
25
The device is not yet
ready for operation (not
initialized)
Bad, maintenance re‐
quirement
DIA_MAINTENANCE_ALARM
None, hard-co‐
ded
1
26
The device is not yet
Bad, maintenance re‐
ready for operation (initi‐ quirement
alization error)
DIA_MAINTENANCE_ALARM
None, hard-co‐
ded
3
27
Reserved
-
-
-
3
28
Reserved
-
-
-
4
29
Device in the Manual
mode (FB in the Manual
mode)
-
DIA_FUNCTION_CHECK
None, hard-co‐
ded
5
30
Device in the Simulation Depends on the simula‐ DIA_FUNCTION_CHECK
mode (FEEDBACK is si‐ ted status
mulated)
None, hard-co‐
ded
6
31
Device in the TRACE
mode
-
None, hard-co‐
ded
7
32
Diagnostics simulation
(diagnostics events are
simulated)
Depends on the simula‐ Depends on the simulated diag‐
ted diagnostics event
nostics event
-
Reserved
-
-
33 ...
48
1)
Effect of the event1)
DIA_FUNCTION_CHECK
-
Effects of the event can be set using the DIAG_EVENT_SWITCH or DIAG_EVENT_SWITCH_2 parameters (default
settings in this case)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
241
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
DIAGNOSTICS_EXTENSION_2 physical block parameter
Byt
e
Bit
0
0
49
General control valve
fault (limit 1)
Good, maintenance re‐
quirement
DIA_MAINTENANCE
M1
1
50
General control valve
fault (limit 2)
Good, maintenance re‐
quirement
DIA_MAINTENANCE_DEMAN‐
DED
M12
2
51
General control valve
fault (limit 3)
Uncertain, maintenance
demand
DIA_MAINTENANCE_ALARM
M
3
52
Pneumatic leakage (lim‐ Good, maintenance re‐
it 1)
quirement
DIA_MAINTENANCE
M1
4
53
Pneumatic leakage (lim‐ Good, maintenance de‐
it 2)
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
5
54
Pneumatic leakage (lim‐ Uncertain, maintenance
it 3)
demand
DIA_MAINTENANCE_ALARM
M
6
55
Static friction (limit 1)
Good, maintenance re‐
quirement
DIA_MAINTENANCE
M1
7
56
Static friction (limit 2)
Good, maintenance de‐
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
0
57
Static friction (limit 3)
Uncertain, maintenance
demand
DIA_MAINTENANCE_ALARM
M
1
58
Lower end stop monitor‐ Good, maintenance re‐
ing (limit 1)
quirement
DIA_MAINTENANCE
M1
2
59
Lower end stop monitor‐ Good, maintenance de‐
ing (limit 2)
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
3
60
Lower end stop monitor‐ Uncertain, maintenance
ing (limit 3)
demand
DIA_MAINTENANCE_ALARM
M
4
61
Upper end stop monitor‐ Good, maintenance re‐
ing (limit 1)
quirement
DIA_MAINTENANCE
M1
5
62
Upper end stop monitor‐ Good, maintenance de‐
ing (limit 2)
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
6
63
Upper end stop monitor‐ Uncertain, maintenance
ing (limit 3)
demand
DIA_MAINTENANCE_ALARM
M
7
64
Limit 1 for path integral
(100% strokes) excee‐
ded
DIA_MAINTENANCE
M1
1
242
No.
Diagnostics events
Effect of the event1)
Quality status code
Good, maintenance re‐
quirement
DIAGNOSTICS bit
Group
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byt
e
Bit
2
0
65
1
3
No.
Diagnostics events
Effect of the event1)
Quality status code
DIAGNOSTICS bit
Limit 2 for path integral
(100% strokes) excee‐
ded
Good, maintenance de‐
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
66
Limit 3 for path integral
(100% strokes) excee‐
ded
Uncertain, maintenance
demand
DIA_MAINTENANCE_ALARM
M
2
67
Limit 1 for changes in di‐ Good, maintenance re‐
rection exceeded
quirement
DIA_MAINTENANCE
M1
3
68
Limit 2 for changes of di‐ Good, maintenance de‐
rection exceeded
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
4
69
Limit 3 for changes of di‐ Uncertain, maintenance
rection exceeded
demand
DIA_MAINTENANCE_ALARM
M
5
70
Limit 1 for position aver‐ Good, maintenance re‐
age exceeded
quirement
DIA_MAINTENANCE
M1, P
6
71
Limit 2 for position aver‐ Good, maintenance de‐
age exceeded
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12, P
7
72
Limit 3 for position aver‐ Uncertain, maintenance
age exceeded
demand
DIA_MAINTENANCE_ALARM
M, P
0
73
PST reference time ex‐
ceeded (limit 1)
Good, maintenance re‐
quirement
DIA_MAINTENANCE
M1
1
74
PST reference time ex‐
ceeded (limit 2)
Good, maintenance de‐
mand
DIA_MAINTENANCE_DEMAN‐
DED
M12
2
75
PST reference time ex‐
ceeded (limit 3)
Uncertain, maintenance
demand
DIA_MAINTENANCE_ALARM
M
Reserved
-
-
-
76 ...
80
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Operating Instructions, 02/2016, A5E00127926-AB
Group
243
Functions/operations using PROFIBUS PA
10.3 Cyclic data transfer
Byt
e
Bit
No.
4
0
81
Permissible device tem‐ Uncertain, process
perature exceeded (lim‐ fault, no maintenance
it 1)
required
DIA_INV_PRO_COND
M1, P
1
82
Permissible device tem‐ Uncertain, process
perature exceeded (lim‐ fault, no maintenance
it 2)
required
DIA_INV_PRO_COND
M12, P
2
83
Permissible device tem‐ Uncertain, process
perature exceeded (lim‐ fault, no maintenance
it 3)
required
DIA_INV_PRO_COND
M, P
3
84
Permissible device tem‐ Uncertain, process
perature undershot (lim‐ fault, no maintenance
it 1)
required
DIA_INV_PRO_COND
M1, P
4
85
Permissible device tem‐ Uncertain, process
perature undershot (lim‐ fault, no maintenance
it 2)
required
DIA_INV_PRO_COND
M12, P
5
86
Permissible device tem‐ Uncertain, process
perature undershot (lim‐ fault, no maintenance
it 3)
required
DIA_INV_PRO_COND
M, P
6
87
Limit for dead zone mon‐ Uncertain, maintenance
itoring exceeded
demand
DIA_MAINTENANCE_ALARM
M
Reserved
-
-
244
Effect of the event1)
Quality status code
88 ...
96
1)
Diagnostics events
-
DIAGNOSTICS bit
Group
Effects of the event can be set using the DIAG_EVENT_SWITCH or DIAG_EVENT_SWITCH_2 parameters (default
settings in this case)
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
11
Alarm, fault and system messages
11.1
Output of system messages in the display
11.1.1
System messages during operation
Remarks about the tables:
nn
/
Stands for variable numeric values
Error symbol
(slash): the texts on the left and right of the slash flash alternately
Messages during operation
Message
Line
Up
CPU
Operating mode
Bot‐
tom
Automat‐ Manual
ic
mode
Meaning/cause
Measure
P man‐
ual mode
START
X
Message after application of elec‐ ● Wait.
trical auxiliary power.
HW / ER‐
ROR
X
Fault in the hardware.
● Replace electronics.
NOINI
X
Positioner is not initialized.
● Start initialization.
nnn.n
X
X
X
AUTnn
X
MANnn
X
oFL /
127.9
X
X
X
X
X
Actual position [in %] for initial‐
ized positioner. Flashing decimal
point shows communication with
a class 2 master.
Automatic mode (nn = setpoint)
X
Manual mode
(nn = setpoint)
● Switch to automatic
mode with mode
button.
X
Display range exceeded.
● Offset friction clutch
so that, when the
actuator moves, the
actual value display
stays between 0.0 and
100.0, or
Possible causes:
● Friction clutch or
● Transmission ratio selector
was moved or
● Positioner was installed on a
different actuator without
being re-initialized.
EXSTP
X
X
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
● transmission ratio
selector, or
● Perform factory
settings (Preset) and
initialization.
Actuator was stopped by the bi‐
nary input.
245
Alarm, fault and system messages
11.1 Output of system messages in the display
Message
Line
Up
Operating mode
Bot‐
tom
Automat‐ Manual
ic
mode
Meaning/cause
Measure
P man‐
ual mode
EX UP
X
X
Actuator is moved to the upper
endstop by the binary input.
EXDWN
X
X
Actuator is moved to the lower
endstop by the binary input.
EXPSt
The partial stroke test was activa‐
ted, e.g. by the binary input.
InPSt
Cyclic partial stroke test.
FST
X
X
Full stroke test running.
SRT
X
X
Step response test running.
MSRT
X
X
Multi-step response test running.
VPT
X
X
Valve performance test running.
LEAKR
X
X
A leakage test started by commu‐
nication is running.
11.1.2
System messages before initialization
Remarks about the tables:
nn
/
Stands for variable numeric values
Error symbol
(slash): the texts on the left and right of the slash flash alternately
Messages before initialization (first commissioning)
Message
Line
Up
CPU
Pnnn.n
Measure
Message after application of electrical auxili‐
ary power
● Maintenance
Down
X
Start
Meaning / cause
X
X
Potentiometer voltage of a non-initialized po‐ ● Check whether the complete travel can be
sitioner (P-manual mode) (actual position val‐
covered using the
and
buttons and
ue in % of the measuring range).
that "P---" is never displayed.
● Execute the initialization process.
P---
NOINI
246
X
X
Measuring range was exceeded, the potenti‐
ometer is in the inactive zone, the transmis‐
sion ratio selector or the effective lever arm
are not adjusted as per the actuator travel.
● Switch the transmission ratio selector to
90°, especially in the case of part-turn
actuators.
Positioner is not initialized.
● Start initialization.
● Adjust the effective lever length of linear
actuators as per the measuring range.
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Alarm, fault and system messages
11.1 Output of system messages in the display
See also
Display (Page 103)
11.1.3
System messages during initialization
Remarks about the tables:
nn
/
Stands for variable numeric values
Error symbol
(slash): the texts on the left and right of the slash flash alternately
Messages during initialization
Message
Line
Up
P---
Meaning/cause
Measure
Measuring range was exceeded, the potenti‐
ometer is in the inactive zone, the transmis‐
sion ratio selectors or the effective lever arm
are not adjusted as per the actuator travel
● Switch the transmission ratio selector to
90°, especially in the case of part-turn
actuators.
Down
X
● Adjust the effective lever length of linear
actuators as per the measuring range.
RUN1
X
Initialization was started, part 1 is active (the
direction of action is determined)
● Wait.
RUN2
X
Initialization part 2 is active (actuator travel
check and determination of endstops)
● Wait.
RUN3
X
Initialization part 3 is active (determination
and display of travel times)
● Wait.
RUN4
X
Initialization part 4 is active (determination of
the minimum controller increment length)
● Wait.
RUN5
X
Initialization part 5 is active (optimization of
the transient response)
● Wait until "FINSH" is displayed.
Initialization was completed successfully.
YEND1
X
The first end position can be approached only
in case of a manual initialization
1. Approach first end position using
key.
2. Acknowledge using
YEND2
X
The second end position can be approached
only in case of a manual initialization
key.
1. Approach second end position using
or
key.
2. Acknowledge using
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
or
key.
247
Alarm, fault and system messages
11.1 Output of system messages in the display
Message
Line
Up
RANGE
Meaning/cause
Measure
Down
X
The end position or the measuring span is be‐ ● Approach a different end position using
yond the permissible measuring range only in
or
key and acknowledge using
case of a manual initialization
key.
● Move the friction clutch until "ok" is
displayed, and then acknowledge with the
key.
● Terminate the initialization process using
the
key, switch to the P-manual mode,
and correct the actuator travel and the
position displacement sensor.
ok
x
The permissible measuring range of end po‐
sitions is achieved only in case of a manual
initialization
● Acknowledge with the operating mode
button; the remaining steps ("RUN1" to
"FINSH") execute automatically.
RUN1 /
ERROR
X
Error in "RUN1", no movement e.g. due to the
lack of compressed air
Possible causes:
● Insufficient supply of compressed air.
● Restrictor(s) blocked.
● Actuator does not move freely.
Measures:
1. Eliminate possible causes.
2. Restart initialization.
d___U
X
Bar graph display of the zero point is outside
the tolerance range
1. Set between "P 4.0" and "P 9.9" ( >0< )
using friction clutch.
2. Continue using
SEt
MIDDL
X
X
Friction clutch was moved; "P 50.0" not dis‐
played when the lever is horizontal
or
key.
1. In the case of linear actuators, use the
or
key to bring the lever
perpendicular to the spindle.
2. Briefly acknowledge using
(initialization is continued).
UP >
X
key
"UP" tolerance range was exceeded or the in‐ 1. Increase the effective lever length of the
active zone of the potentiometer was covered.
linear actuators or switch the transmission
ratio selector to 90°.
2. Briefly acknowledge using
key.
3. Restart initialization.
90_95
U-d>
X
X
Possible only in case of part-turn actuators:
actuator travel is not in the range between 90
and 95%
"Up-Down" measuring span was undershot
1. Use the
or
key to move it in the
range between 90 and 95%.
2. Briefly acknowledge using
key.
1. Decrease the effective lever length of the
linear actuators or switch the transmission
ratio selector to 33°.
2. Briefly acknowledge using
key.
3. Restart initialization.
248
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Alarm, fault and system messages
11.1 Output of system messages in the display
Message
Line
Up
U nn.n
Meaning/cause
Measure
Display of the "Up" travel time
● Wait until initialization continues in RUN4.
Down
X
D->U
X
● To change the travel time, interrupt the
initialization process using the
key.
● Activate the leakage test using the
D nn.n
X
Display of the "Down" travel time
U->d
X
● Wait until initialization continues in RUN4.
● To change the travel time, interrupt the
initialization process using the
key.
● Activate the leakage test using the
NOZZL
X
Actuator stops (the initialization process was
interrupted using the "-" button when the ac‐
tuation speed display was active)
X
LEAKG
nn.n
X
X
%/MIN
nn.n
X
X
FINISH
X
key.
1. The travel time can be changed by
adjusting the restrictor(s).
2. Redetermine the positioning speed using
the
key.
3. Continue using
TESt
key.
key.
Leakage test active (the "+" button was press‐ ● Wait for one minute.
ed when the actuation speed display was ac‐
tive)
Value and unit of the result after the leakage
test
● Rectify the leakage if the value is too large.
● Continue using
key.
Initialization completed successfully with the 1. Briefly acknowledge using
key.
display of actuator travel or the actuator angle 2. Leave configuration level by long pressing
of
key.
See also
System messages before initialization (Page 246)
11.1.4
System messages when exiting the Configuration mode
Remarks about the tables:
nn
/
Stands for variable numeric values
Error symbol
(slash): the texts on the left and right of the slash flash alternately
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
249
Alarm, fault and system messages
11.1 Output of system messages in the display
Messages when exiting the configuration mode:
Message
Line
Up
n.nn.nnnn
X
Error
SLnn
X
Operating mode
Bot‐
tom
Automatic
Manual mode
Meaning / cause
Measure
Software version
● Maintenance
P manual mode
X
Monotony interruption ● Correct the value
of the free character‐
istic on the setpoint
turning point n
X
11.1.5
System messages during operation
Remarks about the tables:
nn
/
Stands for variable numeric values
Error symbol
(slash): the texts on the left and right of the slash flash alternately
Messages during operation:
Message
Line
Meaning/cause
Measure
Message after application of
electrical auxiliary power.
● Wait.
X
HW / ER‐
ROR
X
Fault in the hardware.
● Replace electronics.
NOINI
X
Positioner is not initialized.
● Start initialization.
Top
CPU
START
nnn.n
Operating mode
Bot‐
tom
Automat‐ Manual
ic
P-man‐
ual
X
X
X
X
X
Actual position [in %] for initial‐
ized positioner. Flashing deci‐
mal point shows communication
with a class 2 master.
AUnn
X
X
Automatic mode (nn = setpoint)
FS -- --
X
X
Failsafe (the vent valve is
opened). Possible causes:
● No communication
connection to master.
● Correct the station
address.
● Target mode is at "MA".
● Set the target mode
with class-2 master to
● Master sends a wrong status.
"Automatic".
● Send the "0x80" status
(good).
250
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Alarm, fault and system messages
11.1 Output of system messages in the display
Message
Line
Top
FS nn
Operating mode
Bot‐
tom
X
Automat‐ Manual
ic
X
Meaning/cause
Measure
Controlled using the configured
failsafe position
See above
P-man‐
ual
(Cause: see above).
MM nn
X
X
Positioner is in "Manual" mode.
● Set the target mode
with class-2 master to
"Automatic".
● Send the "0x80" status
(good).
MAnn
X
LO nn
X
X
Manual mode
(nn = setpoint)
● Switch to automatic
mode using operating
mode button.
Positioner is in "Local override"
mode.
● Set the target mode
with class-2 master to
"Automatic".
● Send the "0x80" status
(good).
OS --
X
X
X
Positioner is in "Out of service"
mode.
● Set the target mode
with class-2 master to
"Automatic".
● Send the "0x80" status
(good).
oFL /
127.9
Display range exceeded.
Possible causes:
● Friction clutch or
● Transmission ratio selector
moved or
● Positioner was installed on a
different actuator without
being reinitialized
● Adjust friction clutch so
that when the actuator
moves, the actual
value display stays
between 0.0 and
100.0, or
● Adjust the
transmission ratio
selector or
● Perform factory
settings (preset) and
initialization
EXSTP
X
X
Actuator was stopped by the bi‐
nary input.
EX UP
X
X
Actuator is moved to the upper
endstop by the binary input.
EXDWN
X
X
Actuator is moved to the lower
endstop by the binary input.
EXPSt
The partial stroke test was acti‐
vated, e.g. by a binary input.
InPSt
Cyclic partial stroke test.
FST
X
X
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Full stroke test running.
251
Alarm, fault and system messages
11.2 Diagnostics
Message
Line
Top
Operating mode
Bot‐
tom
Automat‐ Manual
ic
Meaning/cause
Measure
P-man‐
ual
SRT
X
X
Step response test running.
MSRT
X
X
Multi-step response test running.
VPT
X
X
Valve performance test running.
LEAKR
X
X
A leakage test started by com‐
munication is running.
11.2
Diagnostics
11.2.1
Display of diagnostics values
Structure of the diagnostics display
The display in "Diagnostics" mode has a structure similar to that in "Configuration" mode:
● The upper line shows the value of the diagnostics variable.
● The lower line shows the number and the abbreviation of the displayed variable.
Some diagnostics value can be greater than 99999. In such a case, the display switches over
to the exponential view. Example: The value "1234567" is shown as "1.23E6".
General procedure
1. Press all three buttons at the same time for at least 2 seconds. You are now in the
diagnostics display.
2. Use the
3. Press the
button to select the next diagnostics value.
button for at least 2 seconds in order to exit the diagnostics display.
How to show the diagnostics values in reverse order
Press the
and
buttons simultaneously.
How to set values to zero
Specific values can be set to zero by pressing the
button for at least 5 seconds. The
diagnostics values which can be reset are listed in the table in section "Overview of diagnostics
values (Page 253)".
252
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
Alarm, fault and system messages
11.2 Diagnostics
11.2.2
Saving the diagnostics values
The diagnostic values are written into a non-volatile memory every 15 minutes so that, in the
event of a power failure, only the diagnostic values of the previous 15 minutes are lost. The
values in the resettable parameters can be set to zero.
To do this, press the
button for at least 5 seconds.
The diagnostic values which can be reset can be found in the table in section Overview of
diagnostics values (Page 253).
11.2.3
Overview of diagnostics values
Explanatory notes on the following table
● The "Representable diagnostics values" column shows the factory settings for the
diagnostics parameters in bold type.
● The "Properties" column shows the properties of the diagnostics parameters:
①
– ②
– ③
– ④
–
Diagnostics value can be read and reset.
Diagnostics value can be read but not reset.
Diagnostics value can be read but not reset. A function can be executed.
Diagnostics value can be read, manually reset, and manually changed.
Overview of diagnostics values
No.
Abbreviation
Meaning
Representable di‐ Unit
agnostics values
Properties
1
STRKS
Number of total strokes
0 ... 4.29E9
2
CHDIR
3
CNT
4
5
9
TUP
Travel time UP
0.0 / 0 ... 1000
s
10
TDOWN
Travel time DOWN
0.0 / 0 ... 1000
s
11
LEAK
Leakage test
- / 0.0 ... 100.0
%/minute
12
PST
Monitoring of the partial stroke test
OFF / ###.#, FdI‐
nI, notSt, SdtSt,
fdtSt, notoL, Strt,
StoP
s for ###.#
①
①
①
①
①
②
①
②
②
②
③
③
13
PRPST
Time since the last partial stroke test
###, notSt, Sdtst,
fdtSt
Days
②
14
NXPST
Time until the next partial stroke test
OFF / ###
Days
②
-
Number of changes in direction
0 ... 4.29E9
-
Number of fault messages
0 ... 4.29E9
-
A1CNT
Number of alarms 1
0 ... 4.29E9
-
A2CNT
Number of alarms 2
0 ... 4.29E9
Hours
6
HOURS
Number of operating hours
0 ... 4.29E9
7
HOURR
Resettable operating hours counter
0 ... 4.29E9
8
WAY
Determined actuator travel
0 ... 130
SIPART PS2 with PROFIBUS PA
Operating Instructions, 02/2016, A5E00127926-AB
mm or °
253
Alarm, fault and system messages
11.2 Diagnostics
No.
Abbreviation
Meaning
Representable di‐ Unit
agnostics values
Properties
15
DEVI
Dynamic control valve behavior
OFF / 0.0 ... 100.0 %
②
②
②
②
②
②
16
ONLK
Pneumatic leakage
OFF / 0.0 ... 100.0 -
17
STIC
Stiction (slipstick)
OFF / 0.0 ... 100.0 %
18
ZERO
Lower endstop
OFF / 0.0 .. 100.0
%
19
OPEN
Upper endstop
OFF / 0.0 ... 100.0 %
20
PAVG
Average value of position
OFF, IdLE, rEF,
COMP
%
0.0 ... 100.0
21
P0
Potentiometer value of lower endstop (0%)
0.0 ... 100.0
%
22
P100
Potentiometer value of upper endstop (100%)
0.0 ... 100.0
%
23
IMPUP
Impulse length up
6 ... 160
ms
24
IMPDN
Impulse length down
6 ... 160
ms
25
PAUTP
Pulse interval
2 ... 28 ... 320
ms
26
DBUP
Deadband up
0.1 ... 10.0
%
27
DBDN
Deadband down
0.1 ... 10.0
%
28
SSUP
Slow step zone up
0.1 ... 10.0 ...
100.0
%
③
③
④
④
④
②
②
④
29
SSDN
Slow step zone down
0.1 ... 10.0 ...
100.0
%
④
30
TEMP
Current temperature
-50 ... 100
-58 ... 212
°C
°F
②
31
TMIN
Minimum temperature (min/max pointer)
-50 ... 100
-58 ... 212
°C
°F
32
TMAX
Maximum temperature (min/max pointer)
-50 ... 100
-58 ... 212
°C
°F
33
T1
Number of operating hours in temperature range 1
0 ... 4.29E9
Hours
34
T2
Number of operating hours in temperature range 2
0 ... 4.29E9
Hours
35
T3
Number of operating hours in temperature range 3
0 ... 4.29E9
Hours
36
T4
Number of operating hours in temperature range 4
0 ... 4.29E9
Hours
37
T5
Number of operating hours in temperature range 5
0 ... 4.29E9
Hours
38
T6
Number of operating hours in temperature range 6
0 ... 4.29E9
Hours
39
T7
Number of operating hours in temperature range 7
0 ... 4.29E9
Hours
40
T8
Number of operating hours in temperature range 8
0 ... 4.29E9
Hours
41
T9
Number of operating hours in temperature range 9
0 ... 4.29E9
Hours
42
VENT1
Number of switching cycles of pilot valve 1
0 ... 4.29E9
-
43
VENT2
Number of switching cycles of pilot valve 2
0 ... 4.29E9
-
44
VEN1R
Number of switching cycles of pilot valve 1, resettable 0 ... 4.29E9
-
45
VEN2R
Number of switching cycles of pilot valve 2, resettable 0 ... 4.29E9
-
46
STORE
Save the current values as 'last maintenance' (press
key for 5 seconds)
-
-
47
PRUP
Prediction up
1 ... 40
-
48
PRDN
Prediction down
1 ... 40
-
49
WT00
Number of operating hours in the travel range WT00
0 ... 4.29E9
Hours
254
②
②
②
②
②
②
②
②
②
②
②
②
②
①
①
③
④
④
①
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Alarm, fault and system messages
11.2 Diagnostics
No.
Abbreviation
Meaning
Representable di‐ Unit
agnostics values
Properties
50
WT05
Number of operating hours in the travel range WT05
0 ... 4.29E9
Hours
51
WT10
Number of operating hours in the travel range WT10
0 ... 4.29E9
Hours
52
WT30
Number of operating hours in the travel range WT30
0 ... 4.29E9
Hours
53
WT50
Number of operating hours in the travel range WT50
0 ... 4.29E9
Hours
①
①
①
①
①
①
①
54
WT70
Number of operating hours in the travel range WT70
0 ... 4.29E9
Hours
55
WT90
Number of operating hours in the travel range WT90
0 ... 4.29E9
Hours
56
WT95
Number of operating hours in the travel range WT95
0 ... 4.29E9
Hours
11.2.4
Meaning of the diagnostic values
11.2.4.1
Diagnostic value '1.STRKS - Number of total strokes'
Display range:
Purpose:
11.2.4.2
Diagnostic value '2.CHDIR - Number of changes in direction'
Display range:
Purpose:
11.2.4.3
0 ... 4.29E9
Every change in direction of the actuator is noted in the controller
and added to the number of changes in direction.
Diagnostic value '3.\\CNT - Number of fault messages'
Display range:
Purpose:
11.2.4.4
0 ... 4.29E9
In operation, the movements of the actuator are summed up and
displayed in this diagnostics parameter as the number of strokes.
Unit: 100% strokes, i.e. the path between 0 and 100% and back.
0 ... 4.29E9
Every fault is noted in the closed-loop controller with '3. CNT' and
added to the number of fault messages.
Diagnostic value '4.A1CNT - Number of alarms 1' / '5.A2CNT - Number of alarms 2'
Requirement:
Display range:
Purpose:
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'41.AFCT' Alarm function (Page 164) parameter is activated.
0 ... 4.29E9
This value indicates how often the alarm has been triggered.
255
Alarm, fault and system messages
11.2 Diagnostics
11.2.4.5
Diagnostic value '6.HOURS - Number of operating hours'
Display range:
Purpose:
11.2.4.6
Diagnostic value '7.HOURR - Resettable operating hours counter'
Display range:
Purpose:
Description:
11.2.4.7
The travel is set in the '3.YWAY' Range of stroke (Page 156) pa‐
rameter.
0 ... 130
This value in mm or ° specifies the travel determined during the
initialization.
Diagnostic value '9.TUP - Travel time UP' / '10.TDOWN - Travel time DOWN'
Display range:
Purpose:
256
0 ... 4.29E9
The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner. In contrast to Diagnostic
value '6.HOURS - Number of operating hours' (Page 256), this value
can be reset.
In order to minimize the control valve wear resulting from a poor
control quality, it makes sense to optimize the positioner's parame‐
ters. You can recognize optimum parameter settings when the val‐
ues of the Diagnostic value '44.VEN1R' / '45.VEN2R' (Page 265)
are low. Low values mean that the switching frequency of the posi‐
tioner pneumatics is also low. In order to carry out a comparison
with various parameter settings, determine the number of switching
cycles per hour. To do this, use the values of the Diagnostic value
'44.VEN1R' / '45.VEN2R' (Page 265) and '7.HOURR'. These three
parameters can be reset to enable simpler determination of the val‐
ues.
Diagnostic value '8.WAY - Determined travel'
Requirement for
linear actuator:
Display range:
Purpose:
11.2.4.8
0 ... 4.29E9
The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner.
0 ... 1000
This value indicates the current UP or DOWN travel time in seconds
determined during the initialization.
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11.2 Diagnostics
11.2.4.9
Diagnostic value '11.LEAK - Leakage test'
Requirement
Display range:
Purpose:
Description:
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The positioner is initialized and in manual mode (MAN).
● ● 0.0 ... 100.0
You can use this diagnostics parameter to read the last test result
or start an offline leakage test with which you can detect leakages
in the actuator or in the pipe installation. Display is percent stroke
per minute referred to the total stroke. A test result originates from
one of the following options:
● Function '11.LEAK' has already been carried out.
● Leakage test was already carried out during initialization, see
procedure of RUN3 in section Sequence of automatic
initialization (Page 116).
● 'Offline leakage test' function was already executed by a HOST
system.
"-" in the display can have the following causes:
● A leakage test has not yet been carried out.
● Resetting to the factory settings was carried out using the
''48.PRST' Preset (Page 168) > ALL' parameter.
● Positioner is not initialized.
How to start the test
1. Move the actuator to the position at which you wish to start the
test. Recommendation: Set value to approx. 50. The actuator is
in the center position.
2. In 'Diagnostics' mode, go to the '11.LEAK' diagnostic value as
described in section Display of diagnostics values (Page 252).
3. Start the function by pressing the
button for at least 5 seconds.
'Strt' is output in the display. The function is started after 5 seconds.
'tESt' and the current position of the actuator (actual value) are then
displayed alternately for one minute.
After one minute, the display shows the difference in the actuator
position before and after the test. This means: the actuator position
has changed by the displayed value in one minute.
257
Alarm, fault and system messages
11.2 Diagnostics
11.2.4.10
Diagnostic value '12.PST - Monitoring of partial stroke test'
Indication on the display: ● OFF
● C-ERR
● FdInI
● notSt
● ###.#
● SdtSt
● FdtSt
Purpose:
This diagnostics parameter indicates the stroke time measured dur‐
ing the last partial stroke test.
A partial stroke test can be initiated manually or a current partial
stroke test can be interrupted by pressing the
button.
Description of indications ● OFF: The partial stroke test function is deactivated.
on the display:
● C-ERR: Configuration error. Partial stroke test cannot be started.
Settings in the 'A1.STPOS starting position', 'A3.STRKH stroke
height' and 'A4.STRKD direction of stroke' parameters are not
plausible.
● FdInI - Failed PST Initialization: The reference stroke time
measurement of the partial stroke test has failed.
● notSt - No Test: A manual partial stroke test has not yet been
executed.
● ###.#: Corresponds to the measured stroke time in seconds. The
last partial stroke test was successfully executed.
● SdtSt - Stopped Test: The last partial stroke test was interrupted.
● FdtSt - Failed Test: The last partial stroke test has failed.
Status messages:
The following status messages appear when you hold the
button
pressed:
● notoL - No Tolerance: The control valve is beyond the tolerance
range to start the partial stroke test. A manual partial stroke test
is not started.
● Strt - Start: A manual partial stroke test is started five seconds
after pressing the button.
● StoP - Stop: The current partial stroke test is interrupted. 'WAIT'
is output in the display.
Factory setting:
OFF
258
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11.2 Diagnostics
11.2.4.11
Diagnostic value '13.PRPST' - Time since last partial stroke test'
Indication on the display: ● ###
● notSt
● Sdtst
● FdtSt
Purpose:
This diagnostics parameter shows the elapsed time in days since
the last partial stroke test.
Status messages:
● notSt - No Test: A manual partial stroke test has not yet been
executed.
● SdtSt - Stopped Test: The last partial stroke test was interrupted.
● FdtSt - Failed Test: The last partial stroke test has failed.
11.2.4.12
Diagnostic value '14.NXPST - Time until next partial stroke test'
Requirement:
● The partial stroke test is activated in 'Configuration' mode.
● The test interval is set in the 'A8.INTRV' parameter.
Indication on the display: ● OFF
● ###
Purpose:
This diagnostics parameter shows the time in days until the next
partial stroke test. If one of the above-mentioned conditions is not
met, 'OFF' is shown on the display.
11.2.4.13
Diagnostic value '15.DEVI - General control valve fault'
Requirement:
Display range:
Purpose:
11.2.4.14
'50.XDIAG' Activation of extended diagnostics (Page 170) parameter
is activated.
● OFF
● 0.0 ... 100.0
This value in percent provides information about the current dynam‐
ically determined deviation from the model response. If the underly‐
ing function is deactivated, 'OFF' is displayed.
Diagnostic value '16.ONLK - Pneumatic leakage'
Requirement:
Display range:
Purpose:
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Monitoring pneumatic leakage 'C.\\LEAK' (Page 181) parameter is
activated.
● OFF
● 0 ... 100
This diagnostics parameter shows the current leakage indicator. If
the leakage detection is deactivated, 'OFF' is displayed.
259
Alarm, fault and system messages
11.2 Diagnostics
11.2.4.15
Diagnostic value '17.STIC - Stiction (slipstick)'
Requirement:
Display range:
Purpose:
11.2.4.16
Diagnostic value '18.ZERO - Lower endstop'
Requirement:
Display range:
Purpose:
11.2.4.17
'50.XDIAG' Activation of extended diagnostics (Page 170) parame‐
ter is activated.
'36.YCLS' Tight closing with manipulated variable (Page 162) pa‐
rameter is set to 'do' or 'uP do'.
● OFF
● 0.0 ... 100.0
Indication of how many percent the lower endstop has changed
compared to its value during initialization. If the underlying function
is deactivated, 'OFF' is displayed.
Diagnostic value '19.OPEN - Upper endstop'
Requirement:
Display range:
Purpose:
260
Monitoring the stiction (slipstick) 'd.\\STIC' (Page 183) parameter is
activated.
● OFF
● 0.0 ... 100.0
This diagnostics parameter shows the filtered value of the slip jumps
in percent resulting from the stiction.
'50.XDIAG' Activation of extended diagnostics (Page 170) parame‐
ter is activated.
'36.YCLS' Tight closing with manipulated variable (Page 162) pa‐
rameter is set to 'uP' or 'uP do'.
● OFF
● 0.0 ... 100.0
An indication of the current shift of the upper endstop compared to
its initialization value. If the underlying function is deactivated, 'OFF'
is displayed.
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11.2 Diagnostics
11.2.4.18
Diagnostic value '20.PAVG - Average value of position'
Indication on the display: ● OFF
● IdLE
● rEF
● COMP
Purpose:
This value shows the last calculated comparison average. Meaning
of the displays:
● OFF: The underlying function is deactivated in the configuration
menu.
● IdLE : Inactive. The function has not been started yet.
● rEF: The reference average is calculated. The function was
started, and the reference interval is in progress at the moment.
● COMP: The comparison average is calculated. The function was
started, and the comparison interval is in progress at the moment.
11.2.4.19
Diagnostic value '21.P0 - Potentiometer value of lower endstop (0%)' / '22.P100 Potentiometer value of upper endstop (100%)'
Display range:
Requirement 1 read values
Purpose 1
Requirement 2 change values
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● NO
● 0.0 ... 100.0
'NO': Changing the low or upper endstop is not possible in the current
state of the control valve. Initialize the positioner again.
The positioner is initialized.
Read values
You can use the P0 and P100 parameters to read the values for the
lower endstop (0%) and the upper endstop (100%) of the position
measurement as determined during the automatic initialization. The
values of manually approached end positions are applicable for man‐
ual initialization.
● The positioner is initialized and in manual mode (MAN) or
automatic mode (AUT).
● The current position of the actuator is within the range -10 to
+10% of the lower endstop (P0).
● The current position of the actuator is within the range 90 to 110%
of the upper endstop (P100).
261
Alarm, fault and system messages
11.2 Diagnostics
Purpose 2:
Description:
Change values
You can use these two parameters to change the lower endstop (P0)
and the upper endstop (P100).
Since initialization is not usually carried out under process condi‐
tions, the values for the lower endstop (P0) and the upper endstop
(P100) may change when the process is started. These changes
may result from temperature changes with the associated thermal
expansion of the material. If the Monitoring the lower endstop ''F.\
\ZERO' (Page 186) and Monitoring the upper endstop 'G.\\OPEN'
(Page 187) parameters are active, the thresholds set in these two
parameters can be exceeded as a result of thermal expansion. An
error message is output in the display.
The process-dependent thermal expansion may represent the nor‐
mal state in your application. You do not wish to receive an error
message as a result of this thermal expansion. Therefore reset the
'P0' and/or 'P100' parameters after the process-dependent thermal
expansion has had its complete effect on the control valve. The pro‐
cedure is described in the following.
Procedure for manual mode (MAN)
1. Move the actuator to the desired position of the lower endstop
(upper endstop) using the
and
keys.
2. Switch to diagnostics mode.
3. Go to diagnostic value 21.P0 (22.P100).
4. Apply the setting by pressing the
button for at least 5 seconds.
After 5 seconds, '0.0' (with 22.P100: '100.0') is displayed. Result:
The lower endstop (upper endstop) now corresponds to the
current position of the actuator.
5. Switch to manual mode (MAN). Result: Values for the upper
endstop (lower endstop) have changed.
Procedure for automatic mode (AUT)
1. Check in the display whether the current position of the actuator
is at the desired position of the lower endstop (upper endstop).
2. Switch to diagnostics mode.
3. Go to diagnostic value 21.P0 (22.P100).
button for at least 5 seconds.
4. Apply the setting by pressing the
After 5 seconds, '0.0' (with 22.P100: '100.0') is displayed. Result:
The lower endstop (upper endstop) now corresponds to the
current position of the actuator.
5. Switch to automatic mode (AUT).
See also
Changing the operating mode (Page 107)
262
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11.2 Diagnostics
11.2.4.20
Diagnostic value '23.IMPUP - Impulse length UP' / '24.IMPDN - Impulse length DOWN'
Display range:
Purpose:
Factory setting:
11.2.4.21
Diagnostic value '25.PAUTP - Pulse interval'
Display range:
Purpose:
Factory setting:
11.2.4.22
2 ... 320
This value is not changed during an initialization process. Display
in ms.
For applications with high stiction (slipstick), adjusting this parame‐
ter improves the control quality.
This parameter can be set for special applications.
28
Diagnostic value '26.DBUP - Deadband UP' / '27.DBDN - Deadband DOWN'
Display range:
Purpose 1
11.2.4.23
6 ... 160
The smallest impulse lengths that can be used to move the actuator
are determined during the initialization process. They are separately
determined for the 'Up' and 'Down' directions and displayed here.
Display in ms.
In the case of special applications you can additionally set the small‐
est impulse lengths in these two parameters.
6
0.1 ... 10.0
In this parameter, you can read the deadbands of the controller in
the 'Up' and 'Down' directions. Display in percent. The values corre‐
spond either to the manually configured value of the '31.DEBA'
Deadband of controller (Page 160) parameter or to the value auto‐
matically adapted by the device if 'DEBA' was set to 'Auto'.
Diagnostic value '28.SSUP - Slow step zone UP' / '29.SSDN - Slow step zone DOWN'
Display range:
Purpose:
Factory setting:
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0.1 ... 100.0
The slow step zone is the zone of the closed-loop controller in which
control signals are issued in a pulsed manner. Display is in percent.
The impulse length is thus proportional to the control deviation. If
the control deviation is beyond the slow step zone, the valves are
controlled using permanent contact.
This parameter can be set for special applications.
10.0
263
Alarm, fault and system messages
11.2 Diagnostics
11.2.4.24
Diagnostic value '30.TEMP - Current temperature'
Display range:
°C: -50 ... 100
°F: -58 ... 212
Current temperature in the positioner enclosure. The sensor is
present on the basic electronics. In order to switch over the temper‐
ature display between °C and °F, press the
button.
Purpose:
11.2.4.25
Diagnostic value '31.TMIN - Minimum temperature' / '32.TMAX - Maximum temperature'
Display range:
°C: -50 ... 100
°F: -58 ... 212
The minimum and maximum temperatures within the enclosure are
constantly determined and saved as with a slave pointer. This value
can only be reset in the factory.
In order to switch over the temperature display between °C and °F,
press the
button.
Purpose:
11.2.4.26
Diagnostic value '33.T1' ... '41.T9' - Number of operating hours in the temperature range
1 to 9
Display range:
Purpose:
Temperature range [°C]
0 ... 4.29E9
Statistics about the duration of operation in different temperature
ranges is maintained in the device. An average of the measured
temperature is taken every hour and the counter assigned to the
corresponding temperature range is incremented. This helps in
drawing conclusions about the past operating conditions of the de‐
vice and the entire control valve.
The temperature ranges are classified as follows:
T1
T2
T3
T4
T5
T6
T7
T8
T9
-
≥ -30
≥ -15
≥0
≥ 15
≥ 30
≥ 45
≥ 60
≥ 75
≤ -30
< -15
<0
< 15
< 30
< 45
< 60
< 75
-
Operating hours in temperature ranges T1 to T2
11.2.4.27
Diagnostic value '42.VENT1' / '43.VENT2'
'42.VENT1' Number of switching cycles of pilot valve 1
'43.VENT2' Number of switching cycles of pilot valve 2
Display range:
0 ... 4.29E9
264
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Alarm, fault and system messages
11.2 Diagnostics
Purpose:
Description:
11.2.4.28
Control procedures of the pilot valves in the pneumatic block of the
positioner are counted and displayed in this parameter.
The pneumatic block of the positioner pressurizes and depressurizes
the actuator. The pneumatic block contains two pilot valves. The char‐
acteristic service life of the pneumatic block depends on the load. This
amounts on average to approx. 200 million switching cycles for each of
the two pilot valves with symmetrical load. The number of control pro‐
cedures for the switching cycles serves to assess the switching fre‐
quency of the pneumatic block.
Counting procedure for single-acting actuators:
● Pressurize => 42.VENT1
● Depressurize => 43.VENT2
Counting procedure for double-acting actuators:
● Pressurize (Y2) / Depressurize (Y1) => 42.VENT1
● Depressurize (Y1) / Pressurize (Y2) => 43.VENT2
The value is written hourly into a nonvolatile memory.
Diagnostic value '44.VEN1R' / '45.VEN2R'
'44.VEN1R' Number of switching cycles of pilot valve 1, resettable
'45.VEN2R' Number of switching cycles of pilot valve 2, resettable
Display range:
0 ... 4.29E9
Purpose:
Control procedures of the pilot valves in the pneumatic block of the
positioner are counted since the last time this parameter was reset, and
displayed here.
Description:
Corresponds to the description for Diagnostic value '42.VENT1' /
'43.VENT2' (Page 264) referred to the diagnostics parameters 'VEN1R'
and 'VEN2R' described here.
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11.2 Diagnostics
11.2.4.29
Diagnostic value '46.STORE - Save maintenance data'
Purpose:
11.2.4.30
Diagnostic value '47.PRUP - Prediction UP' / '48.PRDN - Prediction DOWN'
Display range:
Purpose:
Factory setting:
11.2.4.31
1 ... 40
This value specifies the prediction of the controller for the up (PRUP)
and down (PRDN) movements.
For more information, refer also to the section Optimization of con‐
troller data (Page 110).
1
Diagnostic value '49.WT00' ... '56.WT95' - Number of operating hours in the travel range
WT00 to WT95
Display range:
Purpose:
266
The minimum and maximum temperatures within the enclosure are
constantly determined and saved as with a slave pointer. This value
can only be reset in the factory. In order to switch over the temper‐
ature display between °C and °F, press the
key for at least 5
seconds in order to initiate a save function. The values of the diag‐
nostics parameters Diagnostic value '8.WAY - Determined travel'
(Page 256) to Diagnostic value '11.LEAK - Leakage test'
(Page 257) and Diagnostic value '21.P0 - Potentiometer value of
lower endstop (0%)' / '22.P100 - Potentiometer value of upper end‐
stop (100%)' (Page 261) to Diagnostic value '28.SSUP - Slow step
zone UP' / '29.SSDN - Slow step zone DOWN' (Page 263) are saved
in the non-volatile memory as 'data of last maintenance'. This diag‐
nostics data contains selected values whose changes can give in‐
formation about mechanical wear and tear of the valve.
This function is normally operated through the PDM, menu com‐
mand 'Diagnostics-> Save maintenance information'. The data of
the last maintenance operation can be compared with the current
data using SIMATIC PDM.
0 ... 4.29E9
When the positioner is in "Automatic" mode, statistics are continu‐
ously maintained regarding the duration for which a valve or a flap
is operated in a particular section of the travel range. The entire
travel range is divided into 8 sections from 0 to 100 %. The positioner
records the current position continuously and increments the run‐
time meter assigned to the corresponding travel range every hour.
This helps in drawing conclusions about the past operating condi‐
tions and especially in assessing the control properties of the control
loop and the entire control valve.
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Alarm, fault and system messages
11.3 Online diagnostics
Travel range
WT00
WT05
WT10
WT30
WT50
WT70
WT90
WT95
Travel range section [%]
-
≥5
≥ 10
≥ 30
≥ 50
≥ 70
≥ 90
≥ 95
<5
< 10
< 30
< 50
< 70
< 90
< 95
-
Division of travel ranges
You can simultaneously set the eight operating hours counters to
zero.
TIP: Since the travel ranges are provided at the end of the diagnos‐
tics parameters, press the
key several times along with the
key. This will help you to access the desired diagnostics parameters
faster.
11.3
Online diagnostics
11.3.1
Overview of online diagnostics
Online diagnostics means diagnostics during ongoing operation. A few important variables
and parameters are continuously monitored during the operation of the positioner. In
"Configuration" mode, you can configure this monitoring in such a way that the fault message
output will be activated if, for instance, a limit is exceeded.
Information about what events can activate the fault message output can be found in the table
in chapter "Overview of error codes (Page 268)".
This chapter contains information about the following situations in particular:
● Possible causes of the fault message.
● Events which activate the fault message output or alarm outputs.
● Setting of parameters needed for event monitoring.
● Canceling a fault message
When the fault message output is triggered in automatic or manual mode, the display shows
which fault triggered the message. Both digits at bottom-left indicate the corresponding error
code. If multiple triggers occur at the same time, they are displayed one after the other cyclically.
See also
Extended diagnostics parameters A to P (Page 173)
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11.3 Online diagnostics
11.3.2
Overview of error codes
Overview of error codes that activate the fault message output
Error
code
Threestage
Event
1
No
2
3
Parameter setting
Error message disappears
when
Possible causes
Control deviation: Always active
Actual value re‐
sponse has excee‐
ded values for TIM
and LIM
... the actual value response
falls below the value for LIM
Compressed air failure, actua‐
tor fault, valve fault (e.g. block‐
ade).
No
Device not in "Au‐
tomatic" mode
**. FCT1)
... the device is changed to
"Automatic" mode.
The device has been config‐
ured or is in the manual mode
No
Binary input BIN1
or BIN2 active
**. FCT1)
... the binary input is no longer
activated.
The contact connected to the
binary input was active (e.g.
packing gland monitoring,
overpressure, temperature
switch).
The total path covered by the
actuator exceeds one of the
configured thresholds.
= nA or = nAB
= nAB and binary
function BIN1 or
BIN2 to "On"
4
Yes
Limit for number of
total strokes ex‐
ceeded
L. STRK≠OFF
... the stroke counter is reset
or the thresholds are in‐
creased
5
Yes
Limit for number of
changes in direc‐
tion exceeded
O. DCHG≠OFF
... the counter for changes of The number of changes of di‐
direction is reset or the thresh‐ rection exceeds one of the
olds are increased.
configured thresholds.
6
Yes
Lower endstop lim‐ F. ZERO≠OFF
it exceeded
**.YCLS = do or up
do
... the deviation of the endstop Wear and tear of the valve
disappears or the device is re- seat, deposits or foreign bod‐
initialized.
ies in the valve seat, mechan‐
ical misalignment, friction
clutch moved.
7
Yes
Upper endstop lim‐ G. OPEN≠OFF
it exceeded
**.YCLS1) = do or
up do
... the deviation of the endstop Wear and tear of the valve
disappears or the device is re- seat, deposits or foreign bod‐
initialized.
ies in the valve seat, mechan‐
ical misalignment, friction
clutch moved.
8
No
Deadband limit ex‐ E. DEBA≠OFF
ceeded
**.DEBA1) = Auto
... the limit is undershot again
9
Yes
Case 1: Reference A. PST≠OFF
stroke time for par‐
tial stroke test is ex‐
ceeded.
Case 1: ... a partial stroke test Case 1: Valve is stuck or rus‐
is successfully executed with‐ ted. Increased stiction.
in the reference stroke time or
the function is deactivated.
Case 2: Start posi‐
tion outside the
start tolerance
Case 2: Move the actuator into Case 2: Valve is present in the
the range of the PST start tol‐ safety position.
erance. Or increase the PST
start tolerance until the actua‐
tor (PST start position) is with‐
in the PST start tolerance.
Start the partial stroke test
again.
268
Increased packing gland fric‐
tion, mechanical gap in the po‐
sition feedback.
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11.3 Online diagnostics
Error
code
Threestage
Event
Parameter setting
Error message disappears
when
Possible causes
10
Yes
Deviation from ex‐
pected dynamic
control valve be‐
havior
b. DEVI≠OFF
... the position is again in a
narrow corridor between the
setpoint and the model, or the
function is deactivated.
Actuator fault, valve fault,
valve jams, increased stiction,
decreased compressed air
11
Yes
Pneumatic leak‐
C. LEAK≠OFF
age limit exceeded
... the leakage drops below the Pneumatic leakage
configured thresholds, or the
function is deactivated.
12
Yes
Stiction limit (slip‐
stick) exceeded
d. STIC≠OFF
... Slipjumps can no longer be Increased stiction, valve no
detected, or the function is de‐ longer moves smoothly but in
activated.
jerky motion.
13
Yes
Temperature un‐
dershot
H. TMIN≠OFF
... the low temperature thresh‐ Ambient temperature too low
olds are no longer undershot.
14
Yes
Temperature over‐ J. TMAX≠OFF
shot
... the high thresholds are no
longer overshot.
Ambient temperature too high
15
Yes
Position average
deviates from the
reference value
P. PAVG≠OFF
... the average position value
calculated after a comparison
interval is again within the
thresholds for the reference
value, or the function is deac‐
tivated.
In the last comparison inter‐
val, the valve trajectory was
changed so severely that a de‐
viating average value of posi‐
tion was calculated.
16
No
Partial stroke test
is to be carried out
with non-plausible
parameter values
A. PST≠OFF
the parameter values entered
in A1.STPOS, A3.STRKH and
A4.STRKD are plausible.
Parameters for partial stroke
test are non-plausible
1)
Refer to the corresponding parameter descriptions for additional information about parameters
See also
Overview of initialization parameters 1 to 5 (Page 146)
Overview of application parameters 6 to 55 (Page 147)
11.3.3
XDIAG parameter
You can use the advance diagnostics parameters to display fault messages in one, two or
three stages. In addition to the fault message output, alarm outputs 1 and 2 are then used. For
this purpose, set the "XDIAG" parameter as described in the following table:
Settings of XDIAG
Message due to
OFF
Advanced diagnostics not activated
On 1
Fault message output for threshold 3 fault messages (one-stage)
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Settings of XDIAG
Message due to
On 2
Fault message output for threshold 3 fault messages and alarm output 2 for threshold 2
fault messages (two-stage)
On 3
Fault message output for threshold 3 fault messages and alarm output 2 for threshold 2
fault messages and alarm output 1 for threshold 1 fault messages (three-stage)
Possible settings of the "XDIAG" parameter
11.3.4
Meaning of error codes
11.3.4.1
1 Remaining control deviation
The deviation between the setpoint and the actual value is continuously monitored in
"Automatic" mode. The fault message for a remaining control deviation is activated depending
on the setting of the application parameters " TIM" - monitoring time for setting the fault
messages - and " LIM" - response threshold for the fault message. The fault message is
cancelled as soon as the control deviation drops below the response threshold. This monitoring
function is always active.
11.3.4.2
2 Device not in "Automatic" mode
When the device is not in automatic mode, an error message is generated if the ' FCT'
parameter (function of fault message output) is set correctly. A warning is then sent to the
control system if the device was switched to manual or configuration mode on-site.
11.3.4.3
3 Binary input BIN1 or BIN2 active
If the binary input is activated, an error message is generated when the " FCT" parameter
(function of fault message output) and the "BIN1" parameter (function of binary input 1) are
set correctly. For example, it can be a switch to monitor the packing glands, a temperature
switch or a limit switch (e.g. for pressure).
Binary input 2 (in the optional alarm module) can be configured in a similar manner.
11.3.4.4
4 Monitoring the number of total strokes
The diagnostics value "1 STRKS" is constantly compared with the thresholds that are
determined from the "L1.LIMIT" to "L4.FACT3" parameters. If the thresholds are exceeded,
the fault message output or the alarm outputs respond depending on the mode of the extended
diagnostics. These two functions can be deactivated using the parameter setting "OFF" for "L.
STRK".
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11.3.4.5
5 Monitoring the number of changes in direction
The diagnostics value "2 CHDIR" is constantly compared with the thresholds that are
determined from the "O1.LIMIT" to "O4.FACT3" parameters. If the thresholds are exceeded,
the fault message output or the alarm outputs respond depending on the mode of the extended
diagnostics. These two functions can be deactivated using the parameter setting "OFF" for "O.
DCHG".
11.3.4.6
6 Monitoring the lower endstop / 7 Monitoring the upper endstop
If the parameter "F. ZERO" is set to "ON", monitoring of the lower endstop is activated. This
function can be used to detect the errors in the valve seat. An overshot limit indicates the
possibility of deposits or foreign bodies in the valve seat. An undershot limit indicates probable
wear and tear of the valve seat or flow restrictor. Even a mechanical misalignment of the
position feedback can trigger this fault message.
Monitoring is always carried out whenever the valve is in the "down tight closing" position. The
current position is compared with the position that was determined as the lower endstop at the
time of initialization. The activation of "down tight closing" ("YCLS" parameter) is therefore the
condition.
Example: A value of 3% is set. The position is normally adopted for "down tight closing". A
fault is reported if a value > 3% or < -3% is determined instead.
The fault message remains activated until either a subsequent monitoring remains within the
tolerance or a re-initialization process is executed. Even the deactivation of monitoring ("F.
ZERO"=OFF) may trigger an error message.
This monitoring function does not deliver any utilizable results if the end stops were not
determined automatically at the time of initialization, but the limits were set manually (manual
initialization, "5.INITM").
Similar diagnostics is carried out for the upper endstop. The "G. OPEN" parameter is used to
set the limit for this. The activation of "up tight closing" ("YCLS" parameter) is therefore the
condition.
11.3.4.7
8 Monitoring deadband
If the deadband increases disproportionately when adjusting it automatically ("DEBA"=Auto
parameter), it indicates an error in the system (e.g. severely increased packing gland friction,
play in the position displacement sensor, leakage). A limit can therefore be entered for this
value ("E1.LEVL3", threshold for deadband monitoring). An error message output is activated
when this value is exceeded.
11.3.4.8
9 Partial stroke test
On the one hand, this fault message appears when a manual or cyclic partial stroke test is
initiated and the test cannot be started since the valve is not within the starting tolerance. On
the other hand, the fault message appears when one of the three thresholds of the partial
stroke test that are determined from the 'A9.PSTIN' reference stroke time multiplied by factors
'AA.FACT1', 'Ab.FACT2' and 'AC.FACT3' is violated. The severity of the fault message is
shown by the number of bars on the display. The severity of the fault message is simultaneously
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11.3 Online diagnostics
displayed using the fault message output or alarm outputs depending on the mode of the
advanced diagnostics.
11.3.4.9
10 Monitoring of dynamic control valve behavior
The monitoring of the operational behavior responds when the actual valve position shifts from
a narrow corridor between the setpoint and the expected position course. In this case, the
deviation between the expected and actual position course is filtered, displayed and compared
with the configured thresholds that are determined from the "b2.LIMIT" limit multiplied by the
factors "b3.FACT1" to "b5.FACT3".
11.3.4.10
11 Monitoring the pneumatic leakage
This fault message appears when the leakage indicator exceeds the configured thresholds.
Keep in mind that the complete sensitivity of this function can be used only if a ramp movement
was initiated after initialization to set the leakage indicator (see explanations for "C1.LIMIT").
11.3.4.11
12 Monitoring of stiction (slipstick)
If the stiction of the control valve increases during operation or if an increasing number of
Slipjumps is detected, "d1.LIMIT" could be exceeded and result in this fault message.
11.3.4.12
13 Monitoring the lower limit temperature
This fault message appears when the lower limit temperature thresholds are undershot.
11.3.4.13
14 Monitoring the upper limit temperature
This fault message appears when the upper limit temperature thresholds are overshot.
11.3.4.14
15 Monitoring the position average value
This fault message appears when a position value calculated after the expiry of a comparison
interval deviates from the reference value by more than the configured thresholds.
11.3.4.15
16 Monitoring the plausibility of values for the partial stroke test
This error message is triggered if, when starting a partial stroke test, the plausibility check of
the "A1.STPOS", "A3.STRKH" and "A4.STRKD" parameters was not successful.
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11.4 Fault correction
11.4
Fault correction
11.4.1
Fault identification
Diagnostics guide
Fault
Corrective measures, see
table
In which mode does a fault occur?
● Initialization
1
● Manual and automatic modes
2
3
4
5
4
In which environment and under which boundary conditions does a fault occur?
● Wet environment (e.g. strong rain or constant condensation)
2
● Vibrating (oscillating) control valves
2
● Impact or shock loads (e.g. vapor shocks or breakaway valves)
5
● Moist (wet) compressed air
2
● Dirty (contaminated with solid particles) compressed air
2
3
● Regularly (reproducible)
1
2
3
● Sporadically (not reproducible)
5
● Mostly after a specific operation time
2
3
5
5
When does a fault occur?
11.4.2
Remedial measures table 1
Fault profile (symptoms)
Possible cause(s)
Corrective measures
● Positioner remains in "RUN 1".
● Initialization started from the end
position and
● A waiting time of up to 1 minute is
essential.
● The response time of a maximum of
1 minute was not observed.
● Do not start initialization from the
end position.
● Supply air PZ not connected or
pressure of supply air PZ too low.
● Ensure supply air PZ.
● Transmission ratio selector and
parameter 2
● Check settings: see leaflet: Fig.
"Device view ⑦" as well as
parameters 2 and 3
● Positioner remains in "RUN 2".
● "YAGL" and the real stroke do not
match.
● Incorrectly set stroke on the lever.
● Check the stroke setting on the
lever. See Table 2.
● Piezo valve does not activate.
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11.4 Fault correction
Fault profile (symptoms)
Possible cause(s)
Corrective measures
● Positioner remains in "RUN 3".
● Actuator travel time is too high.
● Open the restrictor completely and/
or set the pressure PZ (1) to the
highest permissible value.
● Use a booster if required.
● Positioner remains "RUN 5", does
not go up to "FINISH" (waiting time
> 5 min).
● "Gap" (play) in the positioner actuator - control valve system
● Part-turn actuator: check for the
firmness of the grub screw of the
coupling wheel
● Linear actuator: check for the
firmness of the lever on the
positioning shaft.
● Correct any other play between the
actuator and the control valve.
Fault table 1
11.4.3
Remedial measures table 2
Fault profile (symptoms)
Possible cause(s)
Corrective measures
● "CPU testt" blinks on the display
approximately every 2 seconds.
● Water in the pneumatic block (due
to wet compressed air)
● At an early stage, this fault can be
rectified with a subsequent
operating using dry air, if required, in
a temperature cabinet at 50 to 70°C.
● Piezo valve does not activate.
● In the manual and automatic modes,
the actuator cannot be moved or can
be moved only in one direction.
● Moisture in the pneumatic block
● Piezo valve does not activate (a
gentle click sound is not audible
when the "+" or "-" buttons are
pressed in the manual mode.)
● The screw between the shrouding
cover and the pneumatic block has
not been tightened firmly or the
cover got stuck.
● Tighten the screw firmly; if required,
rectify the deadlock.
● Dirt (swarf, particles) in the
pneumatic block
● Repair or a new device; clean and/or
replace the built-in fine screens.
● Deposits on the contacts between
the electronic printed circuit board
and the pneumatic block may
develop due to abrasion owing to
continuous loads resulting from
strong vibrations.
● Clean all contact surfaces with spirit;
if required, bend the pneumatic
block contact springs.
● Otherwise: Repair
Fault table 2
See also
Repair/Upgrading (Page 280)
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11.4 Fault correction
11.4.4
Remedial measures table 3
Fault profile (symptoms)
Possible cause
Corrective measures
● Actuator does not move.
● Compressed air < 1.4 bar
● Set pressure of supply air PZ to
> 1.4 bar.
● Piezo valve does not switch
● Restrictor valve turned off (screw at
(however, a gentle clicking sound
the right end stop)
can be heard when the
or
button is pressed in "Manual" mode.) ● Dirt in the pneumatic block
● Open the restrictor screw by turning
it anticlockwise, see leaflet, Fig.
"Device view ⑥".
● A piezo valve is switched constantly
in stationary automatic mode
(constant setpoint) and in "Manual"
mode.
● Pneumatic leakage in the positioner
- actuator system; start the leakage
test in "RUN 3" (initialization).
● Rectify leakage in the actuator and/
or feed line.
● Dirt in the pneumatic block
● See above
● Repair or a new device; clean and/or
replace the built-in fine screens.
● In case of an intact actuator and tight
feed line: Repair or new device
Fault table 3
See also
Repair/Upgrading (Page 280)
11.4.5
Corrective measures Table 4
Fault profile (symptoms)
Possible cause(s)
● In stationary automatic mode
(constant setpoint) and in "Manual"
mode, both piezo valves continually
switch alternately, and the actuator
oscillates around an average value.
● Stiction of the packing gland from
● Reduce stiction or increase
the control valve or actuator too large
deadband of positioner (parameter
"dEbA") until the oscillation stops.
● Looseness (play) in the positioner/
actuator/control valve system
Corrective measures
● Part-turn actuator: Check for firm
seating of set screw on coupling
wheel.
● Linear actuator: Check for firm
seating of lever on positioner shaft.
● Correct any other play between the
actuator and the control valve.
● Actuator too fast
● Increase travel times using throttle
screws.
● If a quick travel time is needed,
increase the deadband (parameter
"dEbA") until the oscillation stops.
● Positioner doesn't move control
valve to the stop (at 20 mA).
● Supply pressure too low. Load on
the feeding controller or system
output is too low.
● Increase supply pressure, insert
ballast converter
● Select 3/4-wire mode
Error table 4
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11.4 Fault correction
See also
Cleaning of the screens (Page 278)
11.4.6
Remedial measures table 5
Fault profile (symptoms)
Possible cause(s)
Corrective measures
● Zero point displaces sporadically
(> 3%).
● Impact or shock loads result in
accelerations so high that the friction
clutch moves, e.g. due to "vapor
shocks" in vapor lines.
● Rectify the causes for shock loads.
● The device function has completely
failed: No representation on the
display either.
● Electrical auxiliary power supply is
not adequate.
● Check the electrical auxiliary power
supply.
● Re-initialize the position controller.
● In case of very high continuous
● Tighten the screws firmly and secure
loads due to vibrations (oscillations):
using sealing wax.
● Screws of the electrical connecting
terminals may be loosened.
● Electrical connecting terminals and/
or electronic components may be
knocked out.
● Repair
● For prevention: Install the positioner
on the damping pads.
Fault table 5
See also
Repair/Upgrading (Page 280)
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12.1
12
Basic safety instructions
WARNING
Impermissible repair of the device
● Repair must be carried out by Siemens authorized personnel only.
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
● Only use original accessories or original spare parts.
● Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
WARNING
Improper connection after maintenance
Danger of explosion in areas subject to explosion hazard.
● Connect the device correctly after maintenance.
● Close the device after maintenance work.
Refer to Chapter "Connect (Page 77)".
NOTICE
Penetration of moisture into the device
Device damage.
● Make sure when carrying out cleaning and maintenance work that no moisture penetrates
the inside of the device.
CAUTION
Releasing key lock
Improper modification of parameters could influence process safety.
● Make sure that only authorized personnel may cancel the key locking of devices for safetyrelated applications.
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12.2 Cleaning of the screens
WARNING
Electrostatic charge
Danger of explosion in hazardous areas if electrostatic charges develop, for example, when
cleaning plastic surfaces with a dry cloth.
● Prevent electrostatic charging in hazardous areas.
WARNING
Dust layers above 5 mm
Danger of explosion in hazardous areas. Device may overheat due to dust build up.
● Remove dust layers in excess of 5 mm.
Cleaning the enclosure
● Clean the outside of the enclosure with the inscriptions and the display window using a
cloth moistened with water or a mild detergent.
● Do not use any aggressive cleansing agents or solvents, e.g. acetone. Plastic parts or the
painted surface could be damaged. The inscriptions could become unreadable.
12.2
Cleaning of the screens
The positioner is maintenance-free to a large extent. Screens are installed in the pneumatic
connections of the positioners to protect them from rough dirt particles. If there are dirt particles
in the pneumatic auxiliary power supply, they damage the screens and hamper the function
of the positioner. Clean the screens as described in the following two chapters.
12.2.1
Positioners with Makrolon enclosure 6DR5..0, aluminum enclosure 6DR5..3, and
flameproof aluminum enclosure 6DR5..5
DANGER
Risk of explosion due to electrostatic charge
Electrostatic charges develop when cleaning the positioner in the Makrolon enclosure with a
dry cloth, for example.
It is imperative you avoid electrostatic charges in the hazardous environment.
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12.2 Cleaning of the screens
Procedure for removal and cleaning of the screens
1. Disconnect the pneumatic auxiliary power supply.
2. Remove the lines.
3. Unscrew the cover of the Makrolon enclosure 6DR5..0 or aluminum enclosure 6DR5..3.
4. Unscrew the three screws on the pneumatic terminal strip.
5. Remove the screens and O-rings behind the terminal strip.
6. Clean the screens, e.g. using compressed air.
Procedure for installation of the screens
CAUTION
Damage to the Makrolon enclosure
● The enclosure is damaged due to screwing in the self-tapping screws improperly.
● Ensure that the available thread pitches are used.
● Turn the screws anticlockwise until they engage noticeably in the thread pitch.
● Tighten the self-tapping screws only after they have engaged.
1. Insert the screens into the recesses of the enclosure.
2. Place the O-rings on the screens.
3. Insert the pneumatic terminal strip.
4. Tighten the three screws. Note: With the Makrolon enclosure, the screws are self-tapping.
5. Place the cover and tighten it.
6. Reconnect the pipelines and feed the pneumatic power supply.
12.2.2
Positioners with stainless steel enclosure 6DR5..2, flameproof stainless steel
enclosure 6DR5..6, and narrow aluminum enclosure 6DR5..1
Removal, cleaning and installation of the screens
1. Disconnect the pneumatic auxiliary power supply.
2. Remove the pipelines.
3. Remove the metal screen from the bores carefully.
4. Clean the metal screens, e.g. using compressed air.
5. Insert the screens.
6. Connect the pipelines again.
7. Feed the pneumatic auxiliary power supply.
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12.4 Repair/Upgrading
12.3
Replacing the basic electronics with the "Fail in Place" function
Requirements
You have a positioner with the "Fail in place" function, order suffix -Z F01.
Replacing the basic electronics with the "Fail in Place" function
When replacing the basic electronics for positioning controllers with the function "Fail in Place",
order suffix -Z F01, the parameters for the pneumatic type have to be set. The procedure is
described here.
Note
Possible Movement of the Drive
While replacing the basic electronics, the drive can unintentionally vent itself.
● Observe the procedure described below.
1. Switch off the supply air PZ.
2. Remove the enclosure cover of the positioner.
3. Replace the basic electronics as described in section "General information about the
installation of option modules (Page 54)".
4. Set the '49.PNEUM' Fail in place (Page 169) parameter of "Std" to "FIP".
5. Set the '51.FSTY' Safety position (Page 171) parameter to "FSSP" so that the positioner
retains the current position even following switching on again.
6. Install the enclosure cover.
7. Switch on the supply air PZ again.
8. Initialize the positioner as described in section "Commissioning (Page 113)".
12.4
Repair/Upgrading
Send defective devices to the repairs department, together with information on the malfunction
and the cause of the malfunction. When ordering replacement devices, please provide the
serial number of the original device. You can find the serial number on the nameplate.
See also
Nameplate layout (Page 24)
Technical support (Page 312)
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12.6 Disposal
12.5
Return procedure
Enclose the bill of lading, return document and decontamination certificate in a clear plastic
pouch and attach it firmly to the outside of the packaging.
Required forms
● Delivery note
● Return document (http://www.siemens.com/processinstrumentation/returngoodsnote)
with the following information:
– Product (item description)
– Number of returned devices/replacement parts
– Reason for returning the item(s)
● Decontamination declaration (http://www.siemens.com/sc/declarationofdecontamination)
With this declaration you warrant "that the device/replacement part has been carefully
cleaned and is free of residues. The device/replacement part does not pose a hazard for
humans and the environment."
If the returned device/replacement part has come into contact with poisonous, corrosive,
flammable or water-contaminating substances, you must thoroughly clean and
decontaminate the device/replacement part before returning it in order to ensure that all
hollow areas are free from hazardous substances. Check the item after it has been cleaned.
Any devices/replacement parts returned without a decontamination declaration will be
cleaned at your expense before further processing.
The forms can be found on the Internet as well as in the documentation which comes with the
device.
12.6
Disposal
Devices identified by this symbol may not be disposed of in the
municipal waste disposal services under observance of the Di‐
rective 2002/96/EC on waste electronic and electrical equipment
(WEEE).
They can be returned to the supplier within the EC or to a locally
approved disposal service. Observe the specific regulations valid
in your country.
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Technical data
13.1
Rated conditions
Rated conditions
Ambient conditions
For use indoors and outdoors.
Ambient temperature
In hazardous areas, observe the maximum permissible am‐
bient temperature corresponding to the temperature class.
● Permissible ambient temperature for operation 2)3)
-30 ... +80 °C (-22 ... +176 °F)
● Height
2000 m above sea level. At altitudes greater than 2000 m
above sea level, use a suitable power supply.
● Relative humidity
0 ... 100%
Degree of pollution
2
Overvoltage category
II
Degree of protection
IP66 to IEC/EN 60529 / NEMA 4X
1)
Mounting position
Any; in wet environment, pneumatic connections and outlet
opening not upward
Vibration resistance
● Harmonic oscillations (sine) according
to EN 60068-2-6/10.2008
3.5 mm (0.14"), 2 ... 27 Hz, 3 cycles/axle
● Bumping (half-sine) according to EN 60068-2-27/02.2010
150 m/s² (492 ft/s²), 6 ms, 1000 shocks/axle
● Noise (digitally controlled) according to EN
60068-2-64/04.2009
10 ... 200 Hz; 1 (m/s²)²/Hz (3.28 (ft/s²)²/Hz)
98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axle
200 ... 500 Hz; 0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz)
4 hours/axle
● Recommended range of continuous operation of the entire
control valve
≤ 30 m/s² (98.4 ft/s²) without resonance peak
Climate class
According to IEC/EN 60721-3
● Storage
1K5, but -40 ... +80°C (1K5, but -40 ... +176°F)
● Transport
2K4, but -40 ... +80°C (2K4, but -40 ... +176°F)
1)
Max. impact energy 1 Joule for enclosure with inspection window 6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3
2)
At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited. When using position feedback module, only T4 is
permissible.
3)
The following applies to order suffix (order code) -Z M40: -40 ... +80 °C (-40 ... +176°F)
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Technical data
13.3 Construction
13.2
Pneumatic data
Pneumatic data
Auxiliary power (air supply)
Compressed air, carbon dioxide (CO2), nitrogen (N), noble
gases or cleaned natural gas
● Pressure 1)
1.4 ... 7 bar (20.3 to 101.5 psi)
Air quality to ISO 8573-1
● Solid particulate size and density
Class 2
● Pressure dew point
Class 2 (min. 20 K (36°F) below ambient temperature)
● Oil content
Class 2
Unrestricted flow (DIN 1945)
● Inlet air valve (ventilate actuator) 2)
2 bar (29 psi)
4.1 Nm³/h (18.1 USgpm)
4 bar (58 psi)
7.1 Nm³/h (31.3 USgpm)
6 bar (87 psi)
9.8 Nm³/h (43.1 USgpm)
● Exhaust valve (deaerate actuator for all versions except fail
in place) 2)
2 bar (29 psi)
8.2 Nm³/h (36.1 USgpm)
4 bar (58 psi)
13.7 Nm³/h (60.3 USgpm)
6 bar (87 psi)
19.2 Nm³/h (84.5 USgpm)
● Exhaust valve (deaerate actuator for fail in place version)
2 bar (29 psi)
4.3 Nm³/h (19.0 USgpm)
4 bar (58 psi)
7.3 Nm³/h (32.2 USgpm)
6 bar (87 psi)
9.8 Nm³/h (43.3 USgpm)
Valve leakage
< 6⋅10-4 Nm³/h (0.0026 USgpm)
Throttle ratio
Adjustable up to ∞: 1
Auxiliary power consumption in the controlled state
< 3.6⋅10-2 Nm³/h (0.158 USgpm)
Sound pressure level
LA eq < 75 dB
LA max < 80 dB
1)
The following applies to fail in place: 3 ... 7 bar (43.5 to 101.5 psi)
2)
When using device versions Ex d (6DR5..5-... and 6DR5..6-...), values are reduced by approximately 20%.
13.3
Construction
Construction
How does it work?
● Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the posi‐
tioner shaft 16 ... 90°)
● Angle of rotation (part-turn actuator)
30 ... 100°
Mounting method
284
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Technical data
13.3 Construction
Construction
● On the linear actuator
Using mounting kit 6DR4004-8V and, where necessary, an
additional lever arm 6DR4004-8L on actuators according to
IEC 60534-6-1 (NAMUR) with a fin, columns, or a plane
surface.
● On the part-turn actuator
Using mounting kit 6DR4004-8D on actuators with mount‐
ing plane according to VDI/VDE 3845 and IEC 60534-6-2:
The required mount must be provided on the actuator-side.
Weight, positioner without option modules or accessories
● 6DR5..0 Glass-fiber reinforced polycarbonate enclosure
Approximately 0.9 kg (1.98 lb)
● 6DR5..1 aluminum enclosure, narrow
Approx. 1.3 kg (2.86 lb)
● 6DR5..2 stainless steel enclosure
Approx. 3.9 kg (8.6 lb)
● 6DR5..3 aluminum enclosure
Approx. 1.6 kg (3.53 lb)
● 6DR5..5 aluminum enclosure, flameproof
Approx. 5.2 kg (11.46 lb)
● 6DR5..6 stainless steel enclosure, flameproof
Approx. 8.4 kg (18.5 lb)
Material
● Enclosure
6DR5..0 Makrolon
Glass-fiber reinforced polycarbonate (PC)
6DR5..1 aluminum, narrow
GD AISi12
6DR5..2 stainless steel
Austenitic stainless steel 316 Cb, mat. No. 1.4581
6DR5..3 aluminum
GD AlSi12
6DR5..5 aluminum, flameproof
GK AISi12
6DR5..6 stainless steel enclosure, flameproof
Austenitic stainless steel 316 L, mat. No. 1.4409 or 316 Ti,
mat. No. 1.4571
● Pressure gauge block
Aluminum AIMgSi, anodized or stainless steel 316
Versions
● In Makrolon enclosure 6DR5..0
Single-acting and double-acting
● In aluminum enclosure 6DR5..1
Single-acting
● In aluminum enclosures 6DR5..3 and 6DR5..5
Single-acting and double-acting
● In stainless steel enclosures 6DR5..2 and 6DR5..6
Single-acting and double-acting
Torques
● Part-turn actuator fixing screws DIN 933 M6x12-A2
5 Nm (3.7 ft lb)
● Linear actuator fixing screws DIN 933 M8x16-A2
12 Nm (8.9 ft lb)
● Gland pneumatic G¼
15 Nm (11.1 ft lb)
● Gland pneumatic ¼" NPT
Without sealant
12 Nm (8.9 ft lb)
With sealant
6 Nm (4.4 ft lb)
● Cable glands
Screw-in torque for plastic gland in all enclosures
4 Nm (3 ft lb)
Screw-in torque for cable gland made of metal/stainless
steel in Makrolon enclosure
6 Nm (4.4 ft lb)
Screw-in torque for metal/stainless steel glands in alumi‐ 6 Nm (4.4 ft lb)
num/stainless steel enclosure
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285
Technical data
13.4 Controller
Construction
Screw-in torque for NPT adapter made of metal/stainless 8 Nm (5.9 ft lb)
steel in Makrolon enclosure
Screw-in torque for NPT adapter made of metal/stainless 15 Nm (11.1 ft lb)
steel in aluminum/stainless steel enclosure
Screw-in torque for NPT gland in the NPT adapter
68 Nm (50 ft lb)
NOTE: To avoid damage to the device, the NPT adapter
must be held in place while the NPT gland is screwed
into the NPT adapter.
Tightening torque for union nut made of plastic
2.5 Nm (1.8 ft lb)
Tightening torque for union nut made of metal/stainless
steel
4 Nm (3 ft lb)
Manometer
● Degree of protection
Manometer made of plastic
IP31
Manometer, steel
IP44
Manometer made of stainless steel 316
IP54
● Vibration resistance
In accordance with DIN EN 837-1
Connections, electrical
●
Screw terminals
2.5 mm2 AWG30-14
Without Ex protection as well as with Ex i: M20x1.5 or ½-14
NPT
● Cable gland
With explosion protection Ex d: Ex d certified M20x1.5,
½-14 NPT or M25x1.5
Connections, pneumatic
13.4
Female thread G¼ or ¼-18 NPT
Controller
Controller
Control unit
● Five-point controller
Adaptive
● Dead zone
dEbA = auto
Adaptive
dEbA = 0.1 ... 10 %
Can be set as fixed value
Analog-to-digital converter
● Scanning time
10 ms
● Resolution
≤ 0,05 %
● Transmission error
≤ 0,2 %
● Temperature influence
≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
286
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Technical data
13.5 Certificates, approvals, explosion protection
13.5
Certificates, approvals, explosion protection
Certificates and approvals
Classification according to pressure equip‐ For fluid group 1 gases; fulfills requirements according to article 3, paragraph 3
ment directive (PED 97/23/EC)
(good engineering practice SEP)
CE conformity
The applicable directives and applied standards with their revision levels can be
found in the EC declaration of conformity on the Internet.
Explosion protection
Explosion protection
Ex markings
Explosion protection in accordance with
ATEX/IECEx
Flameproof enclosure encapsulation "d",
"XP" 6DR5..5/6
FM/CSA
II 2 G Ex d IIC T6/T4 Gb
FM: XP, Class I, Division 1, GP.ABCD
CSA: XP, Class I, Division 1, GP.CD
FM/CSA:
XP, Class I, Zone 1, AEx d, IIC, T6/T4
Intrinsic safety "i", "IS"
● 6DR5..0/1/2/3
●
6DR5..1/2/3
II 2 G Ex ia IIC T6/T4 Gb
IS / I, II / 1 / A-D
II 3 G Ex ic IIC T6/T4 Gc
IS / 1 / AEx / Ex ib / IIC, Gb
II 2 D Ex ia IIIC T110°C Db
IS / III / 1 / E-G
IS / 21 / AEx / Ex ib / IIIC, Db, T110°C
Non-sparking "nA", "NI"
II 3 G Ex nA IIC T6/T4 Gc
NI / I / 2 / A-D
NI / 2 / AEx / Ex nA, Ex ic / IIC, Gc
Dust, protection by means of enclosure "t",
"DIP"
II 2 D Ex tb IIIC T100°C Db
DIP / II, III / 1 / E-G
DIP / 21 / AEx / Ex tb / IIIC, Db, T100°C
● 6DR5..1-.D/K...
● 6DR5..2-.D/K...
● 6DR5..3-.D/K...
● 6DR5..6-.E...
Breakdown of the article numbers for assignment of the maximum permissible ambient temperature
ranges
6DR5ayb-
0cdef-
g..h-
Z jjj
a = 0, 2, 5, 6
c = E, G, D, F, K
g = 0, 2, 6, 7, 8
A20, A40, C20, D53, D54,
D55, D56, F01, K**, L1A,
M40,
R**, S**, Y**
* = any character
y = 1, 2
d = G, N, M, P, R, S
b = 0, 1, 2, 3
e = 0, 1, 2, 3
h = 0, 1, 2, 3, 4, 9
f = 0, 1, 2, 3
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Technical data
13.6 Electrical specifications
Maximum permissible ambient temperature ranges with types of protection Ex ia, Ex ic and Ex nA
Explosion protection in accordance with
ATEX/IECEx
FM/CSA
● 6DR5ayb-0cdef-g.Ah-Z ...
T4: -30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
T6: -30 ≤ Ta ≤ +50 °C (-22 ≤ Ta ≤ +122 °F)
● 6DR5ayb-0cdef-g.Ah-Z M40
T4: -40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F)
T6: -40 ≤ Ta ≤ +50 °C (-40 ≤ Ta ≤ +122 °F)
Position feedback module (already fitted or
can be retrofitted)
● Already fitted:
6DR5ayb-0cdef-g.Ah-Z ...
with the data (f = 1 or 3)
T4: -30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
● Can be retrofitted 6DR4004-6J
T4: -40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F)
● Already fitted and can be retrofitted:
6DR5ayb-0cdef-g.Ah-Z M40
with the data (f = 1 or 3)
Option modules
● Non contacting sensor (NCS)
6DR4004-6N..-0-...
T4: -40 ≤ Ta ≤ +90 °C
(-40 ≤ Ta ≤ +194 °F)
T6: -40 ≤ Ta ≤ +70 °C
(-40 ≤ Ta ≤ +158 °F)
T4: -40 ≤ Ta ≤ +85 °C
(-40 ≤ Ta ≤ +185 °F)
T6: -40 ≤ Ta ≤ +70 °C
(-40 ≤ Ta ≤ +158 °F)
● External position detection system
C73451-A430-D78
T4: -40 ≤ Ta ≤ +90 °C
(-40 ≤ Ta ≤ +194 °F)
T6: -40 ≤ Ta ≤ +60 °C
(-40 ≤ Ta ≤ +140 °F)
T4: -40 ≤ Ta ≤ +85 °C
(-40 ≤ Ta ≤ +185 °F)
T6: -40 ≤ Ta ≤ +60 °C
(-40 ≤ Ta ≤ +140 °F)
Maximum permissible ambient temperature ranges with type of protection Ex t
Explosion protection in accordance with
ATEX/IECEx
FM/CSA
● 6DR5ayb-0cdef-g.Ah-Z ...
with the data (c = D or K)
-30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
● 6DR5ayb-0cdef-g.Ah-Z M40
with the data (c= D or K)
-40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F)
13.6
Electrical specifications
Basic device without
explosion protection
Basic device with ex‐ Basic device with ex‐ Basic device with ex‐
plosion protection
plosion protection
plosion protection Ex
Ex d
Ex "ia"
"ic", "nA", "t"
Auxiliary power supply bus cir‐
cuit
Bus voltage
Bus-powered
9 ... 32 V
9 ... 32 V
9 ... 24 V
9 ... 32 V
For connecting to circuits with
the following peak values
288
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Technical data
13.6 Electrical specifications
● Bus connector with FISCO
supply unit
Basic device without
explosion protection
Basic device with ex‐ Basic device with ex‐ Basic device with ex‐
plosion protection
plosion protection
plosion protection Ex
Ex d
Ex "ia"
"ic", "nA", "t"
-
-
Ui = 17.5 V
Ii = 380 mA
Pi = 5.32 W
"ic":
Ui = 17.5 V
Ii = 570 mA
"nA"/"t":
Un ≤ 32 V
● Bus connector with barrier
Ui = 24 V
Ii = 250 mA
Pi = 1.2 W
"ic":
Ui = 32 V
"nA"/"t":
Un ≤ 32 V
Effective inner capacitance Ci
-
-
Negligible
Negligible
Effective inner inductance Li
-
-
8 μH
"ic":
8 μH
Current consumption
11.5 mA ± 10 %
Additional fault current
0 mA
Safety shutdown can be activa‐
ted using "Jumper" (terminals
81 and 82)
Electrically isolated from bus circuit and binary input
> 20 kΩ
● Input resistance
● Signal status "0" (shutdown
active)
0 ... 4.5 V or unused
● Signal status "1" (shutdown
inactive)
13 ... 30 V
● For connecting to power
source with the following
peak values
-
-
Ui = 30 V
Ii = 100 mA
Pi = 1 W
"nA":
Un ≤ 30 V
In ≤ 100 mA
"ic":
Ui = 30 V
Ii = 100 mA
● Effective internal
capacitance and inductance
Binary input BE1
(terminals 9 and 10) electrically
connected to the bus circuit
-
Negligible
Negligible
Jumpered or connection to switch contact.
Suitable only for floating contact; max. contact load
< 5 μA with 3 V
Galvanic isolation
● For basic device without Ex
protection and for basic
device with Ex d
Galvanic isolation between the basic device and the input for safety shutdown and the
outputs of option modules.
● For basic device Ex "ia"
The basic device, the input for safety shutdown, and the outputs of option modules are
individual intrinsically safe circuits.
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Technical data
13.7 Technical data for natural gas as actuator medium
Basic device without
explosion protection
● For basic device Ex "ic",
"nA", "t"
Basic device with ex‐ Basic device with ex‐ Basic device with ex‐
plosion protection
plosion protection
plosion protection Ex
Ex d
Ex "ia"
"ic", "nA", "t"
Galvanic isolation between the basic device and the input for safety shutdown and the
outputs of option modules.
Test voltage
13.7
DC 840 V, 1 s
Technical data for natural gas as actuator medium
Introduction
Note when using an actuator with natural gas that this can escape at the following points:
● At the exhaust air outlet with sound absorber.
● At the enclosure vent.
● At the control air outlet near the pneumatic connections.
Note
Exhaust air outlet with a sound absorber
The positioner is supplied as standard with a sound absorber. To provide an outlet for the
exhaust air, replace the sound absorber by a G¼ pipe coupling.
Enclosure ventilation and control air outlet
Enclosure ventilation and control air outlet cannot be collected and channeled off.
Please refer to the following table for the maximum ventilation values.
Maximum values for escaping natural gas
Ventilation process
Ventilation of the enclosure volume. Purge air
switch is at "IN":
Operating
mode
6DR5.1.-.E...
6DR5.2.-.E...
Single-acting
Double-acting
[Nl/min]
[Nl/min]
Operation, typi‐
cal
0.14
0.14
Operation,
max.
0.60
0.60
Error case,
max.
60.0
60.0
1.0
2.0
Operation,
max.
8.9
9.9
Error case,
max.
66.2
91.0
Ventilation via the control air outlet near the pneu‐ Operation, typi‐
matic connections:
cal
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Technical data
13.8 Option modules
Ventilation process
Operating
mode
Ventilation through the exhaust air outlet with a
sound absorber
6DR5.1.-.E...
6DR5.2.-.E...
Single-acting
Double-acting
[Nl/min]
[Nl/min]
358.21)
3391),
1.26
1.23
Operation,
max.
Error case,
max.
Volume
Max. [l]
1) Depending on the actuating pressure and volume of the actuator as well as the frequency of control.
The maximum flow rate is 470 Nl/min at a differential pressure of 7 bar.
See also
Basic safety instructions (Page 113)
Pneumatic connection for 6DR55.0/1/2/3 (Page 96)
13.8
Option modules
13.8.1
Alarm module
Without explosion protec‐
tion or suitable for use in
the SIPART PS2 Ex d
With Ex protection Ex "ia"
With Ex protection
Ex "ic", "nA", "t"
6DR4004-8A
6DR4004-6A
6DR4004-6A
≤ 35 V
-
-
High (not addressed)
Conductive, R = 1 kΩ,
+3/-1 % *)
≥ 2.1 mA
≥ 2.1 mA
Low *) (addressed)
Deactivated, IR < 60 µA
Alarm module
3 binary output circuits
● Alarm output A1: Terminals 41 and 42
● Alarm output A2: Terminals 51 and 52
● Fault message output: Terminals 31 and 32
● Auxiliary voltage UH
● Signal status
*) The status is also Low if the *) When using in the flame‐
basic device is faulty or without proof housing, the current
a auxiliary power.
consumption must be re‐
stricted to 10 mA per out‐
put.
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Operating Instructions, 02/2016, A5E00127926-AB
≤ 1.2 mA
≤ 1.2 mA
Switching thresholds for
supply as per
EN 60947-5-6:
UH = 8.2 V, Ri = 1 kΩ
Switching thresholds for
supply as per
EN 60947-5-6:
UH = 8.2 V, Ri = 1 kΩ
291
Technical data
13.8 Option modules
● For connecting to circuits with the
following peak values
Without explosion protec‐
tion or suitable for use in
the SIPART PS2 Ex d
With Ex protection Ex "ia"
With Ex protection
Ex "ic", "nA", "t"
-
Ui = 15 VDC
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = 15 VDC
I i = 25 mA
"nA"/"t":
Un ≤ 15 VDC
Effective internal capacitance
-
Ci = 5.2 nF
Ci = 5.2 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
1 binary input circuit
● Binary input BI2: Terminals 11 and 12, terminals 21 and 22 (jumper)
● Galvanically connected with the
basic device
Signal status 0
Floating contact, open
Signal status 1
Floating contact, closed
Contact load
3 V, 5 μA
● Electrically isolated from the basic
device
Signal status 0
≤ 4.5 V or open
Signal status 1
≥ 13 V
Internal resistance
≥ 25 kΩ
● Static destruction limit
± 35 V
-
-
● Connecting to circuits with the
following peak values
-
Ui = DC 25.2 V
"ic":
Ui = DC 25.2 V
"nA"/"t":
Un ≤ DC 25.5 V
Effective internal capacitance
-
Ci = negligibly small
Ci = negligibly small
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
The three outputs, the BI2 input and the basic device are galvanically isolated from
each other.
Test voltage
13.8.2
DC 840 V, 1 s
Position feedback module
Position feedback module
Without explosion protec‐
tion or suitable for use in
the SIPART PS2 Ex d
With Ex protection Ex ia
(only in temperature class
T4)
With Ex protection
Ex "ic", "nA", "t"
6DR4004-8J
6DR4004-6J
6DR4004-6J
Direct current output for position feed‐
back
1 current output, terminals 61 and 62
2-wire connection
292
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Technical data
13.8 Option modules
Without explosion protec‐
tion or suitable for use in
the SIPART PS2 Ex d
Rated signal range
With Ex protection Ex ia
(only in temperature class
T4)
With Ex protection
Ex "ic", "nA", "t"
4 ... 20 mA, short-circuit proof
Dynamic range
3.6 ... 20.5 mA
Auxiliary voltage UH
+12 ... +35 V
External load RB [kΩ]
+12 ... +30 V
+12 ... +30 V
≤ (UH [V] - 12 V)/I [mA]
Transmission error
≤ 0.3 %
Temperature influence
≤ 0.1%/10 K (≤ 0.1%/18 °F)
Resolution
≤ 0.1 %
Residual ripple
≤1%
For connecting to circuits with the fol‐
lowing peak values
Ui = DC 30 V
Ii = 100 mA
Pi = 1 W
"ic":
Ui = DC 30 V
Ii = 100 mA
"nA"/"t":
Un ≤ DC 30 V
In ≤ 100 mA
Pn ≤ 1 W
Effective internal capacitance
-
Ci = 11 nF
Ci = 11 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
Safe galvanic isolation from alarm option and basic device
Test voltage
13.8.3
DC 840 V, 1 s
SIA module
SIA module
Without Ex protection
With Ex protection Ex "ia"
With Ex protection Ex "ic",
"nA", "t"
6DR4004-8G
6DR4004-6G
6DR4004-6G
Limit encoder with slotted initiators
and fault message output
2 slotted initiators
● Binary output (limit transmitter) A1: Terminals 41 and 42
● Binary output (limit transmitter) A2: Terminals 51 and 52
● Connection
2 wire technology in accordance with EN 60947-5-6 (NAMUR), for switching amplifi‐
ers connected on load side
● Signal state High
(not triggered)
> 2.1 mA
● Signal state Low (triggered)
< 1.2 mA
● 2 slotted initiators
● Function
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Type SJ2-SN
NC contact (NC, normally closed)
293
Technical data
13.8 Option modules
Without Ex protection
With Ex protection Ex "ia"
With Ex protection Ex "ic",
"nA", "t"
● Connecting to circuits with the
following peak values
Nominal voltage 8 V; cur‐
rent consumption:
≥ 3 mA (limit not activa‐
ted),
≤ 1 mA (limit activated)
Ui = DC 15 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = DC 15 V
Ii = 25 mA
"nA":
Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance
-
Ci = 41 nF
Ci = 41 nF
Effective internal inductance
-
Li = 100 μH
Li = 100 μH
1 fault message output
● Binary output: Terminals 31 and 32
● Connection
At switching amplifier in accordance with EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri =
1 kΩ).
● Signal state High
(not triggered)
R = 1.1 kΩ
> 2.1 mA
> 2.1 mA
● Signal state Low (triggered)
R = 10 kΩ
< 1.2 mA
< 1.2 mA
● Auxiliary power UH
UH ≤ DC 35 V
I ≤ 20 mA
-
-
● Connecting to circuits with the
following peak values
-
Ui = DC 15 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = DC 15 V
Ii = 25 mA
"nA":
Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance
-
Ci = 5.2 nF
Ci = 5.2 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
The 3 outputs are galvanically isolated from the basic device.
Test voltage
13.8.4
DC 840 V, 1 s
Mechanical limit switch module
Mechanical limit switch module
Without Ex protection
With Ex protection Ex ia
With Ex protection Ex "ic",
"t"
6DR4004-8K
6DR4004-6K
6DR4004-6K
4A
-
-
Limit encoder with mechanical switch‐
ing contacts
2 limit contacts
● Binary output 1: Terminals 41 and
42
● Binary output 2: Terminals 51 and
52
● Max. switching current AC/DC
294
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Technical data
13.8 Option modules
● For connecting to circuits with the
following peak values
Without Ex protection
With Ex protection Ex ia
With Ex protection Ex "ic",
"t"
-
Ui = 30 V
Ii = 100 mA
Pi = 750 mW
"ic":
Ui = 30 V
Ii = 100 mA
"t":
Un = 30 V
In = 100 mA
Effective internal capacitance
-
Ci = negligibly small
Ci = negligibly small
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
● Max. switching voltage AC/DC
250 V/24 V
DC 30 V
DC 30 V
1 fault message output
● Binary output: Terminals 31 and 32
● Connection
On switching amplifier according to EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri = 1 kΩ).
● Signal state High
(not triggered)
R = 1.1 kΩ
> 2.1 mA
> 2.1 mA
● Signal state Low (triggered)
R = 10 kΩ
< 1.2 mA
< 1.2 mA
● Auxiliary power
UH ≤ DC 35 V
I ≤ 20 mA
-
-
● Connecting to circuits with the
following peak values
-
Ui = 15 V
Ii = 25 mA
Pi = 64 mW
"ic" :
Ui = 15 V
Ii = 25 mA
"t":
Un = 15 V
In = 25 mA
Effective internal capacitance
-
Effective internal inductance
-
Galvanic isolation
Ci = 5.2 nF
Ci = 5.2 nF
Li = negligibly small
Li = negligibly small
The 3 outputs are galvanically isolated from the basic device
Test voltage
DC 3150 V, 2 s
Rated condition height
13.8.5
Max. 2 000 m mean sea
level Use a suitable power
supply at an altitude of
more than 2 000 m above
sea level.
-
-
EMC filter module
Without Ex protection With Ex protection Ex ia
With Ex protection
Ex "ic", "nA", "t"
EMC filter module type C73451-A430-D23 is required for NCS sensor or an external potentiometer.
External position sensor (potentiometer or NCS; option) with the following maximum values
Resistance of the external potentiometer
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10 kΩ
295
Technical data
13.8 Option modules
Without Ex protection With Ex protection Ex ia
With Ex protection
Ex "ic", "nA", "t"
Maximum values when powered by the
PROFIBUS basic device
-
Uo = 5 V
Io = 75 mA static
Io = 160 mA short-term
Po = 120 mW
Uo = 5 V
Io = 75 mA
Po = 120 mW
Maximum values when powered by other
basic devices
-
Uo = 5 V
Io = 100 mA
Po = 33 mW
Co = 1 μF
Lo = 1 mH
Uo = 5 V
Io = 75 mA
Po = 120 mW
Co = 1 μF
Lo = 1 mH
Galvanic isolation
13.8.6
Galvanically connected with the basic device
NCS 6DR4004-.N.20 and 6DR4004-.N.30
Additional modules
Without Ex protection
With Ex protection
Ex "ia"
With Ex protection
Ex "ic", "nA"
Travel range
● Linear actuator 6DR4004-.N.20
3 to 14 mm (0.12 to 0.55")
● Linear actuator 6DR4004-.N.30
10 to 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
30 to 100°
● Part-turn actuator
Linearity (after corrections made by
positioner)
±1%
Hysteresis
± 0.2 %
Temperature influence (range: rota‐
tion angle 120° or stroke 14 mm)
≤ 0.1 %/10 K (≤ 0.1 %/18 °F) for -20 to +90 °C (-4 to +194 °F)
≤ 0.2%/10 K (≤ 0.2%/18 °F) for -40 to -20 °C (-40 to -4 °F)
Climate class
According to IEC/EN 60721-3
● Storage
1K5, but -40 to +90 °C (-40 to +194 °F)
● Transport
2K4, but -40 to +90 °C (-40 to +194 °F)
Vibration resistance
3.5 mm (0.14"), 2 to 27 Hz, 3 cycles/axis
98.1 m/s² (321.84 ft/s²), 27 to 300 Hz, 3 cycles/axis
● Harmonic oscillations
(sine) according to IEC 60068-2-6
300 m/s2(984 ft/s2), 6 ms, 4000 shocks/axis
● Bumping according to IEC
60068-2-29
Torque for cable gland nut made of
Plastic
Metal
Stainless steel
2.5 Nm (1.8 ft lb)
4.2 Nm (3.1 ft lb)
4.2 Nm (3.1 ft lb)
Housing protection type
IP68 according to IEC/EN 60529; NEMA 4X / Encl. Type 4X
For connecting to circuits with the fol‐ lowing peak values
Ui = 5 V
Ii = 160 mA
Pi = 120 mW
Ui = 5 V
Effective internal capacitance
-
Ci = 180 nF
Ci = 180 nF
Effective internal inductance
-
Li = 922 μH
Li = 922 μH
296
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Technical data
13.8 Option modules
Certificates and approvals
CE conformity
The applicable directives and applied standards with their revision levels can be
found in the EC declaration of conformity on the Internet.
Explosion protection
Types of protection
Ex markings
ATEX/IECEx
FM/CSA
● Intrinsic safety "ia"
Zone 1:
II 2 G Ex ia IIC T6/T4 Gb
IS, Class I, Divison 1, ABCD
IS, Class I, Zone 1, AEx ib, IIC
● Intrinsic safety "ic"
Zone 2:
II 3 G Ex ic IIC T6/T4 Gc
-
● Non-sparking "nA"
Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
NI, Class I, Divison 2, ABCD
NI, Class I, Zone 2, AEx nA, IIC
Perm. ambient temperature
T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)
T4: -40 ... +85 °C (-40 ... +185 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)
13.8.7
Internal NCS modules 6DR4004-5L and 6DR4004-5LE
Additional modules
Without Ex protection
With Ex protection
Ex "ia"
With Ex protection
Ex "ic", "nA" ,"t"
Internal NCS module
6DR4004-5L
6DR4004-5LE
6DR4004-5LE
Linearity (after corrections made by
positioner)
±1%
±1%
±1%
Hysteresis
± 0.2 %
± 0.2 %
± 0.2 %
13.8.8
External position sensing system
13.8.8.1
Rated conditions for external position detection system
1
Ambient temperature
In hazardous areas, observe the maximum permissible am‐
bient temperature corresponding to the temperature class.
● Perm. ambient temperature for operation
-40 ... +90 °C (-40 ... +194 °F)
Degree of protection 1)
IP66 to IEC/EN 60529 / NEMA 4X
Climate class
According to IEC/EN 60721-3
● Storage
1K5, but -40 ... +90 °C (1K5, but -40 ... +194 °F)
● Transport
2K4, but -40 ... +90 °C (2K4, but -40 ... +194 °F)
● Operation
4K3, but -40 ... +90 °C (4K3, but -40 ... +194 °F)
) Impact energy max. 1 joule.
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Technical data
13.8 Option modules
13.8.8.2
Construction for external position detection system
Construction
How does it work?
● Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the posi‐
tioner shaft 16 to 90°)
● Angle of rotation (part-turn actuator)
30 ... 100°
Mounting method
● On the linear actuator
Using mounting kit 6DR4004-8V and, where necessary, an
additional lever arm 6DR4004-8L on actuators according to
IEC 60534-6-1 (NAMUR) with a fin, columns, or a plane
surface.
● On the part-turn actuator
Using mounting kit 6DR4004-8D on actuators with mount‐
ing plane according to VDI/VDE 3845 and IEC 60534-6-2:
The required mount must be provided on the actuator-side.
Material
● Enclosure
Makrolon® glass-fiber reinforced polycarbonate (PC)
Weight, basic device
Approximately 0.9 kg (1.98 lb)
Torque for cable gland nut made of plastic
2.5 Nm
13.8.8.3
Certificates, approvals, explosion protection for external position detection system
Electrical data
For connecting to circuits with the following
peak values
Ui = 5 V
Ii = 100 mA
Pi = 160 mW
Ci = negligibly small
Li = negligibly small
Certificates and approvals
CE conformity
The applicable directives and applied standards with their revision levels can
be found in the EC declaration of conformity on the Internet.
Explosion protection
Ex markings
Explosion protection in accordance with
ATEX
Intrinsic safety "ia"
Zone 1:
II 2 G Ex ia IIC T6/T4 Gb
Zone 21:
II 2 D Ex ia IIIC T110°C Db
Intrinsic safety "ic"
298
Zone 2:
II 3 G Ex ic IIC T6/T4 Gc
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Technical data
13.8 Option modules
Explosion protection
Ex markings
Non-sparking "nA"
Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
Permissible ambient temperature
T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +60 °C (-40 ... +140 °F)
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Technical data
13.8 Option modules
300
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14
Dimension drawings
14.1
Positioner in non-flameproof enclosure
A
>@
>@
>@
①
[
0
>@
C
>@ >@
D
E
O
<
>@
0
[
>@
>@
>@
3=
0
[
<
B
J
>@
>@
>@
>@
<
>@
>@
F
>@
0
>@
>@
N
>@
H
G
M
K
L
M20 x 1.5 or NPT adapter
Figure 14-1
Dimension drawing, dimensions in mm (inch)
6DR5..0
G¼
6DR5..1
6DR5..2
¼-NPT
A
184.5 [7.26]
B
-
186.5 [7.34]
-
6DR5..3 / 6DR64..
G¼
185 [7.28]
186.5 [7.34]
-
15 [0.59]
¼-NPT
186.5 [7.34]
188.5 [7.42]
C
95 [3.74]
84 [3.31]
99 [3.90]
98.6 [3.88]
D
48 [1.89]
34.5 [1.36]
49.5 [1.95]
48.6 [1.91]
E
88.5 [3.48]
88.5 [3.48]
88.8 [3.50]
F*)
29.5 [1.16]
-
29.5 [1.16]
29.5 [1.16]
G
39 [1.54]
44 [1.73]
39 [1.54]
39 [1.54]
90.5 [3.56]
H
14.5 [0.57]
16 [0.63]
16 [0.63]
14.5 [0.57]
J
96.6 [3.80]
96.6 [3.80]
98.5 [3.88]
103 [4.06]
K
18.5 [0.73]
22 [0.87]
18.5 [0.73]
18.5 [0.73]
L
18.5 [0.73]
7 [0.23]
18.5 [0.73]
18.5 [0.73]
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Dimension drawings
14.2 Terminal strip for positioners with Makrolon enclosure 6DR5..0 and aluminum enclosure 6DR5..3
6DR5..0
G¼
6DR5..1
6DR5..2
¼-NPT
M
6DR5..3 / 6DR64..
G¼
-
26.5
41.5
¼-NPT
40
N
-
7.5
7.5
7.5
O
14.5 [0.57]
14.5 [0.57]
14.5 [0.57]
15.5 [0.61]
Dimensions in mm [inch]
*) Dimension does not apply to double-acting actuators
6DR5..0
6DR5..1
6DR5..2
6DR5..3
6DR64..
14.2
Makrolon enclosure; dimensions with pneumatic connection G¼ or ¼-NPT
Aluminum enclosure, narrow, only single-action
Stainless steel enclosure, without inspection window
Aluminum enclosure; dimensions with pneumatic connection G¼ or ¼-NPT
SITRANS VP160; dimensions with pneumatic connection G¼ or ¼-NPT
Terminal strip for positioners with Makrolon enclosure 6DR5..0 and
aluminum enclosure 6DR5..3
[
*RU
ಯ137
[0
①
Thread depth
Figure 14-2
302
0
Terminal strip, dimensions in mm (inch)
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Operating Instructions, 02/2016, A5E00127926-AB
Dimension drawings
14.3 Positioner with flameproof enclosure
Positioner with flameproof enclosure
0
GHHS[
B
0
GHHS[
0
GHHS[
C
00RU
ಯ137[
D
E
A
14.3
ෘ
F
ෘK
G
①
②
All air connections G¼ or ¼" NPT
Air connection Y2, only with double-acting version
Figure 14-3
Dimensions of positioner in flameproof enclosure
6DR5..5
6DR5..6
A
5 [0.2]
-
B
60 [2.36]
-
C
25.7 [1.01]
21.7 [0.85]
D
33.5 [1.32]
25 [0.99]
E
33.5 [1.32]
-
F
158.5 [6.24]
160 [6.3]
G
235.3 [9.26]
227.6 [8.96]
Dimensions in mm [inch]
6DR5..5 Aluminum enclosure, flameproof; dimensions with pneumatic connection G¼ or ¼NPT
6DR5..6 Stainless steel enclosure, flameproof
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Dimension drawings
14.3 Positioner with flameproof enclosure
304
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Spare parts / accessories / scope of delivery
15.1
15
Order data
In order to ensure that the ordering data you are using is not outdated, the latest ordering data
is always available on the Internet:
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
15.2
Overview
WARNING
Assembling the components
When assembling components, ensure that only those positioners and option modules are
combined with each other that are approved for the corresponding operating range.
These conditions particularly apply to safe operation of the positioner in hazardous areas.
Observe the applicable certificates and approvals or the "Technical data (Page 283)".
Basic version
The positioner can be delivered for:
● Double-acting actuators
● Single-acting actuators
The positioner and its option modules are delivered as separate units and with different
versions for the operation in:
● Hazardous environments and atmospheres
● Non-hazardous environments and atmospheres
Enclosure
The electronic unit with display, the position feedback, and the pneumatic block are integrated
in the enclosure.
The enclosure is available in the following versions:
● Makrolon enclosure for single and double-acting actuators
● Aluminum enclosure for single-acting or double-acting actuators
● Stainless steel enclosure for single and double-acting actuators
● Flameproof enclosure for single and double-acting actuators
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Spare parts / accessories / scope of delivery
15.3 Spare parts
Options
The positioner can be equipped with different option modules. The following modules are
normally available:
● Position feedback module: two-wire current output 4 to 20 mA for position feedback
● Alarm module: 3 binary outputs and 1 binary input
● SIA module: one binary output for fault messages, two binary outputs for limit monitors
● Mechanical limit switch module with two switches and one alarm output
● Internal NCS module 6DR4004-5L/-5LE
The SIA module and the mechanical limit switch module cannot be used in device versions
with flameproof enclosure. For more limitations, please refer to section "Technical data
(Page 283)".
Accessories
● Pressure gauge block: 2 or 3 pressure gauges for single and double-acting positioners
● Mounting flange (NAMUR) for safety pneumatic block
● Mounting kits for linear and part-turn actuators
For separate mounting of positioner and position sensor
● External position detection system
● NCS sensor for contactless position detection
Note
The version is identified using a special nameplate.
15.3
306
Spare parts
Description
Order No.
For version
Basic electronics, 2-wire, not Ex, without HART
A5E00082459
6DR50..-.N
Basic electronics 2-wire, Ex, without HART
A5E00082457
6DR50..-.D/E/F/G/K
Basic electronics, 2-wire, not Ex, with HART
A5E00082458
6DR51..-.N
Basic electronics, 2/3/4-wire, Ex, with HART
A5E00082456
6DR52..-.D/E/F/G/K
Basic electronics, 2/3/4-wire, not Ex, without
HART
A5E00102018
6DR53..-.N
Basic electronics, PROFIBUS PA, not Ex
A5E00141523
6DR55..-.N
Basic electronics, PROFIBUS PA, Ex
A5E00141550
6DR55..-.D/E/F/G/K
Basic electronics, FOUNDATION Fieldbus, not Ex A5E00215467
6DR56..-.N
Basic electronics, FOUNDATION Fieldbus, Ex
6DR56.-.D/E/F/G/K
A5E00215466
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Spare parts / accessories / scope of delivery
15.4 Scope of delivery of external position detection system
Description
Order No.
For version
Pneumatic block, single-acting, with seal and
screws
C73451-A430-D80
6DR5...
Pneumatic block, double-acting, with seal and
screws
C73451-A430-D81
6DR5...
Valve manifold for Fail in Place, with seal, cover
panel and screws
A5E34409029
-Z F01
Potentiometer (complete)
C73451-A430-D84
6DR5...
Magnet holder made of fiberglass reinforced poly‐ A5E00078030
ester including magnet for non-contacting position
detection for part-turn actuators
6DR4004-.N.10
Magnet holder made of anodized aluminum in‐
A5E00524070
cluding magnet for non-contacting position detec‐
tion for part-turn actuators
6DR4004-.N.40
Stainless steel sound absorber, 3 units
A5E32527711
6DR5..0; 6DR5..1;
6DR5..2; 6DR5..3
Manometer 0 to 10 bar, metal, G1/8, 3 units
A5E32527731
6DR5...
Manometer 0 to 10 bar, stainless steel, G1/8, 3
units
A5E32527735
6DR5...
Note
See Catalog FI 01 "Field devices for process automation" for additives and possible modules".
15.4
Scope of delivery of external position detection system
Scope of delivery of external position detection system C73451-A430-D78
Quan‐
tity
Designation
1
DVD
with the complete documentation for all variants and accessories
1
External position detection system
1
Gray cable gland
1
Sealing set 2x5 mm for cable gland
1
Plug for sealing set
1
Nameplate for device version without explosion protection
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Spare parts / accessories / scope of delivery
15.6 Scope of delivery EMC filter module
15.5
Scope of delivery of mechanical limit switch module
If the mechanical limit switch module was ordered for later installation, then the following
components are included in the scope of delivery:
● One mechanical limit switch module with accessories
● DVD with product documentation
● One housing cover with enlarged aperture
● One insulating cover
● Two cable ties
● One set of signs; how these are to be attached depends on the version.
15.6
Scope of delivery EMC filter module
Cable glands and adapters
The EMC filter module is supplied with various cable glands and adapters. The following
diagram shows the different variants.
1
2
3
6
5
4
Connections ① to ③ for power supply
①
Adapter M20 to ½-14 NPT for
Connections ④ to ⑥ for optional modules
④
● 6DR5..0/1/2/3-0.N/P
②
M12 connector for device version with
PROFIBUS or FOUNDATION fieldbus
communication
● 6DR55..0-0.G/M/R/S
⑤
③
Cable gland for connection thread M20x1.5
for
● 6DR5..0/1/2/3-0.G/M
Figure 15-1
308
● 6DR56..0-0.G/M/R/S
Dummy plug for device version without op‐
tional modules
● 6DR5...-0..00
● 6DR55..-0.R/S
● 6DR56..-0.R/S
Cable gland for connection thread M20x1.5
with seal insert
⑥
Adapter M20 to ½-14 NPT for
● 6DR5..0/1/2/3-0.N/P
Positioner with the different cable glands and adapter
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Spare parts / accessories / scope of delivery
15.7 Accessories
Scope of delivery EMC filter module
Legend numbers refer to the graphic
Description
EMC filter module C73451-A430-L8
Sealing ring for ⑥
Cable tie
⑥
④
④
Adapter M20 to ½-14 NPT
Cable gland for connection thread, gray
Cable gland for connection thread, blue
Sealing set for ④
Sealing set plug for ④
Screw for plastic
Oval head screw M3x6
15.7
Accessories
For accessories, refer to Catalog FI 01 "Field devices for process automation", for example:
● Option modules
● NCS sensor for contactless position detection
● Mounting kits
● Operating software
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Spare parts / accessories / scope of delivery
15.7 Accessories
310
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A
Appendix
A.1
Operation with boosters
Introduction
In order to shorten the travel times, it is possible to use a booster between the positioner and
actuator. The booster increases the air performance.
With single-acting positioners you require a booster which must be connected to the air output
Y1. With double-acting positioners you require two boosters which must be connected to the
air output Y1 and to Y2.
NOTICE
Avoid pressure variations
Ensure pressure variations do not occur in the supply air PZ on the positioner due to the
booster.
NOTICE
Note when selecting the boosters:
● Only boosters may be used which do not have a continuous air consumption in the setpoint
input.
● The boosters must not have a follow-up time.
A stable operating state will not be reached if these two points are not observed. All process
components involved are subject to faster wear.
Procedure
1. Reduce the air performance. To do this, use the restrictors on the positioner.
2. Set the deadband "DEBA" to the largest value permissible for your process.
3. Start the initialization process.
4. If necessary, adjust the travel times during the initialization process.
If the process value on the display does not remain stable or if a constant manipulated variable
cannot be achieved for a constant setpoint, further optimization of the controller data is
necessary. This is described in section "Optimization of controller data (Page 110)".
See also
Sequence of automatic initialization (Page 116)
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Appendix
A.3 Technical support
A.2
Certificates
The certificates can be found on the DVD supplied and on the Internet at: Certificates (http://
www.siemens.com/processinstrumentation/certificates)
A.3
Technical support
Technical Support
If this documentation does not provide complete answers to any technical questions you may
have, contact Technical Support at:
● Support request (http://www.siemens.com/automation/support-request)
● More information about our Technical Support is available at
Technical support (http://www.siemens.com/automation/csi/service)
Internet Service & Support
In addition to our documentation, Siemens provides a comprehensive support solution at:
● Service&Support (http://www.siemens.com/automation/service&support) where you will
find support news, support documents including EDDs and software, and also support from
experts.
Additional Support
If you have additional questions about the device, please contact your local Siemens
representative.
Find your local contact partner at:
● Partner (http://www.automation.siemens.com/partner)
Documentation for various products and systems is available at:
● Instructions and manuals (http://www.siemens.com/processinstrumentation/
documentation)
See also
E-mail (mailto:[email protected])
SIPART PS2 product information (http://www.siemens.com/sipartps2)
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
312
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B
Abbreviations
B.1
Abbreviations for positioners
Abbreviation
Long form
A/D
Analog-to-digital converter
-
AC
Alternating current
Alternating current
AMS
Asset Management Solutions
Communication software from Emerson Process comparable
with the PDM
AUT
Automatic
Operating mode
ATEX
Atmosphère explosible
Product and operation directive of European Commission for
explosion protection.
CENELEC
Comité Européen de Normalisation
Electrotechnique
European committee for electrotechnical standardization
CPU
Central processing unit
Master processor
CSA
Canadian Standard Association
-
DC
Direct current
Direct current
DI
Digital Input
Digital input
DIN
Deutsche Industrie Norm
-
DO
Digital Output
Digital output
DTM
Device Type Manager
-
EDD
Electronic Device Description
-
Ex
Explosion protection
-
EMC
Electromagnetic compatibility
-
FDT
Field Device Tool
-
FF
FOUNDATION Fieldbus
Fieldbus of the Fieldbus Foundation
FM
Factory Mutual
American testing agency/insurance company
FW
Firmware
Device-specific software
GSD
Device master data
-
HART®
Highway Addressable Remote Trans‐ Communication system for the development of industrial field
ducer
busses.
IP
International Protection
International protection types (long form as per DIN)
Ingress Protection
Seepage protection (long form as used in US)
LC
Liquid crystal
Liquid crystal
MAN
Manual
Operating mode
NAMUR
Standards working group for meas‐
urement and control technology in the
chemicals industry
Association of users in process conductor technology
µC
Microcontroller
One-Chip computer system
NCS
Non Contacting Sensor
Sensor for contactless position detection
NEMA
National Electrical Manufacturers As‐
sociation
US standards institution
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Meaning
National Electrical Manufacturers Association
313
Abbreviations
B.2 Abbreviations for functional safety
Abbreviation
Long form
Meaning
NPT
National Pipe Thread Taper
Pipe threading for self-sealing threads as per ANSI B.1.20.1
OPOS interface
Open Positioner Interface
Standard interface for the connection between a positioner and
a pneumatic linear or part-turn actuator
PA
Process Automation
Process automation
PDM
Process Device Manager
Siemens communication software / Engineering tool
PROFIBUS
Process Field Bus
Fieldbus
SIA
Slit initiator alarm module
-
VDE
Verband der Elektrotechnik, Elektro‐
nik und Informationstechnik e. V.
Industrial and professional association
VDI
Verein Deutscher Ingenieure e. V.
Technical/scientific association
®
B.2
Abbreviations for functional safety
Abbreviation
Full term in English
Meaning
FIT
Failure in Time
Frequency of failure
Number of faults within 109 hours
HFT
Hardware Fault Tolerance
Hardware fault tolerance:
Capability of a function unit to continue executing a required
function in the presence of faults or deviations.
MooN
"M out of N" voting
Classification and description of the safety-instrumented system
in terms of redundancy and the selection procedures used.
A safety-instrumented system or part that consists of "N" inde‐
pendent channels. The channels are connected to each other in
such a way that "M" channels are in each case sufficient for the
device to perform the safety instrumented function.
Example:
Pressure measurement: 1oo2 architecture. A safety-instrumen‐
ted system decides that a specified pressure limit has been ex‐
ceeded if one out of two pressure sensors reaches this limit. In
a 1oo1 architecture, there is only one pressure sensor.
MTBF
Mean Time Between Failures
Average period between two failures
MTTR
Mean Time To Restoration
Average period between the occurrence of a fault in a device or
system and restoration of functionality
PFD
Probability of Dangerous Failure on
Demand
Probability of dangerous failures of a safety function on demand
PFDAVG
Average Probability of Dangerous Fail‐ Average probability of dangerous failures of a safety function on
ure on Demand
demand
SFF
Safe Failure Fraction
Proportion of safe failures:
Proportion of failures without the potential to bring the safety-in‐
strumented system into a dangerous or non-permissible func‐
tional status.
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Abbreviations
B.2 Abbreviations for functional safety
Abbreviation
Full term in English
Meaning
SIL
Safety Integrity Level
The international standard IEC 61508 defines four discrete Safe‐
ty Integrity Levels (SIL 1 to SIL 4). Each level corresponds to a
range of probability for failure of a safety function. The higher the
Safety Integrity Level of the safety-instrumented system, the low‐
er the probability that it will not execute the required safety func‐
tions.
SIS
Safety Instrumented System
A safety-instrumented system (SIS) executes the safety func‐
tions that are required to achieve or maintain a safe status in a
system. It consists of sensors, logic unit/control system and final
controlling elements.
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Abbreviations
B.2 Abbreviations for functional safety
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Glossary
Actuator
Converter that converts electric signals into mechanical or other non-electric variables.
Actuator chamber
For pneumatic actuators which consist of two pressure chambers in double-acting versions
and of a pressure chamber and a spring chamber in single-acting versions.
Analog
A signal type which represents data using continuously varying, measurable and physical
quantities, e.g. current or voltage. Opposite to digital. The range between 4 and 20 mA is often
used to transfer analog signals.
Analog-to-digital converter
An analog-to-digital converter is an interface between the analog environment and the digitally
working computers. Only then can the computers be used for measurement and control tasks.
Analog-to-digital converters convert analog input signals to digital signals. Analog
measurement data is thus converted into digital information. On the other hand, a digital-toanalog converter coverts digital information into analog signals.
Asset Management Solution (AMS)
Software package by Emerson Process. The AMS Device Manager, which is somewhat similar
to the PDM, is the most significant part of the package.
ATEX
ATEX is the abbreviation of the French term "Atmosphère explosible". ATEX stands for the
two directives of the European Community in the field of explosion protection: the ATEX
product directive 94/9/EC and the ATEX operation directive 1999/92/EC.
Auxiliary voltage
Auxiliary voltage is an electric supply or reference voltage that is required by some electric
circuits in addition to the standard supply. The auxiliary voltage can, for example, be specially
stabilized, have a particular level or polarity and/or other properties which are important for the
correct functioning of switch components. Auxiliary voltage is used, for example, with four-wire
systems.
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Glossary
Chamber
A largely or completely enclosed cavity in a machine or apparatus.
Conduit piping system
A piping system for the American market, wherein the electric and pneumatic lines are
protected by a casing.
Configuring
See parameter assignment.
Control fitting
A valve consisting of an actuator + control valve + positioner.
Cornerstone
Management software for process instrumentation.
Decrement
From the Latin word decrementare, decrease. Decrement is the defined amount of change
when decreasing a variable gradually. IT term that refers to a step-by-step decrease in a
numeric value.→Increment.
Degree of protection
The degree of protection of a device indicates the extent of protection. The extent of protection
includes the safety of persons against coming in contact with live or rotating parts, and the
protection of electric resources against the penetration of water, foreign bodies and dust. The
degrees of protection of electric machines are indicated by an abbreviation comprising two
letters and two numbers (e.g. IP55). The degree of protection is coded using the IP code. The
degrees of protection are standardized in DIN EN 60529.
Device category 1
Category 1 devices must be procured such that they ensure an extremely high degree of safety.
Devices in this category must ensure an extremely high degree of safety even for faults that
occur rarely. Even if two faults occur in the device, it should not lead to ignition. Devices in this
category are suitable for use in zone 0 or 20.
Device category 2
Category 2 devices must be procured such that they ensure a high degree of safety. Devices
in this category must ensure the required degree of safety in case of frequent faults or ones
that can be normally expected, e.g. defects in the device, and avoid ignition sources. Devices
in this category are suitable for use in zone 1 or 21.
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Glossary
Device category 3
Category 3 devices must be procured such that they ensure a normal degree of safety. Devices
in this category must ensure the required degree of safety in case of frequent faults or ones
that can be normally expected, e.g. defects in the device, and avoid ignition sources. Devices
in this category are suitable for use in zone 2 or 22.
Digital
Representation of a variable in the form of characters or numbers. The functional course of
an originally changeable analog variable is simulated in predefined stages. Predefined values
are assigned to these stages. Opposite to "analog".
EEPROM
EEPROM (Electrically Erasable Programmable Read-Only Memory) is a non-volatile
electronic memory chip. EEPROMs are often used when individual data bytes change over
long time periods and need to be saved in a manner protected against power failure, e.g.
configuration data or operating hours counters.
Electromagnetic compatibility
Definition as per the EMC law: EMC is the capability of a device to operate satisfactorily in an
electromagnetic environment without itself emitting electromagnetic signals which interfere
with other devices in that environment.
Ex d
"Flameproof enclosure" type of protection. When the potentially explosive mixtures enter the
enclosure of a resource and an ignition source exists in the enclosure. The transfer of the
explosion inside the enclosure to the surrounding space must be ruled out.
● d: flameproof enclosure
Ex ia / Ex ib / Ex ic
If potentially explosive mixtures enter the enclosure of a resource, it should not lead to ignition.
Demarcation of energy and increased temperatures.
Ex n
Equipment containing energy-limiting, non-sparking contacts as well as circuits whose
contacts are supplied with limited energy.
Ex t
Dust ignition protection with "t" enclosure. Dust ignition protection where the electric equipment
has an enclosure providing protection against dust ingress and a measure for limiting the
surface temperature.
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Glossary
Factory Mutual
Industrial property insurer and certification agency in the USA. FM Global is one of the largest
industrial insurers in the world who are specialized in the field of technically-supported property
insurance. It offers services like product research, testing and certification.
Failure that causes a dangerous situation
Failure with the potential to switch a safety-instrumented system to a hazardous or nonfunctioning safety status.
Fieldbus
A fieldbus is an industrial communication system used to connect a number of field devices
with a control device. Field devices include temperature transmitters, pressure transmitters,
and positioners.
Firmware
Firmware (FW) is software that is embedded on a chip in electronic devices – in contrast to
software which is saved on hard disks, CD-ROMs or other media. These days, firmware is
mostly stored in a flash memory or an EEPROM. Firmware is software in the hardware, and
is thus an intermediate between software and hardware. Firmware is normally model-specific.
This means that it does not function on other device models and is delivered by the
manufacturing company. The corresponding devices cannot function without the firmware. The
firmware mostly contains elementary functions to control the device, as well as input and output
routines.
Frequency shift keying
Frequency shift keying (FSK)
Frequency shift keying is a simple modulation format in which digital values 0 and 1 are
represented by two different frequencies.
GSD file
The file that describes the properties of a PROFIBUS DP slave or a PROFINET IO device.
The GSD file is a database file for PROFIBUS devices. The device manufacturer provides the
corresponding GSD file containing the description of device properties. The information in the
file can be read using Engineering Tools.
Increment
From the Latin word incrementare, increase. Increment is the defined amount of change when
increasing a variable gradually. IT term that refers to a step-by-step increase in a numeric
value.→Decrement.
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Glossary
Initialization
Setting the most important basic parameters. Requirement for commissioning the positioner.
IP code
The abbreviation IP stands for International Protection as per DIN. In English-speaking
countries, IP stands for Ingress Protection.
Makrolon
Glass-fiber reinforced polycarbonate (PC).
Microcontroller
Microcontrollers (also µController, µC, MCU) are single-chip computer systems in which almost
all components such as master processor, program memory, working memory and input/output
interfaces are included in a single chip.
NAMUR
Standardization association for measurement and control in chemical industries. NAMUR is
an association of users of process control technology. The members are mainly companies
from German-speaking countries. The association was formed in Leverkusen in 1949.
NEMA
National Electrical Manufacturers Association. NEMA is a standardization institute in the USA.
NEMA was formed in 1926 with the merge of Associated Manufacturers of Electrical Supplies
and the Electric Power Club.
NEMA 4
An enclosure standard of the National Electrical Manufacturers Association. NEMA 4compliant devices are suitable for use in indoor and outdoor applications. Protection is provided
against dust particles, rain as well as spray and splash water.
NEMA 4x
The same protection as NEMA 4. Additional protection of the enclosure from corrosion.
Parameter assignment
Individual parameter settings are specifically changed to adjust the positioner as per the
actuator or other requirements. Parameter assignment is carried out after the complete
commissioning of the positioner.
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Glossary
Piezoelectric effect
Name of a physical phenomenon. Due to mechanical compression loads on a crystal, an
electric potential develops on specific crystal surfaces. In a reverse case, applying an electric
field to specific crystal surfaces leads to crystal deformation.
Potentially explosive atmosphere
Mixture of air, combustible gases, fluff, fibers or dusts.
Pressure chamber
The pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is pressurized and depressurized. The pressure
developed works against a spring. In a double-acting version, two pressure chambers work
against each other. Pressurizing the volume of one chamber simultaneously depressurizes
the volume of the other.
Process Device Manager
PDM is a Siemens software package for configuration, parameter assignment, commissioning
and maintenance of network configurations and field devices. Part of SIMATIC STEP 7. Used
for configuration and diagnostics.
PROFIBUS
PROFIBUS stands for process fieldbus. PROFIBUS is a vendor-independent standard for
networking field devices (e.g. PLCs, actuators, final control elements, and sensors).
PROFIBUS is compatible with protocols such as DP (decentralized peripherals), FMS (fieldbus
message specification) and PA (process automation).
Protection level
● ia: Protection level. Electric equipment operating fault-free, and with existence of two
countable errors.
● ib: Protection level. Electric equipment operating fault-free, and with existence of one
countable error.
● ic: Protection level. Electrical equipment is not able to cause an ignition when operating
fault-free.
Protocols
Protocols contain information about data formats, time sequences and error handling when
exchanging data between computers.
A protocol is a convention about establishing, monitoring and terminating a connection.
Different protocols are required for a data connection. Protocols can be assigned to every layer
of the reference model. Transport protocols are used for the lower four layers of the reference
model and higher protocols are used for control, data provision and application.
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Glossary
Safety function
Defined function executed by a safety-instrumented system with the objective of attaining or
maintaining a safe status of the system by taking a defined hazardous incident into account.
Example: limit pressure monitoring
Safety-instrumented system
A safety-instrumented system (SIS) executes safety functions that are required to attain or
maintain the safe status in a system. It consists of sensors, logic unit/control system and final
controlling elements.
Example: a safety-instrumented system consists of a pressure transmitter, a limit signal
indicator and a servo valve.
Sensor
Converter that converts mechanical or other non-electric variables into electric signals.
SIL
The international standard IEC 61508 defines four discrete safety integrity levels (SIL) from
SIL 1 to SIL 4. Every level indicates a probability range for the failure of the safety function.
The higher the SIL of the safety-instrumented system, the higher the probability that the
required safety function works. The achievable SIL is determined by the following safetyinstrumented characteristics:
● Average probability of dangerous failures of a safety function on demand (PFDAVG)
● Hardware fault tolerance (HFT)
● Safe failure fraction (SFF)
SIMATIC software
Programs for process automation (e.g. PCS 7, WinCC, WinAC, PDM, STEP 7).
Zone 0
Area in which potentially explosive atmospheres build up often, regularly or over long durations
during the normal operation of a device.
Zone 1
Area in which potentially explosive atmospheres build up occasionally during the normal
operation of a device.
Zone 2
Area in which a potentially explosive atmosphere normally never builds up or builds up only
for a short while during the normal operation of a device.
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Glossary
Zone 20
Zone 20 is an area in which a potentially explosive atmosphere in the form of a cloud of
combustible dust in air is present continuously, over a long period, or frequently.
Zone 21
Zone 21 is an area in which a potentially explosive atmosphere in the form of a cloud of
combustible dust in air can be occasionally produced during normal operation.
Zone 22
Zone 22 is an area in which a potentially explosive gaseous atmosphere in the form of a cloud
of combustible dust in air never develops or develops only for a short while during normal
operation.
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Index
A
Accessories, 306
Actuating pressure, 26
Adapter, 308
Additional Support, 312
Alarm module
Installation, 63
Position, 56, 59
Amplifier, (See booster)
Article number
on the nameplate, 24
Attenuator, 290
Auxiliary power supply
Failure, 98
B
Basic electronics, 306, (Motherboard)
Graphic, 28
Position, 56, 59
Booster, 311
Bus cable, 26
Connecting, 82
C
C73451-A430-D23, (See EMC filter module)
C73451-A430-D78, (See position detection system)
Cable gland, 308
Carrier, 45, 147
Carrier pin, 125, 128
Certificates, 17, 312, (Certificates)
characteristics
Safety, 143
Commissioning
Automatically, 125, 131
Cancel, 126, 133
Interrupting, 125
Manual, 127, 134
Compressed air, 38
Connecting
NCS sensor, 86
Position detection system, 87
SIA module, 91
Connection
Pneumatic, 96, 122
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Control air outlet, 290
Control system, 21, 140
Correct usage, (See improper device modifications)
Coupler, 34
Customer Support Hotline, 312
D
Device operating mode
Parameter, 173
Diagnostics, 252
During ongoing operation, 267
Extended, 150, 170
Diagnostics guide, 273
E
EMC filter module
Installation, 74
Scope of delivery, 309
Enclosure, 305
Enclosure ventilation, 290
Ex markings, 287, 297, 298, 299
Exhaust air outlet, 26, 290, 291
Extended diagnostics, 170
Parameter, 150
F
Factory setting
Resetting to ~, 125, 131
Fault identification, 273
Final controlling element, 140
Firmware, 13
FISCO, 34
Five-point controller, 21, 29
Flow rate, 291
Friction clutch, 21, 26, 53
Position, 56
G
Gear
switchable, 21
325
Index
H
Hazardous area
Laws and directives, 17
History, 13
Hotline, 312
I
Improper device modifications, 18
Initialization, (Commissioning)
Automatically, 116
Interrupting, 131
Installation
Alarm module, 63
Position feedback module, 62
SIA module, 65
Internal NCS module
Commissioning, 124
Installation, 51, 70
Technical specifications, 297
Internet, 312
Iy module, (See position feedback module)
L
Leakage
Pneumatic, 151
Leakage test
Offline, 257
Limit monitoring for total strokes, 168
Linear actuator
Automatic commissioning, 125
Automatic commissioning (flowchart), 117
Manual commissioning, 127
Pneumatic connection, integrated, 96
Single-acting, 22
Link, 34
M
Manometer
Mounting, 76
Master
Class-1 master, 32
Class-2 master, 32
Mechanical limit switch module, 115
Position, 56, 59
Mode of operation, 28
326
Module cover
Position, 56, 59
Motherboard, (See basic electronics), (See basic
electronics)
Mount
Dimensions, 49
Mounting kit
Linear actuator, 40
N
Nameplate
Position, 57, 59
Natural gas
Maximum values for ventilation, 290
Operation, 115
NCS, 73
NCS sensor
Connecting to EMC filter module, 86
O
Offline leakage test, 257
Online diagnostics, 267
Operation
Natural gas, 115
Option module
Terminal, 26
Option modules, 306
Installation, 57
Order code, 24
Ordering supplement, 24
P
Parameters 1 to 5
Overview, 146
Parameters 6 to 53
Overview, 147
Parameters A to P
Overview, 151
Part-turn actuator
Automatic commissioning, 131
Automatic commissioning (flowchart), 117
Double-acting, 23
Manual commissioning, 134
Mounting, 45
Pneumatic actuator, 29
Pneumatic block, (See pneumatic block)
Position, 56, 59
Purging air selector, 122
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Index
Pneumatic connections, 122
Position detection system
External, 87
Position feedback module, 91
Installation, 62
Position, 57, 59
Positioner
Replacing, 136
With linear actuator, 22
Potentiometer, 73
External, 87
Position, 56, 59
Pressure gauge block, 22
Printed circuit board, (See basic electronics)
Product name, 24
PROFIBUS, 31
Automation system, 32
Connection, 33
DP, 31
Eigenschaft, 33
PA, 31
Profile, 33
Strand, 33
Topology, 32
Purge air switch, 290
Purging air selector, 26, 122
Pz, 143
servo valve
Integrated, 21
Shield connection, 26
SIA module
Connecting, 91
Installation, 65
Position, 56, 59
SIL 2, 140
Single-channel operation, 140
Slot initiator, (See SIA module)
Sound absorber, 26
Special screw
Position, 56
Station number
Parameter, 172
Support, 312
Symbols, (Refer to warning symbols)
System integration
PDM, 13
System pressure, (see Supply air)
T
R
Terminal strip, 122
Without flameproof enclosure, 83
Terminating resistor, 34
Terminating resistor T, 33
Test certificates, 17
Tight closing, 139
Transmission ratio selector, 26
Position, 56, 60
Transmitter, 140
Travel integral
Refer to limit monitoring for total strokes, 168
Reading initialization parameters, 136
Ribbon cable
Graphic, 56, 59
W
Q
Qualified personnel, 19
S
Safety function, 139
Safety position
Parameter, 172
Safety shutdown, 139
Scope of delivery, 14
EMC filter module, 309
Screen
Cleaning of~, 278
Screw terminal, 83
SELV, 34
Service, 312
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Warning label
Position, 56, 59
Warning symbols, 17
Wiring diagram on module cover, 57
Y
Y1, 143
327
Index
328
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Operating Instructions, 02/2016, A5E00127926-AB
Get more information
www.siemens.com/processautomation
www.siemens.com/positioners
Siemens AG
Process Industries and Drives
Process Automation
76181 Karlsruhe
GERMANY
Subject to change without prior notice
A5E00127926-AB
© Siemens AG 2016
A5E00127926
A5E00127926
www.siemens.com/automation
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