SIPART PS2 with and without HART

SIPART PS2 with and without HART
SIPART PS2 with and without HART
Operating Instructions • 09/2014
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SIPART
Electropneumatic positioners
SIPART PS2 with and without HART
Operating Instructions
Siemens AG
Industry Sector
Sensors and Communication
76181 Karlsruhe
GERMANY
Subject to change without prior notice
A5E00074631-12
© Siemens AG 2014
A5E00074631
A5E00074631
www.siemens.com/automation
A5E00074631D-12
GN: 30690_SIPART PS2
Edition
09/2014
Answers for industry.
SIPART PS2 with and without HART
1
___________________
Introduction
2
___________________
Safety information
SIPART
Electropneumatic positioners
SIPART PS2 with and without
HART
Operating Instructions
3
___________________
Description
4
___________________
Installing/mounting
5
___________________
Connection
6
___________________
Operating
7
___________________
Commissioning
___________________
8
Functional safety
___________________
9
Parameterizing/addressing
Alarm, error, and system
___________________
10
messages
___________________
11
Service and maintenance
___________________
12
Technical data
___________________
13
Dimension drawings
6DR50.. - Positioner without HART
6DR51.. - Positioner with HART, not explosion-proof
6DR52.. - Positioner with HART, explosion-proof
6DR53.. - Positioner without HART, not explosionproof
09/2014
A5E00074631-12
14
___________
Spare
parts/accessories/scope of
delivery
___________________
A
Appendix
___________________
B
Abbreviations
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
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E00074631
Ⓟ 10/2014 Subject to change
Copyright © Siemens AG 2014.
All rights reserved
Table of contents
1
2
3
4
Introduction ........................................................................................................................................... 11
1.1
Purpose of this documentation ...............................................................................................11
1.2
History .....................................................................................................................................11
1.3
Purpose ...................................................................................................................................12
1.4
Checking the consignment .....................................................................................................12
1.5
Transportation and storage .....................................................................................................13
1.6
Product information .................................................................................................................13
1.7
Notes on warranty ...................................................................................................................13
Safety information ................................................................................................................................. 15
2.1
2.1.1
2.1.2
2.1.3
Requirements for safe use ......................................................................................................15
Warning symbols on the device ..............................................................................................15
Laws and directives ................................................................................................................16
Conformity with European directives ......................................................................................16
2.2
Improper device modifications ................................................................................................16
2.3
Requirements for special applications ....................................................................................17
2.4
Use in hazardous areas ..........................................................................................................17
Description ............................................................................................................................................ 19
3.1
Function ..................................................................................................................................19
3.2
3.2.1
3.2.2
Structure .................................................................................................................................19
Overview of structure ..............................................................................................................19
Nameplate layout ....................................................................................................................22
3.3
3.3.1
3.3.2
Device components ................................................................................................................24
Overview of device components .............................................................................................24
Basic electronics .....................................................................................................................25
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
Mode of operation ...................................................................................................................26
Control algorithm.....................................................................................................................27
Block circuit diagram for single-acting or double-acting actuators .........................................28
Mode of operation of the HART function ................................................................................29
HART system configuration ....................................................................................................29
SIMATIC PDM ........................................................................................................................30
Installing/mounting ................................................................................................................................ 31
4.1
4.1.1
Basic safety instructions .........................................................................................................31
Proper mounting .....................................................................................................................34
4.2
Mounting the linear actuator ...................................................................................................34
4.3
Mounting the part-turn actuator ..............................................................................................40
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
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Table of contents
5
6
4.4
Using the positioner in a humid environment ......................................................................... 44
4.5
Positioners subjected to fast acceleration or strong vibration ............................................... 45
4.6
External position detection ..................................................................................................... 48
4.7
4.7.1
4.7.1.1
4.7.1.2
4.7.2
4.7.3
4.7.4
4.7.4.1
4.7.5
4.7.5.1
4.7.5.2
4.7.6
4.7.7
Installing option modules ....................................................................................................... 48
General information on installing option modules .................................................................. 48
Installing optional modules in the standard and intrinsically safe version ............................. 49
Installing the optional modules in the "flameproof enclosure" version ................................... 52
Position feedback module ...................................................................................................... 56
Alarm module ......................................................................................................................... 57
Slot initiator alarm module ..................................................................................................... 59
Setting the limits of the slotted initiator alarm module ........................................................... 61
Mechanical limit switch module.............................................................................................. 62
Setting the limits of the mechanical limit switch module ........................................................ 64
Label set for limit contact module .......................................................................................... 65
EMC filter module................................................................................................................... 66
Accessories ............................................................................................................................ 68
Connection ........................................................................................................................................... 69
5.1
Basic safety instructions ........................................................................................................ 69
5.2
5.2.1
5.2.1.1
5.2.1.2
5.2.2
5.2.2.1
5.2.2.2
5.2.2.3
5.2.3
5.2.4
Electric ................................................................................................................................... 73
Device 6DR5..0/1/2/3-0N or 6DR5..5-0E ............................................................................... 73
Basic electronics with 6DR5..0/1/2/3-0N or 6DR5..5-0E ....................................................... 73
Option modules with 6DR5..0/1/2/3-0N or 6DR5..5-0E ......................................................... 77
Device 6DR5..0/1/2/3-0E/D/F/G/K ......................................................................................... 81
Breakdown of the article numbers 6DR5..0/1/2/3-0E/D/F/G/K .............................................. 81
Basic electronics with 6DR5..0/1/2/3-0E/D/F/G/K.................................................................. 82
Option modules with 6DR5..0/1/2/3-0E/D/F/G/K ................................................................... 86
Connecting NCS to EMC filter module .................................................................................. 91
Connecting the external position detection system to the EMC filter module ....................... 93
5.3
5.3.1
5.3.1.1
5.3.1.2
5.3.1.3
5.3.1.4
5.3.2
Pneumatic .............................................................................................................................. 95
Pneumatic connections .......................................................................................................... 95
Pneumatic connection for 6DR5..0/1/2/3 ............................................................................... 95
Integrated pneumatic connection ........................................................................................... 95
Pneumatic connection for 6DR5..5-0E... ............................................................................... 96
Reaction to failure of auxiliary powers ................................................................................... 97
Pneumatic connection .......................................................................................................... 100
5.4
Restrictors ............................................................................................................................ 101
Operating .............................................................................................................................................103
6.1
6.1.1
6.1.2
6.1.3
Operating elements .............................................................................................................. 103
Display ................................................................................................................................. 103
Buttons ................................................................................................................................. 105
Firmware version.................................................................................................................. 106
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 ............................................................................................. 111
SIPART PS2 with and without HART
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Table of contents
7
8
9
Commissioning ................................................................................................................................... 113
7.1
Basic safety instructions .......................................................................................................113
7.2
Commissioning overview ......................................................................................................115
7.3
Sequence of automatic initialization .....................................................................................117
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.............................................................................125
Manual initialization of linear actuators .................................................................................127
7.6
7.6.1
7.6.2
7.6.3
Commissioning part-turn actuators .......................................................................................131
Preparing part-turn actuators for commissioning ..................................................................131
Automatic initialization of part-turn actuators ........................................................................132
Manual initialization of part-turn actuators ............................................................................134
7.7
Device replacement ..............................................................................................................137
Functional safety ................................................................................................................................. 139
8.1
Range of applications for functional safety ...........................................................................139
8.2
Safety function ......................................................................................................................139
8.3
Safety Integrity Level (SIL) ...................................................................................................141
8.4
Settings .................................................................................................................................142
8.5
Safety characteristics ............................................................................................................143
8.6
Maintenance/check ...............................................................................................................144
Parameterizing/addressing .................................................................................................................. 145
9.1
Parameter chapter ................................................................................................................145
9.2
Configuration schematic for parameter operating principle ..................................................146
9.3
9.3.1
9.3.2
9.3.3
Parameter overview ..............................................................................................................147
Overview of initialization parameters 1 to 5 ..........................................................................147
Overview of application parameters 6 to 52 .........................................................................148
Overview of advanced diagnostics parameters A to P .........................................................152
9.4
9.4.1
9.4.1.1
9.4.1.2
9.4.1.3
9.4.1.4
9.4.1.5
9.4.2
9.4.2.1
9.4.2.2
9.4.2.3
9.4.2.4
9.4.2.5
9.4.2.6
9.4.2.7
Description of parameters .....................................................................................................156
Description of initialization parameters 1 to 5 .......................................................................156
'1.YFCT' Type of actuator .....................................................................................................156
'2.YAGL' Rated angle of rotation of feedback .......................................................................157
'3.YWAY' Range of stroke.....................................................................................................158
'4.INITA' Initialization (automatically) ....................................................................................158
'5.INITM' Initialization (manual) .............................................................................................159
Description of application parameters 6 to 52 ......................................................................159
'6.SCUR' Current range of setpoint ......................................................................................159
'7.SDIR' Setpoint direction ....................................................................................................160
'8.SPRA' Setpoint split range start / '9.SPRE' Setpoint split range end ...............................160
'10.TSUP' Setpoint ramp UP / '11.TSDO' Setpoint ramp DOWN .........................................161
'12.SFCT' Setpoint function ..................................................................................................162
'13.SL0' ... '33.SL20' Setpoint turning point ..........................................................................162
'34.DEBA' Deadband of closed-loop controller .....................................................................163
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
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Table of contents
9.4.2.8
9.4.2.9
9.4.2.10
9.4.2.11
9.4.2.12
9.4.2.13
9.4.2.14
9.4.2.15
9.4.2.16
9.4.2.17
9.4.2.18
9.4.2.19
9.4.2.20
9.4.2.21
9.4.3
9.4.3.1
9.4.3.2
9.4.3.3
9.4.3.4
9.4.3.5
9.4.3.6
9.4.3.7
9.4.3.8
9.4.3.9
9.4.3.10
9.4.3.11
9.4.3.12
10
'35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit ........ 164
'37.YNRM' Standardization of manipulated variable............................................................ 164
'38.YDIR' Direction of manipulated variable for display and position feedback ................... 166
'39.YCLS' Tight closing with manipulated variable .............................................................. 166
'40.YCDO' Lower value for tight closing / '41.YCUP' Upper value for tight closing ............. 166
'42.BIN1' / '43.BIN2' Function binary inputs ......................................................................... 167
'44.AFCT' Alarm function ..................................................................................................... 169
'45.A1' / '46.A2' Response threshold of alarms ................................................................... 170
'47._FCT' Function fault message output ............................................................................ 171
'48._TIM' Monitoring time for setting of fault message "Control deviation" .......................... 172
'49._LIM' Response threshold for fault message "Control deviation" .................................. 172
'50.PRST' Preset .................................................................................................................. 173
'51.PNEUM' Fail in place ..................................................................................................... 174
'52.XDIAG' Activating for extended diagnostics ................................................................... 174
Description of advanced diagnostics parameters A to P ..................................................... 175
Partial stroke test "A._PST" ................................................................................................. 175
Monitoring of dynamic control valve behavior "b._DEVI" ..................................................... 181
Monitoring pneumatic leakage "C._LEAK" ........................................................................... 183
Monitoring the stiction (slipstick) "d._STIC" ......................................................................... 185
Monitoring the deadband "E._DEBA"................................................................................... 187
Monitoring the lower endstop "F._ZERO" ............................................................................ 188
Monitoring the upper endstop "G._OPEN" ........................................................................... 190
Monitoring the lower limit temperature "H._TMIN" ............................................................... 192
Monitoring the upper limit temperature "J._TMAX" .............................................................. 193
Monitoring the number of total strokes "L._STRK" .............................................................. 194
Monitoring the number of changes in direction "O._DCHG" ................................................ 195
Monitoring the position average value "P._PAVG" .............................................................. 197
Alarm, error, and system messages .....................................................................................................199
10.1
10.1.1
10.1.2
10.1.3
10.1.4
Output of system messages in the display .......................................................................... 199
System messages before initialization ................................................................................. 199
System messages during initialization ................................................................................. 200
System messages when exiting the Configuration mode .................................................... 203
System messages during operation..................................................................................... 204
10.2
10.2.1
10.2.2
10.2.3
10.2.3.1
10.2.3.2
10.2.3.3
10.2.3.4
Diagnostics ........................................................................................................................... 205
Display of diagnostics values ............................................................................................... 205
Overview of diagnostics values............................................................................................ 206
Meaning of the diagnostics parameters ............................................................................... 209
Diagnostics parameter '1.STRKS' Number of total strokes ................................................. 209
Diagnostics parameter '2.CHDIR' Number of changes in direction ..................................... 209
Diagnostics parameter '3._CNT' Number of fault messages ............................................... 209
Diagnostics parameters '4.A1CNT' Number of alarms 1 / '5.A2CNT' Number of alarms
2 ........................................................................................................................................... 209
Diagnostics parameter '6.HOURS' Number of operating hours .......................................... 210
Diagnostics parameter '7.HOURR' Resettable operating hours counter ............................. 210
Diagnostics parameter '8.WAY' - Determined travel............................................................ 210
Diagnostics parameters '9.TUP' Travel time UP / '10.TDOWN' Travel time DOWN ........... 210
Diagnostics parameter '11.LEAK' Leakage test................................................................... 211
Diagnostics parameter '12.PST' Monitoring of partial stroke test ........................................ 212
Diagnostics parameter '13.PRPST' Time since last partial stroke test ................................ 212
Diagnostics parameter '14.NXPST' Time until next partial stroke test ................................ 213
Diagnostics parameter '15.DEVI' General control valve fault .............................................. 213
10.2.3.5
10.2.3.6
10.2.3.7
10.2.3.8
10.2.3.9
10.2.3.10
10.2.3.11
10.2.3.12
10.2.3.13
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Operating Instructions, 09/2014, A5E00074631-12
Table of contents
10.2.3.14
10.2.3.15
10.2.3.16
10.2.3.17
10.2.3.18
10.2.3.19
10.2.3.32
Diagnostics parameter '16.ONLK' Pneumatic leakage .........................................................213
Diagnostics parameter '17.STIC' Stiction (slipstick) .............................................................214
Diagnostics parameter '18.ZERO' Lower endstop ................................................................214
Diagnostics parameter '19.OPEN' Displacement of upper end stop ....................................214
Diagnostics parameter '20.PAVG' Position average ............................................................215
Diagnostics parameters '21.P0' Potentiometer value of bottom end stop / '22.P100'
Potentiometer value of top end stop .....................................................................................216
Diagnostics parameters '23.IMPUP' Impulse length UP / '24.IMPDN' Impulse length
DOWN ...................................................................................................................................218
Diagnostics parameter '25.PAUTP' Interpulse period ..........................................................218
Diagnostics parameters '26.DBUP' Deadband UP / '27.DBDN' Deadband DOWN .............218
Diagnostics parameters '28.SSUP' Slow step zone UP / '29.SSDN' Slow step zone
DOWN ...................................................................................................................................219
Diagnostics parameter '30.TEMP' Current temperature .......................................................219
Diagnostics parameters '31.TMIN' Minimum temperature / '32.TMAX' Maximum
temperature ...........................................................................................................................219
Diagnostics parameters '33.T1' ... '41.T9' Number of operating hours in the
temperature range 1 to 9 ......................................................................................................220
Diagnostics parameters '42.VENT1' / '43.VENT2' ................................................................220
Diagnostics parameters '44.VEN1R' / '45.VEN2R' ...............................................................221
Diagnostics parameter '46.STORE' Save maintenance data ...............................................221
Diagnostics parameters '47.PRUP' Prediction UP / '48.PRDN' Prediction DOWN ..............222
Diagnostics parameters '49.WT00' ... '56.WT95' Number of operating hours in the
travel range WT00 to WT95 ..................................................................................................222
Diagnostics parameter '57.mA' Setpoint current ..................................................................222
10.3
10.3.1
10.3.2
10.3.3
10.3.4
10.3.4.1
10.3.4.2
10.3.4.3
10.3.4.4
10.3.4.5
10.3.4.6
10.3.4.7
10.3.4.8
10.3.4.9
10.3.4.10
10.3.4.11
10.3.4.12
10.3.4.13
10.3.4.14
10.3.4.15
Online diagnostics.................................................................................................................223
Overview of online diagnostics .............................................................................................223
Overview of error codes ........................................................................................................224
XDIAG parameter .................................................................................................................226
Meaning of error codes .........................................................................................................226
1 Remaining control deviation ..............................................................................................226
2 Device not in "Automatic" mode ........................................................................................226
3 Binary input BIN1 or BIN2 active .......................................................................................226
4 Monitoring the number of total strokes ..............................................................................227
5 Monitoring the number of changes in direction ..................................................................227
6 Monitoring the lower endstop / 7 Monitoring the upper endstop .......................................227
8 Monitoring deadband .........................................................................................................228
9 Partial stroke test ...............................................................................................................228
10 Monitoring of dynamic control valve behavior .................................................................228
11 Monitoring the pneumatic leakage ...................................................................................228
12 Monitoring of stiction (slipstick) ........................................................................................228
13 Monitoring the lower limit temperature.............................................................................228
14 Monitoring the upper limit temperature ............................................................................228
15 Monitoring the position average value .............................................................................229
16 Monitoring the plausibility of values for the partial stroke test .........................................229
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
Fault correction .....................................................................................................................229
Fault identification .................................................................................................................229
Remedial measures table 1 ..................................................................................................230
Remedial measures table 2 ..................................................................................................231
Remedial measures table 3 ..................................................................................................232
Corrective measures Table 4 ................................................................................................233
10.2.3.20
10.2.3.21
10.2.3.22
10.2.3.23
10.2.3.24
10.2.3.25
10.2.3.26
10.2.3.27
10.2.3.28
10.2.3.29
10.2.3.30
10.2.3.31
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Table of contents
10.4.6
11
Service and maintenance .....................................................................................................................235
11.1
Basic safety instructions ...................................................................................................... 235
11.2
11.2.1
Cleaning of the screens ....................................................................................................... 236
Positioners with Makrolon enclosure 6DR5..0, aluminum enclosure 6DR5..3, and
flameproof aluminum enclosure 6DR5..5 ............................................................................ 236
Positioners with stainless steel enclosure 6DR5..2 and narrow aluminum enclosure
6DR5..1 ................................................................................................................................ 237
11.2.2
12
13
14
Remedial measures table 5 ................................................................................................. 234
11.3
Fail in Place: replacing the basic electronics ....................................................................... 238
11.4
Repair/Upgrading ................................................................................................................. 238
11.5
Return procedure ................................................................................................................. 239
11.6
Disposal ............................................................................................................................... 239
Technical data .....................................................................................................................................241
12.1
Rated conditions .................................................................................................................. 241
12.2
Pneumatic data .................................................................................................................... 242
12.3
Construction ......................................................................................................................... 243
12.4
Controller.............................................................................................................................. 245
12.5
Certificates, approvals, explosion protection ....................................................................... 246
12.6
Electrical data....................................................................................................................... 247
12.7
Technical data for natural gas as actuator medium ............................................................. 249
12.8
12.8.1
12.8.2
12.8.3
12.8.4
12.8.5
12.8.6
12.8.7
Option modules .................................................................................................................... 250
Alarm module ....................................................................................................................... 250
Position feedback module .................................................................................................... 251
SIA module........................................................................................................................... 252
Mechanical limit switch module............................................................................................ 253
EMC filter module................................................................................................................. 254
Non-contacting position sensor............................................................................................ 255
External position detection system ...................................................................................... 256
Dimension drawings .............................................................................................................................259
13.1
Positioner with Makrolon enclosure 6DR5..0 and stainless steel enclosure 6DR5..2 ......... 259
13.2
Positioner with narrow aluminum enclosure 6DR5..1 .......................................................... 260
13.3
Positioner with aluminum enclosure 6DR5..3 ...................................................................... 261
13.4
Terminal strip for positioners with Macrolon enclosure 6DR5..0 and aluminum
enclosure 6DR5..3 ............................................................................................................... 262
13.5
Positioner with flameproof aluminum enclosure 6DR5..5 .................................................... 263
Spare parts/accessories/scope of delivery............................................................................................265
14.1
Overview .............................................................................................................................. 265
14.2
Spare parts ........................................................................................................................... 267
14.3
Scope of delivery of small part sets ..................................................................................... 268
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Table of contents
A
B
14.4
Scope of delivery of external position detection system .......................................................270
14.5
Scope of delivery of mechanical limit switch module ............................................................270
14.6
Scope of delivery EMC filter module .....................................................................................271
14.7
Accessories ...........................................................................................................................272
Appendix............................................................................................................................................. 273
A.1
Operation with boosters ........................................................................................................273
A.2
Certificates ............................................................................................................................274
A.3
Literature and catalogs .........................................................................................................274
A.4
Technical support..................................................................................................................274
Abbreviations ...................................................................................................................................... 277
Glossary ............................................................................................................................................. 281
Index................................................................................................................................................... 291
SIPART PS2 with and without HART
Operating Instructions, 09/2014, A5E00074631-12
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Table of contents
SIPART PS2 with and without HART
10
Operating Instructions, 09/2014, A5E00074631-12
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 for this revision is applicable for the following firmware:
Edition
Firmware identifier nameplate
09/2014
As of FW 5.00.00
The most important changes in the documentation compared with the previous edition are
shown in the following table.
Edition
Note
09/2014
1. Chapter "Parameter overview (Page 147)"
New parameters and values:
–
1.YFCT - Actuator > Initialization of actuators with inverted direction of action
is now possible.
–
50.PRST - Preset > Resetting of individual parameter groups is now possible.
–
51.PNEUM > Fail in place function can now be activated with appropriate
pneumatic system.
2. Chapter "Parameter overview (Page 147)"
New functions for the advanced diagnostics parameters:
–
A5.RPMD and A6.RPRT > Partial stroke test is now possible in ramp mode.
–
A7.FLBH > Response following failed PST can now be defined.
3. Chapter "Diagnostics (Page 205)"
Functions for the diagnostics values:
–
7.HOURR - Resettable operating hours counter added
–
11 LEAK > Offline leakage test added.
–
21 P0 and 22 P100 > Modification of upper and lower end stops now possible without initialization.
–
25 PAUTP > Adjustable no-pulse period added.
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11
Introduction
1.3 Purpose
See also
Structure (Page 19)
Construction (Page 243)
Positioner with flameproof aluminum enclosure 6DR5..5 (Page 263)
1.3
Purpose
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic actuators 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 Chapter "Technical data (Page 241)".
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.
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Introduction
1.5 Transportation and storage
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 241).
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)
Contacts (http://www.siemens.com/processinstrumentation/contacts)
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.
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Introduction
1.7 Notes on warranty
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2
Safety information
2.1
Requirements for safe 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.
2.1.1
Warning symbols on the device
Symbol
Meaning
Consult operating instructions
Hot surface
Isolate the device from power using a circuit-breaker
Protect the device from shocks (otherwise the specified degree of protection is not guaranteed)
Protective insulation; device in protection class II
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Safety information
2.2 Improper device modifications
2.1.2
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)
See also
Certificates (http://www.siemens.com/processinstrumentation/certificates)
2.1.3
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following
European guidelines:
Electromagnetic Compatibil- Directive of the European Parliament and of the Council on the
ity EMC
approximation of the laws of the Member States relating to elec2004/108/EC
tromagnetic compatibility and repealing Directive 89/336/EEC.
Atmosphère explosible
ATEX
94/9/EC
Directive of the European Parliament and the Council on the
approximation of the laws of the Member States concerning
equipment and protective systems intended for use in potentially explosive 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.
2.2
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.
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Safety information
2.3 Requirements for special applications
2.3
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.
2.4
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.
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17
Safety information
2.4 Use in hazardous areas
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 (Page 241)".
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Description
3.1
3
Function
● The electropneumatic positioner, in combination with the actuator, forms a control
system. The current position of the actuator is detected using a potentiometer and
returned as the actual value x. The setpoint and actual value are output simultaneously
on the display.
● The setpoint w forms a current applied to the positioner, which in two-wire mode is also
used to power the positioner. In 3- and 4-wire mode, power is supplied through a 24-V
power input.
● The positioner works as a predictive five-point controller, through whose output value ±Δy
the integrated valves can be controlled by pulse length modulation.
● These positioning signals cause pressure changes in the actuator chamber(s) and thus
repositioning of the actuator until the control deviation returns to zero.
● Using 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 electronics has a binary input (BIN1). This binary input can be
individually configured and used e.g. to block the control levels.
● To be able to use the positioner in a variety of mechanically different rotational and linear
actuators, it has a friction clutch and a switchable gear.
● 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.
3.2
Structure
3.2.1
Overview of structure
The following sections describe the mechanical and electrical structure, components, and
principle functionality of the positioner.
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
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Description
3.2 Structure
Various add-on extensions are available for linear actuators:
● IEC 60534-6-1 (NAMUR)
● Integrated addition to ARCA
● 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
①
②
③
Positioner attached to a single-acting linear actuator
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
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Description
3.2 Structure
①
②
③
④
Single-acting positioner in flameproof aluminum enclosure
Pressure gauge block, single-acting
Yoke / actuator yoke
Actuator
Figure 3-3
①
②
③
Positioner in flameproof aluminum enclosure attached to linear actuator
Part-turn actuator
Double-acting positioner in flameproof aluminum enclosure
Pressure gauge block, double-acting
Figure 3-4
Positioner in flameproof aluminum enclosure attached to part-turn actuator
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Description
3.2 Structure
3.2.2
Nameplate layout
Layout of the nameplate
①
②
③
④
⑤
Manufacturer
Software/hardware version
Built-in option module
⑧
⑨
⑩
⑪
⑫
⑥
⑦
Serial number
⑬
Product name
Safety class
Consult operating instructions
Conformity with country-specific directives
Place of manufacture
Auxiliary power
Ordering supplement (Order code)
Article number
Auxiliary power (supply air PZ)
Figure 3-5
Nameplate layout, example
Layout of Ex nameplate
①
②
Approvals
ATEX/IECEx marking for hazardous area
Figure 3-6
③
④
FM/CSA marking for hazardous area
Permitted ambient temperature for the hazardous
area of the corresponding temperature class
Ex nameplate layout, example
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Description
3.2 Structure
Explanation of Ex information
①
Category for operating range
④
②
③
Type of protection
⑤
Maximum surface temperature (temperature class)
Device protection level
Group (gas, dust)
Figure 3-7
Explanation of Ex information
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23
Description
3.3 Device components
3.3
Device components
3.3.1
Overview of device components
①
②
③
④
⑤
⑥
⑦
⑧
⑨
Input: Supply air PZ
Output: Actuating pressure Y1
Display
Output: Actuating pressure Y2
1)
Buttons
Restrictor Y1 for single-acting actuators
Restrictor Y1 for double-acting actuators
Restrictor Y2 for double-acting actuators
⑩
⑪
⑫
⑬
⑭
⑮
⑯
⑰
Transmission ratio selector 2)
Friction clutch adjustment wheel
Basic electronics
Connecting terminals of option modules
Dummy plug
Cable gland
Wiring diagram on module cover
Purging air selector
Exhaust air outlet with a sound absorber
1)
for double-acting actuators
2)
only possible when positioner is open
Figure 3-8
View of positioner with cover open
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Operating Instructions, 09/2014, A5E00074631-12
Description
3.3 Device components
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)
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
3.3.2
⑧
⑨
⑩
⑪
⑫
⑬
View of positioner in flameproof enclosure, cover opened
Basic electronics
Figure 3-10
Basic electronics, schematic representation
The basic electronics contains:
● CPU
● Memory
● Analog-to-digital converter
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Description
3.4 Mode of operation
● Display
● Buttons
● Terminal strips to connect the option module to the basic electronics
3.4
Mode of operation
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 control value w represents the positioning current of a closed-loop controller or a
manual control station from 0/4 to 20 mA.
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
Non-Contacting 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 the setpoint w. The setpoint w
is connected to terminals 6 and 7 by means of PROFIBUS communication.
● 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.
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.
See also
Block circuit diagram for single-acting or double-acting actuators (Page 28)
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Description
3.4 Mode of operation
3.4.1
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.
In case of medium control deviations, valves are controlled using pulse-length modulated
pulses. This takes place in the so-called slow step zone.
Figure 3-11
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 strokes are
continuously determined during operation and saved every 15 minutes. You can read and
document these parameters using communication programs such as 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.
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Description
3.4 Mode of operation
3.4.2
①
②
③
④
⑤
⑥
⑦
⑧
Block circuit diagram for single-acting or double-acting actuators
Basic electronics with microcontroller and input circuit
Control pad with display and buttons
Single-acting or double-acting pneumatic block
Position feedback module for positioner
Alarm module for three alarm outputs and one binary input
SIA module (slot initiator alarm module)
Spring-loaded pneumatic actuator (single-acting)
Pneumatic actuator (double-acting)
Figure 3-12
Block circuit diagram for the electropneumatic positioner, functional diagram
Note
Alarm module and SIA module
Alarm module ⑤ and SIA module ⑥ can only be alternatively used.
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Description
3.4 Mode of operation
3.4.3
Mode of operation of the HART function
Note
Priority of operation / failure of power supply
• Operation at the positioner has priority over specifications from the HART communicator.
• Failure of the auxiliary power to the positioner also interrupts communications.
Function
The positioner is also available with built-in HART functionality. The HART protocol allows
you to communicate with your device using a HART communicator, PC, or programming
unit. You can do the following with your device:
● Convenient configuration
● Store configurations
● Call up diagnostic data
● Show online measured values
Communication takes place as frequency modulation on the existing signal lines for the
control values of 4 to 20 mA.
The positioner is integrated into the following parameter assignment tools:
● HART communicator
● PDM (Process Device Manager)
● AMS (Asset Management System)
3.4.4
HART system configuration
Overview
The positioner can be used in a number of system configurations:
● Stand-alone, supplied with the required auxiliary power supply; communication with
supplementary units (handheld), for example
● As part of a complex system environment, e.g. SIMATIC S7
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Description
3.4 Mode of operation
System communication
Communication is via the HART protocol, using:
● HART Communicator (load 230 ... 1100 Ω)
● PC with HART modem, on which appropriate software is installed, e.g. SIMATIC PDM
(load 230 ... 500 Ω)
● Control system which can communicate via the HART protocol, e.g. SIMATIC PCS7
Figure 3-13
3.4.5
Typical system configurations
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
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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.
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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.
See also
Construction (Page 243)
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 241)".
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.
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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, you must hold the NPT adapter in place while screwing
the NPT gland into the NPT adapter. Refer to the section "Technical specifications >
Construction (Page 243)" for the torque value.
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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 241) 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 241)" 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 pneumatic mounting. Use the reduced mounting kit 6DR4004-8VK for actuators
with integrated mounting.
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Installing/mounting
4.2 Mounting the linear actuator
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
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 components
Yoke with fin
•
•
•
Yoke with
plane surface
•
•
•
Yoke with
columns
•
•
•
•
Hexagon bolt ⑧
Washer ⑪
Spring lock washer ⑩
Four hexagon bolts ⑧
Washer ⑪
Spring lock washer ⑩
Two U–bolts ⑦
Four hexagon nuts ⑳
Washer ⑪
Spring lock washer ⑩
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Installing/mounting
4.2 Mounting the linear actuator
Procedure
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. No. *)
Quantity
Name
Note
①
1
NAMUR mounting bracket
IEC 60534
Standardized connection point for mount with fin, column or plane
surface
②
1
Pick-up bracket
Guides the pulley with the carrier pin and rotates the lever arm.
③
2
Clamping piece
Installs the pick-up bracket on the actuator spindle
④
1
Carrier pin
Installation with pulley ⑤ on lever ⑥
⑤
1
Pulley
Installation with carrier pin ④ on lever ⑥
⑥
1
Lever
For the range of stroke from 3 mm to 35 mm
⑦
2
U–bolts
Only for actuators with columns
⑧
4
Hexagon bolt
M8x20 DIN 933–A2
⑨
2
Hexagon bolt
M8x16 DIN 933–A2, torque see the section "Technical specifications > Construction (Page 243)"
⑩
6
Spring lock washer
A8 - DIN 127–A2
⑪
6
Washer
B8.4 - DIN 125–A2
⑫
2
Washer
B6.4 - DIN 125–A2
⑬
1
Spring
VD-115E 0.70 x 11.3 x 32.7 x 3.5
⑭
1
Spring lock washer
A6 - DIN 137A–A2
⑮
1
Lock washer
3.2 - DIN 6799–A2
⑯
3
Spring lock washer
A6 - DIN 127–A2
⑰
3
Socket cap screw
M6x25 DIN 7984–A2
⑱
1
Hexagon nut
M6 - DIN 934–A4
⑲
1
Square nut
M6 - DIN 557–A4
⑳
4
Hexagon nut
M8 - DIN 934–A4
The lever 6DR4004–8L is additionally required for ranges of stroke
> 35 mm to 130 mm (not included in the scope of delivery).
*)
the serial numbers refer to the images of the description of the installation steps below.
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4.2 Mounting the linear actuator
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.
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.
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4.2 Mounting the linear actuator
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.
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
Positioner, base plate
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4.2 Mounting the linear actuator
Figure 4-5
Positioner in the flameproof enclosure, base plate
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
pick-up 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.
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.
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4.3 Mounting the part-turn actuator
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.
Procedure
"Part-turn actuator" mounting kit 6DR4004–8D
Sr.
No.
*)
Q Name
ua
nti
ty
Note
①
1
Coupling wheel Installation on positioner shaft
②
1
Carrier
Installation on stump of actuator shaft
③
1
Multiple plate
Display of the position, consisting of scale ⑤ and pointer mark ⑥
④
8
Scale
Different divisions
⑤
2
Pointer mark
Reference arrow for scale
Mount
Actuator-specific, VDI/VDE 3845
⑥
⑦
4
Hexagon bolt
M6x12 DIN 933, torque see the section "Technical specifications > Construction (Page 243)"
⑧
4
Lock washer
S6
⑨
1
Socket cap
screw
M6x16 DIN 84
⑩
1
Washer
6.4 DIN 125
⑪
1
Hexagon
socket-head
screw
For coupling wheel
1
Machinist's
wrench
For hexagon socket-head screw ⑪
*)
The serial numbers refer to the images describing the assembly procedure for a part-turn actuator, with and without
flameproof enclosure.
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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 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
Coupling wheel, flameproof enclosure
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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.
Figure 4-6
Carrier
5. With the coupling wheel: Place the positioner and the mount on the actuator carefully.
The pin of the coupling wheel ① must fit in the carrier ② when you do this.
With the stainless steel coupling: Place the positioner and the mount on the actuator
carefully. Place the stainless steel coupling on the stump of the actuator's positioner
shaft.
Orientation of mount
Orientation of mount, flameproof enclosure
6. Align the positioner/mount at the center of the actuator.
7. Tighten the positioner/mount unit.
8. Initialize the positioner.
9. After commissioning, drive the positioner to the end position.
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4.3 Mounting the part-turn actuator
10.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
H = height of shaft butt
①
②
Fixing level of positioner on mount
Part-turn actuator
Figure 4-7
Dimensions of mount in accordance with VDI/VDE 3845 (depends on actuator)
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4.4 Using the positioner in a humid environment
See also
Preparing part-turn actuators for commissioning (Page 131)
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 4-8
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.
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4.5 Positioners 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
Positioners subjected to fast acceleration or strong vibration
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. Using the accessory
"NCS sensor for non contact position detection", it is possible to mount the controller unit a
certain distance away, e.g. on a mounting pipe or similar.
The locking procedure is illustrated and described below.
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4.5 Positioners subjected to fast acceleration or strong vibration
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°.
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 4-9
Locking friction clutch and transmission ratio
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4.5 Positioners subjected to fast acceleration or strong vibration
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
(Page 24)".
• 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").
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4.6 External position detection
4.6
External position detection
WARNING
External position detection system
Versions with flameproof enclosures may not be operated with an external position
detection system.
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 an integrated friction clutch, potentiometer as well
as different blanking plugs and seals.
● Or a contactless explosion-proof non contacting system (e.g.6DR4004-6N).
● A positioner
● A three-pole cable to connect components.
● 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 always used for the controller unit whenever an external position
detection system is used instead of the internal sensor. An external position detection
system is, for example, a potentiometer with a 10 kΩ resistance or an NCS.
4.7
Installing option modules
4.7.1
General information on installing option modules
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.
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4.7 Installing option modules
4.7.1.1
Installing optional modules in the standard and intrinsically safe version
The following option modules are available for the positioner in the standard and intrinsically
safe version:
● Position feedback module
● Alarm module
● SIA module
● Mechanical limit switch module
● EMC filter module
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4.7 Installing option modules
Overview diagram: Installing optional modules in the standard and intrinsically safe version
①
②
③
Module cover
Fixing screws basic electronics
⑪
⑫
⑬
④
Actuating disk bearings
⑭
⑤
⑥
⑦
Pneumatic block
⑮
⑯
⑰
Fixing screws module cover
Special screw
Transmission ratio selector
Position feedback module
Alarm module
Warning label on the side opposite the
nameplate
SIA module or mechanical limit switch
module
Insulating cover
Basic electronics
Ribbon cable/connector for fitted potentiometer or external position detection
system
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4.7 Installing option modules
⑧
Friction clutch adjustment wheel
⑱
⑨
Nameplate
⑲
⑩
Adapter
⑳
Figure 4-10
Ribbon cable/connector for alarm module, SIA module or mechanical limit
switch module
Ribbon cable/connector for position
feedback module
Wiring diagram
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 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 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 screws ② in a clockwise direction.
6. Continue to assemble the positioner by executing steps 3 to 1 in reverse order.
See also
Position feedback module (Page 56)
Alarm module (Page 57)
Slot initiator alarm module (Page 59)
Mechanical limit switch module (Page 62)
EMC filter module (Page 66)
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4.7 Installing option modules
4.7.1.2
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
● 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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4.7 Installing option modules
Overview diagram: Installing the optional modules in the "flameproof enclosure" version
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
Module cover
Fixing screws module cover
Ribbon cable/connector for fitted potentiometer or
external position detection system
Ribbon cable/connector for alarm module
Ribbon cable/connector for position feedback module
Basic electronics
Alarm module
Position feedback module
Screw cap
⑪
⑫
⑬
Transmission ratio selector
⑭
⑮
⑯
⑰
⑱
⑲
Friction clutch adjustment wheel
Fixing screws adapter
Safety catch
Feedback shaft
Ring gear
Enclosure
Feedback lever bracket with pin
Pin (feedback lever bracket)
Adapter
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4.7 Installing option modules
Figure 4-11
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 ⑬.
3. Unscrew the screw cap ⑨.
4. Completely dismount the positioner from the actuator.
5. The positioner comes with a ring gear ⑯ and a pin (feedback lever bracket) ⑲ which
interlock and ensure backlash-free position feedback. To ensure backlash-free position
feedback make sure to remove the adapter ⑩ carefully. To this end, turn the feedback
shaft ⑮ at the positioner until the pin (feedback lever bracket) ⑲ below the adapter
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
⑯.
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 ⑫.
7. Completely remove the adapter ⑩ from the enclosure ⑰.
NOTICE
Displaced O-rings
There are several O-rings between adapter ⑩ and enclosure ⑰. 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.
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4.7 Installing option 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 screws ② in a clockwise direction.
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 ⑮ can be smoothly turned by 360°.
If you feel resistance, do not continue to turn but turn the feedback shaft ⑮ 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.
See also
Position feedback module (Page 56)
Alarm module (Page 57)
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4.7 Installing option modules
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 4-12
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 on
installing option modules (Page 48)".
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 Installing option modules
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 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 4-13
Alarm module
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4.7 Installing option modules
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.
Requirements
You are familiar with the general procedure described in the section "General information on
installing option modules (Page 48)".
Procedure for installing the alarm module
1. Slide the alarm module into the rack below the basic electronics . Ensure that you slide it
up to the endstop.
2. Connect the module to the basic electronics. For this purpose, use the 8-pin flat ribbon
cable provided.
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4.7 Installing option modules
4.7.4
Slot 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.
Device features
①
②
③
Actuating disk bearings
Special screw
Pin
Figure 4-14
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.
Requirements
You are familiar with the general procedure described in the section "Installing optional
modules in the standard and intrinsically safe version (Page 49)".
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4.7 Installing option modules
Procedure for installing the slot initiator alarm module
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 SIA module from the top up to the upper printed circuit board guide of the rack.
5. Slide the SIA module in the printed circuit board of the rack approximately 3 mm to the
right.
6. 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.
7. Set the limits L1 and L2 as described in the section "Setting the limits of the slotted
initiator alarm module (Page 61)".
8. An insulating cover is provided over the SIA module. Place the insulating cover on one
side under the basic electronics seat on the module cover. The recesses of the insulating
cover must fit in the corresponding webs of the module cover.
9. Place the insulating cover on the SIA module by bending the module covers 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 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.
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Installing/mounting
4.7 Installing option modules
4.7.4.1
Setting the limits of the slotted initiator alarm module
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 serial numbers in the following text refer to the image in the section "Slot initiator alarm
module (Page 59)". 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.
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.
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Installing/mounting
4.7 Installing option modules
4.7.5
Mechanical limit switch module
Requirements
You are familiar with the procedure described in the section "Installing optional modules in
the standard and intrinsically safe version (Page 49)".
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 4-15
Mechanical limit switch module
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.
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4.7 Installing option modules
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 in the section "Setting the limits of the mechanical
limit switch module (Page 64)".
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 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.
15.Establish all electrical connections.
Note
Protective conductor connector
A protective conductor connector is not required for safety reasons and therefore is not
provided.
See also
Label set for limit contact module (Page 65)
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Installing/mounting
4.7 Installing option modules
4.7.5.1
Setting the limits of the mechanical limit switch module
Setting the L1 and L2 limits
To set the limits proceed as follows. The consecutive numbers refer to "Figure 4-15
Mechanical limit switch module (Page 62)".
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 62)
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4.7 Installing option modules
4.7.5.2
Label set for limit contact module
Fasten the included warning label on the side across from the nameplate. There are different
warning labels depending on the enclosure material, as described below.
Figure 4-16
Warning label for a device with a Makrolon enclosure
Figure 4-17
Warning label for a device with an aluminum enclosure
Figure 4-18
Warning label for a device with a stainless steel enclosure
See also
Warning symbols on the device (Page 15)
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Installing/mounting
4.7 Installing option modules
4.7.6
EMC filter module
Requirements
● 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 on installing option modules (Page 48)"
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 4-19
EMC filter module
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4.7 Installing option modules
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 4-20
Installation EMC filter module
1. You have performed the steps described in the section "General information on installing
option modules (Page 48)".
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.
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.
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 on installing
option modules (Page 48)".
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Installing/mounting
4.7 Installing option modules
See also
Scope of delivery of external position detection system (Page 270)
Scope of delivery EMC filter module (Page 271)
4.7.7
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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Connection
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 241)" or on the nameplate.
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
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".
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Connection
5.1 Basic safety instructions
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 (Page 241)".
• Tighten the cable glands in accordance with the torques specified in Chapter "Technical
data (Page 241)".
• When replacing cable glands use only cable glands of the same type.
• After installation check that the cables are seated firmly.
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.
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5.1 Basic safety instructions
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.
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.
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Connection
5.1 Basic safety instructions
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 according to HART.
• Take account of the conditions specified in the technical data for HART communication.
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.
Shield
Figure 5-1
Base plate
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5.2 Electric
5.2
Electric
5.2.1
Device 6DR5..0/1/2/3-0N or 6DR5..5-0E
Table 5- 1
5.2.1.1
Breakdown of the article numbers
Article No.
Selection and ordering data
6DR5..0/1/2/3-0N
SIPART PS2 electropneumatic positioner in Makrolon, aluminum and stainless steel enclosure, without explosion protection
6DR5..5-0E
SIPART PS2 electropneumatic positioner in flameproof aluminum enclosure
6DR50
2-wire (4 to 20 mA) > without HART >
6DR51
2-wire (4 to 20 mA) > with HART, not explosion-proof >
6DR52
2-, 3-, 4-wire (0/4 to 20 mA) > with HART, explosion-proof >
6DR53
2-, 3-, 4-wire (0/4 to 20 mA) > without HART, not explosion-proof >
6DR5.1
For single-action actuator >
6DR5.2
For double-action actuator >
6DR5..0
Makrolon enclosure >
6DR5.11
Aluminum enclosure, narrow, only single-action >
6DR5..2
Stainless steel enclosure >
6DR5..3
Aluminum enclosure >
6DR5..5
Aluminum enclosure > flameproof
Basic electronics with 6DR5..0/1/2/3-0N or 6DR5..5-0E
Connection diagram for article numbers 6DR50.0/1/2/3-0N; 6DR50.5-0E; 6DR51.0/1/2/3-0N;
6DR51.5-0E
HART communicator only for 6DR51.0/1/2/3-0N and 6DR51.5-0E
①
②
Basic electronics
Binary input 1
Figure 5-2
③
④
HART communicator
Signal source
Device version 2-wire
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Connection
5.2 Electric
Connection diagram for article numbers 6DR52.0/1/2/3-0N; 6DR52.5-0E; 6DR53.0/1/2/3-0N;
6DR53.5-0E
HART communicator only for 6DR52.0/1/2/3-0N and 6DR52.5-0E
①
②
Basic electronics
Binary input 1
Figure 5-3
③
④
HART communicator
Signal source
Device version 2-/3-/4-wire, with connection type 2-wire
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5.2 Electric
Connection diagram for article numbers 6DR52.0/1/2/3-0N; 6DR52.5-0E; 6DR53.0/1/2/3-0N;
6DR53.5-0E
HART communicator only for 6DR52.0/1/2/3-0N and 6DR52.5-0E
①
②
③
Basic electronics
Binary input 1
④
⑤
Power source
Signal source
HART communicator
Dotted connection lines: only for three-wire connection
Figure 5-4
Device version 2-/3-/4-wire, with connection type 3-/4-wire
Split range
Device 1 and device 2: Positioner 6DR53.0/1/2/3-0N or 6DR53.5-0E
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Connection
5.2 Electric
①
②
③
④
⑤
Device 1
Travel range 1
Binary input 1
Device 2
⑥
⑦
⑧
⑨
Binary input 2
Total travel range Iy
Signal source
Power source
Travel range 2
Figure 5-5
Series connection of 2 positioners, e.g. split range without Ex
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5.2 Electric
5.2.1.2
Option modules with 6DR5..0/1/2/3-0N or 6DR5..5-0E
Which option module is fitted in which positioner?
The article number of the positioner is present on its nameplate. This coded article number
indicates which option module is already installed in your device. The following table lists the
assignment between positioner and installed option module.
Table 5- 2
List of option modules fitted in positioners without explosion protection
Article number of positioner
Contains the following installed option
module
Article number of installed option module
6DR5...-0N.1.-0.A.
Alarm module
6DR4004-8A
6DR5...-0N.2.-0.A.
SIA module
6DR4004-8G
6DR5...-0N.3.-0.A.
Mechanical limit switch module
6DR4004-8K
6DR5...-0N..1-0.A.
Position feedback module
6DR4004-8J
6DR5...-0N..2-0.A.
EMC filter module
C73453-A430-D23
6DR5...-0N..3-0.A.
Position feedback module
6DR4004-8J
EMC filter module
C73453-A430-D23
Table 5- 3
List of option modules fitted in positioners in flameproof enclosure "Ex d"
Article number of positioner
Contains the following installed option
module
Article number of installed option module
6DR5..5-0E.1.-0.A.
Alarm module
6DR4004-8A
6DR5..5-0E..1-0.A.
Position feedback module
6DR4004-8J
The captions of the following connection graphics for the option modules are made up of the
name and article number of the option module.
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Connection
5.2 Electric
Alarm module 6DR4004-8A with 6DR5..0/1/2/3-0N or 6DR5..5-0E
①
②
③
Alarm module
Binary input 2
Fault message
Figure 5-6
④
⑤
⑥
Limit
Switching amplifier
Switching output
Alarm module
Position feedback module 6DR4004-8J with 6DR5..0/1/2/3-0N or 6DR5..5-0E
①
Position feedback module
Figure 5-7
Position feedback module
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5.2 Electric
SIA module 6DR4004-8G with 6DR5..0/1/2/3-0N
①
②
SIA module
Fault message
Figure 5-8
③
④
Limit
Switching amplifier
SIA module
Mechanical limit switch module 6DR4004-8K with 6DR5..0/1/2/3-0N
DANGER
Low-voltage supply
When you supply the module in the non-intrinsically safe version with low voltage, you must
be sure to observe the following safety rules before starting work on the device:
1. Isolate the device from power. Use a circuit breaker positioned near the device to do
this.
2. Make sure that the device cannot be switched back on inadvertently.
3. Make sure the device is truly isolated from power.
Note
Maximal values for terminals 41/42 and 51/52
The following maximum values concern only terminals 41, 42, 51, and 52:
No safe separation between the terminals can be guaranteed.
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Connection
5.2 Electric
Note
To observe before connecting
Before you connect the mechanical limit switch module, observe the following conditions:
• Isolate all wires from power and make sure the device is truly isolated from power.
• Construct the cross-sectional area of the connection cables in such a way that it is
appropriate for the permitted current load.
Note
Preparing the cables or stranded wires
1. Insulate the cables in such a way that the insulation is flush with the terminal when
plugging in the wires.
2. Fit ferrules to the ends of stranded wires.
①
②
Mechanical limit switch module
Fault message
Figure 5-9
③
④
Limit
Switching amplifier
Mechanical limit switch module
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.
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5.2 Electric
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 5-10
Connecting the cables
5.2.2
Device 6DR5..0/1/2/3-0E/D/F/G/K
5.2.2.1
Breakdown of the article numbers 6DR5..0/1/2/3-0E/D/F/G/K
Table 5- 4
Breakdown of the article numbers
Article No.
Selection and ordering data
6DR5..0/1/2/3
SIPART PS2 electropneumatic positioner in Makrolon, aluminum and stainless steel enclosure
6DR50
2-wire (4 to 20 mA) > without HART >
6DR52
2-, 3-, 4-wire (0/4 to 20 mA) > with HART, explosion-proof >
6DR5.1
For single-action actuator >
6DR5.2
For double-action actuator >
6DR5..0
Makrolon enclosure >
6DR5.11
Aluminum enclosure, narrow, only single-action >
6DR5..2
Stainless steel enclosure >
6DR5..3
Aluminum enclosure >
6DR5..0/1/2/3-0E
Type of protection (ATEX/IECEx): intrinsic safety
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Connection
5.2 Electric
Article No.
Selection and ordering data
6DR5..0/1/2/3-0D
Type of protection (ATEX/IECEx): non-incendive and dust protection by
enclosure
6DR5..0/1/2/3-0F
Type of protection (ATEX/IECEx/FM): intrinsic safety and non-incendive
6DR5..0/1/2/3-0G
Type of protection (ATEX/IECEx): non-incendive
6DR5..0/1/2/3-0K
Type of protection (ATEX/IECEx): intrinsic safety, non-incendive and dust
protection by enclosure
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.
5.2.2.2
Basic electronics with 6DR5..0/1/2/3-0E/D/F/G/K
Connection diagram for article numbers 6DR50..-0E/D/F/G/K...
①
②
③
Non-hazardous area
Explosive atmosphere
④
⑤
Binary input 1
Signal source
Basic electronics
Figure 5-11
Device version 2-wire
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5.2 Electric
Connection diagram for article numbers 6DR52..-0E/D/F/G/K...
①
②
③
Non-hazardous area
Explosive atmosphere
Basic electronics
Figure 5-12
④
⑤
⑥
Binary input 1
HART communicator
Signal source
Device version 2-/3-/4-wire, with connection type 2-wire
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Connection
5.2 Electric
Connection diagram for article numbers 6DR52..-0E/D/F/G/K...
①
②
③
④
Non-hazardous area
Explosive atmosphere
Basic electronics
⑤
⑥
⑦
HART communicator
Signal source
Power source
Binary input 1
Dotted connection lines: only for three-wire connection
Figure 5-13
Device version 2-/3-/4-wire, with connection type 3-/4-wire
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5.2 Electric
Split range
Device 1 and device 2: Positioner 6DR52.0; 6DR52.1; 6DR52.2
①
②
③
④
⑤
⑥
Non-hazardous area
Explosive atmosphere
Device 1
Travel range 1
Binary input 1
⑦
⑧
⑨
⑩
⑪
Travel range 2
Binary input 2
Total travel range Iy
Signal source
Power source
Device 2
Figure 5-14
Series connection of 2 positioners, e.g. split range (auxiliary power wired separately),
Ex i
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5.2 Electric
5.2.2.3
Option modules with 6DR5..0/1/2/3-0E/D/F/G/K
Which option module is fitted in which positioner
The article number of the positioner is present on its nameplate. This coded article number
indicates which option module is already installed in your device. The following table lists the
assignment between positioner and installed option module.
List of option modules fitted in positioners with the following types of protection:
● Intrinsic safety "Ex i"
● Non-incendive "Ex nA"
● Protection by enclosure "Ex t"
Article number of posi- Contains the following installed option
tioner
module
Article number of installed option module
6DR5..a-0b.1.-0.A.
Alarm module ATEX and FM/CSA
6DR4004-6A; 6DR4004-7A
6DR5..a-0b.2.-0.A.
SIA module
6DR4004-6G
6DR5..a-0b.3.-0.A.
Mechanical limit switch module
6DR4004-6K
6DR5..a-0b..1-0.A.
Position feedback module ATEX and
FM/CSA
6DR4004-6J; 6DR4004-7J
6DR5..a-0b..2-0.A.
Position feedback module ATEX and
FM/CSA
6DR4004-6J; 6DR4004-7J
6DR5..a-0b..3-0.A.
EMC filter module
C73453-A430-D23
a = 0; 1; 2 or 3
b = E, D, F, G, K
The captions of the following connection graphics for the option modules are made up of the
name and article number of the option module.
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5.2 Electric
Alarm modules 6DR4004-6A and -7A with 6DR5..0/1/2/3-0E/D/F/G/K
①
②
③
④
Non-hazardous area
Explosive atmosphere
Alarm module
Binary input 2
Figure 5-15
⑤
⑥
⑦
⑧
Fault message
Limit
Switching amplifier
Switching output
Alarm module (Ex i)
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Connection
5.2 Electric
Position feedback modules 6DR4004-6J and -7J with 6DR5..0/1/2/3-0E/D/F/G/K
①
②
Non-hazardous area
Explosive atmosphere
Figure 5-16
③
④
Position feedback module
④
⑤
⑥
Fault message
Feed splitter
Position feedback module (Ex i)
SIA module 6DR4004-6G with 6DR5..0/1/2/3-0E/D/F/G/K
①
②
③
Non-hazardous area
Explosive atmosphere
SIA module
Figure 5-17
Limit
Switching amplifier
SIA module (Ex i)
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5.2 Electric
Mechanical limit switch module 6DR4004-6K with 6DR5..0/1/2/3-0E/D/F/G/K
①
②
③
④
Non-hazardous area
Explosive atmosphere
Mechanical limit switch module
⑤
⑥
⑦
Limit
Isolation amplifier
Switching amplifier/isolation amplifier
Fault message
Figure 5-18
Mechanical limit switch module 6DR4004-6K (Ex i)
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.
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Connection
5.2 Electric
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 5-19
Connecting the cables
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5.2 Electric
5.2.3
Connecting NCS to EMC filter module
Requirements
You need the EMC filter module with article number C73451-A430-D23 to connect the NCS
to the positioner. The positioner supplies auxiliary power to the NCS 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 5-20
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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Connection
5.2 Electric
Procedure
The NCS 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 is inevitably bonded to ground potential of the system by
mounting the console. This ground connection is only functional if there is a lowimpedance connection to ground potential of the system. Ensure this state by measuring
ground resistance. If necessary, ensure proper grounding by means of an additional
cable from the NCS to ground potential.
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5.2 Electric
5.2.4
Connecting the external position detection system to the EMC filter module
Requirements
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.
Wiring diagram
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 detection
Ribbon cable connector of fitted potentiometer, or ribbon cable connector of EMC
filter module
Basic electronics
Screw
⑩
⑪
⑫
⑬
External position detection system
C73451-A430-D78
External position detection system terminals
External position detection system cable
gland
Cable
EMC filter module cable gland
Input signal for positioner
EMC filter module C73451-A430-D23
Figure 5-21
Connection to positioner
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Connection
5.2 Electric
Preparing the positioner
1. You have performed the steps described in the section "General information on installing
option modules (Page 48)".
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.
5. Insert the connector of the ribbon cable (A) into the slot as shown below.
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 270)", items
"Nameplate for device version without explosion protection" and "Gray cable gland".
For further information on fitting of an option module, refer to the operating instructions of the
respective positioner version in section "Installing/mounting > Installing option modules".
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.
See also
Installing optional modules in the standard and intrinsically safe version (Page 49)
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Connection
5.3 Pneumatic
5.3
Pneumatic
5.3.1
Pneumatic connections
5.3.1.1
Pneumatic connection for 6DR5..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 5-22
5.3.1.2
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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Connection
5.3 Pneumatic
①
②
Actuating pressure Y1
Exhaust air outlet
Figure 5-23
5.3.1.3
Integrated pneumatic connection
Pneumatic connection for 6DR5..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 5-24
Pneumatic connection in the flameproof enclosure
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Connection
5.3 Pneumatic
5.3.1.4
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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Connection
5.3 Pneumatic
Figure 5-25
Regulating action of pneumatic connection
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Connection
5.3 Pneumatic
Overview of positioning effect for fail in place version
Figure 5-26
Pneumatic connections for positioning effect with fail in place version
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Connection
5.3 Pneumatic
5.3.2
Pneumatic connection
WARNING
Pneumatic auxiliary power
Owing to safety reasons, the pneumatic auxiliary power supply must be fed after installation
only if the positioner is switched to the "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 242)".
● 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 vented
– Positioner with double-acting pneumatic system: Y1 ventilated (maximum actuating
pressure), Y2 vented
– 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 97)
Changing the operating mode (Page 107)
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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 5-27
Restrictors
See also
Pneumatic connection for 6DR5..5-0E... (Page 96)
Sequence of automatic initialization (Page 117)
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Connection
5.4 Restrictors
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Operating
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.
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Operating
6.1 Operating elements
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
Configuring
Manual mode (MAN)
Automatic (AUT)
Diagnostics
Pos.
Legend
①
Potentiometer setting [%]
②
Blinking indicator for the non-initialized status.
①
Potentiometer setting [%]
②
Display of the current status of initialization or a fault
message.
③
Indicator for ongoing initialization or a fault message.
①
Parameter value
②
Parameter name
③
Parameter number
①
Position [%]
②
Setpoint [%]
③
Fault message
①
Position [%]
②
Setpoint [%]
③
Fault message
①
Diagnostics value
②
Diagnostics name
③
Diagnostics number
See also
System messages before initialization (Page 199)
Changing the operating mode (Page 107)
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Operating
6.1 Operating elements
6.1.2
Buttons
①
②
③
④
Display
Operating mode button
Decrement button
Increment button
Figure 6-1
Display and buttons of the positioner
● 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.
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Operating
6.2 Operating modes
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.
6.1.3
and
buttons are pressed
Firmware version
The current firmware version is displayed when you exit the operating mode "Configuration".
Figure 6-2
Firmware version, e.g. Version 5.00.00
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
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Operating
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.
Figure 6-3
Switching between the operating modes
See also
Display (Page 103)
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Operating
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":
Figure 6-4
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.
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Operating
6.2 Operating modes
Configuration and initialization
To get to the "Configuration" mode, press the
button for at least 5 seconds.
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
until 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)
In this mode, you move the actuator with
or
. The setting selected here is retained
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.
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Operating
6.2 Operating modes
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.:
● 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
Commissioning overview (Page 115)
Overview of advanced diagnostics parameters A to P (Page 152)
Overview of diagnostics values (Page 206)
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Operating
6.2 Operating modes
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 273)"
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
or
button for at least 5 seconds.
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.
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Operating
6.2 Operating modes
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 "Control algorithm (Page 27)".
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.
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.
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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 241)".
• 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 31)".
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 241)" 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.
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7.2 Commissioning 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 the "Ex ia" version of the positioner and option modules with the "Ex ia" type of
protection may be operated with natural gas. Positioners with other types of protection,
e.g. flameproof enclosure or versions for zones 2 and 22 are not permitted.
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 249)".
4. The limit contact module may 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
Commissioning 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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7.2 Commissioning overview
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)
Positioners subjected to fast acceleration or strong vibration (Page 45)
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7.3 Sequence of automatic initialization
7.3
Sequence of automatic initialization
Overview
The automatic initialization takes place in the following phases:
Automatic initialization phase
Description
Start
-
RUN1
Establishing the direction of action.
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
Part-turn actuator
Closed
Closed
Open
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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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7.3 Sequence of automatic initialization
Sequence of RUN2 for part-turn actuators
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.
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7.3 Sequence of automatic initialization
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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7.3 Sequence of automatic initialization
Sequence of RUN3 to RUN5
This structured chart describes:
● 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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7.4 Purge air switching
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.
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7.5 Commissioning linear actuators
7.5
Commissioning linear actuators
7.5.1
Preparing linear actuators for commissioning
Requirements
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" blinks in the lower 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
The following is applicable for the flameproof enclosure version:
The inner friction clutch is fixed. Therefore, only move the outer friction clutch.
See also
Mounting the linear actuator (Page 34)
Installing the optional modules in the "flameproof enclosure" version (Page 52)
External position detection (Page 48)
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7.5 Commissioning linear actuators
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.
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
button for at least 5
seconds. The display shows the following:
2. Call the "2.YAGL" parameter. To do this, briefly press the
button. The following is
shown on the display depending on the setting:
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°.
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7.5 Commissioning linear actuators
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.
button. The display
– Call the "3.YWAY" parameter. To do this, briefly press the
shows the following:
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.
5. Call the "4.INITA" parameter. To do this, briefly press the
button. The display shows
the following:
6. Start the initialization process. To do this, press the
button for at least 5 seconds until
the display shows the following:
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:
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7.5 Commissioning linear 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 positioner is not
initialized.
See also
Sequence of automatic initialization (Page 117)
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".
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7.5 Commissioning linear actuators
Initializing the linear actuator automatically
1. Switch to the "Configuration" mode. To do this, press the
button for at least 5 seconds
until the display shows the following:
2. Call the "2.YAGL" parameter. To do this, briefly press the
button. The following is
shown on the display depending on the setting:
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°.
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
button. The display
shows the following:
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.
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7.5 Commissioning linear actuators
5. Call the "5.INITM" parameter. To do this, press the
button twice. The display shows
the following:
6. Start the initialization process. To do this, press the
button for at least 5 seconds until
the display shows the following:
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
9. Press the
or
button.
button. The current position of the actuator is applied. The display shows
the following:
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. Move the actuator to another position using the
or
button.
4. Abort the manual initialization process by pressing the
button.
5. Then return to "P manual mode" mode.
6. Correct the actuator travel and the position detection.
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7.5 Commissioning linear actuators
10.Determine the upper endstop of the actuator spindle. Move the actuator to the desired
position using the
11.Press the
or
button.
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
2. Press the
or
button.
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.
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
software status is displayed. After releasing the
button for at least 5 seconds. The
button, the positioner is in "P manual
mode". The positioner is not initialized.
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7.6 Commissioning part-turn actuators
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.
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.
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7.6 Commissioning part-turn actuators
See also
Pneumatic connection (Page 100)
External position detection (Page 48)
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.
1. Switch to the "Configuration" mode. To do this, press the
button for at least 5 seconds
until the display shows the following:
2. Use the
button to change from linear actuator to part-turn actuator until the display
shows the following:
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7.6 Commissioning part-turn actuators
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
button. The display shows
the following:
5. Start the initialization process. To do this, press the
button for at least 5 seconds until
the display shows the following:
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 117)
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
button for at least 5 seconds
until the display shows the following:
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
button twice. The display shows the
following:
5. Start the initialization process. Press the
button for at least 5 seconds until the display
shows the following:
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
or
button.
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7.6 Commissioning part-turn actuators
9. Press the
button. The current position of the actuator is applied. The display shows
the following:
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. Move the actuator to another position using the
or
button.
4. Abort the manual initialization process by pressing the
button.
5. Then return to "P manual mode" mode.
6. Correct the actuator travel and the position detection.
10.Determine the upper endstop of the actuator. Move the actuator to the desired position
using the
11.Press the
or
button.
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
button, see section "Description of
operating modes (Page 108)".
11.Release the fixing of the actuator.
See also
Sequence of automatic initialization (Page 117)
Automatic initialization of linear actuators (Page 125)
Automatic initialization of part-turn actuators (Page 132)
Manual initialization of linear actuators (Page 127)
Manual initialization of part-turn actuators (Page 134)
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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
Depressurizing of the connected actuator is the safety function for the SIPART PS2
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.
The positioner starts the depressurizing process of the connected pneumatic actuator at the
latest 100 ms after the request. The progress of the depressurizing process depends on the
connections and properties of the pneumatic actuator.
This safety function can be triggered by:
● With 2-wire connection: a signal source with 0 mA.
● With 3/4-wire connection: a power supply source with 0 V.
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
Disregard can result in a malfunction of the process plant or application, e.g. 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.
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8.2 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 HART communication. For further details,
see Diagnostics parameters '42.VENT1' / '43.VENT2' (Page 220).
Safety-instrumented system in single-channel operation (SIL 2)
Figure 8-1
Safety-instrumented system in single-channel operation
The combination of transmitter, automation system and final controlling element forms a
safety-instrumented 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.
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Functional safety
8.3 Safety Integrity Level (SIL)
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.
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:
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
(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
No special parameter settings are required for the safety function.
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
● On the positioner, switch the signal source to 0 mA or the power supply source to 0 V.
● Always carry out the validation of the safety function with positioner and valve under
operating conditions.
Result
The actuator brings the valve to the specified safety position.
See also
Safety function (Page 139)
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8.5 Safety characteristics
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".
● The positioner is blocked against unwanted and unauthorized changes/operation.
● The signal source with 0 mA or the power supply source with 0 V for the SIPART PS2
positioner is generated by a safe system that fulfills SIL 2 for single-channel operation.
● The connected single-acting type actuator returns the valve to the safe end position by
spring force in the following scenarios:
– With a chamber pressure (Y1 connection) up to a third of the maximum available
supply air 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 a failure whereby the pressure outlet is not
depressurized or the safety position is not reached when the signal source is 0 mA or the
power supply source is 0 V.
See also
Settings (Page 142)
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Functional safety
8.6 Maintenance/check
8.6
Maintenance/check
Interval
We recommend that the functioning of the positioner is checked at regular intervals of one
year.
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).
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Parameterizing/addressing
9.1
9
Parameter chapter
In this chapter, how the parameters work is explained in the form of a configuration
schematic. Afterwards, there is a tabular overview of all parameters. Finally, the individual
parameters and their functionality are described.
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Parameterizing/addressing
9.2 Configuration schematic for parameter operating principle
9.2
Figure 9-1
Configuration schematic for parameter operating principle
Configuration block schematic
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Parameterizing/addressing
9.3 Parameter overview
9.3
Parameter overview
9.3.1
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 the positioner in detail, 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
Actuator
2.YAGL
Parameter values
Unit
Normal
Inverted
Part-turn actuator
turn
-turn
Linear actuator
WAY
-WAY
Linear actuator without sine LWAY
correction
-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
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9.3 Parameter overview
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.
9.3.2
Overview of application parameters 6 to 52
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.
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9.3 Parameter overview
Overview
Parameter
Function
6.SCUR
Current range of setpoint
7.SDIR
Parameter values
Unit
0 ... 20 mA
0 MA
4 ... 20 mA
4 MA
Setpoint direction
Rising
riSE
Falling
FALL
8.SPRA
Setpoint split range start
0.0 ... 100.0
%
9.SPRE
Setpoint split range end
10.TSUP
Setpoint ramp UP
11.TSDO
Setpoint ramp DOWN
12.SFCT
Setpoint function
Linear
Equal percentage
Inverse equal percentage
13.SL0
%
s
0 ... 400
s
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
13.SL0 ...
33.SL20 1)
0.0 ... 100.0
Auto / 0 ... 400
FrEE
Setpoint turning point
In
0%
14.SL1 ....
5 % ...
32.SL19
95 %
33.SL20
100 %
0.0 ... 100.0
%
Auto / 0.1 ... 10.0
%
34.DEBA
Deadband of closed-loop controller
35.YA
Start of the manipulated variable limit
0.0 ... 100.0
%
36.YE
End of the manipulated variable limit
0.0 ... 100.0
%
37.YNRM
Standardization of manipulated variable
38.YDIR
39.YCLS
Mechanical
MPOS
On flow
FLoW
Direction of action of manipulated variable for display and position feedback
Rising
riSE
Falling
FALL
Tight closing with manipulated variable
None
no
Up only
uP
Down only
Up and down
40.YCDO
Lower value for tight closing
do
uP do
0.0 ... 0.5 ... 100.0
%
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9.3 Parameter overview
Parameter
Function
41.YCUP
Upper value for tight closing
42.BIN1
Function of binary input 1
2)
Parameter values
Normally open
None
Message only
OFF
-on
bLoc1
Block configuration and manual
bLoc2
Drive valve to position YE
uP
-uP
Drive valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Function of binary input 2
PSt
-PSt
Normally open
Normally closed
None
44.AFCT
3)
%
Normally closed
on
Block configuration
Partial stroke test
43.BIN2 2)
Unit
0.0 ... 99.5 ... 100.0
OFF
Message only
on
-on
Drive valve to position YE
uP
-uP
Drive valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Partial stroke test
PSt
-PSt
Alarm function
Normal
None
Inverted
OFF
A1 = Min, A2 = Max
A1 = Min, A2 = Min
A1 = Max, A2 = Max
45.A1
Response threshold, alarm 1
46.A2
Response threshold, alarm 2
47.
FCT 3)
Function for fault message output
0.0 ... 10.0 ... 100.0
%
0.0 ... 90.0 ... 100.0
%
Normal
Inverted
Fault
Fault + not automatic 4)
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9.3 Parameter overview
Parameter
Function
Parameter values
Unit
Fault + not automatic + BIN4)
48.
TIM
Monitoring time for setting of fault message
"Control Deviation"
Auto / 0 ... 100
s
49.
LIM
Response threshold for fault message "Control deviation"
Auto / 0 ... 100
%
50.PRST
51.PNEUM
52.XDIAG
Preset
Reset all parameters which can be
reset by "Init", "PArA" and "diAg".
ALL
Reset initialization parameters
1.YFCT to 5.INITM.
Init
Reset parameters 6.SCUR to
49.LIM.
PArA
Reset parameters A to P of the
extended diagnostics function as
well as parameter 52.XDIAG.
diAg
Fail in Place
Standard pneumatic block
Std
Fail in Place pneumatic block
FIP
Activating for extended diagnostics
Off
OFF
Single-stage alarm
On1
Two-stage alarm
On2
Three-stage alarm
On3
1)
Setpoint turning points only appear when "12.SFCT = FrEE" is selected.
2)
"Normally closed" means: Action with switch open or Low level
"Normally open" means: Action with switch closed or High level
3)
"Normal" means: High level, no fault message
"Inverse" means: Low level, no fault message
4)
"+" means: Logical OR combination
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9.3 Parameter overview
9.3.3
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 "'52.XDIAG' Activating for extended diagnostics
(Page 174)" with setting "On1", "On2" or "On3".
Overview parameter A
Parameter
A. PST
Function
Parameter values
Unit
Partial stroke test with the following parameters:
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
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
%/s
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9.3 Parameter overview
Overview parameter b
Parameter
b. DEVI
Function
Parameter values
Unit
Monitoring of dynamic control valve behavior with the following parameters:
b1.TIM
Time constant
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
C. LEAK
Function
Parameter values
Unit
Monitoring of pneumatic leakage with the following parameters:
C1.LIMIT
Limit
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
%
Overview parameter d
Parameter
d. STIC
Function
Parameter values
Unit
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
%
Overview parameter E
Parameter
E. DEBA
E1.LEVL3
Function
Parameter values
Unit
Monitoring of deadband with the following parameters:
Threshold
0.1 ... 2.0 ... 10.0
%
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9.3 Parameter overview
Overview parameter F
Parameter
F. ZERO
Function
Parameter values
Unit
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
G. OPEN
Function
Parameter values
Unit
Monitoring of upper endstop with the following parameters:
G1.LEVL1
Threshold 1
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
H. TMIN
Function
Parameter values
Unit
Monitoring of lower limit temperature with the following parameters:
H1.TUNIT
Temperature unit
°C
°F
°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
Overview parameter J
Parameter
J. TMAX
Function
Parameter values
Unit
Monitoring of upper limit temperature with the following parameters:
J1.TUNIT
Temperature unit
°C
°F
°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
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9.4 Description of parameters
Overview parameter L
Parameter
L. STRK
Function
Parameter values
Unit
Monitoring of number of total strokes with the following parameters:
L1. LIMIT
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
O. DCHG
Function
Parameter values
Unit
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
Overview parameter P
Parameter
P. PAVG
Function
Parameter values
Unit
Monitoring the position average value with the following parameters:
P1.TBASE
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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9.4 Description of parameters
9.4
Description of parameters
9.4.1
Description of initialization parameters 1 to 5
9.4.1.1
'1.YFCT' Type of actuator
Requirement:
Type of actuator as well as mounting type and direction of action
are known.
Possible settings:
Actuator with normal direction
of action
Actuator with inverted direction of
action
• turn
• -turn
• WAY
• -WAY
• LWAY
• -WAY
• ncSt
• -ncSt
• ncSL
• -ncSL
• ncSLL
• -ncLL
Purpose:
Use this parameter to adjust the positioner to the respective actuator.
• turn/-turn: Use this setting for a part-turn actuator with a directly
mounted positioner.
• WAY/-WAY: Use this setting for a linear actuator.
• 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).
In the case of actuators with inverted direction of action, use the
settings with the minus sign, e.g. -turn.
Description:
Meaning of actuator with normal direction of action:
• Part-turn actuator closes when the drive shaft, positioner shaft
or NCS rotates in the clockwise direction.
• Linear actuator closes when the actuator spindle rotates
downwards and the positioner shaft or NCS rotates in an anticlockwise direction.
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9.4 Description of parameters
Meaning for actuator with inverted direction of action:
• Part-turn actuator closes when the drive shaft, positioner shaft
or NCS rotates in an anti-clockwise direction.
• Linear actuator closes when the actuator spindle rotates
downwards and the positioner shaft or NCS rotates in the
clockwise direction.
Additional information:
• The "'3.YWAY' Range of stroke (Page 158)" parameter is
displayed with the setting "WAY", "-WAY", "ncSLL" or "-ncLL".
• turn/-turn: The "'2.YAGL' Rated angle of rotation of feedback
(Page 157)" 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.
Factory setting:
9.4.1.2
WAY
'2.YAGL' Rated angle of rotation of feedback
Requirement:
Transmission ratio selector and the value set in the "2.YAGL" parameter match. Only then does the value shown on the display
match the actual position.
Possible settings:
• 33°
• 90°
Purpose:
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
following is applicable:
• 33°: Strokes ≤ 20 mm
• 90°: Strokes 25 ... 35 mm
• 90°: Strokes > 40 ... 130 mm
Use the:
• Mounting set 6DR4004-8V for strokes up to 35 mm
• Mounting set 6DR4004-8L for strokes greater than 35 to
130 mm
The setting "turn" or "-turn" automatically sets an angle of 90° for
part-turn actuators.
Factory setting:
33°
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9.4 Description of parameters
See also
Sequence of automatic initialization (Page 117)
9.4.1.3
'3.YWAY' Range of stroke
Requirement:
• 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 34)", "Figure 4-2 Lever with carrier pin
(Page 37)".
Possible settings:
• 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
Purpose:
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 possible setting, use the next higher value. Use the value specified on
the nameplate of the actuator for this purpose.
Factory setting:
9.4.1.4
OFF
'4.INITA' Initialization (automatically)
Possible settings:
• NOINI
• no / ###.#
• Strt
Purpose:
Use this parameter to start the automatic initialization process.
1. Select the "Strt" setting.
2. Then press the
button for at least 5 seconds.
The sequence of the initialization process from "RUN1" to "RUN5"
is output in the bottom line of the display.
Factory setting:
NOINI
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9.4 Description of parameters
9.4.1.5
'5.INITM' Initialization (manual)
Possible settings:
• NOINI
• no / ###.#
• Strt
Purpose:
Use this parameter to start the manual initialization process.
1. Select the "Strt" setting.
2. Then press the
Description:
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.
Factory setting:
NOINI
9.4.2
Description of application parameters 6 to 52
9.4.2.1
'6.SCUR' Current range of setpoint
Requirement:
• You have a SIPART PS2 in version "2-, 3-, 4-wire".
• Positioner is connected in accordance with the connection
graphics for 2-/3-/4-wire systems shown in sections "Device
6DR5..0/1/2/3-0N or 6DR5..5-0E (Page 73)" and "Device
6DR5..0/1/2/3-0E/D/F/G/K (Page 81)".
Possible settings:
• 0 MA
• 4 MA
Purpose:
This parameter is used to set the current range of the setpoint.
The selection of the current range depends on the type of connection. The "0 MA" setting (0 to 20 mA) is only possible for three-wire
and four-wire connections.
Factory setting:
4 MA
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9.4 Description of parameters
9.4.2.2
'7.SDIR' Setpoint direction
Possible settings:
• riSE
• FALL
Purpose:
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 split-range mode and
for single-acting actuators with the safety setting "uP".
Factory setting:
9.4.2.3
riSE
'8.SPRA' Setpoint split range start / '9.SPRE' Setpoint split range end
Adjustment range:
0.0 ... 100.0
Purpose:
With these two parameters in combination with parameter
"'7.SDIR' Setpoint direction (Page 160)", you can limit the effective
setpoint. This allows split range tasks with the following characteristic curves to be solved:
• rising/falling
• falling/rising
• falling/falling
• rising/rising
Factory setting:
With "SPRA": 0.0
With "SPRE": 100.0
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9.4 Description of parameters
Figure 9-2
9.4.2.4
Example: Split range operation with two positioners
'10.TSUP' Setpoint ramp UP / '11.TSDO' Setpoint ramp DOWN
Possible settings:
With "TSUP"
With "TSDO"
• Auto
• 0 ... 400
• 0 ... 400
Purpose:
The setpoint ramp is effective in "Automatic" mode and limits the
speed of change of the effective setpoint. 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 value "TSUP = Auto" means that the slower of the
two travel times determined during initialization is used for the
setpoint ramp. Parameter value "TSDO" then has no effect.
Factory setting:
0
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9.4 Description of parameters
9.4.2.5
'12.SFCT' Setpoint function
Possible settings:
• Lin
• 1 - 25
• 1 - 33
• 1 - 50
• n1 - 25
• n1 - 33
• n1 - 50
• FrEE
Purpose:
This parameter is used to linearize nonlinear valve characteristics.
Optional flow characteristics as shown in the figure in the description of the "'13.SL0' ... '33.SL20' Setpoint turning point (Page 162)"
parameter are simulated for linear valve characteristics.
Factory setting:
Lin
Seven valve characteristics are stored in the positioner and are selected using the "SFCT"
parameter:
Valve characteristics
Set with parameter value
Linear
Lin
Equal percentage
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
9.4.2.6
FrEE
'13.SL0' ... '33.SL20' Setpoint turning point
Adjustment range:
0.0 ... 100.0
Purpose:
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 characteristic; see figure below.
Factory setting:
"0", "5" ... "95", "100"
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9.4 Description of parameters
Setpoint characteristic curves, standardization of manipulated variables, and tight closing
function
Input of the setpoint turning points is only possible if the "'12.SFCT' Setpoint function
(Page 162)" 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%.
9.4.2.7
'34.DEBA' Deadband of closed-loop controller
Possible settings:
• Auto
• 0.1 ... 10.0
Purpose:
This parameter is used with the "Auto" setting to adjust the deadband in automatic mode continually and adaptively to the requirements 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. Control oscillations can then be suppressed. The smaller the deadband, the better the control accuracy.
Factory setting:
Auto
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9.4 Description of parameters
9.4.2.8
'35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit
Adjustment range:
0.0 ... 100.0
Purpose:
These parameters are used to limit the mechanical actuator travel
from stop to stop to the configured values. 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 "'37.YNRM' Standardization
of manipulated variable (Page 164)" parameter.
Factory setting:
With "YA": 0.0
With "YE": 100.0
Note
"YE" must always be set larger than "YA".
9.4.2.9
'37.YNRM' Standardization of manipulated variable
Possible settings:
• MPOS
• FLoW
Purpose:
Use the "'35.YA' Start of manipulated variable limit / '36.YE' End of
manipulated variable limit (Page 164)" parameters to limit the manipulated 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
position is not influenced by the "'35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit (Page 164)"
parameters. The "YA" und "YE" parameters are shown in the
MPOS scale.
The FLoW scale is the standardization from 0 to 100% in the
range between the "YA" und "YE" parameters. Over this range, the
setpoint w is also always 0 to 100%. This results in a more or less
flow-proportional display and position feedback "IY". The flowproportional display and position feedback "IY" also result when
using valve characteristics.
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
illustrate the dependence of the stroke on the scaling as well as on
the "YA" and "YE" parameters; see the following figure.
Factory setting:
MPOS
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9.4 Description of parameters
Figure 9-3
YNRM = MPOS or YNRM = FLoW; default: YA = 0 % and YE = 100 %
Figure 9-4
Example: YNRM = MPOS with YA = 10 % and YE = 80 %
Figure 9-5
Example: YNRM = FLoW with YA = 10 % and YE = 80 %
See also
'39.YCLS' Tight closing with manipulated variable (Page 166)
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9.4 Description of parameters
9.4.2.10
'38.YDIR' Direction of manipulated variable for display and position feedback
Possible settings:
• riSE
• FALL
9.4.2.11
Purpose:
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.
Factory setting:
riSE
'39.YCLS' Tight closing with manipulated variable
Possible settings:
• no
• uP
• do
• uP do
Purpose:
This parameter is used to move the valve into its seat with the
maximum force of the actuator (permanent contact of the piezo
valves). The tight closing function is activated on one side or for
both end positions. The parameter "39.YCLS" becomes effective if
the effective setpoint is below the parameter "40.YCDO" or above
the parameter "41.YCUP".
Factory setting:
no
See the figure in the description of the "'37.YNRM' Standardization of manipulated variable
(Page 164)" parameter and the figure in the description of the "'13.SL0' ... '33.SL20' Setpoint
turning point (Page 162)" parameter.
Note
Activated tight closing function
If the tight closing function is activated, and if parameter "49. is LIM", monitoring of the
control deviation in the respective overflow direction is switched off. In this case, parameter
"YCDO: < 0%" and parameter "YCUP: > 100%". This functionality is especially
advantageous for valves with soft seats. For long-term monitoring of the end stop positions,
we recommend that you activate the "F. ZERO" and "G. OPEN" parameters.
9.4.2.12
'40.YCDO' Lower value for tight closing / '41.YCUP' Upper value for tight closing
Adjustment range:
0.0 ... 100.0
Purpose:
These parameters are used to set the values for "Lower value for
tight closing " (YCDO) and "Upper value for tight closing" (YCUP)
in %.
Factory setting:
With "YCDO": 0.5
With "YCUP": 99.5
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9.4 Description of parameters
Note
The value in the "YCDO" parameter is always smaller than that in "YCUP". The tight closing
function has a fixed hysteresis of 1%. The "YCDO" and "YCUP" parameters are relative to
the mechanical stops. The "YCDO" and "YCUP" parameters are independent of the values
set in the "'7.SDIR' Setpoint direction (Page 160)" and "'38.YDIR' Direction of manipulated
variable for display and position feedback (Page 166)" parameters.
9.4.2.13
'42.BIN1' / '43.BIN2' Function binary inputs
Setting option
• Binary input 1
Normally open
Normally closed
OFF
on
bloc1
bloc2
uP
doWn
StoP
PST
OFF
-on
-uP
-doWn
-StoP
-PST
• Binary input 2
Purpose:
Normally open
Normally closed
OFF
on
uP
doWn
StoP
PST
OFF
-on
-uP
-doWn
-StoP
-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.
• 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.
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9.4 Description of parameters
• 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 "'35.YA' Start of manipulated variable limit /
'36.YE' End of manipulated variable limit (Page 164)"
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".
Factory setting:
OFF
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9.4 Description of parameters
9.4.2.14
'44.AFCT' Alarm function
Possible settings:
See representation below
Purpose:
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 out over the HART communicator (optional).
The direction of action of the binary outputs can be adjusted from
"High active" to "Low active" for the next system.
Factory setting:
OFF
Direction of action and hysteresis
Alarm module
Examples
A1 = 48
A1
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
A1 = 52
Active
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
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9.4 Description of parameters
Note
If the extended diagnostic is activated using parameter "'52.XDIAG' Activating for extended
diagnostics (Page 174)" with setting "On2" or "On3", then the alarms will not be output
through the alarm module. Notification through HART communication is possible at any time,
however.
9.4.2.15
'45.A1' / '46.A2' Response threshold of alarms
Adjustment range:
0.0 ... 100.0
Purpose:
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 "'37.YNRM' Standardization of manipulated variable (Page 164)" parameter. The MPOS scale corresponds to the mechanical travel.
Depending on the setting of the alarm function in the "'44.AFCT'
Alarm function (Page 169)" parameter, the alarm is triggered upon
an upward violation (Max) or downward violation (Min) of this response threshold.
Factory setting:
With "A1": 10.0
With "A2": 90.0
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9.4 Description of parameters
9.4.2.16
'47._FCT' Function fault message output
Requirement:
At least one of the following modules is fitted
• Alarm module
• Slot initiator alarm module (SIA module)
• Mechanical limit switch module
Possible settings:
Purpose:
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 error message of extended diagnostics.
See "'52.XDIAG' Activating for extended diagnostics
(Page 174) parameter - Activating for extended diagnostics".
Note that the fault message cannot be switched off. It can however
be suppressed (factory setting) when you switch over to "No automatic mode". If you also want to generate a fault message here,
you will need to set the "47. FCT" parameter to " nA".
You also have an option to "or" the fault message with the status
of the binary inputs. For this purpose, set the "47. FCT" parameter to " nAb".
Select the "- " setting if you want the fault message to be output
with inverted direction of action.
Factory setting:
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9.4 Description of parameters
9.4.2.17
'48._TIM' Monitoring time for setting of fault message "Control deviation"
Possible settings:
• Auto
• 0 ... 100
Purpose:
The "48. TIM" parameter is used to set the time in seconds within
which the positioner must have reached the regulated condition.
The corresponding response threshold is specified in the "49.
LIM" parameter.
When the configured time is exceeded, the fault message output is
set.
Factory setting:
Auto
Note
Activated tight closing function
If the tight closing function is activated, then for parameter "49. LIM" the monitoring of
control deviation is turned off in the appropriate overflow direction. Here, "YCDO: < 0 %" and
"YCUP: > 100 %" apply. This functionality is especially advantageous for valves with lining.
For long-term monitoring of the endstop positions, we recommend activating the parameters
"F. ZERO" and G. OPEN".
9.4.2.18
'49._LIM' Response threshold for fault message "Control deviation"
Possible settings:
• Auto
• 0 ... 100
Purpose:
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 parameters "48. TIM" and "49. LIM" 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%.
Factory setting:
Auto
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9.4 Description of parameters
Note
Activated tight closing function
If the tight closing function is activated, then for parameter "49. LIM" the monitoring of
control deviation is turned off in the appropriate overflow direction. "YCDO: < 0 %" and
"YCUP: > 100 %" are applicable in such a case. This functionality is especially
advantageous for valves with lining. For long-term monitoring of the endstop positions, we
recommend activating the parameters "F. ZERO" and G. OPEN".
9.4.2.19
'50.PRST' Preset
Possible settings:
• ALL
• Init
• PArA
• diAg
Purpose:
Use this parameter to restore the factory settings for most parameters. 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 application parameters "6.SCUR" to "49.
LIM".
• diAg: Reset parameters A to P of the extended diagnostics as
well as parameter "52.XDIAG".
An overview of the parameters and factory settings can be found in
section "Parameter overview (Page 147)".
In order to select one of the parameter groups listed above, repeatedly press the
button until the desired setting is output in the
display. Start the function by repeatedly pressing the
button
until "oCAY" is output in the display. The values of the parameter
group are now the factory settings.
Description:
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" setting.
Factory setting:
ALL
See also
Display of diagnostics values (Page 205)
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9.4 Description of parameters
9.4.2.20
'51.PNEUM' Fail in place
Requirement:
You have a positioner with the "Fail in Place" function, article number with order code -Z F01.
Possible settings:
• Std
• FIP
Purpose:
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". The parameter must be set to "FIP" again if the
basic electronics is replaced.
9.4.2.21
'52.XDIAG' Activating for extended diagnostics
Use this parameter to activate the extended diagnostics and simultaneously the online
diagnostics. At the factory, extended diagnostics are deactivated. Parameter "52.XDIAG" is
set to "OFF". To activate extended diagnostics, there are three modes available:
● On1: Extended diagnostics are activated. Threshold 3 error messages will be output over
the error message output. Single-stage alarm.
● On2: Extended diagnostics are activated. Threshold 2 error messages will be activated
using alarm output 2. Threshold 3 error messages will also be output over the error
message output. Two-stage alarm.
● On3: Extended diagnostics are activated. Threshold 1 error messages will be activated
using alarm output 1. Threshold 2 error messages will be activated using alarm output 2.
Threshold 3 error messages will also be output over the error message output. Threestage alarm.
Note
Activating for extended diagnostics
Please note that the parameters of extended diagnostics will only be shown in the
display, from "A. PST" to "P. PAVG", following selection of one of the modes "On1" to
"On3".
In the factory settings, parameters "A. PST" to "P. PST" are deactivated by default.
Parameter "52.XDIAG" is set to "OFF". The corresponding parameters are only displayed
after you activate the appropriate menu item with "On".
With extended diagnostics, the threshold of the error message is displayed using columns in
addition to the error code. These columns are shown on the display as follows:
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9.4 Description of parameters
Figure 9-6
Display of a threshold 1 error message
Figure 9-7
Display of a threshold 2 error message
Figure 9-8
Display of a threshold 3 error message
The factory setting is "OFF".
9.4.3
Description of advanced diagnostics parameters A to P
9.4.3.1
Partial stroke test "A._PST"
A. PST - Partial Stroke Test
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
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9.4 Description of parameters
Purpose:
Use this parameter to activate and deactivate the partial stroke
test. The associated sub-parameters are displayed when you activate the parameter with "On".
Trigger the partial stroke test using:
• Buttons on the device
• A binary input
• Communication
• A cyclic test interval
Sub-parameters are described below.
Description:
The current value is displayed in "Diagnostics parameter '15.DEVI'
General control valve fault (Page 213)".
Factory setting:
OFF
A1.STPOS - Start position
Adjustment range:
0.0 ... 100.0
Purpose:
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
position 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).
Factory setting:
100.0
A2.STTOL - Start tolerance
Adjustment range:
0.1 ... 10.0
Purpose:
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".
Example: You have set 50% as a start position and 2% as a start
tolerance. In this case, a partial stroke test is initiated during operation only between a current position of 48 and 52%.
Factory setting:
2.0
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9.4 Description of parameters
A3.STRKH - Stroke height
Adjustment range:
0.1 ... 100.0
Purpose:
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". The actuator moves during the partial stroke test from the
start position 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).
Factory setting:
10.0
A4.STRKD - Stroke direction
Possible settings:
• uP
• do
• uP do
Purpose:
Use this sub-parameter to set the stroke direction of the partial
stroke test. The following parameter values are available:
• uP: Actuator moves upward
• do: Actuator moves downward
• uP do: Actuator moves up and down
uP (only upward):
• The actuator moves from its start position to the target position.
• After reaching the target position, the actuator moves back to
the start position.
The target position is determined from the start position
(A1.STPOS) plus the stroke height (A3.STRKH).
do (only downward): The same procedure is applicable in the reverse order.
uP do (upward and downward):
• The actuator first moves from its start position to the high target
position.
• It then moves from the high target position to the low target
position.
• After reaching the low target position, the actuator moves back
to the start position.
The high target position is determined from the start position
(A1.STPOS) plus the stroke height (A3.STRKH). The low target
position is determined from the start position (A1.STPOS) minus
the stroke height (A3.STRKH).
Factory setting:
do
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9.4 Description of parameters
A5.RPMD - Ramp mode
Setting options:
• OFF
• On
Purpose:
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.
Factory setting:
OFF
A6.RPRT - Ramp rate
Adjustment range:
0.1 ... 100.0 %/s
Purpose:
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.
Factory setting:
1.0 %/s
A7.FLBH - Behavior after failed PST
Setting options:
• Auto
• HOLd
• AirIn
• AirOu
Purpose:
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.
Factory setting:
Auto
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9.4 Description of parameters
A8.INTRV - Test interval
Adjustment range:
OFF, 1 ... 365
Purpose:
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.
Factory setting:
OFF
A9.PSTIN - Reference stroke time for partial stroke test
Purpose:
Status for reference stroke time
Description:
Use this sub-parameter to measure the reference stroke time for
the partial stroke test.
The unit is seconds. The reference stroke time corresponds to the
controlled movement from the start position to the target position.
The positioner must be initialized in order to measure a reference
stroke time. If the positioner is not yet initialized, the display shows
"NOINI". If the positioner has already been initialized, the calculated average travel time of the control valve is displayed as a reference value.
Example: An average travel time of 1.2 seconds 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.
Set the sub-parameters "A1" to "A5" as per your requirements.
Then start measuring the reference stroke time by pressing the
button for at least 5 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.
When the test is completed, the measured reference stroke time in
seconds is shown. "Fdini" is displayed if the start position cannot
be approached or the stroke target cannot be achieved. "Fdini"
stands for "failed PST initialization".
Factory setting:
NOINI
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9.4 Description of parameters
AA.FACT1 - Factor 1
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1.
Set the factor in a range from "0.1" to "100.0". The limit 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 error message is displayed when the limit threshold 1 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
1.5
Ab.FACT2 - Factor 2
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 2.
Set the factor in a range from "0.1" to "100.0". The limit 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 error message is displayed when the limit threshold 2 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
3.0
AC.FACT3 - Factor 3
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 3.
Set the factor in a range from "0.1" to "100.0". The limit threshold
is the product of the reference stroke time and "AC.FACT3". Determining the reference stroke time is described under "A9.PSTIN".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
The positioner responds in accordance with the option set in the
sub-parameter "A7.FLBH" - Behavior after failed PST".
Factory setting:
5.0
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9.4 Description of parameters
9.4.3.2
Monitoring of dynamic control valve behavior "b._DEVI"
b. DEVI - Monitoring of dynamic control valve behavior
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
This parameter allows you to monitor the dynamic control valve
behavior. 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. To activate monitoring, set the parameter to "On".
Sub-parameters are displayed.
The current value is displayed in "Diagnostics parameter '15.DEVI'
General control valve fault (Page 213)". The positioner triggers a
fault message if the current value exceeds one of the three configurable limit thresholds.
Sub-parameters are described below.
Factory setting:
OFF
b1.TIM - Time constant of low-pass filter
Possible settings:
• Auto
• 1 ... 400
Purpose:
Use this sub-parameter to define the attenuation effect of the lowpass filter. The unit is seconds. This sub-parameter is set to "Auto"
if the device is initialized automatically. The "b1.TIM" time constant
is calculated from the travel times "uP" and "doWn" determined
during the initialization.
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 too weak an attenuation.
• Setting "400" indicates too strong an attenuation.
The current value is displayed in "Diagnostics parameter '15.DEVI'
General control valve fault (Page 213)". The positioner triggers a
fault message if the current value exceeds one of the three configurable limit thresholds.
Factory setting:
Auto
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9.4 Description of parameters
b2.LIMIT - Limit for dynamic control valve behavior
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set a base limit in percent. The base
limit defines the magnitude of the permissible deviation from the
expected 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".
Factory setting:
1.0
b3.FACT1 - factor 1
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "b2.LIMIT" and "b3.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
5.0
b4.FACT2 - factor 2
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "b2.LIMIT" and "b4.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
10.0
b5.FACT3 - factor 3
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "b2.LIMIT" and "b5.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
15.0
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9.4 Description of parameters
9.4.3.3
Monitoring pneumatic leakage "C._LEAK"
C. LEAK - Monitoring pneumatic leakage
Note
Accuracy of results
Please note that this monitoring delivers unambiguous results only in the case of singleacting, spring-loaded actuators.
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
Use this parameter to detect leakages in the actuator or in the pipe
installation. The associated sub-parameters are displayed when
you activate the parameter with "On".
The current value is displayed in "Diagnostics parameter
'16.ONLK' Pneumatic leakage (Page 213)". The positioner triggers
an error message if the current value exceeds one of the three
configurable limit thresholds.
Sub-parameters are described below.
Factory setting:
OFF
C1.LIMIT - Limit for leakage indicator
Adjustment range:
0.1 ... 100.0
Purpose:
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 calibrated in such a way during the initialization (see section
"Commissioning (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 application.
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9.4 Description of parameters
To optimize the sensitivity of the monitoring of the pneumatic leakage 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 "Diagnostics parameter
'16.ONLK' Pneumatic leakage (Page 213)" provides information
about the actual values. Define the limit of the leakage indicator
accordingly.
The positioner triggers an error message if the current value exceeds one of the three configurable limit thresholds. How to set the
three limit thresholds is described below.
Factory setting:
30.0
C2.FACT1 - Factor 1
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "C1.LIMIT" and "C2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The process to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
1.0
C3.FACT2 - Factor 2
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 2. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "C1.LIMIT" and "C3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The process to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
1.5
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9.4 Description of parameters
C4.FACT3 - Factor 3
Adjustment range:
0.1 ... 100.0
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 3. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of "C1.LIMIT" and "C4.FACT3" .
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
9.4.3.4
2.0
Monitoring the stiction (slipstick) "d._STIC"
d. STIC - Monitoring the stiction (slipstick)
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
Use this parameter to continuously monitor the current stiction
(slipstick) 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.
The current value is displayed in "Diagnostics parameter '17.STIC'
Stiction (slipstick) (Page 214)". The positioner triggers an error
message if the current value exceeds a limit threshold.
Sub-parameters are described below.
Factory setting:
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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9.4 Description of parameters
d1.LIMIT - limit for slipstick detection
Adjustment range:
0.1 ... 100.0 %
Purpose:
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".
Factory setting:
1.0 %
d2.FACT1 - Factor 1
Adjustment range:
0.1 ... 100.0 %
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 1. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of the values entered for "d1.LIMIT"
and "d2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
2.0
d3.FACT2 - Factor 2
Adjustment range:
0.1 ... 100.0 %
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 2. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of the values entered for "d1.LIMIT"
and "d3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
5.0
d4.FACT3 - Factor 3
Adjustment range:
0.1 ... 100.0 %
Purpose:
Use this sub-parameter to set the factor for the formation of limit
threshold 3. Set the factor in a range from "0.1" to "100.0". The
limit threshold is the product of the values entered for "d1.LIMIT"
and "d4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
Factory setting:
10.0
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9.4 Description of parameters
9.4.3.5
Monitoring the deadband "E._DEBA"
E. DEBA - Monitoring the deadband
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
This parameter allows you to activate monitoring of the deadband.
This test can be used to monitor the automatic adjustment of
deadbands continuously.
Configure the following settings to activate the function:
1. Ensure that the "34.DEBA" parameter is set to "Auto".
2. Set the "E. DEBA" parameter to "On". The sub-menu to set
the threshold value is displayed. Monitoring is activated.
3. Change the parameter in the sub-menu if required. The setting
option is described below.
The positioner triggers a fault message if the current value exceeds the configurable limit threshold.
The sub-parameter is described below.
Factory setting:
OFF
E1.LEVL3 - Deadband threshold
Adjustment range:
0.1 ... 10.0
Purpose:
Use this sub-parameter to set the limit threshold to the deadband.
Set the threshold in a range from "0.1" to "10.0".
The threshold 3 fault message is displayed when the current
deadband exceeds the threshold limit during the test. The procedure to activate and display this error message is described in the
"XDIAG" parameter.
Factory setting:
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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9.4 Description of parameters
9.4.3.6
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:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
Use this parameter to activate continuous monitoring of the lower
endstop. The monitoring is executed whenever the valve is in the
"down tight closing" position. It checks whether the lower endstop
has changed compared to its value during initialization.
Configure the following settings to activate the function:
1. Ensure that the "'39.YCLS' Tight closing with manipulated
variable (Page 166)" parameter is set to "do" or "uP do".
2. Set the "F. ZERO" parameter to "On". Sub-parameters are
displayed. Monitoring is activated.
3. Set the suitable parameter values in sub-parameters. The
setting options available in sub-parameters are described
below.
The current value is displayed in "Diagnostics parameter
'18.ZERO' Lower endstop (Page 214)". The positioner triggers a
fault message if the current value exceeds one of the three configurable limit thresholds.
If the value undershoots a threshold, the fault message is saved in
a power fail-safe manner until:
• A fault no longer occurs.
• The device is re-initialized.
• The "F. ZERO" parameter is deactivated.
Sub-parameters are described below.
Factory setting:
OFF
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9.4 Description of parameters
F1.LEVL1 - threshold 1
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the lower endstop and the initialization value undershoots threshold 1. The process to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
1.0
F2.LEVL2 - threshold 2
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the lower endstop and the initialization value undershoots threshold 2. The process to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
2.0
F3.LEVL3 - threshold 3
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the lower endstop and the initialization value undershoots threshold 3. The process to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
4.0
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9.4 Description of parameters
9.4.3.7
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 an error message.
Requirement:
The "'52.XDIAG' Activating for extended diagnostics (Page 174)"
parameter is set to "On".
Possible settings:
• OFF
• On
Purpose:
Use this parameter to activate continuous monitoring of the upper
endstop. The monitoring is executed whenever the valve is in the
"Lower tight closing" position. It checks whether the upper endstop
has changed compared to its value during initialization.
Configure the following settings to activate the function:
1. Ensure that the "'39.YCLS' Tight closing with manipulated
variable (Page 166)" parameter is set to "uP" or "do uP".
2. Set the "G. OPEN" parameter to "On". Sub-parameters are
displayed. Monitoring is activated.
3. Set the suitable parameter values in sub-parameters. The
setting options available in sub-parameters are described
below.
The current value is displayed in "Diagnostics parameter
'19.OPEN' Displacement of upper end stop (Page 214)". The positioner triggers a fault message if the current value exceeds one of
the three configurable limit thresholds.
If the value undershoots a threshold, the fault message is saved in
a power fail-safe manner until:
• A fault no longer occurs.
• The device is re-initialized.
• The "G. OPEN" parameter is deactivated.
Sub-parameters are described below.
Factory setting:
OFF
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9.4 Description of parameters
G1.LEVL1 - threshold 1
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the upper endstop and the initialization value undershoots threshold 1. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
1.0
G2.LEVL2 - threshold 2
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the upper endstop and the initialization value undershoots threshold 2. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
2.0
G3.LEVL3 - threshold 3
Adjustment range:
0.1 ... 10.0
Purpose:
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 fault message if the difference between
the upper endstop and the initialization value undershoots threshold 3. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
Factory setting:
4.0
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9.4 Description of parameters
9.4.3.8
Monitoring the lower limit temperature "H._TMIN"
H. TMIN - Monitoring the lower limit temperature
Use this parameter to activate continuous monitoring of the lower limit temperature inside the
enclosure. The current temperature in the enclosure is recorded by a sensor on the basic
electronics. The limit temperature is monitored in three stages.
Configure the following settings to activate the function:
1. Set the "H. TMIN" parameter to "On". Sub-parameters are displayed. Monitoring is
activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The positioner triggers a fault message if the current value exceeds a threshold.
The factory setting is "OFF".
H1.TUNIT - temperature unit
Use this sub-parameter to set the temperature unit "°C" or "°F". The selected temperature
unit is then also applicable for all other temperature-based parameters.
The factory setting is "°C".
H2.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 1 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 1. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
The factory setting is "-25.0C".
H3.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 2 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 2. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
The factory setting is "-30.0C".
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9.4 Description of parameters
H4.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 3 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 3. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
The factory setting is "-40.0C".
9.4.3.9
Monitoring the upper limit temperature "J._TMAX"
J. TMAX - monitoring the high limit temperature
Use this parameter to activate continuous monitoring of the upper limit temperature inside
the enclosure. The current temperature in the enclosure is recorded by a sensor on the basic
electronics. The limit temperature is monitored in three stages.
Configure the following settings to activate the function:
1. Set the "J. TMAX" parameter to "On". Sub-parameters are displayed. Monitoring is
activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The positioner triggers a fault message if the current value exceeds a threshold.
The factory setting is "OFF".
J1.TUNIT - temperature unit
Use this sub-parameter to set the temperature unit "°C" or "°F". The selected temperature
unit is then also applicable for all other temperature-based parameters.
The factory setting is "°C".
J2.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 1 to monitor the high
limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 1. The procedure to activate and display this error message is described
in the "XDIAG" parameter.
The factory setting is "75.0C".
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9.4 Description of parameters
J3.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 2 to monitor the high
limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 2. The procedure to activate and display this error message is described
in the "XDIAG" parameter.
The factory setting is "80.0C".
J4.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 3 to monitor the high
limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 3. The procedure to activate and display this error message is described
in the "XDIAG" parameter.
The factory setting is "90.0C".
9.4.3.10
Monitoring the number of total strokes "L._STRK"
L. STRK - Monitoring the number of total strokes
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
actuator are added together into total strokes.
Configure the following settings to activate the function:
1. Set the "L. STRK" parameter to "On". Sub-parameters are displayed. Monitoring is
activated.
2. Set the suitable values in sub-parameters. The setting options available in subparameters are described below.
The current value is displayed in Diagnostics parameter '1.STRKS' Number of total strokes
(Page 209). The positioner triggers an error message if the current value exceeds a limit
threshold.
The factory setting is "OFF".
L1.LIMIT - Limit for number of total strokes
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".
The factory setting is "1.00E6".
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9.4 Description of parameters
L2.FACT1 - Factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "1.0".
L3.FACT2 - Factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "2.0".
L4.FACT3 - Factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "5.0".
See also
Display of diagnostics values (Page 205)
9.4.3.11
Monitoring the number of changes in direction "O._DCHG"
O. DCHG - Monitoring the number of changes in direction
Use this parameter to continuously monitor the number of changes in direction of the
actuator beyond the deadband.
Configure the following settings to activate the function:
1. Set the "O. DCHG" parameter to "On". Sub-parameters are displayed. Monitoring is
activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The current value is displayed in the "2 CHDIR" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds a limit threshold.
The factory setting is "OFF".
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9.4 Description of parameters
O1.LIMIT - Limit for number of changes in direction
Use this sub-parameter to set the base limit for the number of changes of direction of the
actuator. Set the base limit in a range from "1" to "1.00E8".
The factory setting is "1.00E6".
O2.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "1.0".
O3.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "2.0".
O4.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "5.0".
See also
Display of diagnostics values (Page 205)
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9.4 Description of parameters
9.4.3.12
Monitoring the position average value "P._PAVG"
P. PAVG - Monitoring the position average value
Use this parameter to activate the test to calculate and monitor the average value of position.
Configure the following settings to activate the test:
1. Set the "P. PAVG" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
During the test, the average values of position and reference are always compared at the
end of a time interval. The positioner triggers an error message if the current average value
of position exceeds a threshold.
The factory setting is "OFF".
P1.TBASE - Time basis of average value generation
Use this sub-parameter to set the time interval to calculate the average 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 expiry 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.
The factory setting is "0.5 h".
P2.STATE - Status of monitoring position average value
Use this sub-parameter to start the calculation for average value of position. If an average
value of reference has never been determined, 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.
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Parameterizing/addressing
9.4 Description of parameters
When the time interval expires, the calculated average value of reference is shown on the
display.
Note
Current average value of position
The respective current average value of position is displayed in the "19.PAVG" diagnostics
parameter. If no average value of position has been calculated, "COMP" is displayed in the
"19.PAVG" diagnostics parameter.
The factory setting is "IdLE".
P3.LEVL1 - threshold 1
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. 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 1. The procedure to activate
and display this error message is described in the "XDIAG" parameter.
The factory setting is "2.0".
P4.LEVL2 - threshold 2
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. 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 procedure to activate
and display this error message is described in the "XDIAG" parameter.
The factory setting is "5.0".
P5.LEVL3 - threshold 3
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. 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 3. The procedure to activate
and display this error message is described in the "XDIAG" parameter.
The factory setting is "10.0".
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Alarm, error, and system messages
10.1
Output of system messages in the display
10.1.1
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 auxiliary power
•
Maintenance
•
Check whether the complete travel can
Down
X
Start
Meaning / cause
X
X
Potentiometer voltage of a non-initialized
positioner (P-manual mode) (actual position
value in % of the measuring range).
be covered using the
and
buttons
and that "P---" is never displayed.
P---
NOINI
X
Measuring range was exceeded, the potentiometer is in the inactive zone, the transmission ratio selector or the effective lever arm
are not adjusted as per the actuator travel.
X
Positioner is not initialized.
•
Execute the initialization process.
•
Switch the transmission ratio selector to
90°, especially in the case of part-turn actuators.
•
Adjust the effective lever length of linear
actuators as per the measuring range.
•
Start initialization.
See also
Display (Page 103)
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10.1 Output of system messages in the display
10.1.2
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
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10.1 Output of system messages in the display
Messages during initialization
Message
Line
Up
P--
Meaning / cause
Measure
Measuring range was exceeded, the potentiometer is in the inactive zone, the transmission ratio selectors or the effective lever arm
are not adjusted as per the actuator travel
•
Switch the transmission ratio selector to
90° especially in case of part-turn actuators
•
Adjust the effective lever length of linear
actuators as per the measuring range
Down
X
RUN1
X
Initialization was started, part 1 is active (the
direction of action is determined)
•
Maintenance
RUN2
X
Initialization part 2 is active (actuator travel
check and determination of end stops)
•
Maintenance
RUN3
X
Initialization part 3 is active (determination
and display of travel times)
•
Maintenance
RUN4
X
Initialization part 4 is active (determination of
the minimum controller increment length)
•
Maintenance
RUN5
X
Initialization part 5 is active (optimization of
the transient response)
•
Wait until "FINSH" is displayed (initialization completed successfully)
•
Acknowledge by pressing the operating
mode button briefly and exit the configuration level by pressing it longer
•
Approach the first end position using the
"+" or "-" button
•
Acknowledge using the operating mode
button
•
Approach the second end position using
the "+" or "-" button
•
Acknowledge using the operating mode
button
•
Approach another end position using the
"+" and "-" buttons and acknowledge with
the operating mode button, or
•
Move the friction clutch until "ok" is displayed, and then acknowledge with the
operating mode button, or
•
Terminate the initialization process by
pressing the operating mode button,
switch to the P-manual mode and correct
the actuator travel and the position displacement sensor
•
Acknowledge with the operating mode
button; the remaining steps ("RUN1" to
"FINSH") execute automatically
YEND1
YEND2
RANGE
ok
X
X
X
x
The first end position can be approached
only in case of a manual initialization
The second end position can be approached
only in case of a manual initialization
The end position or the measuring span is
beyond the permissible measuring range
only in case of a manual initialization
The permissible measuring range of end
positions is achieved only in case of a manual initialization
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10.1 Output of system messages in the display
Message
Line
Up
RUN1 /
ERROR
SEt
X
X
MIDDL
X
X
UP >
X
90_95
X
U-d>
U nn.n
X
D->U
D nn.n
U->d
Measure
Error in "RUN1", no movement e.g. due to
the lack of compressed air
•
Down
X
d___U
Meaning / cause
Bar graph display of the zero point; zero
point is beyond the tolerance range
Friction clutch was moved; "P 50.0" not displayed when the lever is horizontal
"UP" tolerance range was exceeded or the
inactive zone of the potentiometer was covered
Open the restrictor(s)
Restart the initialization process
•
Set between "P 4.0" and "P 9.9" ( >0< )
using a friction clutch
•
Continue with the "+" or "-" button
•
In case of linear actuators, use the "+"
and "-" buttons to bring the lever perpendicular to the spindle
•
Press the operating mode button slightly
to acknowledge (the initialization process
is continued)
•
Increase the effective lever length of the
linear actuators or switch the transmission ratio selector to 90°
•
Press the operating mode button slightly
to acknowledge
•
Restart the initialization process
Use the "+" and "-" buttons to move it in
the range between 90 and 95%
"Up-Down" measuring span was undershot
•
Decrease the effective lever length of the
linear actuators or switch the transmission ratio selector to 33°
•
Press the operating mode button slightly
to acknowledge
•
Restart the initialization process
•
Wait, or
•
To change the travel time, interrupt the
initialization process with the "-" button,
or
•
Activate the leakage test with the "+"
button
•
Wait, or
•
To change the travel time, interrupt the
initialization process with the "-" button,
or
•
Activate the leakage test with the "+"
button
X
Display of the "Down" travel time
X
•
•
Possible only in case of part-turn actuators:
•
actuator travel is not in the range between 90
and 95%
•
Display of the "Up" travel time
X
Provide adequate compressed air
Press the operating mode button slightly
to acknowledge
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10.1 Output of system messages in the display
Message
Line
Up
X
X
LEAKG
nn.n
X
X
%/MIN
nn.n
Measure
Actuator stops (the initialization process was
interrupted using the "-" button when the
actuation speed display was active)
•
The travel time can be changed by adjusting the restrictor(s)
•
Redetermine the speed of shifting using
the "-" button
•
Continue with the "+" button
Leakage test active (the "+" button was
pressed when the actuation speed display
was active)
•
Wait for 1 minute
•
Continue with the "+" button
Value and unit of the result after the leakage
test
•
Rectify the leakage if the value is too
large
•
Continue with the "+" button
•
Acknowledge by pressing the operating
mode button briefly and exit the configuration level by pressing it longer
Down
NOZZL
TESt
Meaning / cause
X
X
FINISH
X
Initialization completed successfully with the
display of actuator travel or the actuator
angle
See also
System messages before initialization (Page 199)
10.1.3
System messages when exiting the Configuration mode
Remarks about the tables:
nn
stands for variable numeric values
Error symbol
/
(slash): the text to the left and right of the slash blink interchangeably.
Messages when exiting the configuration mode:
Message
Goals
Up
n.nn.nnV
ER
X
ErrorSLnn
X
Down
Operating mode
Automatic
Manual mode
Meaning / Cause
Measure
Software version
•
P Manual mode
X
X
Monotony interruption •
of the free characteristic on the setpoint
turning point n
Wait
Correct value
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10.1 Output of system messages in the display
10.1.4
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
Abov
e
CPU
Operating mode
Below Automatic
Manual
Meaning / cause
Measure
P-manual
X
Message after application
of electrical auxiliary power
•
START
Maintenance
HW /
ERROR
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
initialized 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
•
transmission ratio
selector, or
•
perform factory
settings (Preset)
and initialization
Possible causes:
•
Friction clutch or
•
transmission ratio
selector was disturbed
or
•
Positioner was installed on a different
actuator without being
reinitialized
EXSTP
X
X
Actuator was stopped with
the binary input
EX UP
X
X
Actuator is moved to the
upper stop with binary
input
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10.2 Diagnostics
Message
Line
Abov
e
EXDWN
Operating mode
Below Automatic
X
Manual
X
Meaning / cause
Measure
P-manual
Actuator is moved to the
lower stop with binary
input
EXTPSt
The partial stroke test was
activated, e.g. using a
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
communication is running
10.2
Diagnostics
10.2.1
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.
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10.2 Diagnostics
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 206)".
10.2.2
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 "Reset possible" column contains an "X" if the diagnostics value can be set to zero.
● The "Properties" column shows the properties of the diagnostics parameters:
① Diagnostics value can be read and reset.
– ② Diagnostics value can be read but not reset.
– ③ Diagnostics value can be read but not reset. A function can be executed.
– ④ Diagnostics value can be read, manually reset, and manually changed.
–
Overview of diagnostics values
No.
Abbreviation
Meaning
Representable
diagnostics values
Unit
Properties
1
STRKS
Number of total strokes
0 ... 4.29E9
-
①
2
CHDIR
Number of changes in direction
0 ... 4.29E9
-
①
Number of fault messages
0 ... 4.29E9
-
①
3
CNT
4
A1CNT
Number of alarms 1
0 ... 4.29E9
-
①
5
A2CNT
Number of alarms 2
0 ... 4.29E9
-
①
6
HOURS
Number of operating hours
0 ... 4.29E9
Hours
②
7
HOURR
Resettable operating hours counter
0 ... 4.29E9
8
WAY
Determined actuator travel
0 ... 130
mm or °
②
9
TUP
Travel time UP
0.0 / 0 ... 1000
s
②
10
TDOWN
Travel time DOWN
0.0 / 0 ... 1000
s
②
①
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10.2 Diagnostics
No.
Abbreviation
Meaning
Representable
diagnostics values
Unit
Properties
11
LEAK
Leakage
- / 0.0 ... 100.0
%/minute
③
12
PST
Partial stroke tests
OFF / ###.#, fdini, s for ###.#
notSt, SdtSt,
fdtSt, notd, Strt,
StoP
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
15
DEVI
Dynamic control valve behavior
OFF / 0.0 ...
100.0
%
②
16
ONLK
Pneumatic leakage
OFF / 0.0 ...
100.0
-
②
17
STIC
Stiction (slipstick)
OFF / 0.0 ...
100.0
%
②
18
ZERO
Lower endstop
OFF / 0.0 .. 100.0
%
②
19
OPEN
Upper endstop
OFF / 0.0 ...
100.0
%
②
20
PAVG
Average value of position
OFF, IdLE, rEF,
COMP
%
②
21
P0
Potentiometer value of lower endstop (0%)
0.0 ... 100.0
%
③
22
P100
Potentiometer value of upper endstop (100%)
0.0 ... 100.0
%
③
23
IMPUP
Impulse length up
6 ... 160
ms
④
24
IMPDN
Impulse length down
6 ... 160
ms
④
25
PAUTP
Pulse interval
2 ... 28 ... 320
ms
④
26
DBUP
Deadband up
0.1 ... 10.0
%
②
27
DBDN
Deadband down
0.1 ... 10.0
%
②
28
SSUP
Slow step zone up
0.1 ... 10.0 ...
100.0
%
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
②
32
TMAX
Maximum temperature ("min/max pointer")
-50 ... 100
-58 ... 212
°C
°F
②
33
T1
Number of operating hours in temperature range 1
0 ... 4.29E9
Hours
②
34
T2
Number of operating hours in temperature range 2
0 ... 4.29E9
Hours
②
35
T3
Number of operating hours in temperature range 3
0 ... 4.29E9
Hours
②
0.0 ... 100.0
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10.2 Diagnostics
No.
Abbreviation
Meaning
Representable
diagnostics values
Unit
Properties
36
T4
Number of operating hours in temperature range 4
0 ... 4.29E9
Hours
②
37
T5
Number of operating hours in temperature range 5
0 ... 4.29E9
Hours
②
38
T6
Number of operating hours in temperature range 6
0 ... 4.29E9
Hours
②
39
T7
Number of operating hours in temperature range 7
0 ... 4.29E9
Hours
②
40
T8
Number of operating hours in temperature range 8
0 ... 4.29E9
Hours
②
41
T9
Number of operating hours in temperature range 9
0 ... 4.29E9
Hours
②
42
VENT1
Number of switching cycles of pilot valve 1
0 ... 4.29E9
-
②
43
VENT2
Number of switching cycles of pilot valve 2
0 ... 4.29E9
-
②
44
VEN1R
Number of switching cycles of pilot valve 1, resettable
0 ... 4.29E9
-
①
45
VEN2R
Number of switching cycles of pilot valve 2, resettable
0 ... 4.29E9
-
①
46
STORE
-
-
③
Save the current value as "last maintenance" (press
button for 5 seconds)
47
PRUP
Prediction up
1 ... 40
-
④
48
PRDN
Prediction down
1 ... 40
-
④
49
WT00
Number of operating hours in the travel range WT00
0 ... 4.29E9
Hours
①
50
WT05
Number of operating hours in the travel range WT05
0 ... 4.29E9
Hours
①
51
WT10
Number of operating hours in the travel range WT10
0 ... 4.29E9
Hours
①
52
WT30
Number of operating hours in the travel range WT30
0 ... 4.29E9
Hours
①
53
WT50
Number of operating hours in the travel range WT50
0 ... 4.29E9
Hours
①
54
WT70
Number of operating hours in the travel range WT70
0 ... 4.29E9
Hours
①
55
WT90
Number of operating hours in the travel range WT90
0 ... 4.29E9
Hours
①
56
WT95
Number of operating hours in the travel range WT95
0 ... 4.29E9
Hours
①
57
mA
Setpoint current
0.0 ... 20.0
mA
②
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10.2 Diagnostics
10.2.3
Meaning of the diagnostics parameters
Note
Saving diagnostics values
The diagnostics values are written into a non-volatile memory every 15 minutes so that, in
the event of a power failure, only the 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 values which can be reset can be found in the table in section "Overview of diagnostics
values (Page 206)".
10.2.3.1
10.2.3.2
10.2.3.3
Diagnostics parameter '1.STRKS' Number of total strokes
Display range:
0 ... 4.29E9
Purpose:
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.
Diagnostics parameter '2.CHDIR' Number of changes in direction
Display range:
0 ... 4.29E9
Purpose:
Every change in direction of the actuator is noted in the closedloop controller and added to the number of changes in direction.
Diagnostics parameter '3._CNT' Number of fault messages
Display range:
0 ... 4.29E9
Purpose:
Every fault is noted in the closed-loop controller with '3. CNT' and
added to the number of fault messages.
10.2.3.4
Diagnostics parameters '4.A1CNT' Number of alarms 1 /
'5.A2CNT' Number of alarms 2
Requirement:
Alarm function is activated by means of the "'44.AFCT' Alarm function (Page 169)" parameter.
Display range:
0 ... 4.29E9
Purpose:
This value indicates how often the alarm has been triggered.
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10.2.3.5
10.2.3.6
Diagnostics parameter '6.HOURS' Number of operating hours
Display range:
0 ... 4.29E9
Purpose:
The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner.
Diagnostics parameter '7.HOURR' Resettable operating hours counter
Display range:
0 ... 4.29E9
Purpose:
The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner. In contrast to Diagnostics parameter '6.HOURS' Number of operating hours
(Page 210), this value can be reset.
Press the
10.2.3.7
10.2.3.8
button until "0" is output in the display.
Description:
In order to minimize the control valve wear resulting from a poor
control quality, it makes sense to optimize the positioner's parameters. You can recognize optimum parameter settings when the
values of the Diagnostics parameters '44.VEN1R' / '45.VEN2R'
(Page 221) are low. Low values mean that the switching frequency
of the positioner 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 Diagnostics parameters '44.VEN1R' / '45.VEN2R' (Page 221) and
'7.HOURR'. These three parameters can be reset to enable simpler determination of the values.
Factory setting:
0
Diagnostics parameter '8.WAY' - Determined travel
Requirement for linear
actuator:
The travel is set in the "'3.YWAY' Range of stroke (Page 158)"
parameter.
Display range:
0 ... 130
Purpose:
This value in mm or ° specifies the travel determined during the
initialization.
Diagnostics parameters '9.TUP' Travel time UP / '10.TDOWN' Travel time DOWN
Display range:
0 ... 1000
Purpose:
This value indicates the current UP or DOWN travel time in seconds determined during the initialization.
Factory setting:
0.0
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10.2 Diagnostics
10.2.3.9
Diagnostics parameter '11.LEAK' Leakage test
Requirements
The positioner is initialized and in manual mode (MAN).
Display range:
• • 0.0 ... 100.0
Purpose:
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. 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 chapter "Sequence of automatic
initialization (Page 117)".
• "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
"50.PRST > 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" diagnostics
parameter as described in section "Display of diagnostics
values (Page 205)".
3. Start the function by pressing the
button for at least 5
seconds.
Description:
"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.
Factory setting:
-
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10.2 Diagnostics
10.2.3.10
Diagnostics parameter '12.PST' Monitoring of partial stroke test
Indication on the display: • OFF
• FdInI
• notSt
• ###.#
• SdtSt
• FdtSt
Purpose:
This diagnostics parameter indicates the stroke time measured
during 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 in the
on the display:
configuration menu.
• FdIni - Failed PST Initialization: The reference stroke time
measurement of the partial stroke test has failed.
• notSt - No Test: A 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
but-
ton 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 after pressing
the button for five seconds.
• StoP - Stop: The currently running partial stroke test is
interrupted.
Factory setting:
10.2.3.11
OFF
Diagnostics parameter '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.
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Status messages:
• notSt - No Test: A 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
Factory setting:
10.2.3.12
notSt
Diagnostics parameter '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
• ###
10.2.3.13
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.
Factory setting:
OFF
Diagnostics parameter '15.DEVI' General control valve fault
Requirement:
• General fault of control valve "b. DEVI" is activated, see
section "Monitoring of dynamic control valve behavior "b._DEVI"
(Page 181)".
Display range:
• OFF
• 0.0 ... 100.0
Purpose:
This value in percent provides information about the current dynamically determined deviation from the model response. If the
underlying function is deactivated in the configuration menu, "OFF"
is displayed.
Factory setting:
OFF
See also
Partial stroke test "A._PST" (Page 175)
10.2.3.14
Diagnostics parameter '16.ONLK' Pneumatic leakage
Requirement:
Pneumatic leakage is activated, "Monitoring pneumatic leakage
"C._LEAK" (Page 183)".
Display range:
• OFF
• 0 ... 100
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10.2 Diagnostics
10.2.3.15
Purpose:
This diagnostics parameter shows the current leakage indicator. If
the leakage detection is deactivated in the configuration menu,
"OFF" is displayed.
Factory setting:
OFF
Diagnostics parameter '17.STIC' Stiction (slipstick)
Requirement:
Monitoring of stiction is activated, "Monitoring the stiction (slipstick)
"d._STIC" (Page 185)".
Display range:
• OFF
• 0.0 ... 100.0
10.2.3.16
Purpose:
This diagnostics parameter shows the filtered value of the slip
jumps in percent resulting from the stiction.
Factory setting:
OFF
Diagnostics parameter '18.ZERO' Lower endstop
Display range:
• OFF
• 0.0 ... 100.0
Purpose:
Indication of how many percent the lower endstop has changed
compared to its value during initialization. The activation of the
"down tight closing function" is a condition to determine this. If the
underlying function is deactivated in the configuration menu, "OFF"
is displayed.
Factory setting:
OFF
See also
'39.YCLS' Tight closing with manipulated variable (Page 166)
10.2.3.17
Diagnostics parameter '19.OPEN' Displacement of upper end stop
Display range:
• OFF
• 0.0 ... 100.0
Purpose:
Display of the current displacement of the upper hard end stop
with respect to its initialization value. The activation of the "up tight
closing function" is a condition to determine this. If the underlying
function is deactivated in the configuration menu, "OFF" is displayed.
Factory setting:
OFF
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See also
'39.YCLS' Tight closing with manipulated variable (Page 166)
10.2.3.18
Diagnostics parameter '20.PAVG' Position average
Indication on the display: • OFF
• IdE
• 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.
Factory setting:
OFF
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10.2 Diagnostics
10.2.3.19
Diagnostics parameters '21.P0' Potentiometer value of bottom end stop / '22.P100'
Potentiometer value of top end stop
Display range:
• 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.
Requirement 1 read values
The positioner is initialized.
Purpose 1
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 manual initialization.
Requirement 2 change values
• 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 (zero point P0).
• The current position of the actuator is within the range 90 to
110% of the upper endstop (P100).
Purpose 2:
Change values
You can use these two parameters to change the lower endstop
(zero point P0) and the upper endstop (P100).
Since initialization is not usually carried out under process conditions, the values for the lower endstop (zero point 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 "F.ZERO" or
"G.OPEN" 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 normal 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
procedure is described in the following.
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Description:
Procedure for "Manual" mode (MAN)
1. Move the actuator to the desired position of the upper endstop
or lower endstop using the
or
button respectively.
2. Switch to "Diagnostics" mode.
3. Go to diagnostics parameter 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 diagnostics parameter 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 "Automatic" mode (AUT).
See also
Display of diagnostics values (Page 205)
Monitoring the lower endstop "F._ZERO" (Page 188)
Monitoring the upper endstop "G._OPEN" (Page 190)
Changing the operating mode (Page 107)
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10.2 Diagnostics
10.2.3.20
Diagnostics parameters '23.IMPUP' Impulse length UP / '24.IMPDN' Impulse length
DOWN
Display range:
6 ... 160
Purpose:
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.
These two parameters can be set for special applications.
Factory setting:
6
See also
Control algorithm (Page 27)
Optimization of controller data (Page 111)
10.2.3.21
Diagnostics parameter '25.PAUTP' Interpulse period
Display range:
2 ... 320
Purpose:
The value for the "25.PAUTP" parameter is factory-set to 28 ms.
This value is not changed during an initialization process. Display
in ms.
For applications with high stiction (slipstick), adjusting this parameter improves the control quality.
This parameter can be set for special applications.
Factory setting:
28
See also
Control algorithm (Page 27)
10.2.3.22
Diagnostics parameters '26.DBUP' Deadband UP / '27.DBDN' Deadband DOWN
Display range:
26.DBUP: 0.1 ... 10.0
27.DBDN: -01. ... 10.0
Purpose 1
In this parameter, you can read the deadbands of the controller in
the "Up" and "Down" directions. Display in percent. The values
correspond either to the manually configured value of the
"'34.DEBA' Deadband of closed-loop controller (Page 163)" parameter or to the value automatically adapted by the device if "DEBA"
was set to "Auto".
Factory setting:
10.0
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10.2 Diagnostics
10.2.3.23
Diagnostics parameters '28.SSUP' Slow step zone UP / '29.SSDN' Slow step zone
DOWN
Display range:
0.1 ... 100.0
Purpose:
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.
Factory setting:
10.0
See also
Control algorithm (Page 27)
Optimization of controller data (Page 111)
10.2.3.24
Diagnostics parameter '30.TEMP' Current temperature
Display range:
°C: -50 ... 100
°F: -58 ... 212
Purpose:
Current temperature in the positioner enclosure. The sensor is present on the basic electronics. In order to switch over the temperature display between °C and °F, press the
10.2.3.25
button.
Diagnostics parameters '31.TMIN' Minimum temperature / '32.TMAX' Maximum
temperature
Display range:
°C: -50 ... 100
°F: -58 ... 212
Purpose:
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.
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10.2 Diagnostics
10.2.3.26
Diagnostics parameters '33.T1' ... '41.T9' Number of operating hours in the
temperature range 1 to 9
Display range:
0 ... 4.29E9
Purpose:
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
device and the entire control valve.
The temperature ranges are classified as follows:
Temperature range [°C]
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
Factory setting:
10.2.3.27
0
Diagnostics parameters '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
Purpose:
Control procedures of the pilot valves in the pneumatic block of the
positioner are counted and displayed in this parameter.
Description:
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.
This amounts on average to approx. 200 million switching cycles for
each of the two pilot valves with symmetrical load. The number of
control procedures for the switching cycles serves to assess the
switching frequency 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.
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10.2 Diagnostics
10.2.3.28
Diagnostics parameters '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
10.2.3.29
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 "Diagnostics parameters
'42.VENT1' / '43.VENT2' (Page 220)" referred to the diagnostics parameters "VEN1R" and "VEN2R" described here.
Factory setting:
0
Diagnostics parameter '46.STORE' Save maintenance data
Purpose:
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 for at least 5 seconds in order to initiate a
save function. The values of the diagnostics parameters
"Diagnostics parameter '8.WAY' - Determined travel (Page 210)" to
"Diagnostics parameter '11.LEAK' Leakage test (Page 211)" and
"Diagnostics parameters '21.P0' Potentiometer value of bottom
end stop / '22.P100' Potentiometer value of top end stop
(Page 216)" to "Diagnostics parameters '28.SSUP' Slow step zone
UP / '29.SSDN' Slow step zone DOWN (Page 219)" are saved in
the non-volatile memory as "data of last maintenance". This diagnostics data contains selected values whose changes can give
information about mechanical wear and tear of the valve.
This function is normally operated through the PDM, menu command "Device-> Save maintenance info". The data of the last
maintenance operation can be compared with the current data
using SIMATIC PDM.
Factory setting:
-
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10.2 Diagnostics
10.2.3.30
Diagnostics parameters '47.PRUP' Prediction UP / '48.PRDN' Prediction DOWN
Display range:
1 ... 40
Purpose:
This value specifies the prediction of the controller for the up
(47.PRUP) and down (48.PRDN) movements.
For more information, refer also to the section "Optimization of
controller data (Page 111)".
Factory setting:
10.2.3.31
1
Diagnostics parameters '49.WT00' ... '56.WT95' Number of operating hours in the
travel range WT00 to WT95
Display range:
0 ... 4.29E9
Purpose:
When the positioner is in "Automatic" mode, statistics are continuously 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
runtime meter assigned to the corresponding travel range every
hour. This helps in drawing conclusions about the past operating
conditions and especially in assessing the control properties of the
control loop and the entire control valve.
Factory setting:
0
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 diagnostics parameters, press the
the
button several times along with
button. This will help you to access the desired diagnostics
parameters faster.
Factory setting:
10.2.3.32
0
Diagnostics parameter '57.mA' Setpoint current
Here you can display the current setpoint in mA.
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10.3 Online diagnostics
10.3
Online diagnostics
10.3.1
Overview of online diagnostics
Online diagnostics means diagnostics during ongoing operation. During operation of the
positioner, a few important values and parameters are continually monitored. In configuration
mode, you can configure that monitoring so 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 section "Overview of error codes (Page 224)".
This section contains particular information about the following situations:
● Possible causes of the fault message.
● Events which activate the fault message output or alarm outputs.
● Settings of parameters needed for event monitoring.
● Cancelling an error message
When the fault message output is triggered in "Automatic" or "Manual" mode, the display
shows which fault triggered the message. The two digits on the lower left show the
corresponding error code. If multiple triggers occur at the same time, they are displayed one
after the other cyclically. The device status, including all fault messages, can be called up
using command "#48" over HART.
See also
'52.XDIAG' Activating for extended diagnostics (Page 174)
Description of advanced diagnostics parameters A to P (Page 175)
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10.3 Online diagnostics
10.3.2
Overview of error codes
Overview of error codes that activate the fault message output
Error
code
1
2
3
Threestage
Event
Parameter setting
Error message disappears
when
Possible causes
No
Actual-value response has exceeded values for
TIM and LIM
Always active
... the actual-value response
falls below the value for LIM
Compressed air failure, actuator fault, valve fault (e.g.
blockade).
No
Device not in "Automatic" mode
... the device is changed to
"Automatic" mode.
The device has been configured or is in the manual mode
No
Binary input BIN1
or BIN2 active
... the binary input is no longer active.
The contact connected to the
binary input was active (e.g.
packing gland monitoring,
overpressure, temperature
switch).
**. FCT1)
= nA or =
**.
nAB
FCT1)
= nAB and binary
function BIN1 or
BIN2 on "On"
4
5
6
7
Yes
Limit for number of
L. STRK≠OFF
total strokes exceeded
... the stroke counter is reset
or the thresholds are increased
The total path covered by the
actuator exceeds one of the
configured thresholds.
Yes
Limit for number of
O. DCHG≠OFF
changes in direction exceeded
... the counter for changes of
direction is reset or the
thresholds are increased.
The number of changes of
direction exceeds one of the
configured thresholds.
Yes
Lower endstop
limit exceeded
Yes
Upper endstop
limit exceeded
... the deviation of the endstop disappears or the device
**.YCLS = do or up is re-initialized.
do
Wear and tear of the valve
seat, deposits or foreign bodies in the valve seat, mechanical misalignment, friction
clutch moved.
... the deviation of the endstop disappears or the device
is re-initialized.
Wear and tear of the valve
seat, deposits or foreign bodies in the valve seat, mechanical misalignment, friction
clutch moved.
... the limit is undershot again
Increased packing gland
friction, mechanical gap in the
position feedback.
F. ZERO≠OFF
G. OPEN≠OFF
**.YCLS1) = do or
up do
8
9
No
Yes
Deadband limit
exceeded
E. DEBA≠OFF
**.DEBA1) = Auto
Case 1: Reference
A. PST≠OFF
stroke time for
partial stroke test
is exceeded.
Case 1: ... a partial stroke test Case 1: Valve is stuck or
is successfully executed
rusted. Increased stiction.
within the reference stroke
time or the function is deactivated.
Case 2: Start position outside the
start tolerance
Case 2: Move the actuator
into the range of the PST
start tolerance. Or increase
the PST start tolerance until
the actuator (PST start position) is within the PST start
tolerance. Start the partial
stroke test again.
Case 2: Valve is present in
the safety position.
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10.3 Online diagnostics
Error
code
Threestage
Event
10
Yes
Deviation from
expected dynamic
control valve behavior
11
Yes
12
Error message disappears
when
Possible causes
... the position is again in a
narrow corridor between the
reference variable and the
model, or the function is deactivated.
Actuator fault, valve fault,
valve jams, increased stiction,
decreased compressed air
Pneumatic leakC. LEAK≠OFF
age limit exceeded
... the leakage drops below
the configured thresholds, or
the function is deactivated.
Pneumatic leakage
Yes
Stiction limit (slipstick) exceeded
d. STIC≠OFF
... Slipjumps can no longer be Increased stiction, valve no
detected, or the function is
longer moves smoothly but in
deactivated.
jerky motion.
13
Yes
Temperature undershot
H. TMIN≠OFF
14
Yes
15
16
1)
Parameter setting
b. DEVI≠OFF
... the low temperature
thresholds are no longer
undershot.
Ambient temperature too low
Temperature overJ. TMAX≠OFF
shot
... the high thresholds are no
longer overshot.
Ambient temperature too high
Yes
Position average
deviates from the
reference value
... the average value of position calculated after a comparison interval is again
within the thresholds for the
reference value, or the function is deactivated.
In the last comparison interval, the valve trajectory was
changed so severely that a
deviating average value of
position was calculated.
No
Partial stroke test
is to be carried out
with non-plausible
parameter values
the parameter values entered
in A1.STPOS, A3.STRKH
and A4.STRKD are plausible.
Parameters for partial stroke
test are non-plausible
P. PAVG≠OFF
A. PST≠OFF
Refer to the corresponding parameter descriptions for additional information about parameters
See also
Overview of initialization parameters 1 to 5 (Page 147)
Overview of application parameters 6 to 52 (Page 148)
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10.3 Online diagnostics
10.3.3
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)
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
10.3.4
Meaning of error codes
10.3.4.1
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.
10.3.4.2
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.
10.3.4.3
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.
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10.3 Online diagnostics
10.3.4.4
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".
10.3.4.5
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".
10.3.4.6
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.
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10.3 Online diagnostics
10.3.4.7
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.
10.3.4.8
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, this fault message appears when one of the three thresholds of the partial
stroke test that are determined from the "A6.PSTIN" reference stroke time multiplied by
factors "A7.FACT1" to "A9.FACT3" is violated. The degree of the fault message is shown in
the number of columns on the display. The degree of the fault message is simultaneously
displayed using the fault message output or alarm outputs depending on the mode of the
extended diagnostics.
10.3.4.9
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 reference variable 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".
10.3.4.10
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").
10.3.4.11
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.
10.3.4.12
13 Monitoring the lower limit temperature
This fault message appears when the lower limit temperature thresholds are undershot.
10.3.4.13
14 Monitoring the upper limit temperature
This fault message appears when the upper limit temperature thresholds are overshot.
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10.4 Fault correction
10.3.4.14
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.
10.3.4.15
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.
10.4
Fault correction
10.4.1
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
2
3
3
5
5
When does a fault occur?
•
Regularly (reproducible)
1
•
Sporadically (not reproducible)
5
•
Mostly after a specific operation time
2
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10.4 Fault correction
See also
Remedial measures table 2 (Page 231)
Remedial measures table 3 (Page 232)
Corrective measures Table 4 (Page 233)
Remedial measures table 5 (Page 234)
10.4.2
Remedial measures table 1
Fault profile (symptoms)
•
•
•
•
Positioner remains in "RUN 1".
Positioner remains in "RUN 2".
Positioner remains in "RUN 3".
Positioner remains "RUN 5", does
not go up to "FINISH" (waiting time
> 5 min).
Possible cause(s)
Corrective measures
•
Initialization started from the end
position and
•
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
•
•
"YAGL" and the real stroke do not
match.
Check settings: see leaflet: Fig.
"Device view ⑦" as well as parameters 2 and 3
•
Check the stroke setting on the
lever. See Table 2.
•
Open the restrictor completely
and/or set the pressure PZ (1) to
the highest permissible value.
•
Use a booster if required.
•
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.
•
•
Incorrectly set stroke on the lever.
•
Piezo valve does not activate.
•
Actuator travel time is too high.
•
"Gap" (play) in the positioner - actuator - control valve system
A waiting time of up to 1 minute is
essential.
Fault table 1
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10.4 Fault correction
10.4.3
Remedial measures table 2
Fault profile (symptoms)
Possible cause(s)
•
"CPU testt" blinks on the display
approximately every 2 seconds.
•
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
•
Otherwise: Repair
•
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.
•
Water in the pneumatic block (due
to wet compressed air)
Corrective measures
Clean all contact surfaces with
spirit; if required, bend the pneumatic block contact springs.
Fault table 2
See also
Repair/Upgrading (Page 238)
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10.4 Fault correction
10.4.4
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 (how-
•
Restrictor valve turned off (screw at
the right end stop)
•
Open the restrictor screw by turning
it anticlockwise, see leaflet, Fig.
"Device view ⑥".
•
Dirt in the pneumatic block
•
Repair or a new device; clean
and/or replace the built-in fine
screens.
Pneumatic leakage in the positioner •
- actuator system; start the leakage
test in "RUN 3" (initialization).
•
Rectify leakage in the actuator
and/or feed line.
ever, a gentle clicking sound can be
heard when the
or
button is
pressed in "Manual" mode.)
•
A piezo valve is switched constantly •
in stationary automatic mode (constant setpoint) and in "Manual"
mode.
•
Dirt in the pneumatic block
•
In case of an intact actuator and
tight feed line: Repair or new device
See above
Fault table 3
See also
Repair/Upgrading (Page 238)
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10.4 Fault correction
10.4.5
Corrective measures Table 4
Fault profile (symptoms)
•
In stationary automatic mode (constant setpoint) and in "Manual"
mode, both piezo valves continually
switch alternately, and the actuator
oscillates around an average value.
Possible cause(s)
•
Stiction of the packing gland from
the control valve or actuator too
large
•
Reduce stiction or increase deadband of positioner (parameter "dEbA") until the oscillation stops.
•
Looseness (play) in the positioner/actuator/control valve system
•
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.
•
Increase travel times using throttle
screws.
•
If a quick travel time is needed,
increase the deadband (parameter
"dEbA") until the oscillation stops.
•
Increase supply pressure, insert
ballast converter
•
Select 3/4-wire mode
•
•
Positioner doesn't move control
valve to the stop (at 20 mA).
Corrective measures
•
Actuator too fast
Supply pressure too low. Load on
the feeding controller or system
output is too low.
Error table 4
See also
Cleaning of the screens (Page 236)
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10.4 Fault correction
10.4.6
Remedial measures table 5
Fault profile (symptoms)
•
•
Possible cause(s)
Corrective measures
•
Rectify the causes for shock loads.
•
Re-initialize the position controller.
Electrical auxiliary power supply is
not adequate.
•
Check the electrical auxiliary power
supply.
•
In case of very high continuous
loads due to vibrations (oscillations):
•
Tighten the screws firmly and secure using sealing wax.
•
•
Screws of the electrical connecting
terminals may be loosened.
Repair
•
•
Electrical connecting terminals
and/or electronic components may
be knocked out.
For prevention: Install the positioner
on the damping pads.
Zero point displaces sporadically
(> 3%).
•
The device function has completely
failed: No representation on the
display either.
•
Impact or shock loads result in
accelerations so high that the friction clutch moves, e.g. due to "vapor shocks" in vapor lines.
Fault table 5
See also
Repair/Upgrading (Page 238)
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11.1
11
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.
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
safety-related applications.
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.
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11.2 Cleaning of the screens
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 and the display window using a cloth moistened with
water or a mild detergent.
● Do not use aggressive cleaning agents or solvents. Plastic components or painted
surfaces could be damaged.
11.2
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.
11.2.1
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.
Removal and cleaning of the screens
1. Disconnect the pneumatic auxiliary power supply.
2. Remove the lines.
3. Unscrew the cover.
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.
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11.2 Cleaning of the screens
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.
11.2.2
Positioners with stainless steel enclosure 6DR5..2 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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11.3 Fail in Place: replacing the basic electronics
11.3
Fail in Place: replacing the basic electronics
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
If you are using a positioner with the "Fail in Place" function, the following procedure must be
observed when replacing the basic electronics so as to prevent damage to the device.
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 on installing
option modules (Page 48)".
4. Set the "'51.PNEUM' Fail in place (Page 174)" parameter from "Std" to "FIP".
5. Install the enclosure cover.
6. Switch on the supply air PZ again.
7. Initialize the positioner as described in section "Commissioning (Page 113)"
CAUTION
Damage to the device through a surge of compressed air
Following replacement of the basic electronics, there is a danger that the device could be
damaged due to a surge of compressed air.
• Observe the procedure described above.
11.4
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
Technical support (Page 274)
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11.5 Return procedure
11.5
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.
11.6
Disposal
Devices identified by this symbol may not be disposed of in the
municipal waste disposal services under observance of the
Directive 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
12.1
Rated conditions
Rated conditions
Ambient conditions
For use indoors and outdoors.
Ambient temperature
In hazardous areas, observe the maximum permissible
ambient temperature corresponding to the temperature
class.
•
Permissible ambient temperature for operation 1)
-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
Degree of protection
2)
Mounting position
II
IP66 to IEC/EN 60529 / NEMA 4X
Any; in wet environment, pneumatic connections and
outlet opening not upward
Vibration resistance
Harmonic oscillations (sine) according to EN 60068-26/10.2008
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 60068-264/04.2009
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 ≤ 30 m/s² (98.4 ft/s²) without resonance peak
control valve
Climate class
According to DIN EN 60721-3-4
•
Storage
1K5, but -40 ... +80°C (1K5, but -40 ... +176°F)
•
Transport
2K4, but -40 ... +80°C (2K4, but -40 ... +176°F)
•
Operation 1)3)4)
4K3, but -30 ... +80 °C (4K3, but -22 ... +176 °F)
1)
The following applies to fail in place: Without explosion protection: -20 ... +60 °C (-4 ... +140 °F); with explosion protection: T4: -20 ... +60 °C (-4 ... +140 °F) T6: -20 ... +50 °C (-4 ... +122 °F)
2)
Max. impact energy 1 Joule for enclosure with inspection window 6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3 (in
development).
3)
At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited. When using position feedback module, only T4 is
permissible.
4)
-20 to +80 °C (-4 to +176 °F) for 6DR55..-0G ..., 6DR56..-0G ..., 6DR55..-0D ... and 6DR56..-0D...
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Technical data
12.2 Pneumatic data
12.2
Pneumatic data
Pneumatic data
Auxiliary power (air supply)
Pressure 1)
•
Compressed air, carbon dioxide (CO2), nitrogen (N), noble
gases or cleaned natural gas
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 version Ex d (6DR5..5-...), values are reduced by approximately 20%.
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Technical data
12.3 Construction
12.3
Construction
Construction
How does it work?
•
Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the positioner 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 mounting plane according to VDI/VDE 3845 and IEC 60534-6-2:
The required mount must be provided on the actuatorside.
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)
Material
•
•
Enclosure
6DR5..0 Makrolon
Glass-fiber reinforced polycarbonate (PC)
6DR5..1 aluminum, narrow
GD AISi12
6DR5..2 stainless steel
Austenitic stainless steel 316Cb, mat. No. 1.4581
6DR5..3 aluminum
GD AlSi12
6DR5..5 aluminum, flameproof
GK AISi12
Pressure gauge block
Aluminum AIMgSi, anodized
Versions
•
In Makrolon enclosure 6DR5..0
Single-acting and double-acting
•
In aluminum enclosure 6DR5..1
Single-acting
•
In aluminum enclosure 6DR5..3 and 6DR5..5
Single-acting and double-acting
•
In stainless steel enclosure 6DR5..2
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)
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Technical data
12.3 Construction
Construction
•
•
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 6 Nm (4.4 ft lb)
steel in Makrolon enclosure
Screw-in torque for metal/stainless steel glands in aluminum/stainless steel enclosure
6 Nm (4.4 ft lb)
Screw-in torque for NPT adapter made of metal/stainless steel in Makrolon enclosure
8 Nm (5.9 ft lb)
Screw-in torque for NPT adapter made of metal/stainless steel in aluminum/stainless steel enclosure
15 Nm (11.1 ft lb)
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 in 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
•
Cable gland
Without Ex protection as well as with Ex i: M20x1.5 or ½14 NPT
With explosion protection Ex d: Ex d certified M20x1.5, ½14 NPT or M25x1.5
Connections, pneumatic
Female thread G¼ or ¼-18 NPT
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Technical data
12.4 Controller
12.4
Controller
Controller
Control unit
•
Five-point controller
•
Dead zone
Adaptive
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)
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Technical data
12.5 Certificates, approvals, explosion protection
12.5
Certificates, approvals, explosion protection
Certificates and approvals
Classification according to pressure
equipment directive (PED 97/23/EC)
For fluid group 1 gases; fulfills requirements according to article 3, paragraph
3 (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
Ex markings
Explosion protection in accordance with
ATEX/IECEx
Flameproof enclosure encapsulation "d",
"XP"
Intrinsic safety "i", "IS"
II 2 G Ex d IIC T6/T4 Gb
II 2 G Ex ia IIC T6/T4 Gb
II 3 G Ex ic IIC T6/T4 Gc
FM/CSA
XP, Class I, Division 1, GP.ABCD
XP, Class I, Zone 1, AEx d, IIC, T6/T4
IS / I, II, III / 1 / A-G
IS / 1 / AEx / Ex ib / IIC, Gb
IS / 21 / AEx / Ex ib / IIIC, Db, T110°C
II 2 D Ex ia IIIC T110°C Db
Non-sparking "nA", "NI"
Dust, protection by means of enclosure
"t", "DIP"
•
For aluminum enclosure, narrow,
single-acting, without window
6DR5..1-.D...-..A.-Z...
•
For stainless steel enclosure
6DR5..2-.D...-..A.-Z...
•
For aluminum enclosure, with window
6DR5..3-.K...-..A.-Z...
II 3 G Ex nA IIC T6/T4 Gc
II 2 D Ex tb IIIC T100°C Db
NI / I / 2 / A-D
NI / 2 / AEx / Ex nA, Ex ic / IIC, Gc
DIP / II, III / 1 / E-G
DIP / 21 / AEx / Ex tb / IIIC, Db,
T100°C
Permissible ambient temperature
With and without HART 1)2)
•
6DR501. / 6DR502. / 6DR521. /
6DR522. 1)
T4: -30 ... +80 °C (-22 ... +167 °F)
T6: -30 ... +50 °C (-22 ... +122 °F)
•
6DR5.1 / 6DR5.25
T4: -30 ... +80 °C (-22 ... +176 °F)
T6: -30 ... +50 °C (-22 ... +122 °F)
1)
PROFIBUS PA or
FOUNDATION Fieldbus 1)2)
•
6DR551. / 6DR552 / 6DR561. /
6DR562. 1)
T4: -20 ... +75 °C (-4 ... +167 °F)
T6: -20 ... +50 °C (-4 ... +122 °F)
•
6DR5515 / 6DR5525 / 6DR5615 /
6DR5625 1)
T4: -30 ... +80 °C (-22 ... +176 °F)
T6: -30 ... +50 °C (-22 ... +122 °F)
1)
At ≤ -10 °C (+14 °F), the refresh rate of the display is limited. The following is valid for explosion-proof positioners:
When using position feedback module, only T4 is permissible.
2)
The following applies to fail in place: T4: -20 ... +60 °C (-4 ... +140 °F) as well as T6: -20 ... +50 °C (-4 ... +122 °F)
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Technical data
12.6 Electrical data
12.6
Electrical data
Basic electronics
without explosion
protection
Basic electronics
with explosion protection Ex d
Basic electronics
with explosion protection Ex "ia"
Basic electronics
with explosion protection Ex "ic", "nA",
"t"
Current input IW
•
Rated signal range
0/4 ... 20 mA
•
Test voltage
DC 840 V, 1 s
•
Binary input BIN1 (terminals
9/10; galvanically connected to basic device)
Suitable only for floating contact; max. contact load
< 5 μA with 3 V
2-wire connection
6DR50.. and 6DR53.. Without HART
6DR51.. and 6DR52.. With HART
Current to maintain the auxiliary power
≥ 3,6 mA
Required load voltage UB (corresponds to Ω at 20 mA)
•
•
•
•
•
Without HART (6DR50..)
Typical
6.36 V (= 318 Ω)
6.36 V (= 318 Ω)
7.8 V (= 390 Ω)
7.8 V (= 390 Ω)
Max.
6.48 V (= 324 Ω)
6.48 V (= 324 Ω)
8.3 V (= 415 Ω)
8.3 V (= 415 Ω)
Typical
7.9 V (= 395 Ω)
-
-
-
Max.
8.4 V (= 420 Ω)
-
-
-
Typical
6.6 V (= 330 Ω)
6.6 V (= 330 Ω)
-
-
Max.
6.72 V (= 336 Ω)
6.72 V (= 336 Ω)
-
-
Typical
-
8.4 V (= 420 Ω)
8.4 V (= 420 Ω)
8.4 V (= 420 Ω)
Max.
-
8.8 V (= 440 Ω)
8.8 V (= 440 Ω)
8.8 V (= 440 Ω)
± 40 mA
± 40 mA
-
-
-
-
Without HART (6DR53..)
With HART (6DR51..)
With HART (6DR52..)
Static destruction limit
Effective inner capacitance Ci
•
Without HART
-
-
11 nF
"ic": 11 nF
•
With HART
-
-
11 nF
"ic": 11 nF
-
-
Effective inner inductance Li
•
Without HART
-
-
207 µH
"ic": 207 µH
•
With HART
-
-
310 µH
"ic": 310 µH
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Technical data
12.6 Electrical data
For connecting to circuits with
the following peak values
Basic electronics
without explosion
protection
Basic electronics
with explosion protection Ex d
Basic electronics
with explosion protection Ex "ia"
Basic electronics
with explosion protection Ex "ic", "nA",
"t"
-
-
Ui = DC 30 V
Ii = 100 mA
Pi = 1 W
"ic":
Ui = 30 V
Ii = 100 mA
"nA"/"t":
Un ≤ 30 V
In ≤ 100 mA
3-/4-wire connection
6DR52.. With HART, explosion-protected
6DR53.. Without HART, not explosion-protected
Load voltage at 20 mA
≤ 0.2 V (= 10 Ω)
≤ 0.2 V (= 10 Ω)
≤ 1 V (= 50 Ω)
≤ 1 V (= 50 Ω)
Auxiliary power UH
DC 18 ... 35 V
DC 18 ... 35 V
DC 18 ... 30 V
DC 18 ... 30 V
•
(UH - 7.5 V)/2.4 kΩ [mA]
Current consumption IH
For connecting to circuits with
the following peak values
-
-
Ui = 30 V
Ii = 100 mA
Pi = 1 W
"ic":
Ui = 30 V
Ii = 100 mA
"nA"/"t":
Un ≤ 30 V
In ≤ 100 mA
Effective inner capacitance Ci
-
-
22 nF
22 nF
Effective inner inductance Li
-
-
0.12 mH
0.12 mH
Galvanic isolation
Between UH and IW
Between UH and IW
Between UH and IW
(2 intrinsically safe
circuits)
Between UH and IW
HART communication
HART version
PC parameter assignment
software
7
SIMATIC PDM; supports all device objects. The software is not included in the scope of
delivery.
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Technical data
12.7 Technical data for natural gas as actuator medium
12.7
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":
Ventilation via the control air outlet near the
pneumatic connections:
Ventilation through the exhaust air outlet with a
sound absorber
Operating
mode
6DR5.1.-.E...
6DR5.2.-.E...
Single-acting
Double-acting
[Nl/min]
[Nl/min]
Operation,
typical
0.14
0.14
Operation,
max.
0.60
0.60
Error case,
max.
60.0
60.0
Operation,
typical
1.0
2.0
Operation,
max.
8.9
9.9
Error case,
max.
66.2
91.0
Operation,
max.
358.21)
3391),
1.6
1.23
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.
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Technical data
12.8 Option modules
See also
Basic safety instructions (Page 113)
Pneumatic connection for 6DR5..0/1/2/3 (Page 95)
12.8
Option modules
12.8.1
Alarm module
Without explosion protection 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
≤ 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
Ui = 15 VDC
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = 15 VDC
I i = 25 mA
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
basic device is faulty or without flameproof housing, the
a auxiliary power.
current consumption must
be restricted to 10 mA per
output.
•
For connecting to circuits with the
following peak values
-
"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
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Technical data
12.8 Option modules
Without explosion protection or suitable for use in
the SIPART PS2 Ex d
With Ex protection Ex "ia"
Contact load
•
With Ex protection
Ex "ic", "nA", "t"
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
12.8.2
DC 840 V, 1 s
Position feedback module
Position feedback module
Without explosion protection 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
feedback
1 current output, terminals 61 and 62
2-wire connection
Rated signal range
4 ... 20 mA, short-circuit proof
Dynamic range
Auxiliary voltage UH
3.6 ... 20.5 mA
+12 ... +35 V
External load RB [kΩ]
Transmission error
Temperature influence
Resolution
Residual ripple
+12 ... +30 V
+12 ... +30 V
≤ (UH [V] - 12 V)/I [mA]
≤ 0.3 %
≤ 0.1%/10 K (≤ 0.1%/18 °F)
≤ 0.1 %
≤1%
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Technical data
12.8 Option modules
Without explosion protection or suitable for use in
the SIPART PS2 Ex d
For connecting to circuits with the
following peak values
With Ex protection Ex ia
(only in temperature class
T4)
With Ex protection
Ex "ic", "nA", "t"
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
12.8.3
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
•
Signal state High
(not triggered)
> 2.1 mA
•
Signal state Low (triggered)
< 1.2 mA
•
2 slotted initiators
•
Function
•
Connecting to circuits with the
following peak values
2 wire technology in accordance with EN 60947-5-6 (NAMUR), for switching
amplifiers connected on load side
Type SJ2-SN
NC contact (NC, normally closed)
Nominal voltage 8 V;
current consumption:
≥ 3 mA (limit not activated),
≤ 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
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Technical data
12.8 Option modules
Without Ex protection
With Ex protection Ex "ia"
With Ex protection Ex "ic",
"nA", "t"
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
12.8.4
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",
"nA", "t"
6DR4004-8K
6DR4004-6K
6DR4004-6K
-
-
Ui = DC 30 V
Ii = 100 mA
Pi = 750 mW
"ic":
Ui = 30 V DC
Ii = 100 mA
Limit encoder with mechanical
switching contacts
2 limit contacts
•
1 binary output: Terminals 41 and 42
•
2 binary output: Terminals 51 and 52
•
Max. switching current AC/DC
•
For connecting to circuits with the following peak values
4A
"nA": Un ≤ 15 V DC
Effective internal capacitance
-
Ci = negligibly small
Ci = negligibly small
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
250 V/24 V
DC 30 V
DC 30 V
•
Max. switching voltage AC/DC
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Technical data
12.8 Option modules
Without Ex protection
With Ex protection Ex ia
With Ex protection Ex "ic",
"nA", "t"
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 ≤ 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
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
DC 3150 V, 2 s
Rated condition height
12.8.5
Max. 2 000 m mean sea
level
Use a suitable power
supply at an altitude of
more than 2 000 m (6,562
ft.) 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
10 kΩ
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
Galvanically connected with the basic device
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Technical data
12.8 Option modules
12.8.6
Non-contacting position sensor
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 ... 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
•
Part-turn actuator
30 ... 100°
Linearity (after corrections made by
positioner)
±1%
Hysteresis
± 0.2%
Temperature influence (range:
rotation 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 DIN EN 60721-3-4
•
Storage
1K5, but -40 to +90 °C (-40 to +194 °F)
•
Transport
2K4, but -40 to +90 °C (-40 to +194 °F)
Vibration resistance
•
Harmonic oscillations
(sine) according to IEC 600682-6
•
Bumping according to IEC
60068-2-29
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
300 m/s2(984 ft/s2), 6 ms, 4000 shocks/axis
Torque for cable gland nut made of Plastic
2.5 Nm (1.8 ft lb)
Housing protection type
Metal
Stainless steel
4.2 Nm (3.1 ft lb)
4.2 Nm (3.1 ft lb)
IP68 according to IEC/EN 60529; NEMA 4X / Encl. Type 4X
For connecting to circuits with the
following 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
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.
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Technical data
12.8 Option modules
Explosion protection
Types of protection
Intrinsic safety "ia"
•
Ex markings
ATEX/IECEx
FM/CSA
Zone 1:
IS, Class I, Divison 1, ABCD
IS, Class I, Zone 1, AEx ib, IIC
II 2 G Ex ia IIC T6/T4 Gb
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
Permissible ambient temperature
12.8.7
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)
External position detection system
Ambient temperature
Permissible ambient temperature for operation
•
NI, Class I, Divison 2, ABCD
NI, Class I, Zone 2, AEx nA, IIC
Degree of protection 1)
Climate class
In hazardous areas, observe the maximum permissible
ambient temperature corresponding to the temperature
class.
-40 ... +90 °C (-40 ... +194°F)
IP66 according to IEC/EN 60529 / NEMA 4X
According to DIN EN 60721-3-4
•
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.
1
Construction
How does it work?
•
Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the positioner 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 mounting plane according to VDI/VDE 3845 and IEC 60534-6-2:
The required mount must be provided on the actuatorside.
Material
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Technical data
12.8 Option modules
Construction
•
Makrolon® glass-fiber reinforced polycarbonate (PC)
Enclosure
Weight, basic device
Approximately 0.9 kg (1.98 lb)
Torque for cable gland nut made of plastic
2.5 Nm
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 standards applied 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 110°C Db
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
Permissible ambient temperature
T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +60 °C (-40 ... +140 °F)
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Technical data
12.8 Option modules
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Dimension drawings
13.1
①
②
③
13
Positioner with Makrolon enclosure 6DR5..0 and stainless steel
enclosure 6DR5..2
Dimensions with pneumatic terminal block NPT
All air connections G¼ or ¼" NPT
M20 x 1.5 or NPT adapter
Dimensions of stainless steel version (see superscript footnotes in the graphic)
1)
99 mm (3.89 inch)
2)
74 mm (2.91 inch)
3)
98 mm (3.86 inch)
Figure 13-1
Macrolon and stainless steel enclosure versions (see footnotes for dimensions), dimensions in mm (inch)
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Dimension drawings
13.2 Positioner with narrow aluminum enclosure 6DR5..1
13.2
①
②
Positioner with narrow aluminum enclosure 6DR5..1
All air connections G¼ or ¼" NPT
M20 x 1.5 or NPT adapter
Figure 13-2
Narrow aluminum enclosure version, dimensions in mm (inch)
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Dimension drawings
13.3 Positioner with aluminum enclosure 6DR5..3
13.3
①
②
③
Positioner with aluminum enclosure 6DR5..3
Dimensions with pneumatic terminal block NPT
All air connections G¼ or ¼" NPT
M20 x 1.5 or NPT adapter
Figure 13-3
Aluminum enclosure version, dimensions in mm (inch)
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Dimension drawings
13.4 Terminal strip for positioners with Macrolon enclosure 6DR5..0 and aluminum enclosure 6DR5..3
13.4
Terminal strip for positioners with Macrolon enclosure 6DR5..0 and
aluminum enclosure 6DR5..3
①
Thread depth
Figure 13-4
Terminal strip, dimensions in mm (inch)
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Dimension drawings
13.5 Positioner with flameproof aluminum enclosure 6DR5..5
13.5
①
②
Positioner with flameproof aluminum enclosure 6DR5..5
All air connections G¼ or ¼" NPT
Air connection Y2, only with double-acting version
Figure 13-5
Version with flameproof enclosure, dimensions in mm (inch)
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Dimension drawings
13.5 Positioner with flameproof aluminum enclosure 6DR5..5
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Spare parts/accessories/scope of delivery
14.1
14
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 241)".
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
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
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Spare parts/accessories/scope of delivery
14.1 Overview
● 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.
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 241)".
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
● Non-contacting sensor (NCS)
Note
The version is identified using a special nameplate.
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Spare parts/accessories/scope of delivery
14.2 Spare parts
14.2
Spare parts
Description
Order No.
For version
Plastic cover with 4 screws and circumferential
sealing ring
C73451-A430-D82
6DR5..0
Aluminum cover with 4 screws and circumferential sealing ring
C73451-A430-D83
6DR5..1
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
A5E00215466
6DR56.-.D/E/F/G/K
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
polyester including magnet for non-contacting
position detection for part-turn actuators
A5E00078030
6DR4004-.N.10
Magnet holder made of anodized aluminum inA5E00524070
cluding magnet for non-contacting position detection 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...
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Spare parts/accessories/scope of delivery
14.3 Scope of delivery of small part sets
Description
Order No.
For version
Small parts set 1/4" NPT
A5E33519994
6DR5..0; 6DR5..3
Small parts set G1/4
A5E33519995
6DR5..0; 6DR5..3
Note
See Catalog FI 01 "Field devices for process automation" for additives and possible
modules".
14.3
Scope of delivery of small part sets
Small part set 1
The small part set 1 with the article number C73451-A430-D85 contains the following items:
Position
Quantity
[unit]
Clamping piece
2
Pick-up bracket
1
Screw DIN 7984 M6x25-A2
2
Spring lock washer DIN 127 B6-SN06031
2
Screw SN 62217 G4x45-/16WN1452-TX-ST
5
Screw SN 62217 G4x14-combi-Torx-TX-ST
5
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Spare parts/accessories/scope of delivery
14.3 Scope of delivery of small part sets
Position
Quantity
[unit]
Screw SN 62217 G5x18-WN1452-T20-A2
3
Screw SN 62217 H5x8-WN1451-TX-A2
2
Screw DIN 7964 M4x16x6-A4-70-F
4
Cable gland MET 20-GR
3
Cable gland MET 20-BL
3
Blind plug M20 SW
3
Slide switch
1
Leaf spring
1
Label, printed
1
Small part set 2
The small part set 2 with the article number C73451-A430-D86 contains the following items:
Position
Terminal strip C73451-A430-C21
Quantity
[unit]
1
Terminal strip C73451-A430-C22
1
Screen, molded
10
O-ring 14-P431ANBR75 (black)
10
O-ring 5.5-P431ANBR75 (black)
6
Screw SN 62217 G5x18-WN1452-T20-A2
3
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Spare parts/accessories/scope of delivery
14.4 Scope of delivery of external position detection system
Position
14.4
Quantity
[unit]
Attenuator
5
Lip non-return valve
3
Plug 12 PE
10
Seal
3
Installation instructions
1
Label, printed
1
Scope of delivery of external position detection system
Scope of delivery of external position detection system C73451-A430-D78
14.5
Quantity
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
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.
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Spare parts/accessories/scope of delivery
14.6 Scope of delivery EMC filter module
14.6
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.
Connections ① to ③ for power supply
①
Adapter M20 to ½-14 NPT for
•
②
③
④
6DR5..0/1/2/3-0.N/P
M12 connector for device version with
PROFIBUS or FOUNDATION fieldbus
communication
•
6DR55..-0.R/S
•
6DR56..-0.R/S
Cable gland for connection thread
M20x1.5 for
•
Connections ④ to ⑥ for optional modules
6DR5..0/1/2/3-0.G/M
Figure 14-1
⑤
Cable gland for connection thread
M20x1.5 with seal insert
•
6DR55..0-0.G/M/R/S
•
6DR56..0-0.G/M/R/S
Dummy plug for device version without
optional modules
•
⑥
6DR5...-0..00
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
14.7 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
Adapter M20 to ½-14 NPT
④
Cable gland for connection thread, gray
④
Cable gland for connection thread, blue
Sealing set for ④
Sealing set plug for ④
Screw for plastic
Oval head screw M3x6
14.7
Accessories
For accessories, refer to Catalog FI 01 "Field devices for process automation", for example:
● Option modules
● Non-contacting position sensor (NCS)
● Mounting kits
● Operating software
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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 111)".
See also
Sequence of automatic initialization (Page 117)
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Appendix
A.2 Certificates
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
Literature and catalogs
Table A- 1
No.
Title
Publisher
Article number
/1/
Catalog ST 70 SIMATIC
Products for Totally Integrated Automation
Siemens AG
E86060-K4670-A111-B1
/2/
Catalog ST 70 NSIMATIC
News
Products for Totally Integrated Automation
Siemens AG
E86060-K4670-A151-A3
/3/
Catalog ST 80 SIMATIC
HMI operation and observation products
Siemens AG
E86060-K4680-A101-B4
/4/
Catalog IK PI
Industrial Communication
Siemens AG
Internet address:
IK PI catalog (www.siemens.com/simaticnet/catalogs)
/5/
Catalog FI 01
Field devices for process
automation
Siemens AG
E86060-K6201-A101-B1
/6/
Catalog CA 01
The interactive catalog of
Industry Automation and
Drive Technologies
Siemens AG
E86060-D4001-A500-C7 (DVD)
E86060-K6710-A101-B5
A.4
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)
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Appendix
A.4 Technical support
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:
● SIPART PS2 product information (http://www.siemens.com/sipartps2)
See also
Instructions and manuals (http://www.siemens.com/processinstrumentation/documentation)
E-mail (mailto:[email protected])
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
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Appendix
A.4 Technical support
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B
Abbreviations
Abbreviation
Long form
Meaning
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
Transducer
Communication system for the development of industrial field
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 measurement and control technology in
the chemicals industry
Association of users in process conductor technology
µC
Microcontroller
One-Chip computer system
NCS
Non-Contacting Position Sensor
Non-contacting sensor
NEMA
National Electrical Manufacturers
Association
US standards institution
National Electrical Manufacturers Association
NPT
National Pipe Thread Taper
Pipe threading for self-sealing threads as per ANSI B.1.20.1
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Abbreviations
Abbreviation
Long form
Meaning
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 unit
-
SIL
Safety Integrity Level
Safety requirement level as per IEC 61508/IEC 61511
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik e. V.
Industrial and professional association
VDI
Verein Deutscher Ingenieure e. V.
Technical/scientific association
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" independent 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 safetyinstrumented system decides that a specified pressure limit has
been exceeded 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
Failure on Demand
Average probability of dangerous failures of a safety function on
demand
SFF
Safe Failure Fraction
Proportion of safe failures:
Proportion of failures without the potential to bring the safetyinstrumented system into a dangerous or non-permissible functional status.
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Abbreviations
Abbreviation
Full term in English
Meaning
SIL
Safety Integrity Level
The international standard IEC 61508 defines four discrete
Safety 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 lower the probability that it will not execute the
required safety functions.
SIS
Safety Instrumented System
A safety-instrumented system (SIS) executes the safety functions 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
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Glossary
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 a part of the package.
ATEX
ATEX is the abbreviation of the French term "Atmosphère explosible". ATEX stands for both
the directives of the European Community for 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 many electric
circuits in addition to the standard supply. The auxiliary voltage can be extremely stabilized,
have a specific level or polarity and/or other properties having decisive significance for the
correct functioning of parts in the circuit. Auxiliary voltage is used, for example, with four-wire
systems.
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.
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Glossary
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(s) 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.
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.
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Glossary
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".
Drive 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.
EEPROM
EEPROM (Electrically Erasable Programmable Read-Only Memory; literally: elektrisch
löschbarer, programmierbarer Nur-Lese-Speicher in German) is a non-volatile electronic
memory. 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 work satisfactorily in the
electromagnetic environment without causing electromagnetic interferences that are
unacceptable for other devices present in this 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 technicallysupported 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.
Fieldbus Foundation
Syndicate of manufacturers of measurement and control systems. The syndicate develops
the open fieldbus specifications of the FOUNDATION Fieldbus.
Final controlling element
Converter that converts electric signals into mechanical or other non-electric variables.
Firmware
Firmware (FW) is the software embedded in a chip in electronic devices. It is not like
software that is stored on hard disks, CD-ROMs or other mediums. These days, the firmware
is mostly stored in a flash memory or an EEPROM. Firmware is software in the hardware,
and is thus an intermediate between the software and the 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.
FOUNDATION Fieldbus
Fieldbus to connect sensors and final control elements in hazardous areas in accordance
with IEC 61158-2. The FOUNDATION Fieldbus uses a common 2-wire cable for data
communication and power supply. Data communication and power supply. The
FOUNDATION Fieldbus uses bus types such as High Speed Ethernet and Foundation H1.
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Glossary
Frequency shifting process
ENGLISH: Frequency shift keying (FSK)
The frequency shifting process 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.
HART
HART (Highway Addressable Remote Transducer) is a standardized and widely used
communication system for erecting industrial fieldbuses. This communication system
enables digital communication of multiple participants (field devices) using a common data
bus. HART implements the widely used 4/20 mA standard to transfer analog sensor signals.
Existing cables of the old system can be used directly and both systems can be operated
simultaneously. HART specifies several protocol levels in the OSI model. HART enables
transfer of process and diagnostics information and control signals between field devices
and superordinated control system. Standardized parameter sets can be used for
manufacturer-independent operation of all HART devices.
HART communicator
Connection with a two-wire line is directly established for the parameter assignment with the
HART communicator. For the parameter assignment with a laptop or a PC, a HART modem
is connected in between.
Increment
From the Latin word incrementare, increase. Increment is the defined amount of change
when increasing a variable(s) gradually. In informatics, it is referred to as the stepwise
increase in a numeric value.→Decrement.
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.
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Glossary
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 the
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 merger of Associated Manufacturers of Electrical
Supplies and the Electric Power Club.
NEMA 4
An enclosure standard of the National Electrical Manufacturers Association. The NEMA 4
compliant 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 like 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.
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 gaseous atmosphere
Mixture of air, combustible gases, fluff, fibers or dusts.
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Glossary
Pressure chamber
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.
Process device manager
PDM is a Siemens software package for project planning, parameter assignment,
commissioning and maintenance of network configuration and field devices. Part of SIMATIC
Step7. Is 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).
PROFIBUS PA
PA is an abbreviation of process automation. PROFIBUS PA is used in process engineering.
This fieldbus is used to control the measuring devices using a process control system. This
version of PROFIBUS is suitable for hazardous areas of zones 0 and 1. Only a weak current
flows through an intrinsically safe circuit in the bus cables, and hence sparks are not
generated even in case of a fault.
PA enhances PROFIBUS DP with an intrinsically safe transmission technique compliant with
the international standard IEC 61158-2.
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 mode 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. PCS7, WinCC, WinAC, PDM, Step7).
Zone 0
Area in which hazardous potentially explosive gaseous atmospheres build up often, regularly
or over long durations during the normal operation of a device.
Zone 1
Area in which potentially explosive gaseous atmospheres build up occasionally during the
normal operation of a device.
Zone 2
Area in which a potentially explosive gaseous atmosphere normally never builds up or builds
up only for a short while during 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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Glossary
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Index
6
0B
6DR4004-6K (with Ex), (See mechanical limit switch
module)
A
1B
Accessories, 266
Actuating disk bearings
Position, 50
Actuating pressure
Position, 24
Adapter, 271
Position, 53
Additional Support, 275
Alarm module
Connecting, 78, 87
Installation, 57
Position, 50, 53
Amplifier, (See booster)
Appendix, 274
Article number
on the nameplate, 22
Attenuator, 249
Auxiliary power supply
Failure, 97
B
2B
Basic device
Connecting, 82
Basic electronics, 267
Graphic, 25, 53
Position, 24, 50
Binary input/output, (See alarm module)
Block circuit diagram
Mode of operation, 28
Booster, 273
Buttons
Position, 24
C
Cable gland, 271
Position, 24
Carrier, 40, 148
Carrier pin, 126, 128
Certificates, 16, 274, (Certificates)
characteristics
Safety, 143
Commissioning
Cancel, 127
Interrupting, 125
Manual, 128, 135
Compressed air, 32
Connecting
Alarm module, 78, 87
Exi, Ex nA, Ex t option modules, 86
Mechanical limit switch module, 80, 89
NCS, 91
Option modules without Ex/with Ex d, 77
Position detection system, 93
Position feedback module, 88
SIA module, 79, 88
Connecting terminals
Option modules, 24
Connection
Pneumatic, 95, 122
Control air outlet, 249
Control system, 19, 140
control valve
integrated, 19
Correct usage, (See improper device modifications)
Customer Support Hotline, 274
D
4B
Diagnostics, 205
During ongoing operation, 223
Extended, 152, 174
Diagnostics guide, 229
Display
Position, 24
Documentation
Edition, 11
Dummy plug
Position, 24
3B
C73451-A430-D23, (See EMC filter module )
C73451-A430-D78, (See position detection system)
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Index
E
5B
EMC filter module, (See EMC filter module)
Installation, 67
Scope of delivery, 272
Enclosure, 265
Enclosure ventilation, 249
Ex markings, 246, 256, 257
Exhaust air outlet, 249, 249
Position, 24
Extended diagnostics, 174
Parameter, 152
F
6B
Factory setting
Resetting to ~, 125, 132
Fault identification, 229
Feedback lever bracket
Position, 53
Feedback shaft
Position, 53
Final controlling element, 140
Firmware, 11
Five-point controller, 19
Flow rate, 249
Friction clutch, 19, 47
Position, 24, 51, 53
G
7B
gear
switchable, 19
H
8B
HART
Modem, 30
HART module, 29
Hazardous area
Laws and directives, 16
History, 11
Hotline, 274
I
9B
Improper device modifications, 16
Initialization, (Commissioning)
Automatically, 117
Cancel, 134
Interrupting, 132
Installation
Alarm module, 57
Position feedback module, 56
SIA module, 60
Internet, 275
Iy module, (See position feedback module)
L
10B
Label set, 65
Leakage
Pneumatic, 153
Leakage test
Offline, 211
Limit contact module, 115
Linear actuator
Add-on extensions, 20
Automatic commissioning, 125
Automatic commissioning (sequence diagram), 117
Manual commissioning, 128
Mounting, 34
Pneumatic connection, integrated, 95
Single-acting, 20
M
11B
Manometer
Mounting, 68
Mechanical limit switch module
Connecting, 80, 89
Position, 50
Mode of operation, 26
Module cover
Position, 50, 53
Motherboard, (See basic electronics), (See basic
electronics)
Mount
Dimensions, 43
Mounting kit
Linear actuator, 34
N
12B
Nameplate
Position, 51
Natural gas
Maximum values for ventilation, 249
Operation, 115
NCS, 66
Connecting to EMC filter module, 91
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Index
O
Q
13B
15B
Offline leakage test, 211
Online diagnostics, 223
Operation
Natural gas, 115
Option modules, 265
Connection without Ex/with Ex d, 77
Exi, Ex nA, Ex t connection, 86
Installation, 51
Ordering supplement, 22
Qualified personnel, 17
P
14B
Parameters 1 to 5
Overview, 147
Parameters 6 to 51
Overview, 149
Parameters A to P
Overview, 152
Part-turn actuator
Automatic commissioning, 132
Automatic commissioning (sequence diagram), 117
Double-acting, 20
Manual commissioning, 135
Mounting, 40
Pin (feedback lever bracket)
Position, 53
Pneumatic actuator, 26
Pneumatic block, (See pneumatic block)
Position, 50
Purging air selector, 122
Pneumatic connections, 122
Position detection system
External, 93
Position feedback module
Connecting, 78, 88
Installation, 56
Position, 50, 53
Positioner
Replacing, 137
Potentiometer, 66
External, 93
Pressure gauge block, 20
Printed circuit board, (See basic electronics)
Product name, 22
Purge air switch, 249
Purging air selector, 122
Position, 24
R
16B
Reading initialization parameters, 137
Restrictor
Position, 24
Ribbon cable
Graphic, 50
Position, 53
Ring gear
Position, 53
S
17B
Safety catch
Position, 53
Scope of delivery, 12
EMC filter module, 272
Screen
Cleaning of~, 236
Serial number, 22
Series connection, 85
Service, 275
Settings, 142
SIA module
Connecting, 79, 88
Installation, 59, 60
Position, 50
SIL 2, 140
Single-channel operation, 140
Slot initiator, (See SIA module )
Sound absorber
Position, 24
Split range
Connecting, 76, 85
Supply air
Position, 24
Supply air PZ, 143
Support, 275
Symbols, (Refer to warning symbols)
System integration
PDM, 11
System pressure, (see Supply air)
T
18B
Terminal strip, 122
Test certificates, 16
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Index
Transmission ratio selector
Position, 24, 50, 53
Transmitter, 140
W
19B
Warning label, (See label set)
Warning symbols, 15
Wiring diagram
Position, 24, 51
Y
20B
Y1, 143
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SIPART PS2 with and without HART
Operating Instructions • 09/2014
Get more information
www.siemens.com/processautomation
www.siemens.com/positioners
SIPART
Electropneumatic positioners
SIPART PS2 with and without HART
Operating Instructions
Siemens AG
Industry Sector
Sensors and Communication
76181 Karlsruhe
GERMANY
Subject to change without prior notice
A5E00074631-12
© Siemens AG 2014
A5E00074631
A5E00074631
www.siemens.com/automation
A5E00074631D-12
GN: 30690_SIPART PS2
Edition
09/2014
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