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SITRANS VP160
Operating Instructions • 03/2014
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SITRANS
Electropneumatic positioners
SITRANS VP160
Operating Instructions
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Subject to change without prior notice
A5E32923823-01
© Siemens AG 2014
A5E32923823
A5E32923823
www.siemens.com/automation
A5E32923823-01
GN: 30710_Sitrans VP160
Edition
03/2014
Answers for industry.
Compact Operating Instructions • 02/2014
SSIPART PS2 with and without HART
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Edition
A5E03436620-04
GN: 30690_SIPART PS2
02/2014
SITRANS VP160
1
___________________
Introduction
2
___________________
Safety information
SITRANS
Electropneumatic positioners
SITRANS VP160
3
___________________
Description
4
___________________
Installing/mounting
5
___________________
Connection
6
___________________
Operating
Operating Instructions
7
___________________
Commissioning
8
___________________
Parameterizing/addressing
Alarm, error, and system
9
___________________
messages
10
___________________
Service and maintenance
11
___________________
Technical data
12
___________________
Dimension drawings
13
___________
Spare
parts/accessories/scope of
delivery
___________________
A
Appendix
6DR64..
03/2014
A5E32923823-01
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: A5E32923823
Ⓟ 04/2014 Subject to change
Copyright © Siemens AG 2014.
All rights reserved
Table of contents
1
2
3
4
Introduction ............................................................................................................................................. 7
1.1
Purpose of this documentation ...................................................................................................... 7
1.2
History ............................................................................................................................................ 7
1.3
Purpose .......................................................................................................................................... 7
1.4
Checking the consignment ............................................................................................................. 8
1.5
Transportation and storage ............................................................................................................ 8
1.6
Product information ........................................................................................................................ 8
1.7
Notes on warranty .......................................................................................................................... 9
Safety information ................................................................................................................................. 11
2.1
2.1.1
Requirements for safe use ...........................................................................................................11
Laws and directives .....................................................................................................................11
2.2
Improper device modifications .....................................................................................................12
2.3
Requirements for special applications .........................................................................................12
Description ............................................................................................................................................ 13
3.1
Function .......................................................................................................................................13
3.2
3.2.1
3.2.2
Structure .......................................................................................................................................13
Overview of structure ...................................................................................................................13
Layout of the nameplate ..............................................................................................................15
3.3
3.3.1
3.3.2
Device components .....................................................................................................................16
Overview of device components ..................................................................................................16
Basic electronics ..........................................................................................................................16
3.4
3.4.1
3.4.2
3.4.3
Mode of operation ........................................................................................................................17
Control loop ..................................................................................................................................17
Control algorithm ..........................................................................................................................17
Block circuit diagram for single-acting or double-acting .............................................................18
Installing/mounting ................................................................................................................................ 19
4.1
4.1.1
Basic safety instructions ..............................................................................................................19
Proper mounting...........................................................................................................................21
4.2
Mounting the linear actuator ........................................................................................................21
4.3
Mounting the part-turn actuator....................................................................................................26
4.4
Using the positioner in a humid environment ...............................................................................30
4.5
4.5.1
4.5.2
Positioners subjected to fast acceleration or strong vibration .....................................................31
Positioners subjected to fast acceleration or strong vibration .....................................................31
Procedure locking the setting.......................................................................................................32
4.6
Position feedback module ............................................................................................................33
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Table of contents
4.7
5
6
7
Accessories ................................................................................................................................. 34
Connection ........................................................................................................................................... 35
5.1
5.1.1
5.1.1.1
5.1.1.2
5.1.2
5.1.3
5.1.4
Electric......................................................................................................................................... 35
Basic safety instructions .............................................................................................................. 35
Improvement of interference immunity VP160 ............................................................................ 36
Standard cable gland/torque ....................................................................................................... 36
Electrical connections ................................................................................................................. 36
2-wire basic device ...................................................................................................................... 37
Position feedback module ........................................................................................................... 37
5.2
5.2.1
5.2.1.1
5.2.1.2
5.2.2
Pneumatic ................................................................................................................................... 37
Pneumatic connections ............................................................................................................... 37
Integrated pneumatic connection ................................................................................................ 38
Pneumatic connection versions .................................................................................................. 39
Pneumatic connection ................................................................................................................. 41
5.3
Restrictors ................................................................................................................................... 42
Operating .............................................................................................................................................. 43
6.1
6.1.1
6.1.2
6.1.3
Operating elements ..................................................................................................................... 43
Display......................................................................................................................................... 43
Buttons ........................................................................................................................................ 45
Firmware version ......................................................................................................................... 46
6.2
6.2.1
6.2.2
6.2.3
Operating modes ......................................................................................................................... 46
Overview of operating modes ..................................................................................................... 46
Changing the operating mode ..................................................................................................... 47
Description of operating modes .................................................................................................. 47
6.3
Optimizing the controller data ..................................................................................................... 49
Commissioning ..................................................................................................................................... 51
7.1
Basic safety instructions .............................................................................................................. 51
0
General information about commissioning ................................................................................................. 52
8
7.3
Sequence of automatic initialization ............................................................................................ 53
7.4
Purge air switching ...................................................................................................................... 58
7.5
7.5.1
7.5.2
7.5.3
Commissioning linear actuators .................................................................................................. 59
Preparing linear actuators for commissioning ............................................................................. 59
Automatic initialization of linear actuators ................................................................................... 60
Manual initialization of linear actuators ....................................................................................... 61
7.6
7.6.1
7.6.2
7.6.3
Commissioning part-turn actuators ............................................................................................. 64
Preparing part-turn actuators for commissioning ........................................................................ 64
Automatic initialization of part-turn actuators .............................................................................. 65
Manual initialization of part-turn actuators .................................................................................. 66
7.7
Device replacement .................................................................................................................... 69
Parameterizing/addressing.................................................................................................................... 71
8.1
Parameter chapter ...................................................................................................................... 71
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Table of contents
8.2
Configuration schematic for parameter operating principle .........................................................71
8.3
Parameter overview .....................................................................................................................72
0
Description of parameters ...........................................................................................................................74
9
Alarm, error, and system messages ...................................................................................................... 79
9.1
9.1.1
9.1.2
9.1.3
9.1.4
Output of system messages in the display ..................................................................................79
System messages before initialization .........................................................................................79
System messages during initialization .........................................................................................79
System messages when exiting the Configuration mode ............................................................82
System messages during operation.............................................................................................83
9.2
9.2.1
9.2.2
Diagnostics parameters ...............................................................................................................84
Overview of diagnostics values....................................................................................................84
Meaning of the diagnostics parameters .......................................................................................85
0
Fault correction ............................................................................................................................................88
9.3.1
Fault identification ........................................................................................................................88
9.3.2
Remedial measures table 1 .........................................................................................................89
9.3.3
Remedial measures table 2 .........................................................................................................89
9.3.4
Remedial measures table 3 .........................................................................................................90
9.3.5
Remedial measures table 4 .........................................................................................................91
9.3.6
Remedial measures table 5 .........................................................................................................91
10
11
Service and maintenance ...................................................................................................................... 93
10.1
10.1.1
Basic safety instructions ..............................................................................................................93
Impermissible accessories and spare parts .................................................................................93
10.2
Cleaning of the screens ...............................................................................................................94
10.3
Repair/Upgrading .........................................................................................................................94
10.4
Return procedure .........................................................................................................................95
Technical data ...................................................................................................................................... 97
11.1
Rated conditions ..........................................................................................................................97
11.2
Pneumatic data ............................................................................................................................97
11.3
Construction .................................................................................................................................98
11.4
Electrical data.............................................................................................................................100
11.5
Controller....................................................................................................................................100
11.6
Certificates, approvals ...............................................................................................................100
0
Position feedback module .........................................................................................................................101
12
Dimension drawings ............................................................................................................................ 103
12.1
SITRANS VP160 positioner .......................................................................................................103
12.2
Terminal strip .............................................................................................................................104
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Table of contents
13
A
Spare parts/accessories/scope of delivery............................................................................................105
13.1
Overview ................................................................................................................................... 105
13.2
Spare parts ................................................................................................................................ 106
13.3
Accessories ............................................................................................................................... 106
Appendix .............................................................................................................................................107
A.1
Certificates ................................................................................................................................ 107
A.2
Operation with boosters ............................................................................................................ 107
A.3
Literature and catalogs .............................................................................................................. 108
A.4
Technical support ...................................................................................................................... 109
Glossary ..............................................................................................................................................111
Index ...................................................................................................................................................115
SITRANS VP160
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Operating Instructions, 03/2014, A5E32923823-01
1
Introduction
1.1
Purpose of this documentation
These instructions contain all information required to commission and use the device. It is
your responsibility to read the instructions carefully prior to installation and commissioning. In
order to use the device correctly, first review its principle of operation.
The instructions are aimed at persons mechanically installing the device, connecting it
electronically, configuring the parameters and commissioning it, as well as service and
maintenance engineers.
1.2
History
This history establishes the correlation between the current documentation and the valid
firmware of the device.
The documentation of this edition is applicable for the following firmware:
Edition
Firmware identifier nameplate
03/2014
From FW 1.00.00
The most important changes in the documentation as compared to the respective previous
edition are given in the following table.
1.3
Edition
Comment
03/2014
First edition
Purpose
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic actuators in the following industries.
● Food and beverages
● Pulp and paper
● Water/waste water
Operate the device according to the specifications in section "Technical data (Page 97)".
SITRANS VP160
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7
Introduction
1.4 Checking the consignment
1.4
Checking the consignment
1. Check the packaging and the device for visible damage caused by inappropriate handling
during shipping.
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.
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 97).
1.6
Product information
The manual can be found on the supplied CD. The programming manual is also available on
the Siemens homepage.
The CD also contains the catalog excerpt with the order data.
SITRANS VP160
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Introduction
1.7 Notes on warranty
See also
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
Contacts (http://www.siemens.com/processinstrumentation/contacts)
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.
SITRANS VP160
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9
Introduction
1.7 Notes on warranty
SITRANS VP160
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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.
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
2.1.1
Laws and directives
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation.
SITRANS VP160
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11
Safety information
2.2 Improper device modifications
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.
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.
SITRANS VP160
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Description
3.1
3
Function
● The electropneumatic positioner, in combination with the drive, forms a regulation 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.
● The positioner works as a predictive five-point positioner, through whose output value
±Δy the integrated valves can be controlled by pulse length modulation.
● These positioning signals cause pressure changes in the drive chamber(s) and thus a
repositioning of the drive until the regulation 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 unit has a binary input (BE1). This binary input can be individually
configured and used e.g. to block the control levels.
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 SITRANS VP160 positioner is available in an
aluminum enclosure:
● For 4 to 20 mA control technology
● For single and double-acting actuators
The positioner is used to move and control pneumatic actuators. The positioner works
electropneumatically, using compressed air as auxiliary power. The positioner is used to
control valves, for example, with:
● Linear actuator
● Part-turn actuator VDI/VDE 3845
Various add-on extensions are available for linear actuators:
● IEC 60534-6-1 (NAMUR)
● Integrated addition to ARCA
● Integrated addition to SAMSON
SITRANS VP160
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13
Description
3.2 Structure
①
②
③
④
Valve
Yoke / actuator yoke
Single-acting positioner
Actuator
Figure 3-1
①
②
Positioner attached to a single-acting linear actuator
Part-turn actuator
Double-acting positioner
Figure 3-2
Positioner attached to double-acting part-turn actuator
SITRANS VP160
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Operating Instructions, 03/2014, A5E32923823-01
Description
3.2 Structure
3.2.2
Layout of the nameplate
Layout of the nameplate
①
②
③
④
⑤
⑥
Manufacturer
Consult operating instructions
Safety class
Built-in option module
Manufacturer serial number
Auxiliary power (supply air PZ)
Figure 3-3
⑦
⑧
⑨
⑩
⑪
⑫
Software version
Place of manufacture
Auxiliary power
Ordering supplement (Order code)
Order number
Product name
Nameplate layout, example
SITRANS VP160
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15
Description
3.3 Device components
3.3
Device components
3.3.1
Overview of device components
①
②
③
④
⑤
⑥
⑦
⑧
Input: Supply air PZ
Output: Actuating pressure Y1
Display
Output: Actuating pressure Y2
Buttons
Restrictor Y1 for single-acting actuators
Restrictor Y1 for double-acting actuators
Restrictor Y2 for double-acting actuators
Figure 3-4
3.3.2
⑨
⑩
⑪
⑫
⑬
⑭
⑮
⑯
Exhaust air outlet with a sound absorber
Friction clutch adjustment wheel
Basic electronics
Connecting terminals of option module
Dummy plug
Cable gland
Wiring diagram on module cover
Purging air selector
View of positioner with cover open
Basic electronics
The basic electronics contains:
● CPU
● Memory
● Analog-to-digital converter
● Display
● Buttons
● Terminal strips to connect the option module to the basic electronics
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Description
3.4 Mode of operation
3.4
Mode of operation
3.4.1
Control loop
Control loop
The electropneumatic positioner forms a control loop with the pneumatic drive:
● The actual value x represents the position of the drive spindle for linear actuators or the
position of the drive shaft for part-turn actuators.
● The control variable w represents the positioning current of a closed-loop controller or a
manual control station from 4 to 20 mA.
The lifting or rotary movement of the actuator is transferred to a potentiometer using suitable
attachments, positioner axis and a backlash-free gear drive, and then to the analog input of
the microcontroller.
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.
3.4.2
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 3-5
Functional principle of five-point controller
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17
Description
3.4 Mode of operation
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 the 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 mechanical end stops
● Actuating times
● The deadband size
3.4.3
①
②
③
④
⑤
⑥
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
Spring-loaded pneumatic actuator (single-acting)
Pneumatic actuator (double-acting)
Figure 3-6
Block circuit diagram for the electropneumatic positioner, functional diagram
SITRANS VP160
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Operating Instructions, 03/2014, A5E32923823-01
Installing/mounting
4.1
4
Basic safety instructions
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.
CAUTION
Impermissible accessories and spare parts
Device damage
• Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
WARNING
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.
SITRANS VP160
Operating Instructions, 03/2014, A5E32923823-01
19
Installing/mounting
4.1 Basic safety instructions
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.
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.
SITRANS VP160
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Operating Instructions, 03/2014, A5E32923823-01
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 Chapter "Technical
data (Page 97)", for example installation torques 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 97)" 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 and for integrated pneumatic mounting.
Use the reduced mounting kit 6DR4004-8VK for actuators with integrated mounting.
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
10 to 35 mm. For a larger stroke range, you require a lever 6DR4004-8L which is to be
ordered separately. Keep the suitable installation parts ready:
SITRANS VP160
Operating Instructions, 03/2014, A5E32923823-01
21
Installing/mounting
4.2 Mounting the linear actuator
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
SITRANS VP160
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Installing/mounting
4.2 Mounting the linear actuator
Procedure
"Linear actuator IEC 60534 (10 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
Guide 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 10 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 98)"
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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Installing/mounting
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.
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 value specified on the nameplate of the actuator for this
purpose. If none of the values on the scale matches the value on the actuator nameplate,
select the next higher scaling value. Position the pin center ④ on the matching value of
the scale.
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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 end stop on the positioner shaft. Fasten the
lever ⑥ using a 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 ⑩ and 2 flat washers ⑪.
Figure 4-4
Linear actuator
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Installing/mounting
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. The mount and the bolts are included in the product package of the corresponding
actuator. Ensure that the mount has a sheet metal thickness of > 4 mm and reinforcements.
Procedure
"Part-turn actuator" mounting kit 6DR4004–8D
Sr. No.
*)
Quantit
y
Name
Note
①
1
Coupling wheel
Installation on positioner shaft
②
1
Carrier
Installation on stump of actuator's positioner shaft
③
1
Multiple plate
Display of the position, consisting of scale ⑤ and pointer mark ⑥
④
8
Scale
Different divisions
⑤
1
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 98)"
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
Pre-installed with coupling wheel
1
Machinist's wrench
For hexagon socket-head screw ⑪
*)
The serial numbers refer to the figures in the description of the installation steps for a part-turn actuator.
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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.
Figure 4-5
Pointer mark
Push the coupling wheel ① or the stainless steel coupling up to the end stop 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. 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
(Order No. TGX: 16300-1556).
Figure 4-6
Coupling
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Installing/mounting
4.3 Mounting the part-turn actuator
3. Place the carrier ② on the stump of the actuator's positioner shaft. Tighten the carrier ②
using the socket cap screw ⑨ and the washer ⑩.
Figure 4-7
Carrier
4. 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.
Figure 4-8
Coupling wheel and carrier
5. Align the positioner/mount unit at the center of the actuator.
6. Tighten the positioner/mount unit.
7. Initialize the positioner.
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Installing/mounting
4.3 Mounting the part-turn actuator
8. After commissioning, drive the positioner to the end position.
9. 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.
Figure 4-9
Scale
H = height of shaft butt
①
②
Fixing level of positioner on mounting plate
Part-turn actuator
Figure 4-10
Dimensions of mounting plate in accordance with VDI/VDE 3845 (depends on actuator)
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Installing/mounting
4.4 Using the positioner in a humid environment
4.4
Using the positioner in a humid environment
Introduction
This information contains important notes for the installation and operation of the positioner
in a wet environment with frequent and heavy rains and/or continuous tropical dew.
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.
Figure 4-11
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.
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.
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4.5 Positioners subjected to fast acceleration or strong vibration
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
4.5.1
Positioners subjected to fast acceleration or strong vibration
The electropneumatic positioner has an anchorage for the friction clutch.
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.
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Installing/mounting
4.6 Position feedback module
4.5.2
Procedure locking the setting
Overview diagram
①
②
Friction clutch
Friction clutch latch
Figure 4-12
③
④
Locking friction clutch
Release friction clutch
Friction clutch latch
Requirements
● The positioner is mounted.
● The positioner has been commissioned successfully, i.e. initialization was completed with
"FINISH".
Procedure
Fix the setting acquired by initialization as follows:
1. To fix the friction clutch ① insert a standard wide screwdriver approx. 4 mm in the friction
clutch gear latch ②.
2. Use the screwdriver to turn the friction clutch gear latch ② counterclockwise until it
engages. The friction clutch ① is locked.
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4.6 Position feedback module
4.6
Position feedback module
Function and equipment features
● The optional position feedback module indicates the current position as a two-wire signal
with the actuating range Iy = 4 to 20 mA. The position feedback module is electrically
isolated from the basic device. Thanks to the dynamic control, this module can report the
arising operational faults automatically.
● The current position is indicated only after successful initialization.
Figure 4-13
Position feedback module
The position feedback module is:
● Single channel
● Potentially separated from the basic device.
Procedure
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. To do this, unscrew the two screws.
4. Slide the position feedback module up to the end stop in the lower bay of the rack.
5. Connect the module to the basic electronics. Use the 6-pin flat ribbon cable provided for
this.
6. Now start with the assembly. Install the module cover. Turn the screws counterclockwise
until they noticeably engage in the thread pitch. The module cover protects and locks the
optional modules mechanically.
Carefully tighten both screws clockwise.
7. Continue to assemble the positioner by executing steps 3 to 1 in reverse order.
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Installing/mounting
4.7 Accessories
4.7
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, Y2
Actuating pressure
PZ
Supply air
Figure 4-14
Pressure gauge blocks
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
Electric
5.1.1
Basic safety instructions
5
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 (68°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 (68 °F) higher.
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 Electric
5.1.1.1
Improvement of interference immunity VP160
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.
5.1.1.2
Standard cable gland/torque
Note
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.
5.1.2
Electrical connections
The connecting terminals of the device and of the position feedback module are located on
the front left edge.
The module cover protects components from being pulled out and prevents an incorrect
assembly.
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Connection
5.2 Pneumatic
5.1.3
2-wire basic device
Connection diagram
①
②
③
Basic electronics
Binary input 1
Signal source
Figure 5-1
5.1.4
Device version 2-wire
Position feedback module
①
Position feedback module
Figure 5-2
Position feedback module 6DR4004-8J
5.2
Pneumatic
5.2.1
Pneumatic connections
Structure
The pneumatic connections are provided on the right side of the positioner.
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Connection
5.2 Pneumatic
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 5-3
5.2.1.1
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.
①
②
Actuating pressure Y1
Exhaust air outlet
Figure 5-4
Integrated pneumatic connection
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Connection
5.2 Pneumatic
5.2.1.2
Pneumatic connection versions
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
5.2 Pneumatic
Figure 5-5
Regulating action of pneumatic connection
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Connection
5.2 Pneumatic
5.2.2
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 97)".
● 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 at the bottom of the device. Remove the
sound absorber if required.
– PZ: Supply air 1.4 to 7 bar
● For double-acting actuators, connect actuating pressures Y1 or Y2 depending on the
desired safety position. Safety position in case of electrical auxiliary power supply failure:
– Y1: Single-acting, depressurized
– Y1: Double-acting, maximum actuating pressure
– Y2: double-acting, depressurized
Note
Leakage
Besides continuous air consumption, the positioner may try to compensate the
position deviation due to leakage. This will lead to premature wear in the entire control
unit.
• After installing the pneumatic connections, check the tightness of the entire control
valve.
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Connection
5.3 Restrictors
5.3
Restrictors
● Reduce the air output to achieve actuating 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 5-6
Restrictors
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6
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
P manual mode
Initialization mode
Configuring
Manual mode (MAN)
Automatic (AUT)
Diagnostics
Representation in the display
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 an
error message.
③
Indicator for ongoing initialization or an error
message.
①
Parameter value
②
Parameter name
③
Parameter number
①
Position [%]
②
Mode and setpoint [%]
①
Position [%]
②
Mode and setpoint [%]
①
Diagnostics value
②
Diagnostics name
③
Diagnostics number
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Operating
6.1 Operating elements
6.1.2
Buttons
Note
Degree of protection
The IP66/NEMA 4x degree of protection is not ensured as long as the positioner is open.
①
②
③
④
Display
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.
● Remove the enclosure cover to operate the buttons.
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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.
button is used to select parameter values when configuring. You can use this
● The
button to move the actuator in manual mode.
● The
button is also used to select parameter values when configuring. 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 configuration menu.
Figure 6-2
Firmware version, e.g. Version 1.00.00
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.
6.2.3
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.
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Operating
6.2 Operating modes
Switch to "Configuration" and "Initialization mode" to adapt the actuator as per the positioner.
Alarms or position feedbacks can be triggered after initializing the positioner completely.
Configuration and initialization
To get to the "Configuration" mode, press the
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.
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.
Diagnostics
Proceed as follows to call the "Diagnostics" mode from the "Automatic" or "Manual" modes:
Press the three buttons of the positioner at the same time for at least 2 seconds.
Current operating data can be called and displayed in this mode, e.g.:
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Operating
6.3 Optimizing the controller data
● Stroke number
● 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 a control variable in the automatic mode.
• The last reached position is retained in the manual mode.
6.3
Optimizing the 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 case of minor overshoots.
The adjustment can be accelerated or the attenuation can be intensified by optimizing the
data.
The following special cases are ideal examples for a targeted data optimization:
● Small actuators with actuating times < 1 s.
● Operation with boosters, described in section "Operation with boosters (Page 107)"
Procedure
1. Select the parameters in the diagnostics menu. Press the three buttons of the positioner
at the same time for at least 2 seconds.
2. Activate the setting function. Press the
or
button for at least 5 seconds.
3. When you change the selected parameter, it is immediately updated. The effects on the
controller results can then be tested.
In order to optimize the controller data, change the values of the parameters listed below.
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Operating
6.3 Optimizing the controller data
8 lmpulse length UP / 9 lmpulse length DOWN
You can use these parameters to determine the smallest impulse lengths for each actuating
direction. The actuator is then moved with these lengths. The optimum value depends on the
volume of the actuator in particular. 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 in case of small actuators.
10 Slow step zone up / 11 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 17)".
Select small values to achieve high speeds of shifting with small control deviations already.
Select large values to reduce overshoots particularly in case of large changes in the setpoint.
NOTICE
Overshoots or too low speeds of shifting
Too small values can result in overshoots.
• Enter a higher value.
Too large values result in too slow speeds of shifting near the adjusted status.
• Enter a smaller value.
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Commissioning
7.1
7
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 97)" 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 General information about commissioning
7.2
General information about commissioning
Introduction
After installing the positioner on a pneumatic actuator, you must supply electric and
pneumatic auxiliary power to it.
The positioner is in the "P manual mode" before initialization. At the same time, "NOINI"
blinks in the lower line of the display.
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
– Movement times 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 actuators
with soft end stops.
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.
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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 zero point
and the stroke.
RUN3
Establishing and display of the actuating time (leak
monitoring)
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.
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7.3 Sequence of automatic initialization
Linear actuator
Open
Part-turn actuator
Closed
Closed
Open
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 the information about the sequence for trimming the zero point and the stroke.
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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 the information about the sequence for trimming the zero point and the stroke.
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7.3 Sequence of automatic initialization
Sequence of RUN3 to RUN5
This structured chart describes:
● Determination and display of actuating time and triggering of leak measurement 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.
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.: "P12.3", 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.
Setting the actuator
1. Check whether the mechanical unit can be moved freely in the entire actuating range.
or button.
Move the drive to the respective end position for this purpose using the
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.
See also
Mounting the linear actuator (Page 21)
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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.INITA" parameter. To do this, briefly press the
button. The display shows
the following:
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7.5 Commissioning linear actuators
3. Start the initialization process. To do this, press the
the display shows the following:
button for at least 5 seconds until
The positioner runs through five initialization steps during the automatic initialization
process. Displays for the initialization steps from "RUN 1" to "RUN 5" are shown in the
lower line on the display. The initialization process depends on the actuator used, and
takes up to 15 minutes.
4. The following display indicates that the automatic initialization is complete:
Aborting the automatic initialization process
1. Press the
button. The display shows the following:
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The software status is displayed.
After releasing the
button, the positioner is in "P manual mode". The positioner is not
initialized.
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 end stops. The start and end positions of the actuator travel are set manually. When the
control parameters are optimized, the further initialization process runs automatically.
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7.5 Commissioning linear actuators
Requirements
The following requirements must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on linear actuators.
2. The actuator spindle can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Initializing the linear actuator automatically
1. Switch to the "Configuration" mode. To do this, press the
button for at least 5 seconds
until the display shows the following:
2. Call the "3.INITM" parameter. To do this, press the
button twice. The display shows
the following:
3. Start the initialization process. To do this, press the
the display shows the following:
button for at least 5 seconds until
The current potentiometer position is output on the display after 5 seconds. Examples of
the displayed potentiometer positions are given below:
4. Determine the end position 1 of the actuator spindle.
5. Move the actuator to the desired position using the
or
button.
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7.5 Commissioning linear actuators
6. 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
4. Abort the manual initialization process by pressing the
button.
button.
5. Then return to "P manual mode" mode.
6. Correct the actuator travel and the position detection.
7. Determine the end position 2 of the actuator spindle. Move the actuator to the desired
or button.
position using the
8. Press the
button. The current position of the actuator is applied.
Note
Fault message "Set Middl"
The lever arm is not in the horizontal position if the "Set Middl" message is output on the
display. To correct the fault, set the reference point of the sine correction. Proceed as
follows:
1. Move the lever arm to the horizontal position using the
2. Press the
or
button.
button.
9. 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:
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7.6 Commissioning part-turn actuators
Aborting the manual initialization process
1. Press the
button. The display shows the "5.INITM" parameter. The positioner is in the
"Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
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.
7.6
Commissioning part-turn actuators
7.6.1
Preparing part-turn actuators for commissioning
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 actuating 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
7.6.2
Automatic initialization of part-turn actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The actuating 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:
3. Call the "2.INITA" parameter. To do this, briefly press the
button. The display shows
the following:
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7.6 Commissioning part-turn actuators
4. Start the initialization process. To do this, press the
the display shows the following:
button for at least 5 seconds until
The positioner runs through five initialization steps during the automatic initialization
process. Displays for the initialization steps from "RUN1" to "RUN5" are shown in the
lower line on the display. The initialization process depends on the actuator used, and
takes up to 15 minutes.
5. The following display indicates that the automatic initialization is complete.
Aborting the automatic initialization process
1. Press the
button. The display shows the following:
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The software status is displayed.
After releasing the
button, the positioner is in "P manual mode". The part-turn actuator
is not initialized.
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 end stops. The start and end positions of the actuator travel are set manually. When the
control parameters are optimized, the further initialization process runs automatically.
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7.6 Commissioning part-turn actuators
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".
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 "1.YFCT" parameter to "turn". To do this, press
following:
3. Call the "3.INITM" parameter. To do this, press the
. The display shows the
button twice. The display shows
the following:
4. Start the initialization process. Press the
shows the following:
button for at least 5 seconds until the display
5. The current potentiometer position is output on the display after 5 seconds:
6. Determine the end position 1 of the actuator.
7. Move the actuator to the desired position using the
or
button.
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7.6 Commissioning part-turn actuators
8. 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
4. Abort the manual initialization process by pressing the
button.
button.
5. Then return to "P manual mode" mode.
6. Correct the actuator travel and the position detection.
9. Determine the end position 2 of the actuator. Move the actuator to the desired position
or button.
using the
10.Press the
button. The current position of the actuator is applied.
11.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 "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". "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, the
described procedure 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
Procedure
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.
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7.7 Device replacement
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 mode button (manual button), see section
"Description of operating modes (Page 47)".
11.Release the fixing of the actuator.
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Parameterizing/addressing
8.1
8
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.
8.2
Configuration schematic for parameter operating principle
Figure 8-1
Configuration block schematic
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8.3 Parameter overview
8.3
Parameter overview
Note
Factory-set parameter values are printed in bold in the following tables.
Basic parameters
These parameters are used to adjust the positioner to the actuator. Normally the parameter
setup 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.
Parameter
Function
Parameter values
1.YFCT
Type of actuator
Unit
turn (part-turn actuator)
WAY (linear actuator)
-turn (part-turn actuator, inverted direction of
action)
-WAY (linear actuator, inverted direction of
action)
2.INITA
Initialization (automatic)
NOINI | no / ###.# | Strt
3.INITM
Initialization (manual)
NOINI | no / ###.# | Strt
Parameters for additional functions
The following 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
Parameter
Function
4.SDIR
Setpoint direction
Parameter values
Unit
Rising
riSE
Falling
FALL
5.TSUP
Setpoint ramp UP
0 ... 5
s
6.TSDO
Setpoint ramp DOWN
0 ... 5
s
7.SFCT
Setpoint function
Linear
Lin
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8.3 Parameter overview
Parameter
Function
Equal percentage
Inverse equal
percentage
Parameter values
Unit
1 : 25
1 - 25
1 : 33
1 - 33
1 : 50
1 - 50
25 : 1
n1 - 25
33 : 1
n1 - 33
50 : 1
n1 - 50
8.DEBA
Deadband of closed-loop controller
9.YDIR
Direction of action of manipulated variable for display and position feedback
10.YCLS
0.2 ... 1.0
Rising
riSE
Falling
FALL
Tight closing with manipulated variable
None
no
Top only
uP
Bottom only
do
Top and bottom
11.BIN1
1)
Function of the BE1
uP do
Normally open
None
2)
bloc1
Block configuration and manual
bloc2
uP
-uP
Drive valve to 0% position
doWn
-doWn
Block movement
StoP
-StoP
Reset all parameters which can
be reset by "Init" and "PArA".
ALL
Reset initialization parameters
1.YFCT to 3.INITM.
Init
Reset parameters 4.SDIR to
11.BIN1.
1)
Normally closed
OFF
Block configuration
Drive valve to 100% position
12.PRST
%
PArA
"Normally open" means: Action with closed switch
"Normally closed" means: Action with open switch
2)
Preset results in "NOINI"!
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8.4 Description of parameters
8.4
Description of parameters
1.YFCT - Actuator type
Requirement:
• Direction of action of the actuator is known.
• Mounting type is known.
• Direction of action of the actuator is known.
Possible settings:
Purpose:
Actuator with normal direction of
action
Actuator with inverted direction of action
• turn
• -turn
• WAY
• -WAY
Use this parameter to adjust the positioner to the respective actuator.
• turn/-turn: Use this parameter value for a part-turn actuator with a directly
mounted positioner. -turn for actuator with inverted direction of action
• WAY/-WAY: Use this parameter value for a linear actuator. -WAY for
actuator with inverted direction of action.
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 anti-clockwise direction.
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:
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 such that it displays values between "P49.0" and "P51.0" when the
lever on the positioner shaft is perpendicular to the linear actuator spindle.
Factory setting:
WAY
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8.4 Description of parameters
2.INITA - Automatic initialization
Possible settings:
• NOINI
• no / ###.#
• Strt
Purpose:
Use this parameter to start the automatic initialization process.
1. Select the "Strt" parameter value.
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
3.INITM - Manual initialization
Possible settings:
• NOINI
• no / ###.#
• Strt
Purpose:
Use this parameter to start the manual initialization process.
1. Select the "Strt" parameter value.
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.
Description:
If the positioner has already been initialized and if the "2.INITA" and "3.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
4.SDIR - Setpoint direction
This parameter is used to set the setpoint direction. The setpoint direction is used to reverse
the direction of action of the setpoint. The setpoint direction is primarily used for single-acting
actuators with the safety setting "up".
The factory setting is "riSE".
5.TSUP - Setpoint ramp UP
and
6.TSDO - Setpoint ramp DOWN
The setpoint ramp is effective in automatic mode and limits the speed of change of the
effective setpoint. When switching from manual to automatic mode, the setpoint ramp is
used to adjust the effective setpoint to the setpoint occupied by the positioner.
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8.4 Description of parameters
This smooth switching from manual to automatic mode prevents pressure excess in long
pipelines.
The factory setting is "0".
7.SFCT - Setpoint function
This parameter is used to linearize nonlinear valve characteristics. For linear valve
characteristics, arbitrary flow characteristics are formed.
Seven valve characteristics are stored in the positioner:
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
The factory setting is "Lin".
8.DEBA - Deadband of closed-loop controller
The deadband is set using the values 0.2 to 1.0. Control oscillations can then be
suppressed. The smaller the deadband, the better the control accuracy.
The factory setting is "0.2".
9.YDIR - Direction of manipulated variable for display
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.
The factory setting is "riSE".
10.YCLS - Tight closing with manipulated variable
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 automatically
activated on one side or for both end positions above the following values:
● Down (do) starting at 0.5%
● Up (uP) starting at 99.5%
The factory setting is "uP do'".
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8.4 Description of parameters
11.BIN1 - Function binary input 1
This parameter determines the function of the binary input. The possible functions are
described below. The direction of action can be adapted to a normally closed or normally
open mode.
● BIN1 = bLoc1
With this parameter value, you can lock the "configuration" operation mode against
reconfiguration. The lock is performed e.g. with a jumper between terminals 9 and 10.
● BIN1 = bLoc2
If binary input 1 is activated, then manual mode is also blocked in additional to the
configuration operation mode.
● BIN1 = uP or doWn NO contact or -uP or -doWn NC contact.
Valve moves to the set position.
● BIN1 NO contact StoP or -StoP NC contact.
If the binary input is activated in automatic mode, the piezo valves are blocked. The
actuator remains at the last position. Leakage measurements can be performed in this
way without using the initialization function.
● BIN1 = OFF (factory setting)
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, then when the mode button is pushed
the firmware version will be displayed.
12.PRST - Preset
Possible settings:
• ALL
• Init
• PArA
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"
and "PArA".
• Init: Reset initialization parameters 1.YFCT to 3.INITM.
• PArA: Reset parameters 4.SDIR to 11.BIN1.
An overview of the parameters and factory settings can be found in
section "Parameter overview (Page 72)".
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.
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Parameterizing/addressing
8.4 Description of parameters
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
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Alarm, error, and system messages
9.1
Output of system messages in the display
9.1.1
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
P---
X
X
X
NOINI
9.1.2
Measure
Message after application of electrical
auxiliary power.
•
Maintenance.
Potentiometer voltage of a non-initialized
positioner (P-manual mode) (actual position
value in % of the measuring range).
•
Check whether the complete travel can
be covered using the
and
buttons
and that "P---" is never displayed.
•
Execute the initialization process.
Measuring range was exceeded, the
potentiometer is in the inactive zone or the
effective lever arm is not adjusted as per the
actuator travel.
•
Adjust the effective lever length of linear
actuators as per the measuring range.
Positioner is not initialized.
•
Start initialization.
Down
X
START
Pnnn.n
Meaning / cause
X
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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Alarm, error, and system messages
9.1 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 or the
effective lever arm is not adjusted as per the
actuator travel.
•
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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9.1 Output of system messages in the display
Message
Line
Up
RUN1 /
ERROR
SEt
X
X
MIDDL
X
UP >
X
90_95
X
U-d>
U nn.n
X
X
D->U
D nn.n
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 restrictor(s).
Restart initialization.
•
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
linear actuators.
•
Press the operating mode button slightly
to acknowledge.
•
Restart initialization.
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
linear actuators.
•
Press the operating mode button slightly
to acknowledge.
•
Restart initialization.
•
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
U->d
•
•
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
Ensure there is enough compressed air.
Display of the "Down" travel time.
X
Press the operating mode button slightly
to acknowledge.
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9.1 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
Initialization was completed successfully.
FINISH
X
9.1.3
System messages when exiting the Configuration mode
Remarks about the tables:
nn
stands for changeable numeric values
Error symbol
/
(slash): the text on the left and right of the slash blink alternately.
Messages when exiting the configuration mode:
Message
Line
Up
n.nn.nnV
ER
Down
X
X
Operating mode
Automatic
Manual mode
Meaning / cause
Measure
Software version
•
P Manual mode
Wait
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9.1 Output of system messages in the display
9.1.4
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
Up
CPU
Down
Operating mode
Automatic
Manual
Meaning / cause
Measure
•
Maintenance.
•
Replace
electronics.
P-manual
START
X
Message after application
of electrical auxiliary
power.
HW /
ERROR
X
Fault in the hardware.
NOINI
X
nnn.n
X
X
X
AUTnn
X
MANnn
X
oFL /
127.9
X
X
X
X
X
Positioner is not initialized. •
Start initialization.
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
•
perform factory
settings (Preset)
and initialization.
Possible causes:
•
Friction clutch was
maladjusted.
•
Positioner was
installed on a different
actuator without being
re-initialized.
EXSTP
X
X
Actuator was stopped by
the binary input.
EX UP
X
X
Actuator is moved to the
upper end stop by the
binary input.
EXDWN
X
X
Actuator is moved to the
lower end stop by the
binary input.
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9.2 Diagnostics parameters
9.2
Diagnostics parameters
9.2.1
Overview of diagnostics values
Explanation about the table
The following table provides an overview of values that can be displayed. The last column
contains "X" if the value can be set to zero.
Overview of diagnostics values
No.
Abbreviation
Meaning
Values that can be
displayed
Unit
Reset
1
STRKS
Number of strokes
0 ... 4.29E9
-
X
2
CHDIR
Number of changes of direction
0 ... 4.29E9
-
X
3
HOURS
Operating hours
0 ... 4.29E9
Hours
-
4
TUP
Travel time up
0 ... 1000
s
-
5
TDOWN
Travel time down
0 ... 1000
s
-
6
P0
Potentiometer value of lower end stop (0%)
0.0 ... 100.0
%
-
7
P100
Potentiometer value of upper end stop (100%) 0.0 ... 100.0
%
-
8
IMPUP
impulse length up
6 ... 160
ms
-
9
IMPDN
impulse length down
6 ... 160
ms
-
10
SSUP
slow step zone up
0.1 ... 100.0
%
-
11
SSDN
slow step zone down
0.1 ... 100.0
%
-
12
TMIN
Minimum temperature ("min/max pointer")
-50 ... 100
-58 ... 212
°C
°F
-
13
TMAX
Maximum temperature ("min/max pointer")
-50 ... 100
-58 ... 212
°C
°F
-
14
VENT1
Counter for pilot valve 1
0 ... 4.29E9
-
-
15
VENT2
Counter for pilot valve 2
0 ... 4.29E9
-
-
16
WT00
Number of operating hours in the actuating
range WT00
0 ... 4.29E9
Hours
X
17
WT05
Number of operating hours in the actuating
range WT05
0 ... 4.29E9
Hours
X
18
WT10
Number of operating hours in the actuating
range WT10
0 ... 4.29E9
Hours
X
19
WT30
Number of operating hours in the actuating
range WT30
0 ... 4.29E9
Hours
X
20
WT50
Number of operating hours in the actuating
range WT50
0 ... 4.29E9
Hours
X
21
WT70
Number of operating hours in the actuating
range WT70
0 ... 4.29E9
Hours
X
possible
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9.2 Diagnostics parameters
No.
Abbreviation
Meaning
Values that can be
displayed
Unit
Reset
possible
22
WT90
Number of operating hours in the actuating
range WT90
0 ... 4.29E9
Hours
X
23
WT95
Number of operating hours in the actuating
range WT95
0 ... 4.29E9
Hours
X
24
mA
Setpoint current
0.0 ... 20.0
mA
-
9.2.2
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 84)".
1 STRKS - Number of strokes
In operation, the movements of the actuator are summed up and displayed in this
diagnostics value as the number of strokes. Unit: 100% strokes, i.e. the path between 0 and
100% and back.
2 CHDIR - Number of changes in direction
Every change of direction of the actuator caused in the deadband is noted in the closed-loop
controller and added to the number of changes of direction.
3 HOURS - Operating hours
The runtime meter is incremented every hour as soon as electric auxiliary power is supplied
to the positioner.
4 TUP - Response time open and
5 TDOWN - Response time closed
These values indicate the actuating times determined during the initialization process. The
unit is seconds.
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9.2 Diagnostics parameters
6 P0 - Potentiometer value of bottom end stop and
7 P100 - Potentiometer value of top end stop
Both these values indicate the measured values of the position displacement sensor
(potentiometer) on the lower or upper hard end stop, as they were determined during
automatic initialization. The values of manually approached end positions are applicable for
manual initialization.
8 IMPUP - Impulse length UP and
9 IMPDN - Impulse length DOWN
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.
This parameter can be set for special applications.
10 SSUP - Slow step zone UP and
11 SSDN - Slow step zone DOWN
The slow step zone is the zone of the closed-loop controller in which control signals are
issued in a pulsed manner. 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.
12 TMIN - Minimum temperature (slave pointer) and
13 TMAX - Maximum temperature (slave pointer)
The minimum and maximum temperatures inside the enclosure are continuously determined
and saved using a min/max pointer. They can be reset only in the factory.
In order to switch over the temperature display between °C and °F, press the
button.
14 VENT1 - Counter for pilot valve 1 and
15 VENT2 - Counter for pilot valve 2
Control procedures of the pilot valves in the pneumatic block of the positioner are counted
and displayed in these two parameters.
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 => 14 VENT1
● Depressurize => 15 VENT2
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9.2 Diagnostics parameters
Counting procedure for double-acting actuators:
● Pressurize (Y2) / Depressurize (Y1) => 14 VENT1
● Depressurize (Y1) / Pressurize (Y2) => 15 VENT2
16 WT00 bis 23 WT95 - Number of operating hours in the actuating ranges WT00 to WT95
When the positioner is in the automatic mode, statistics regarding the duration for which a
valve or a flap operated in a particular section of the actuating range are continuously
maintained. The entire actuating 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 actuating 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.
The actuating range is divided as follows:
Actuating range
WT00
WT05
WT10
WT30
WT50
WT70
WT90
WT95
Actuating range section [%]
-
≥5
≥ 10
≥ 30
≥ 50
≥ 70
≥ 90
≥ 95
<5
< 10
< 30
< 50
< 70
< 90
< 95
-
Division of actuating range
You can simultaneously set the eight operating hours counters to zero. To do this, press the
button for at least 5 seconds.
TIP: Since the actuating ranges are provided at the end of the diagnostics menu, press the
decrement button several times along with the
button. This will help you in accessing
the diagnostics numbers faster.
Note
Updating of the diagnostics values
All diagnostics values are updated in the non-volatile memory every 15 minutes so that, in
case of a power failure, only the values of the previous 15 minutes may be lost.
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Alarm, error, and system messages
9.3 Fault correction
9.3
Fault correction
9.3.1
Fault identification
Diagnostics guide
Fault
Remedial 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
See also
Remedial measures table 2 (Page 89)
Remedial measures table 3 (Page 90)
Remedial measures table 5 (Page 91)
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9.3 Fault correction
9.3.2
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)
Remedial 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.
•
Incorrectly set stroke on the lever.
•
•
Piezo valve does not activate.
Check settings: see leaflet: Fig.
"Device view (7)".
•
Check the stroke setting on the
lever, Section "Remedial measures
table 2 (Page 89)".
•
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.
•
•
Actuator actuating 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
9.3.3
Remedial measures table 2
Fault profile (symptoms)
Possible cause(s)
•
"CPU testt" blinks on the display
approximately every 2 seconds.
•
Piezo valve does not activate.
•
•
In the manual and automatic
modes, the actuator cannot be
moved or can be moved only in one
direction.
Moisture in the pneumatic block
Piezo valve does not activate (a
gentle click sound is not audible
when the "+" or "-" buttons are
pressed in the manual mode.)
The screw between the shrouding
cover and the pneumatic block has
not been tightened firmly or the
cover got stuck.
•
•
•
Water in the pneumatic block (due
to wet compressed air)
Remedial measures
•
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.
•
Otherwise: Repair
•
Tighten the screw firmly; if required,
rectify the deadlock.
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9.3 Fault correction
Fault profile (symptoms)
Possible cause(s)
Remedial measures
•
Dirt (swarf, particles) in the
pneumatic block
•
Repair or a new device; clean
and/or replace the built-in fine
screens.
•
Deposits on the contacts between
the electronic printed circuit board
and the pneumatic block may
develop due to abrasion owing to
continuous loads resulting from
strong vibrations.
•
Clean all contact surfaces with
spirit; if required, bend the
pneumatic block contact springs.
Fault table 2
See also
Repair/Upgrading (Page 94)
9.3.4
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
(however, a gentle clicking sound
can be heard when the
or
button is pressed in "Manual"
mode.)
•
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.
•
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 94)
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9.3 Fault correction
9.3.5
Remedial 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 a mean value.
Possible cause(s)
•
Sticking friction of the packing gland •
from the control valve or actuator
too large
Reduce friction or increase dead
zone 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 actuating times using
throttle screws.
•
If a quick actuating time is needed,
increase the dead zone (parameter
"dEbA") until the oscillation stops.
•
Increase supply pressure, insert
ballast converter
•
•
Positioner doesn't move control
valve to the stop (at 20 mA).
Remedial measures
•
Actuator too fast
Supply pressure too low. Load on
the feeding controller or system
output is too low.
Error table 4
9.3.6
Remedial measures table 5
Fault profile (symptoms)
•
•
Possible cause(s)
Remedial 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
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Alarm, error, and system messages
9.3 Fault correction
See also
Repair/Upgrading (Page 94)
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Service and maintenance
10.1
Basic safety instructions
10.1.1
Impermissible accessories and spare parts
10
CAUTION
Impermissible accessories and spare parts
Device damage
• Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
WARNING
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.
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Service and maintenance
10.2 Cleaning of the screens
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.
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.
10.2
Cleaning of the screens
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.
Installation of the screens
1. Insert the screens into the recesses of the enclosure.
2. Place the O-rings on the screens.
3. Fit the pneumatic terminal strip on both studs so that it fits flushly.
4. Screw in the three screws.
5. Place the cover and tighten it.
6. Reconnect the pipelines and feed the pneumatic power supply.
10.3
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
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Service and maintenance
10.4 Return procedure
provide the serial number of the original device. You can find the serial number on the
nameplate.
10.4
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.
Devices/replacement parts which are returned without a decontamination declaration will
be cleaned at your expense before further processing.
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Service and maintenance
10.4 Return procedure
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11
Technical data
11.1
Rated conditions
Rated conditions
Permissible ambient temperature for operation
-30 ... +80 °C (-22 ... +176 °F)
Degree of protection
IP66 to EN 60529/NEMA 4X
Mounting position
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/axis
•
Bumping (half-sine) according to EN 60068-2-27/02.2010
150 m/s² (492 ft/s²), 6 ms, 1000 shocks/axis
•
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/axis
200 ... 500 Hz; 0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz)
4 hours/axis
•
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)
4K3, but -30 ... +80°C (4K3, but -22 ... +176°F)
1)
At ≤ -10 °C (≤ 14 °F), the refresh rate of the display is limited.
11.2
Pneumatic data
Pneumatic data
Auxiliary power (air supply)
•
Pressure
Compressed air, carbon dioxide (CO2), nitrogen (N), or noble
gases
1.4 ... 7 bar (20.3 ... 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)
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Technical data
11.3 Construction
Pneumatic data
•
•
Inlet air valve (ventilate actuator)
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)
Outlet air valve (depressurize actuator)
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)
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)
11.3
Construction
Construction
Connections, electrical
•
Screw terminals
2.5 AWG28-12
•
Cable gland
M20x1.5 or ½-14 NPT
Connections, pneumatic
Female thread G¼ or ¼-18 NPT
How does it work?
•
Range of stroke (linear actuator)
10 ... 130 mm (0.39 ... 5.12") (angle of positioner shaft
16 ... 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 rib, bars or flat face.
•
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 actuator-side.
Weight, basic device in aluminum enclosure
Approx. 1.6 kg (3.53 lb)
Material
•
Aluminum enclosure
GD AISi12
•
Pressure gauge block
Aluminum AIMgSi, anodized
Device version in aluminum enclosure
Single-acting and double-acting
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Technical data
11.3 Construction
Construction
Torques
•
Part-turn actuator fixing screws DIN 933 M6x12-A2
5 Nm (3.7 ft lb)
•
Linear actuator fixing screws DIN 933 M8x16-A2
12 Nm (8.9 ft lb)
•
Gland pneumatic G¼
15 Nm (11.1 ft lb)
•
Gland pneumatic ¼ NPT
•
Without sealant
12 Nm (8.9 ft lb)
With sealant
6 Nm (4.4 ft lb)
Cable glands
Screw-in torque for plastic gland in all enclosures
4 Nm (3 ft lb)
Screw-in torque for cable gland made of
metal/stainless steel in Makrolon enclosure
6 Nm (4.4 ft lb)
Screw-in torque for metal/stainless steel glands in
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 (50.2 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
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Technical data
11.4 Electrical data
11.4
Electrical data
Electrical data
Current input IW
•
Rated signal range
4 ... 20 mA
•
Binary input BE1 (terminals 9/10; galvanically
connected to basic device)
Suitable only for floating contact; max. contact load
< 5 μA with 3 V
Current to maintain the auxiliary power
≥ 3,6 mA
Required load voltage UB (corresponds to Ω at
20 mA)
•
Maximum
6.48 V (= 324 Ω)
•
Static destruction limit
± 40 mA
11.5
Controller
Controller
Control unit
Adaptive
•
Five-point controller
•
Deadband dEbA = 0.2 ... 1% (factory setting 0.2%) Adjustable
Analog-to-digital converter
•
Scanning time
10 ms
•
Resolution
≤ 0.13%
•
Transmission error
≤ 0.2%
•
Temperature influence
≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
Cycle time
11.6
20 ms
Certificates, approvals
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)
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Technical data
11.7 Position feedback module
11.7
Position feedback module
Position feedback module
Direct current output for position feedback
6DR4004-8J
1 current output, terminals 61 and 62
2-wire connection
Rated signal range
4 ... 20 mA, short-circuit proof
Dynamic range
3.6 ... 20.5 mA
Auxiliary voltage UH
+12 ... +35 V
External load RB [kΩ]
≤ (UH [V] - 12 V)/i [mA]
Transmission error
≤ 0.3%
Temperature influence
≤ 0.1%/10 K (≤ 0.1%/18 °F)
Resolution
≤ 0.1%
Residual ripple
≤1%
Galvanic isolation
Safe electrical isolation from the basic device
Test voltage
DC 840 V, 1 s
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Technical data
11.7 Position feedback module
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Dimension drawings
12.1
①
②
③
12
SITRANS VP160 positioner
Dimension for electrical connection ½-14 NPT due to adapter: 203 mm (8 inch)
All air connections G¼ or ¼ NPT
M20 x 1.5 or NPT adapter
Figure 12-1
Dimension drawing SITRANS VP160, dimensions in mm (inch)
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Dimension drawings
12.2 Terminal strip
12.2
Terminal strip
①
Thread depth
Figure 12-2
Terminal strip, dimensions in mm (inch)
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Spare parts/accessories/scope of delivery
13.1
13
Overview
Basic version
The positioner can be delivered for:
● Double-acting actuators
● Single-acting actuators
The positioner and its option module are delivered as separate units.
Enclosure
The electronic unit with display, the position feedback, and the pneumatic block are
integrated in the enclosure.
The enclosure is available in aluminum for single and double-acting actuators.
Options
The positioner can be equipped with a position feedback module:
● Position feedback module: two-wire current output 4 to 20 mA for position feedback
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
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Spare parts/accessories/scope of delivery
13.2 Spare parts
13.2
Spare parts
Description
Order no.
Aluminum cover with 4 screws and circumferential sealing ring
2-wire basic electronics
A5E33344289
Pneumatic block, single-acting, with seal and screws
C73451-A430-D80
Pneumatic block, double-acting, with seal and screws
C73451-A430-D81
Potentiometer (complete)
A5E33519996
1/4" NPT
A5E33519994
Small parts set G1/4
A5E33519995
Note
For add-ons and possible modules, see catalog FI 01 "Field Instruments for Process
Automation"".
13.3
Accessories
For accessories, refer to Catalog FI 01 "Field devices for process automation", for example:
● Option module
● Mounting kits
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A
Appendix
A.1
Certificates
The certificates are available on the supplied CD.
A.2
Operation with boosters
Introduction
In order to shorten the actuating 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 actuating 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 Chapter "Optimizing the controller data (Page 49)".
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Appendix
A.3 Literature and catalogs
A.3
Literature and catalogs
Table A- 1
No.
Title
Publisher
Order no.
/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
E86060-K6710-A101-B5
/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)
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Appendix
A.4 Technical support
A.4
Technical support
Technical support
You can contact Technical Support for all IA and DT products:
● Via the Internet using the Support Request:
Support request (http://www.siemens.com/automation/support-request)
● E-mail (mailto:[email protected])
● Phone: 400-810-4288.
● Fax: (010) 6471 9991.
Further information about our technical support is available on the Internet at
Technical support (http://www.siemens.com/automation/csi/service)
Industry Online Support
In addition to our range of documentation, we provide a comprehensive database on the
Internet at the following address:
Service&Support (http://www.siemens.com/automation/service&support)
There you will find:
● The latest product information, FAQs, downloads, tips and tricks.
● The newsletter with the most recent information on our products.
● A Knowledge Manager to find the right documents for you.
● Our forum, where users and specialists throughout the world share their knowledge.
● Your local Industry Automation and Drive Technologies representative in our contact
database.
● Information on local service, repairs, spare parts and much more under "Services".
Additional support
If you have any questions relating to the products described in this manual, and do not find
the answers in this documentation, please contact your Siemens partner at our local offices.
You will find information on who to contact at:
Partner (http://www.automation.siemens.com/partner)
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Appendix
A.4 Technical support
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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.
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.
Configuring
See parameter assignment.
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.
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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".
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.
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.
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.
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.
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Glossary
IP code
The abbreviation IP stands for International Protection as per DIN. In English-speaking
countries, IP stands for Ingress Protection.
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.
Sensor
Converter that converts mechanical or other non-electric variables into electric signals.
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Glossary
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Index
6
0B
6DR4004-8J,
A
1B
Position, 16
Documentation
Edition, 7
Dummy plug
Position, 16
E
5B
Accessories, 105
Actuating pressure
Position, 16
Additional support, 109
Amplifier,
Appendix, 108
Enclosure, 105
Exhaust air outlet
Position, 16
F
6B
B
2B
Basic electronics, 106
Position, 16
Booster, 107
Buttons
Position, 16
C
3B
Factory setting
Resetting to ~, 60, 65
Fault identification, 88
Firmware, 7
Five-point controller, 13
Friction clutch, 32
Position, 16
Functional principles, 17
H
7B
Cable gland
Position, 16
Carrier, 26
Certificates,
Commissioning
Cancel, 61
Interrupting, 60
Manual, 62, 67
Compressed air, 20
Connecting terminals, 36
Option modules, 16
Connection
Pneumatic, 38, 58
control valve
integrated, 13
Correct usage,
Customer support hotline, 109
D
4B
Diagnostics guide, 88
Display
History, 7
Hotline, 109
I
8B
Improper device modifications, 12
Initialization,
Automatically, 53
Cancel, 66
Interrupting, 65
Internet, 109
L
9B
Linear actuator
Add-on extensions, 13
Automatic commissioning, 60
Automatic commissioning (sequence diagram), 54
Automatic initialization parameter (2.INITA), 75
Manual commissioning, 62
Mounting, 21
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Index
Pneumatic connection, integrated, 38
Single-acting, 14
M
10B
Manometer
Mounting, 34
Manufacturer serial number, 15
Module cover, 36
Mount
Dimensions, 29
Mounting kit
Linear actuator, 21
S
14B
Scope of delivery, 8
Service, 109
Sound absorber
Position, 16
Supply air
Position, 16
Support, 109
Symbols,
System integration
PDM, 7
T
15B
O
Terminal strip, 58
11B
Option module
Installation, 33
Option modules, 105
Order number, 15
Ordering supplement, 15
W
16B
Warning symbols, 11
Wiring diagram
Position, 16
P
12B
Parameters 1 to 3
Actuator (1.YFCT), 74
Automatic initialization (2.INITA), 75
Description, 74
Part-turn actuator
Automatic commissioning, 65
Automatic commissioning (sequence diagram), 54
Automatic initialization parameter (2.INITA), 75
Double-acting, 14
Manual commissioning, 67
Mounting, 26
Pneumatic block,
Purging air selector, 58
Pneumatic connections, 58
Position feedback module
Connecting, 37
Product name, 15
Purging air selector, 58
Position, 16
R
13B
Regulation system, 13
Restrictor
Position, 16
SITRANS VP160
116
Operating Instructions, 03/2014, A5E32923823-01
Compact Operating Instructions • 02/2014
SSIPART PS2 with and without HART
Nur Online-Version: Rückenbreite für Druck überprüfen !
Edition
A5E03436620-04
GN: 30690_SIPART PS2
02/2014
SITRANS VP160
Operating Instructions • 03/2014
Get more information
www.siemens.com/processautomation
www.siemens.com/positioner
SITRANS
Electropneumatic positioners
SITRANS VP160
Operating Instructions
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Subject to change without prior notice
A5E32923823-01
© Siemens AG 2014
A5E32923823
A5E32923823
www.siemens.com/automation
A5E32923823-01
GN: 30710_Sitrans VP160
Edition
03/2014
Answers for industry.
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