SIPART PS2 with PROFIBUS PA
SIPART PS2 with PROFIBUS PA
Operating Instructions • 10/2013
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SIPART
Electropneumatic positioners
SIPART PS2 with PROFIBUS PA
Operating Instructions
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Subject to change without prior notice
A5E00127926-09
© Siemens AG 2013
A5E00127926-09
www.siemens.com/automation
A5E00127926-09
A5E00127926-09
GN: 30020_SIPART PS2_neu
Edition
10/2013
Answers for industry.
SIPART PS2 with PROFIBUS PA
1
___________________
Introduction
2
___________________
Safety information
SIPART
Electropneumatic positioner
SIPART PS2 with PROFIBUS PA
3
___________________
Description
4
___________________
Installing/mounting
5
___________________
Connect
6
___________________
Operation
Operating Instructions
7
___________________
Commissioning
8
___________________
Functional safety
Parameter
9
___________________
assignment/Addressing
Functions/operations using
10
___________________
PROFIBUS PA
Alarm, fault and system
11
___________________
messages
12
___________________
Service and maintenance
13
___________________
Technical data
14
___________________
Dimension drawings
6DR55..
Spare
parts/accessories/scope of
delivery
15
A
___________________
Appendix
10/2013
A5E00127926-09
B
___________________
Abbreviations
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E00127926
Ⓟ 09/2013 Technical data subject to change
Copyright © Siemens AG 2013.
All rights reserved
Table of contents
1
2
3
Introduction ........................................................................................................................................... 11
1.1
Purpose of this documentation ....................................................................................................11
1.2
History ..........................................................................................................................................11
1.3
Purpose ........................................................................................................................................12
1.4
Checking the consignment ...........................................................................................................12
1.5
Transportation and storage ..........................................................................................................13
1.6
Product information ......................................................................................................................13
1.7
Notes on warranty ........................................................................................................................13
Safety information ................................................................................................................................. 15
2.1
2.1.1
2.1.2
2.1.3
Prerequisites for safe use ............................................................................................................15
Warning symbols on the device ...................................................................................................15
Laws and directives .....................................................................................................................15
Conformity with European directives ...........................................................................................16
2.2
Improper device modifications .....................................................................................................16
2.3
Requirements for special applications .........................................................................................17
2.4
Use in hazardous areas ...............................................................................................................17
Description ............................................................................................................................................ 19
3.1
Function .......................................................................................................................................19
3.2
3.2.1
3.2.2
3.2.3
Structure .......................................................................................................................................19
Design overview ...........................................................................................................................19
Nameplate layout .........................................................................................................................22
Explanation of Ex information ......................................................................................................23
3.3
3.3.1
3.3.2
Device components .....................................................................................................................24
Overview of device components ..................................................................................................24
Basic electronics ..........................................................................................................................26
3.4
3.4.1
3.4.2
3.4.3
3.4.4
Functional principle ......................................................................................................................26
Pneumatic actuator ......................................................................................................................27
Control algorithm ..........................................................................................................................27
PROFIBUS system configuration.................................................................................................28
SIMATIC PDM..............................................................................................................................29
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
PROFIBUS PA .............................................................................................................................29
Overview ......................................................................................................................................29
Transmission technology .............................................................................................................29
Bus topology ................................................................................................................................29
Properties .....................................................................................................................................31
Profile ...........................................................................................................................................31
Connection ...................................................................................................................................31
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3.5.7
3.5.8
4
5
Number of connectable devices .................................................................................................. 33
Assigning the device addresses ................................................................................................. 33
Installing/mounting ................................................................................................................................ 35
4.1
4.1.1
Basic safety instructions .............................................................................................................. 35
Proper mounting .......................................................................................................................... 38
4.2
Mounting the linear actuator........................................................................................................ 38
4.3
Mounting the part-turn actuator ................................................................................................... 44
4.4
Using the positioner in a humid environment .............................................................................. 48
4.5
4.5.1
4.5.2
Position controllers subjected to fast acceleration or strong vibration ........................................ 49
Introduction locking the setting ................................................................................................... 49
Procedure locking the setting ...................................................................................................... 50
4.6
External position detection .......................................................................................................... 52
4.7
4.7.1
4.7.1.1
4.7.1.2
4.7.1.3
4.7.2
4.7.3
4.7.4
4.7.4.1
4.7.4.2
4.7.4.3
4.7.5
4.7.5.1
4.7.5.2
4.7.5.3
4.7.5.4
4.7.6
4.7.7
Installing the optional modules .................................................................................................... 53
General information about the installation of option modules ..................................................... 53
Unsuitable device for the hazardous area .................................................................................. 53
Installing optional modules in the standard and intrinsically safe version .................................. 53
Installing the optional modules in the "flameproof enclosure" version ........................................ 56
Iy module ..................................................................................................................................... 59
Alarm unit .................................................................................................................................... 60
Slotted initiator alarm unit............................................................................................................ 62
SIA module functioning and features .......................................................................................... 62
Installing the slotted initiator alarm unit ....................................................................................... 63
Setting the limits of the slotted initiator alarm unit ...................................................................... 64
Mechanical limit switch module ................................................................................................... 65
Mechanical limit switch module - functioning and features ......................................................... 65
Installing the mechanical limit switch module ............................................................................. 66
Setting the limits of the mechanical limit switch module ............................................................. 67
Label set for mechanical limit switch module .............................................................................. 67
EMC filter module ........................................................................................................................ 69
Accessories ................................................................................................................................. 72
Connect ................................................................................................................................................ 73
5.1
5.1.1
5.1.1.1
5.1.1.2
5.1.1.3
5.1.2
5.1.3
5.1.3.1
5.1.3.2
5.1.3.3
5.1.4
5.1.4.1
5.1.4.2
5.1.5
5.1.5.1
5.1.5.2
Electric......................................................................................................................................... 73
Basic safety instructions .............................................................................................................. 73
Standard cable gland/torque ....................................................................................................... 76
Interference immunity .................................................................................................................. 77
Safety shutdown .......................................................................................................................... 77
Electrical connections ................................................................................................................. 78
Bus cable..................................................................................................................................... 78
Preparation of bus cable ............................................................................................................. 78
Bus cable for device version without flameproof enclosure ........................................................ 79
Bus cable for device version with flameproof enclosure ............................................................. 80
Device without explosion protection/device in flameproof enclosure.......................................... 81
Basic device without Ex protection / in flameproof enclosure "Ex d" .......................................... 81
Option modules without Ex protection / in flameproof enclosure "Ex d" ..................................... 82
Device with Ex i/Ex n/Ex t type of protection............................................................................... 87
Basic device Ex i/Ex n/Ex t.......................................................................................................... 87
Option modules Ex i/Ex n/Ex t..................................................................................................... 88
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6
7
8
9
5.2
5.2.1
5.2.1.1
5.2.1.2
5.2.1.3
5.2.1.4
5.2.2
Pneumatic ....................................................................................................................................92
Pneumatic connections ................................................................................................................92
Pneumatic connection on the standard controller ........................................................................92
Integrated pneumatic connection .................................................................................................93
Pneumatic connection in the flameproof enclosure .....................................................................94
Pneumatic connection versions ...................................................................................................95
Pneumatic connection ..................................................................................................................97
5.3
Restrictors ....................................................................................................................................98
Operation .............................................................................................................................................. 99
6.1
6.1.1
6.1.2
6.1.3
Operating elements ......................................................................................................................99
Display .........................................................................................................................................99
Buttons .......................................................................................................................................101
Firmware version........................................................................................................................102
6.2
6.2.1
6.2.2
6.2.3
6.2.4
Operating modes........................................................................................................................103
Overview of operating modes ....................................................................................................103
Changing the operating mode....................................................................................................104
Overview of configuration ..........................................................................................................105
Description of operating modes .................................................................................................105
6.3
Optimizing the controller data ....................................................................................................108
Commissioning ................................................................................................................................... 111
7.1
7.1.1
Basic safety instructions ............................................................................................................111
Safety notes for operation with natural gas ...............................................................................113
7.2
Overview ....................................................................................................................................114
7.3
Sequence of automatic initialization ..........................................................................................115
7.4
Purge air switching .....................................................................................................................121
7.5
7.5.1
7.5.2
7.5.3
Commissioning the linear actuators ...........................................................................................122
Preparing linear actuators for commissioning ............................................................................122
Automatic initialization of linear actuators ..................................................................................124
Manual initialization of linear actuators ......................................................................................127
7.6
7.6.1
7.6.2
7.6.3
Commissioning the part-turn actuators ......................................................................................131
Preparing part-turn actuators for commissioning .......................................................................131
Automatic initialization of part-turn actuators .............................................................................132
Manual initialization of part-turn actuators .................................................................................134
7.7
Device replacement ...................................................................................................................137
Functional safety ................................................................................................................................. 139
8.1
Range of applications for functional safety ................................................................................139
8.2
Safety function ...........................................................................................................................139
8.3
Safety Integrity Level (SIL) .........................................................................................................141
8.4
Settings ......................................................................................................................................142
8.5
Safety characteristics .................................................................................................................143
Parameter assignment/Addressing ...................................................................................................... 145
9.1
Overview of the parameters .......................................................................................................145
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9.1.1
9.1.2
9.1.3
Overview of parameters 1 to 5 .................................................................................................. 145
Overview of parameters 6 to 53 ................................................................................................ 147
Overview parameters A to P ..................................................................................................... 151
9.2
9.2.1
9.2.1.1
9.2.2
9.2.2.1
9.2.2.2
9.2.2.3
9.2.2.4
9.2.2.5
9.2.2.6
9.2.2.7
9.2.2.8
9.2.2.9
9.2.2.10
9.2.2.11
9.2.2.12
9.2.2.13
9.2.2.14
9.2.2.15
9.2.2.16
9.2.2.17
9.2.2.18
9.2.2.19
9.2.2.20
9.2.2.21
9.2.2.22
9.2.2.23
9.2.3
9.2.3.1
9.2.3.2
9.2.3.3
9.2.3.4
9.2.3.5
9.2.3.6
9.2.3.7
9.2.3.8
9.2.3.9
9.2.3.10
9.2.3.11
9.2.3.12
Description of parameters ......................................................................................................... 155
Description of parameters 1 to 5 ............................................................................................... 155
Description of parameters 3 to 5 ............................................................................................... 156
Description of parameters 6 to 53 ............................................................................................. 157
Description of parameter 6 ........................................................................................................ 157
Description of parameters 7 and 8 ............................................................................................ 157
Description of parameter 9 ........................................................................................................ 158
Description of parameters 10 to 30 ........................................................................................... 159
Description of parameter 31 ...................................................................................................... 160
Description of parameters 32 and 33 ........................................................................................ 160
Description of parameter 34 ...................................................................................................... 161
Description of parameter 35 ...................................................................................................... 162
Description of parameters 36 and 37 ........................................................................................ 163
Description of parameters 38 and 39 ........................................................................................ 163
Description of parameter 40 ...................................................................................................... 164
Description of parameters 41 and 42 ........................................................................................ 166
Description of parameter 43 ...................................................................................................... 166
Description of parameter 44 ...................................................................................................... 167
Description of parameter 45 ...................................................................................................... 167
Description of parameter 46 ...................................................................................................... 168
Description of parameter 47 ...................................................................................................... 168
Description of parameter 48 ...................................................................................................... 169
Description of parameter 49 ...................................................................................................... 170
Description of parameter 50 ...................................................................................................... 170
Description of parameter 51 ...................................................................................................... 171
Description of parameter 52 ...................................................................................................... 171
Description of parameter 53 ...................................................................................................... 171
Description of parameters A to P .............................................................................................. 172
Description of parameter A ....................................................................................................... 172
Description of parameter b ........................................................................................................ 175
Description of parameter C ....................................................................................................... 177
Description of parameter d ........................................................................................................ 178
Description of parameter E ....................................................................................................... 180
Description of parameter F........................................................................................................ 180
Description of parameter G ....................................................................................................... 182
Description of parameter H ....................................................................................................... 183
Description of parameter J ........................................................................................................ 184
Description of parameter L ........................................................................................................ 186
Description of parameter O ....................................................................................................... 187
Description of parameter P ....................................................................................................... 188
Functions/operations using PROFIBUS PA ..........................................................................................191
10.1
System integration .................................................................................................................... 191
10.2
10.2.1
10.2.2
10.2.2.1
10.2.2.2
Acyclic data transfer .................................................................................................................. 191
Acyclic data transfer using SIMATIC PDM ............................................................................... 191
"Device" menu ........................................................................................................................... 192
Communication path ................................................................................................................. 192
Load into devices ...................................................................................................................... 192
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10.2.2.3 Load into PG/PC ........................................................................................................................192
10.2.2.4 Update diagnostics status ..........................................................................................................192
10.2.2.5 Set address ................................................................................................................................193
10.2.2.6 Operation ...................................................................................................................................193
10.2.2.7 Simulation ..................................................................................................................................196
10.2.2.8 Partial stroke test (PST) .............................................................................................................197
10.2.2.9 PST trace characteristic .............................................................................................................197
10.2.2.10
Status monitoring ..................................................................................................................198
10.2.2.11
Initialization parameters ........................................................................................................198
10.2.2.12
Initialization ...........................................................................................................................199
10.2.2.13
Reset PDM parameters ........................................................................................................200
10.2.2.14
Reset the field device............................................................................................................200
10.2.2.15
Write lock ..............................................................................................................................201
10.2.3 "View" menu ...............................................................................................................................201
10.2.3.1 Measured value display .............................................................................................................201
10.2.3.2 Characteristic .............................................................................................................................202
10.2.3.3 Device status..............................................................................................................................202
10.2.3.4 Maintenance information ............................................................................................................203
10.2.3.5 Trend characteristic ...................................................................................................................204
10.2.3.6 Histograms .................................................................................................................................205
10.2.3.7 Adjusting the view of SIMATIC PDM .........................................................................................205
10.3
10.3.1
10.3.2
10.3.3
10.3.3.1
10.3.3.2
10.3.4
10.3.4.1
10.3.4.2
10.3.4.3
10.3.4.4
10.3.4.5
10.3.4.6
Cyclic data transfer ....................................................................................................................206
Cyclic data transfer ....................................................................................................................206
Configuration ..............................................................................................................................206
Useful data through PROFIBUS ................................................................................................209
Possible combinations of the useful data ..................................................................................211
Diagnostics .................................................................................................................................216
Adjustable status (condensed status) ........................................................................................217
Diagnostics messages in case of deactivated condensed status..............................................220
Diagnostics messages in case of activated condensed status ..................................................222
Definition of the status ...............................................................................................................224
Sub-status for deactivated condensed status ............................................................................225
Sub-status for activated condensed status ................................................................................226
List of diagnostics events with status and diagnostics message for deactivated
condensed status .......................................................................................................................226
10.3.4.7 List of diagnostics events with status and diagnostics message for activated condensed
status ..........................................................................................................................................229
11
Alarm, fault and system messages ...................................................................................................... 233
11.1
11.1.1
11.1.2
11.1.3
11.1.4
Representation of system messages on the display .................................................................233
System messages before initialization .......................................................................................233
System messages during initialization .......................................................................................234
System messages when exiting the Configuration mode ..........................................................237
System messages during operation...........................................................................................238
11.2
11.2.1
11.2.2
11.2.3
Diagnostics .................................................................................................................................241
Display of diagnostics values .....................................................................................................241
Overview of diagnostics values..................................................................................................242
Meaning of the diagnostics values .............................................................................................244
11.3
11.3.1
11.3.2
Online diagnostics ......................................................................................................................251
Overview of online diagnostics ..................................................................................................251
Overview of error codes .............................................................................................................251
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13
14
15
11.3.3
11.3.4
XDIAG parameter ...................................................................................................................... 253
Meaning of error codes ............................................................................................................. 253
11.4
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
Fault correction ......................................................................................................................... 256
Fault identification ..................................................................................................................... 256
Remedial measures table 1 ...................................................................................................... 257
Remedial measures table 2 ...................................................................................................... 258
Remedial measures table 3 ...................................................................................................... 259
Remedial measures table 4 ...................................................................................................... 260
Remedial measures table 5 ...................................................................................................... 260
Service and maintenance .....................................................................................................................263
12.1
Basic safety instructions ............................................................................................................ 263
12.2
12.2.1
12.2.2
Cleaning of the screens ............................................................................................................ 265
Positioner in macrolon enclosure .............................................................................................. 265
Positioner in stainless steel, aluminum and flameproof aluminum enclosure .......................... 266
12.3
Repair/Upgrading ...................................................................................................................... 266
12.4
Return procedure ...................................................................................................................... 267
Technical data .....................................................................................................................................269
13.1
Rated conditions ....................................................................................................................... 269
13.2
Pneumatic data ......................................................................................................................... 270
13.3
Construction .............................................................................................................................. 271
13.4
Controller ................................................................................................................................... 273
13.5
Certificates, approvals, explosion protection for all device versions ........................................ 273
13.6
Electrical specifications ............................................................................................................. 275
13.7
Technical data for natural gas as actuator medium .................................................................. 277
13.8
13.8.1
13.8.2
13.8.3
13.8.4
13.8.5
13.8.6
13.8.7
13.8.7.1
13.8.7.2
13.8.7.3
Option modules ......................................................................................................................... 278
Alarm module ............................................................................................................................ 278
Iy module ................................................................................................................................... 280
SIA module ................................................................................................................................ 281
Limit value contact module........................................................................................................ 282
EMC filter module ...................................................................................................................... 283
Non-contacting position sensor ................................................................................................. 284
External position sensing system .............................................................................................. 285
Operating conditions for all device versions ............................................................................. 285
Constructional design for all device versions ............................................................................ 286
Certificates, approvals, explosion protection for all device versions ........................................ 286
Dimension drawings .............................................................................................................................289
14.1
Positioner with Makrolon enclosure 6DR5..0 and stainless steel enclosure 6DR5..2 .............. 289
14.2
Terminal strip for positioner with Macrolon enclosure .............................................................. 290
14.3
Positioner with aluminum enclosure 6DR5..1 ........................................................................... 291
14.4
Positioner with flameproof enclosure 6DR5..5 .......................................................................... 292
Spare parts/accessories/scope of delivery............................................................................................293
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A
B
15.1
Overview ....................................................................................................................................293
15.2
Spare parts .................................................................................................................................295
15.3
Scope of delivery of small part sets ...........................................................................................296
15.4
Scope of delivery of external position detection system ............................................................298
15.5
Scope of delivery of mechanical limit switch module .................................................................298
15.6
Scope of delivery EMC filter module ..........................................................................................299
15.7
Accessories ................................................................................................................................300
Appendix............................................................................................................................................. 301
A.1
Operation with boosters .............................................................................................................301
A.2
Certificates .................................................................................................................................302
A.3
Literature and catalogs ..............................................................................................................302
A.4
Technical support .......................................................................................................................303
Abbreviations ...................................................................................................................................... 305
B.1
Abbreviations for PS2 positioners ..............................................................................................305
Glossary ............................................................................................................................................. 309
Index................................................................................................................................................... 317
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Operating Instructions, 10/2013, A5E00127926-09
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 code
10/2013
From FW 5.00.05
The most important changes in the documentation as compared to the respective previous
edition are given in the following table.
Edition
Remark
10/2013
•
Safety information updated throughout the entire instructions.
•
Chapter 3 "Description" > 3.2 "Structure (Page 19)": Nameplates revised.
•
Chapter 4 "Mounting":
–
Chapters 4.2 "Mounting the linear actuator (Page 38)" and 4.3 "Mounting the partturn actuator (Page 44)" restructured.
–
Chapter 4.5 "Position controllers subjected to fast acceleration or strong vibration
(Page 49)" graphics and text supplemented.
–
Chapter 4.7.5 "Mechanical limit switch module (Page 65)" extended.
•
Chapter 5 "Connect (Page 73)"
•
Chapter 8 "Functional safety (Page 139)"
•
Chapter 13 "Technical data (Page 269)": Restructured and content changes
•
Chapter 14 "Dimension drawings (Page 289)": Some dimensions changed. New
graphic in Chapter 14.4 "Positioner with flameproof enclosure 6DR5..5 (Page 292)"
new graphic.
•
Chapters 15.4 "Scope of delivery of external position detection system (Page 298)",
15.5 "Scope of delivery of mechanical limit switch module (Page 298)" and 15.6
"Scope of delivery EMC filter module (Page 299)" are new.
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Introduction
1.3 Purpose
See also
Certificates, approvals, explosion protection for all device versions (Page 273)
Construction (Page 271)
Option modules (Page 278)
1.3
Purpose
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic drives in the following industries.
● Chemicals
● Oil and gas
● Energy production
● Food and beverages
● Pulp and paper
● Water/waste water
● Pharmaceutical industry
● Offshore plants
Operate the device according to the specifications in Chapter "Technical data (Page 269)".
For additional information, refer to the operating instructions for the device.
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.
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Introduction
1.5 Transportation and storage
1.5
Transportation and storage
To guarantee sufficient protection during transport and storage, observe the following:
● Keep the original packaging for subsequent transportation.
● Devices/replacement parts should be returned in their original packaging.
● If the original packaging is no longer available, ensure that all shipments are properly
packaged to provide sufficient protection during transport. Siemens cannot assume
liability for any costs associated with transportation damages.
CAUTION
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
• Provide additional packaging as necessary.
Special conditions for storage and transportation of the device are listed in "Technical data"
(Page 269).
1.6
Product information
The programming manual is an integral part of the CD, which is either supplied or can be
ordered. The programming manual is also available on the Siemens homepage.
On the CD, you will also find the catalog extract with the ordering data, the Software Device
Install for SIMATIC PDM for additional installation, and the required software.
See also
SIPART PS2 product information (http://www.siemens.com/sipartps2)
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
1.7
Notes on warranty
The contents of this manual shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. The sales contract contains all obligations on
the part of Siemens as well as the complete and solely applicable warranty conditions. Any
statements regarding device versions described in the manual do not create new warranties
or modify the existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right
to make technical changes in the course of further development.
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Introduction
1.7 Notes on warranty
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Safety information
2.1
Prerequisites for safe use
This device left the factory in good working condition. In order to maintain this status and to
ensure safe operation of the device, observe these instructions and all the specifications
relevant to safety.
Observe the information and symbols on the device. Do not remove any information or
symbols from the device. Always keep the information and symbols in a completely legible
state.
2.1.1
Warning symbols on the device
Symbol
Meaning
Consult operating instructions
Hot surface
Isolate the device from power using a circuit-breaker
Protect the device from shocks (otherwise the specified
degree of protection is not guaranteed)
Protective insulation; device in protection class II
2.1.2
Laws and directives
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation. These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)
● Canadian Electrical Code (CEC) (Canada)
Further provisions for hazardous area applications are for example:
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Safety information
2.2 Improper device modifications
● IEC 60079-14 (international)
● EN 60079-14 (EC)
2.1.3
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following
European guidelines:
Electromagnetic
Compatibility EMC
2004/108/EC
Directive of the European Parliament and of the Council on the
approximation of the laws of the Member States relating to
electromagnetic compatibility and repealing Directive
89/336/EEC.
Atmosphère explosible
ATEX
94/9/EC
Directive of the European Parliament and the Council on the
approximation of the laws of the Member States concerning
equipment and protective systems intended for use in
potentially explosive atmospheres.
The applied standards can be found in the EC conformity declaration of the device.
See also
Certificates (http://www.siemens.com/processinstrumentation/certificates)
2.2
Improper device modifications
WARNING
Improper device modifications
Danger to personnel, system and environment can result from modifications to the device,
particularly in hazardous areas.
• Only carry out modifications that are described in the instructions for the device. Failure
to observe this requirement cancels the manufacturer's warranty and the product
approvals.
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Safety information
2.3 Requirements for special applications
2.3
Requirements for special applications
Due to the large number of possible applications, each detail of the described device
versions for each possible scenario during commissioning, operation, maintenance or
operation in systems cannot be considered in the instructions. If you need additional
information not covered by these instructions, contact your local Siemens office or company
representative.
Note
Operation under special ambient conditions
We highly recommend that you contact your Siemens representative or our application
department before you operate the device under special ambient conditions as can be
encountered in nuclear power plants or when the device is used for research and
development purposes.
2.4
Use in hazardous areas
Qualified personnel for hazardous area applications
Persons who install, connect, commission, operate, and service the device in a hazardous
area must have the following specific qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures,
aggressive, and hazardous media.
● They are authorized, trained, or instructed in carrying out work on electrical circuits for
hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the pertinent safety regulations.
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and
labelled accordingly.
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Safety information
2.4 Use in hazardous areas
WARNING
Loss of safety of device with type of protection "Intrinsic safety Ex i"
If the device has already been operated in non-intrinsically safe circuits or the electrical
specifications have not been observed, the safety of the device is no longer ensured for use
in hazardous areas. There is a danger of explosion.
• Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe
circuit.
• Observe the specifications for the electrical data on the certificate and in Chapter
"Technical data".
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Description
3.1
3
Function
● The electropneumatic positioner and an actuator form a control system. The current
position of the actuator is recorded by a servo potentiometer and the actual value x is fed
back. The setpoint and the actual value are also shown simultaneously on the display.
● The reference variable w is provided digitally through the PROFIBUS.
● The positioner works as a predictive five-point positioner, through whose output value
±Δy the integrated valves can be controlled by pulse length modulation.
● These input signals change pressure in the actuator chamber(s) and displace the
actuator until the control deviation becomes zero.
● Using the three buttons and the display with the enclosure cover removed, operation
(manual mode) and configuration (structuring, initialization, and parameter assignment)
can be performed.
● The standard controller has one binary input (BE1) by default. This binary input can be
individually configured and used, for example, to block the control levels.
● It has a friction clutch and a switchable gear so that the positioner can be used with
different mechanical part-turn and linear actuators.
3.2
Structure
3.2.1
Design overview
The mechanical and electrical assembly, the device components and functional principle of
the positioner are described in the following chapter.
The positioner and the PROFIBUS PA communication interface function as components in a
digital process automation system. It functions as a slave and communicates with the master
through the PROFIBUS PA fieldbus. Apart from communication, the fieldbus also supplies
electrical auxiliary power to the positioner.
The positioner is available in the following configurations:
● For single-acting actuators: In Makrolon, stainless steel or aluminum enclosure, as well
as flameproof aluminum enclosure
● For double-acting actuators: In Makrolon, stainless steel or aluminum enclosure, as well
as flameproof aluminum enclosure
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Description
3.2 Structure
● For non-hazardous applications
● For hazardous applications in the versions
– Intrinsic safety type of protection
– Flameproof enclosure type of protection
– Non-sparking type of protection
– Dust protection by enclosure type of protection
The positioner is used to move and control pneumatic actuators. The positioner works
electropneumatically; compressed air is used as an auxiliary power supply. The positioner is
used to control valves with:
● Linear actuator
● Part-turn actuator VDI/VDE 3845
Difference attachment extensions are available for linear actuators:
● NAMUR or IEC 534
● Integrated attachment to ARCA
● Integrated attachment to SAMSON in the non-flameproof enclosure
①
②
③
④
⑤
Pressure gauge block, single-acting
Valve
Yoke / actuator yoke
Single-acting positioner in non-flameproof aluminum enclosure
Actuator
Figure 3-1
Positioner attached to a single-acting linear actuator
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Description
3.2 Structure
①
②
③
Part-turn actuator
Pressure gauge block, double-acting
Double-acting positioner in macrolon enclosure
Figure 3-2
①
②
③
④
Positioner attached to double-acting part-turn actuator
Single-acting positioner in flameproof aluminum enclosure
Pressure gauge block, single-acting
Yoke / actuator yoke
Actuator
Figure 3-3
Positioner in flameproof aluminum enclosure attached to linear actuator
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Description
3.2 Structure
①
②
③
Part-turn actuator
Double-acting positioner in flameproof aluminum enclosure
Pressure gauge block, double-acting
Figure 3-4
3.2.2
Positioner in flameproof aluminum enclosure attached to part-turn actuator
Nameplate layout
Design of the nameplate
①
②
③
④
⑤
⑥
⑦
Manufacturer
Consult operating instructions
Safety class
Conformity with country-specific directives
Built-in option module
Manufacturer serial number
⑧
⑨
⑩
⑪
⑫
⑬
Software version
Place of manufacture
Auxiliary power
Ordering supplement (Order code)
Order no.
Product name
Auxiliary power (air supply)
Figure 3-5
Nameplate_design, example
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Description
3.2 Structure
Layout of Ex nameplate
①
②
Approvals
ATEX/IECEX marking for hazardous area
Figure 3-6
3.2.3
③
④
FM/CSA marking for hazardous area
Permissible ambient temperature for the
hazardous area of the corresponding
temperature class
Layout of Ex nameplate
Explanation of Ex information
Explanation of Ex information
①
Category for operating range
④
②
③
Type of protection
⑤
Maximum surface temperature
(temperature class)
Device protection level
Group (gas, dust)
Figure 3-7
Explanation of Ex information
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Description
3.3 Device components
3.3
Device components
3.3.1
Overview of device components
①
②
③
④
⑤
⑥
⑦
⑧
Bus cable
Restrictor Y1 for single-acting actuators
Buttons
⑩
⑪
⑫
⑬
⑭
⑮
⑯
⑰
⑨
Restrictor Y2 for double-acting actuators
⑱
Cable gland
Wiring diagram on module cover
Display
Purging air selector
Output: Actuating pressure Y1
Input: Supply air
Output: Actuating pressure Y2
Figure 3-8
Restrictor Y1 for double-acting actuators
Exhaust air outlet with a sound absorber
Transmission ratio selector
Friction clutch adjustment wheel
Basic electronics
Connecting terminals of option modules
Shield connection (only with a Makrolon
enclosure)
View of the positioner (cover open; Makrolon enclosure)
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Description
3.3 Device components
①
②
③
④
⑤
⑥
Input: Supply air
Output: Actuating pressure Y1
Display
Output: Actuating pressure Y2 1)
Buttons
Transmission ratio selector 2)
1)
for double-acting actuators
2)
only possible when positioner is open
Figure 3-9
⑦
⑧
⑨
⑩
⑪
⑫
Restrictor Y1
Restrictor Y2 1)
Friction clutch adjustment wheel
Connecting terminals of option modules
Connecting terminals of basic device
Safety catch
View of positioner in flameproof enclosure
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Description
3.4 Functional principle
3.3.2
Basic electronics
Figure 3-10
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
3.4
Functional principle
The electropneumatic positioner and an actuator form a control system. The current position
of the actuator is recorded by a servo potentiometer and the actual value x is fed back. The
setpoint and the actual value are shown simultaneously on the display.
The control system provides the setpoint digitally to the positioner through the fieldbus. The
bus interface of the fieldbus version of the positioner differs from the previous versions.
However, the basic functions of the positioner as well as the operation and the display are
almost unchanged.
The lifting or rotary movement of the actuator is transferred to a potentiometer using suitable
attachments, positioner axis and a backlash-free, switchable gear drive, and then to the
analog input of the microcontroller. The current position can also be forwarded to the
positioner using an external sensor. A Non-Contacting Position Sensor (NCS) is used to
record the lifting or rotation angle directly on the actuator.
The microcontroller:
● Corrects the angle error of the shaft pick-up if necessary.
● Compares the potentiometer voltage as actual value x with the setpoint w. The setpoint w
is connected to terminals 6 and 7 by means of PROFIBUS communication.
● Calculates the manipulated variable increments ±∆y.
The piezo-controlled inlet or exhaust air valve is opened depending on the magnitude and
direction of the control deviation (x-w). The actuator volume integrates the controller
increment for the actuating pressure y which is proportional to the drive rod or the drive
shaft. This controller increment change the actuating pressure until the control deviation
becomes zero.
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Description
3.4 Functional principle
3.4.1
Pneumatic actuator
Pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is ventilated and depressurized. The pressure
developed works against a spring. In a double-acting version, two pressure chambers work
against each other. Ventilating the volume of one chamber simultaneously depressurizes the
volume of the other.
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 3-11
Functional principle of five-point controller
Small control deviations do not send control pulses in the zone. This takes place in the socalled adaptive deadband. The deadband adaptation and the continuous adaptation of
minimum pulse lengths in 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
The number of fault messages, changes in direction and the stroke number are continuously
determined during operation and saved after every 15 minutes. You can read and document
these parameters using communication programs such as PDM and AMS. By comparing the
old values with the current ones, you can draw conclusions about the wear and tear of the
control valve. You can use the diagnostics function for this.
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Description
3.4 Functional principle
3.4.3
PROFIBUS system configuration
Overview
The positioner can be used in a number of system configurations.
Use with the SIMATIC PCS 7 Automation System is described below.
System communication
The Operator Station of the SIMATIC PCS 7 process control system allows easy and safe
control of the process by the operating personnel using OS Multi-Clients.
The Maintenance Station assists the maintenance engineer in guaranteeing high plant
availability, securing this long-term using optimization measures, and implementing the
maintenance measures using a minimum of personnel, materials, energy, costs etc.
The field devices are integrated over PROFIBUS PA with:
● PA Link to the gateway between PROFIBUS PA and PROFIBUS DP
● Control system, e.g. SIMATIC PCS 7 Automation System, which communicates over
PROFIBUS
● Engineering Station, SIMATIC PDM (Process Device Manager) which communicates
over Industrial Ethernet
Figure 3-12
Typical system configuration
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Description
3.5 PROFIBUS PA
3.4.4
SIMATIC PDM
SIMATIC PDM is a software package for configuring, parameter assignment, commissioning,
diagnostics and maintenance of this device and other process devices.
SIMATIC PDM offers simple monitoring of process values, alarms, and device status
information.
SIMATIC PDM allows the process device data to be:
● displayed
● set
● modified
● saved
● diagnosed
● checked for plausibility
● managed
● simulated
3.5
PROFIBUS PA
3.5.1
Overview
The Process Fieldbus (PROFIBUS) is an open communications system for automation
technology and is specified in the international standard IEC 61158.
PROFIBUS Process Automation (PROFIBUS PA) is a variant of PROFIBUS Decentral
Peripherals (PROFIBUS DP), which is widely used in process technology.
3.5.2
Transmission technology
PROFIBUS PA uses a special transmission technology, enabling it to fulfill the requirements
of process automation and process technology. This transmission technology is defined in
the international standard IEC 61158-2. The low transmission rate reduces the power loss in
comparison to PROFIBUS DP, enabling an intrinsically safe technology for use in hazardous
zones with explosive atmospheres. The PROFIBUS PA and PROFIBUS DP protocols are
identical.
3.5.3
Bus topology
The bus topology is mainly able to be selected as desired. Therefore, line, star and tree
structures, and mixed forms are possible. All types of field devices such as transmitters,
actors, analysis devices, etc. can be connected to the PROFIBUS PA.
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Description
3.5 PROFIBUS PA
Advantages include:
● Savings on installation costs
● More extensive diagnostics, leading to increased availability of installation sections
● Automatic management of installation documentation
● Installation optimization on the fly during operation
In an automation system, there are generally multiple PROFIBUS PA lines connected to fast
PROFIBUS DP via coupler units. This is also connected to the process control system.
Both bus systems use the same protocol layer. This makes PROFIBUS PA a
"communications-compatible" extension of the PROFIBUS DP into the field.
Figure 3-13
Functional principle of the PROFIBUS automation system
The figure shows a section of a typical PROFIBUS automation system. The control system
consists of two masters with distributed tasks.
The class-1 master recognizes the control and regulation tasks. The class-2 master enables
the operating and monitoring functions. Between the class-1 master and the field devices
there is a periodic exchange of measurement and settings data. The status information from
the field devices is transmitted parallel to this data, and evaluated in the class-1 master.
Assignment of parameters for the field devices or the reading of additional device information
is not performed during periodic operation.
Besides periodic operation, one or more class-2 masters can access the field devices
asynchronously. Using this type of communication, additional information can be retrieved
from the devices or settings sent to them.
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Description
3.5 PROFIBUS PA
3.5.4
Properties
PROFIBUS PA allows bidirectional communication between a bus master and field devices.
At the same time, the shielded two-strand wiring provides auxiliary power to the two-wire
field devices.
3.5.5
Profile
As an extension to the EN 50170 standard, the PROFIBUS user organization (PNO) defined
the functionality of the individual field device types in a so-called profile description. This
profile determines minimum functional requirements and optional extensions. The deviceinternal "Device Management" provides the configuration tool of the control system with all
necessary basic information to find profile parameters. One parameter assignment tool
serves all profile-conforming devices, regardless of type or manufacturer.
Depending on the size of the installation (and therefore the number of field devices) and the
time behavior required, you implement the system with one or more PROFIBUS PA strands.
One PROFIBUS PA strand consists of the components shown in the following figure.
FD
Field device
PC
Personal Computer
T
Terminating resistor
PCS
Process control system
Figure 3-14
PROFIBUS PA strand
Reference
PNO PROFIBUS-PA interest group
3.5.6
Connection
Control is performed by the central process control system (PCS) or by a PC for lowerperformance requirements.
In general, the following functions are combined into one coupling assembly:
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Description
3.5 PROFIBUS PA
● DP/PA signal transfer
● Bus power
● Bus termination
Depending on the number of the PROFIBUS PA field devices to be operated in the
automation system and the time behavior required, a DP/PA coupler or a DP/PA link is used.
For standard requirements, you use a DP/PA coupler; for higher requirements, a more
powerful DP/PA link.
For reasons related to transmission technology, the bus is also equipped on the far end with
a terminating resistance T. When using the recommended bus cable, the theoretical
maximum cable length is 1900 meters. The theoretical maximum cable length is the sum of
all cable segments. During planning, also take into account the voltage drop over the wires
powering the field devices.
However, the power requirements of the individual nodes and the voltage drop on the cable
must also be calculated during projection. The individual field devices (FD) can be connected
at nearly any point in the bus system.
DP/PA couplers or DP/PA links are supplied using a safety extra-low voltage (SELV) power
supply. This power supply must have sufficient reserves to bridge over temporary power
failures.
The maximum number of devices which can be connected to one bus strand depends on
their power consumption and the conditions of use. When operated in the safe zone, the
couplers or links supply the bus with up to 400 mA.
When operated in explosive atmospheres, intrinsic safety is only guaranteed if all devices,
components, etc. connected to the bus (e.g. bus terminator) fulfill the following requirements:
● They are certified as intrinsically safe equipment.
● They fulfill the requirements of the FISCO model (Fieldbus Intrinsic Safety Concept).
Power supply devices in particular (bus couplers) must be certified as so-called FISCO
power supplies. Observe the safety-relevant maximum values and other specifications of the
EG type test certificate.
Connect power supplies (bus couplers) which are not explosion protected and certified to
intermediate EX-certified zener barriers. Observe the specifications of the EG type test
certificate.
WARNING
For power supply to intrinsically safe PROFIBUS, use only power supplies, DP/PA
couplers, or DP/PA links certified as compliant with the FISCO model.
Switch through zener barriers if using non-EX-protected power supplies. See the
requirements of the EG type test certificate.
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Description
3.5 PROFIBUS PA
3.5.7
Number of connectable devices
The number of devices which can be connected to a bus strand can be calculated from the
sum of the maximum power consumption of the devices and the power available. By default,
assume 10 mA per device. For safety reasons, plan for a power reserve. Otherwise you run
the risk of a defective device overloading the bus with an increased power consumption. This
can interrupt the power supply and communication with the functioning nodes. The amount
of power reserved is based on the nominal power increase given by the manufacturer in
case of failure.
3.5.8
Assigning the device addresses
So that the connected process devices can be distinguished from one another, each device
has its own address.
Be sure that the device addresses are set before operating two or more field devices on the
bus. Each address may only be given once to make sure they are unique.
Principally, the address range is from 1 to 125. The address 126 is set for the delivery state.
Normally, masters in PROFIBUS systems receive lower addresses. Therefore, we
recommend starting at 30 when assigning addresses to the positioners. Either use the keys
on the positioner or the SIMATIC PDM software via the bus to set the addresses. In the last
case, a new positioner is always connected to the bus and the new address is set via the
software. The next positioner is then connected to the bus and processed the same way.
We recommend writing the set address on the field device with a wipe resistant pen.
See also
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
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Description
3.5 PROFIBUS PA
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Installing/mounting
4.1
4
Basic safety instructions
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and
labelled accordingly.
WARNING
High operating force with pneumatic drives
Risk of injury when working on control valves due to the high operating force of the
pneumatic drive.
• 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 drive.
• Do not reach into the range of motion of the lever following mounting of the positioner
and mounting kit.
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
• Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
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Installing/mounting
4.1 Basic safety instructions
WARNING
It is possible to damage the cover gasket
If the cover gasket is not positioned correctly in the groove of the base plate, it could be
damaged when the cover is mounted and screwed tight.
• Therefore make sure that the gasket is seated correctly.
WARNING
Open cable inlet or incorrect cable gland
Danger of explosion in hazardous areas.
• Close the cable inlets for the electrical connections. Only use cable glands or plugs
which are approved for the relevant type of protection.
See also
Construction (Page 271)
WARNING
Exceeded maximum ambient or process media temperature
Danger of explosion in hazardous areas.
Device damage.
• Make sure that the maximum permissible ambient and process media temperatures of
the device are not exceeded. Refer to the information in Chapter "Technical data
(Page 269)".
CAUTION
Unsuitable compressed air
Device damage. As a general rule, the positioner must only be operated with dry and clean
compressed air.
• Use the customary water separators and filters. An additional dryer is required in
extreme cases.
• Use dryers, especially if you operate the positioner at low ambient temperatures.
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Installing/mounting
4.1 Basic safety instructions
CAUTION
Please note the following before working on the control valve and when attaching the
positioner
Danger of injury.
• Prior to working on the control valve, you must move the control valve into a completely
pressureless state. Proceed as follows:
– Depressurize the drive chambers.
– Switch off the supply air Pz.
– Lock the valve in its position.
• Make sure that the valve has reached the pressureless state.
• If you interrupt the pneumatic auxiliary power to the positioner, the pressureless position
may only be reached after a certain waiting time.
• When mounting, observe the following sequence imperatively to avoid injuries or
mechanical damage to the positioner/mounting kit:
– Mount the positioner mechanically.
– Connect the electrical auxiliary power supply.
– Connect the pneumatic auxiliary power supply.
– Commission the positioner.
WARNING
Mechanical impact energy
Protect the 6DR5...0-.G...-.... version of the positioner from mechanical impact energy
greater than 1 joule; this ensures adherence to the IP66 degree of protection.
NOTICE
Impact energy and torque
For versions 6DR5a.b-.Gc..-...., where a = 0, 2, 5, 6; b = 0, 1; c = G, N, M, P, Q, the
following is applicable:
The device must be protected against power surges of over one joule.
For versions 6DR5a.b-.Gc..-...., where a = 0, 2, 5, 6; b = 0; c = G, N, M, P, Q, the following
is applicable:
The maximum torque on the thread of the cable gland should not exceed 67 Nm.
See also
Construction (Page 271)
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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 269)", 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 269)" 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 chapter describes how to connect the positioner to the actuator using the mounting kit
6DR4004-8V. You require different installation parts of this mounting kit depending on the
selected actuator type. All installation parts listed in the following table are included in the
product package of the mounting kit 6DR4004-8V. The mounting kit is suitable for a stroke of
3 to 35 mm. For a larger stroke range, you require a lever 6DR4004-8L which is to be
ordered separately. Keep the suitable installation parts ready:
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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
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4.2 Mounting the linear actuator
Procedure
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. No.
Quantity
Name
Note
①
1
NAMUR mounting bracket
IEC 60534
Standardized connection point for mount with fin, column or plane
surface
②
1
Pick-up bracket
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 3 mm to 35 mm
⑦
2
U–bolts
Only for actuators with columns
⑧
4
Hexagon bolt
M8x20 DIN 933–A2
⑨
2
Hexagon bolt
M8x16 DIN 933–A2, torque see the chapter "Technical
specifications > Construction (Page 271)"
⑩
6
Spring lock washer
A8 - DIN 127–A2
⑪
6
Washer
B8.4 - DIN 125–A2
⑫
2
Washer
B6.4 - DIN 125–A2
⑬
1
Spring
VD-115E 0.70 x 11.3 x 32.7 x 3.5
⑭
1
Spring lock washer
A6 - DIN 137A–A2
⑮
1
Lock washer
3.2 - DIN 6799–A2
⑯
3
Spring lock washer
A6 - DIN 127–A2
⑰
3
Socket cap screw
M6x25 DIN 7984–A2
⑱
1
Hexagon nut
M6 - DIN 934–A4
⑲
1
Square nut
M6 - DIN 557–A4
⑳
4
Hexagon nut
M8 - DIN 934–A4
*)
The lever 6DR4004–8L is additionally required for ranges of stroke
> 35 mm to 130 mm (not included in the scope of delivery).
*)
the serial numbers refer to the images of the description of the installation steps below.
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4.2 Mounting the linear actuator
1. Install the clamping pieces ③ on the actuator spindle. Use spring lock washers ⑯ and
socket cap screws ⑰ for this purpose.
2. Slide the pick-up bracket ② into the milled recesses of the clamping pieces ③.
Figure 4-1
Pick-up bracket
3. Set the necessary length.
4. Tighten the screws ⑰ so that you can still shift the pick-up bracket.
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. If you need the value of actuator travel after initialization in mm: ensure that the
configured stroke value matches the value of the "3.YWAY" parameter.
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4.2 Mounting the linear actuator
7. Install the following components on the lever ⑥: Socket cap screw ⑰, spring lock
washer ⑯, flat washer ⑫, square nut ⑲.
Figure 4-3
Components on the lever
8. Push the pre-installed lever ⑥ up to the 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 in non-flameproof enclosure
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4.2 Mounting the linear actuator
Figure 4-5
Linear actuator in flameproof enclosure
10.Select the row of holes. The selection of the row of holes depends on the yoke width of
the actuator. Select the row of holes such that the carrier pin ④ meshes with the pick-up
bracket ② near the spindle. Ensure that the pick-up bracket ②does not touch the
clamping pieces③.
11.Keep the positioner and the fastening bracket on the actuator. Ensure that the carrier pin
④ is guided inside the pick-up bracket ②.
12.Tighten the pick-up bracket ② .
13.Fasten the positioner on the yoke. Use the installation parts suitable for the
corresponding actuator.
Note
Height adjustment of the positioner
When you fasten the positioner on the yoke, the following applies for its height
adjustment:
1. Set the height of the positioner such that the horizontal lever position is near the
center of the stroke.
2. Orient yourself by the lever scale of the actuator.
3. If symmetrical mounting is not possible, you must always ensure that the horizontal
lever position is maintained within the range of stroke.
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4.3 Mounting the part-turn actuator
4.3
Mounting the part-turn actuator
Requirements
You require an actuator-specific VDI/VDE 3845 mount to install the positioner on a part-turn
actuator. 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 actuator position, consists of scale ⑤ and pointer mark
④
8
Scale
Different divisions
⑤
1
Pointer mark
Reference arrow for scale
Mount
Actuator-specific, VDI/VDE 3845
⑥
⑥
⑦
4
Hexagon bolt
M6x12 DIN 933, torque see the chapter "Technical specifications >
Construction (Page 271)"
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 images describing the assembly procedure for a part-turn actuator, with and without
flameproof enclosure.
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4.3 Mounting the part-turn actuator
1. Rest the actuator-specific VDI/VDE 3845 mount ⑥ on the rear side of the positioner.
Tighten the mount using the hexagon bolts ⑦ and lock washers ⑧.
2. Stick the pointer mark ⑤ on the mount. Position the pointer mark at the center of the
centering hole.
Non-flameproof enclosure
Flameproof enclosure
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).
Coupling, non-flameproof enclosure
Coupling/clutch, flameproof enclosure
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.
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4.3 Mounting the part-turn actuator
Figure 4-6
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.
Actuator, non-flameproof enclosure
Actuator, flameproof enclosure
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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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.
Part-turn actuator in non-flameproof enclosure
Part-turn actuator in flameproof enclosure
H = height of shaft butt
①
②
Fixing level of positioner on mounting plate
Part-turn actuator
Figure 4-7
Dimensions of mounting plate in accordance with VDI/VDE 3845 (depends on actuator)
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4.4 Using the positioner in a humid environment
See also
Preparing part-turn actuators for commissioning (Page 131)
4.4
Using the positioner in a humid environment
Introduction
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. The IP66
degree of protection is no longer adequate in this environment, especially when there is a
risk of water freezing.
Favorable and unfavorable mounting positions
Avoid the unfavorable mounting positions:
● To prevent fluids seeping through during normal operation of the device, e.g. through
exhaust air openings.
● Otherwise the display becomes poorly legible.
Figure 4-8
Favorable and unfavorable mounting positions
Additional measures to prevent liquids from seeping through
Take additional measures to prevent liquids from seeping through if the conditions force you
to operate the positioner in an unfavorable mounting position.
Additional measures required to prevent liquids from seeping through depend on the
selected mounting position. You may also require:
● Gland with sealing ring, e.g. FESTO: CK - 1 / 4-PK-6
● Approximately 20 to 30 cm plastic hose, e.g. FESTO: PUN - 8 x 1.25 SW
● Cable tie; the number and the length depend on the local conditions.
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4.5 Position controllers subjected to fast acceleration or strong vibration
Procedure
1. Install the casing such that rain water or condensate running along the pipes can be
drained before the terminal strip of the positioner.
2. Check the seals of electrical connections for perfect fitting.
3. Check the seal in the enclosure cover for damage and contaminations. Clean and/or
replace if required.
4. Install the positioner such that the sintered bronze attenuator at the bottom side of the
enclosure points downwards in the vertical mounting position. If this is not possible,
replace the attenuator with a suitable gland with a plastic hose.
Procedure for installing the plastic hose on the gland
1. Unscrew the sintered bronze attenuator from the exhaust air opening at the bottom side
of the enclosure.
2. Screw in the aforementioned gland into the exhaust air opening.
3. Install the aforementioned plastic hose into the gland and check whether it fits firmly.
4. Fasten the plastic hose with a cable tie onto the control valve such that the opening
points downwards.
5. Ensure that the plastic hose does not have any kinks and the exhaust air flows out
without any hindrance.
4.5
Position controllers subjected to fast acceleration or strong vibration
4.5.1
Introduction locking the setting
The electropneumatic positioner has an gear latch for the friction clutch and for the
transmission ratio selector.
Strong acceleration forces act on control valves that are subjected to heavy mechanical
loads, e.g. breakaway valves, strongly shaking or vibrating valves, as well as in case of
"vapor shocks". These forces may be much higher than the specified data. This may cause
the friction clutch to move in extreme cases.
The positioner is equipped with an gear latch for the friction clutch to counter these extreme
cases. The setting of the transmission ratio selector can also be locked.
The locking procedure is illustrated and described below.
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4.5 Position controllers subjected to fast acceleration or strong vibration
4.5.2
Procedure locking the setting
Overview diagram
NOTICE
Wrong registration of the rotary or part-turn movement
A different setting of the transmission ratio selector and the gear latch results in a
hysteresis in position registration. The hysteresis in position registration can result in
unstable control behavior of the higher level control loop.
• Make sure the transmission ratio selector ⑤ and the gear latch ① are set to the same
value, either to 33° or to 90°.
①
②
③
④
⑤
Gear latch
Locking transmission ratio to 33°
Neutral position
Locking transmission ratio to 90°
⑥
⑦
⑧
⑨
Friction clutch
Friction clutch latch
Locking friction clutch
Release friction clutch
Transmission ratio selector
Figure 4-9
Locking friction clutch and transmission ratio
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4.5 Position controllers subjected to fast acceleration or strong vibration
Requirements
● The positioner is mounted.
● You know whether the transmission ratio is to be set to 33° or 90°.
● The positioner has been commissioned successfully, i.e. initialization was completed with
"FINISH".
Procedure
NOTICE
The following is applicable for the "flameproof enclosure" version:
• A friction clutch is provided on the outside of the positioner axis. Change the work area
using this friction clutch, legend number ⑨ in "Figure 3-9 View of positioner in
flameproof enclosure (Page 25)".
• Do not open the flameproof enclosure of the positioner in explosion-prone atmospheres.
Fix the setting acquired by initialization as follows:
1. Make sure the gear latch ① is in neutral position ③. The neutral position is between 33°
and 90°.
2. Make sure the transmission ratio selector ⑤ is in the correct position.
3. Fix the transmission ratio with the gear latch ①. Turn the gear latch ① with a standard
approx. 4 mm wide screwdriver until the gear latch ① locks. Turning right locks the
transmission ratio to 33°②. Turning left locks the transmission ratio to 90°④. The
transmission ratio is locked.
Note
Changing the setting of the transmission ratio selector
The setting of the transmission ratio selector ⑤ can only be changed effectively if the
gear latch ① is in the neutral position ③.
4. To fix the friction clutch ⑥ insert a standard approx. 4 mm wide screwdriver in the friction
clutch gear latch ⑦.
5. Use the screwdriver to turn the friction clutch gear latch ⑦ anticlockwise until it engages.
The friction clutch ⑥ is locked.
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4.6 External position detection
4.6
External position detection
WARNING
External position detection system
Versions with flameproof enclosures may not be operated with an external position
detection system.
The aforementioned measures are not adequate in some applications. For example,
continuous and strong vibrations, high or too low ambient temperatures and nuclear
radiation.
The position detection system and the control unit are mounted separately for these
applications. A universal component is available for this purpose. It is suitable for part-turn
and linear actuators. You will require the following:
● An external position detection system with the order number C73451-A430-D78
comprising a positioner enclosure with an integrated friction clutch, potentiometer as well
as different blanking plugs and seals.
● Or a contactless explosion-proof non contacting system (e.g.6DR4004-6N).
● A positioner
● A three-pole cable to connect components.
● An EMC filter module with the order number C73451-A430–D23 is provided in a set along
with cable clamps and M20 cable glands.
The EMC filter module is always used for the control unit whenever an external position
detection system is used instead of the internal position sensor. An external position
detection system is, for example, a potentiometer with a 10 kΩ resistance or a non
contacting system.
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4.7 Installing the optional modules
4.7
Installing the optional modules
4.7.1
General information about the installation of option modules
4.7.1.1
Unsuitable device for the hazardous area
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and
labelled accordingly.
4.7.1.2
Installing optional modules in the standard and intrinsically safe version
The following option modules are available for the positioner in the standard and intrinsically
safe version:
● Iy module
● Alarm module
● SIA module
● Limit contact module
● EMC filter module
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4.7 Installing the optional modules
Overview diagram: Installing optional modules in the standard and intrinsically safe version
①
②
③
Module cover
④
⑤
⑥
⑦
Actuating disk bearings
Fixing screws module cover
Fixing screws basic electronics
Pneumatic block
Special screw
Transmission ratio selector
⑪
⑫
⑬
Iy module
⑭
⑮
⑯
⑰
SIA module or limit contact module
Alarm module
Warning label on the side opposite the
nameplate
Insulating cover
Basic electronics
Ribbon cable/connector for fitted
potentiometer or external position
detection system
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4.7 Installing the optional modules
⑧
Friction clutch adjustment wheel
⑱
⑨
⑩
Nameplate
⑲
⑳
Adapter
Figure 4-10
Ribbon cable/connector for alarm
module, SIA module or limit contact
module
Ribbon cable/connector for Iy module
Wiring diagram
Installing the optional modules in the standard and intrinsically safe version
General procedure for optional modules in the standard and intrinsically safe version
1. Open the positioner. Unscrew the four fixing screws of the enclosure cover.
2. Disconnect the power supply lines or de-energize them.
3. Remove the module cover ①. To do this, unscrew the two screws ②.
4. Install the optional modules as described in the corresponding chapters for the individual
optional modules.
5. Now start with the assembly. Install the module cover①. To this end, turn the screws ②
counter clockwise until they noticeably engage in the thread pitch. The module cover
protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using self-tapping screws. You can prevent the module
cover from wearing untimely by adhering to the installation instructions.
Carefully tighten both screws ② in a clockwise direction.
6. Continue to assemble the positioner by executing steps 3 to 1 in reverse order.
See also
Iy module (Page 59)
Alarm unit (Page 60)
Slotted initiator alarm unit (Page 62)
Mechanical limit switch module (Page 65)
EMC filter module (Page 69)
Label set for mechanical limit switch module (Page 67)
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4.7 Installing the optional modules
4.7.1.3
Installing the optional modules in the "flameproof enclosure" version
Introduction
The following option modules are available for the positioner in the flameproof enclosure:
● Iy module
● Alarm module
● EMC filter module
DANGER
Risk of explosion
You must fulfill the following conditions before supplying auxiliary power to the positioner in
potentially hazardous areas:
• The installed electronic unit has been approved.
• The enclosure of the positioner is closed.
• The duct openings for electronic connections must be closed. Only use the Ex d certified
cable entries or sealing plugs.
• You must install an ignition trap if you use a "conduit piping system". The maximum
distance between the ignition trap and the positioner enclosure is 46 cm or 18".
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4.7 Installing the optional modules
Overview diagram: Installing the optional modules in the "flameproof enclosure" version
①
②
③
Module cover
④
⑤
⑥
⑦
⑧
⑨
⑩
Ribbon cable/connector for alarm module
Fixing screws module cover
Ribbon cable/connector for fitted potentiometer or
external position detection system
Ribbon cable/connector for Iy module
Basic electronics
Alarm module
Iy module
Screw cap
⑪
⑫
⑬
Transmission ratio selector
⑭
⑮
⑯
⑰
⑱
⑲
Friction clutch adjustment wheel
Fixing screws adapter
Safety catch
Feedback shaft
Ring gear
Enclosure
Feedback lever bracket with pin
Pin (feedback lever bracket)
Adapter
Figure 4-11
Installing the optional modules in the "flameproof enclosure" version
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4.7 Installing the optional modules
General procedure for optional modules in the "flameproof enclosure" version
1. Disconnect the power supply lines or de-energize them.
2. Open the safety catch ⑬.
3. Unscrew the screw cap ⑨.
4. Completely dismount the positioner from the actuator.
5. The positioner comes with a ring gear ⑯ and a pin (feedback lever bracket) ⑲ which
interlock and ensure backlash-free position feedback. To ensure backlash-free position
feedback make sure to remove the adapter ⑩ carefully. To this end, turn the feedback
shaft ⑮ at the positioner until the pin (feedback lever bracket) ⑲ below the adapter
shows in the direction of removal. You determine the position of the pin by looking into
the enclosure below the adapter. Now, the pin can be easily removed from the ring gear
⑯.
Note
Damage to the ring gear
The ring gear consists of two washers fastened staggered to each other. This offset
ensures that path detection is backlash-free.
• Do not change this offset mechanically.
6. Unlatch the four fixing screws ⑫.
7. Completely remove the adapter ⑩ from the enclosure ⑰.
NOTICE
Displaced O-rings
There are several O-rings between adapter ⑩ and enclosure ⑰. These O-rings may
come off during removal.
• Carefully remove the adapter. Make sure the O-rings do not get lost during removal.
8. Remove the module cover ①. Unlatch both screws ② using a screwdriver.
9. Install the optional modules as described in the corresponding chapters for the individual
optional modules.
10.Now start with the assembly. Install the module cover①. To this end, turn the screws ②
counter clockwise until they noticeably engage in the thread pitch. The module cover
protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using self-tapping screws. You can prevent the module
cover from wearing untimely by adhering to the installation instructions.
Carefully tighten both screws ② in a clockwise direction.
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4.7 Installing the optional modules
11.Continue to assemble the positioner by performing steps 7 to 5 in reverse order. Check
whether the position of the O-rings is correct. Make sure no loose items in the enclosure
interfere with the assembly.
12.Now check carefully whether the feedback shaft ⑮ can be smoothly turned by 360°.
If you feel resistance, do not continue to turn but turn the feedback shaft ⑮ back again to
the point of removal, making sure to remember the previously performed steps.
13.Once you have completed all previous steps successfully, continue by performing steps 4
to 1 in reverse order.
4.7.2
Iy module
Function
● The optional Iy module indicates the current actuator position as a dual line signal with
Iy = 4 to 20 mA. The Iy module is potentially separated from the basic device. Thanks to
the dynamic control, this module can report the arising operational faults automatically.
● The current actuator position is indicated only after a successful initialization.
Device features
Figure 4-12
Iy module
The Iy module is:
● Single channel
● Potentially separated from the basic device.
Requirements
You are familiar with the general procedure described in the chapter "General information
about the installation of option modules (Page 53)".
Procedure for installing the Iy module
1. Slide the Iy module up to the end stop in the lower stack of the rack.
2. Connect the module to the basic electronics. For this purpose, use the 6-pole flat ribbon
cable provided.
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4.7 Installing the optional modules
4.7.3
Alarm unit
Function
The alarm module triggers fault messages and alarms using binary outputs. The message
function is based on the change in the signal status:
● If the signal status is "HIGH", there is no alarm message and the binary inputs are
conductive.
● If the signal status is "LOW", the module reports an alarm by shutting down binary
outputs using a high-resistance.
● Operational faults are signaled at a high-resistance output. Set the following parameters
to activate and configure the output of alarms and fault messages:
– "AFCT" - Alarm function
– "A1" - Trigger threshold, alarm 1
– "A2" - Trigger threshold, alarm 2
– "FCT" - Fault message output function
– "TIM" - Monitoring time
– "LIM" - Trigger threshold
Apart from binary outputs, the alarm module has a double-acting binary input BE2.
Depending on the selected parameters, it is used to block the actuator or to move it to its
end position. Configure the suitable settings on parameter "BIN2".
Device features
Figure 4-13
Alarm module
The alarm module has the following features:
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● Available in two versions.
– Explosion-proof version for connecting to a switching amplifier in conformity with
EN 60947-5-6.
– Non-explosion-proof version for connecting to power sources having a maximum of
35 V.
● Three binary outputs. Binary inputs are potentially separated from the basic configuration
and from each other.
● The binary input has dual functionality. Both inputs are implemented as logical OR
combination.
– Potentially separated for voltage level
– Not potentially separated for floating contacts
Requirements
You are familiar with the general procedure described in the chapter "General information
about the installation of option modules (Page 53)".
Procedure for installing the alarm module
1. Slide the alarm module into the rack below the basic electronics . Ensure that you slide it
up to the end stop.
2. Connect the module to the basic electronics. For this purpose, use the 8-pole flat ribbon
cable provided.
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4.7.4
Slotted initiator alarm unit
4.7.4.1
SIA module functioning and features
Function
If the standard controller requires electrically independent limit value messages, the slotted
initiator alarm unit with slotted initiators is used instead of the alarm unit.
● A binary output is used to display a collective fault message. Compare with the function of
the alarm unit. The floating binary output is implemented as an automatic fault indicating
semiconductor output.
● The other two binary outputs are used to signal the two limits L1 and L2 which can be
adjusted mechanically using slotted initiators. Both these binary outputs are electrically
independent from the remaining electronic unit.
Device features
①
②
③
Actuating disk bearings
Special screw
Pin
Figure 4-14
④
⑤
⑥
Upper actuating disk for limit L1, terminals 41/42
Lower actuating disk for limit L2, terminals 51/52
Binary inputs
SIA module
The slotted initiator alarm unit, short SIA module, consists of three binary outputs
⑥.
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4.7.4.2
Installing the slotted initiator alarm unit
Requirements
You are familiar with the general procedure described in the chapter "Installing optional
modules in the standard and intrinsically safe version (Page 53)".
Procedure for installing the slot initiator alarm module
1. Disconnect all electrical connections of the basic electronics.
2. Loosen the two fixing screws of the basic electronics.
3. Disengage the basic electronics by carefully bending the four brackets.
4. Insert the SIA module from the top up to the upper printed circuit board guide of the rack.
5. Slide the SIA module in the printed circuit board of the rack approximately 3 mm to the
right.
6. Screw in the special screw ② through the SIA module into the positioner shaft. Tighten
the special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align the pin ③ before it touches the special screw ②.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that
the pin ③ is inserted into the special screw ②.
7. Set the limits L1 and L2 as described in the chapter "Setting the limits of the slotted
initiator alarm unit (Page 64)".
8. An insulating cover is provided over the SIA module. Place the insulating cover on one
side under the basic electronics seat on the module cover. The recesses of the insulating
cover must fit in the corresponding webs of the module cover.
9. Place the insulating cover on the SIA module by bending the module covers carefully.
10.Engage the basic electronics into the four brackets.
11.Fix the basic electronics using both the fixing screws.
12.Reestablish all electrical connections between the basic electronics and the option
modules. Connect the basic electronics and the option modules to the ribbon cables
provided. Connect the basic electronics and the potentiometer to the potentiometer cable.
13.Using both the screws, fasten the module cover provided. Do not use the standard
module cover.
14.Select the labels that already exist on the standard version of the module cover from the
label set provided. Affix the selected labels on the installed module cover as per the
standard version.
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4.7.4.3
Setting the limits of the slotted initiator alarm unit
Procedure: Determining the switch status of the slotted initiators
You will require a suitable display device to determine the switch status. For example, use
the initiator tester type 2 / Ex from Pepperl + Fuchs.
1. Connect the display device to the following terminals of the SIA module:
– 41 and 42
– 51 and 52
2. Read the switch status of slotted initiators.
Procedure: Setting the L1 and L2 limits
The serial numbers in the following text refer to the image in the chapter "SIA module
functioning and features (Page 62)". With linear actuators, proceed as follows to set the
limits:
1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 41 and 42
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc ④ beyond the switching point until you reach the next
switching point.
3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 51 and 52
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc ⑤ beyond the switching point until you reach the next
switching point.
Note
Adjusting the actuating disk
The actuating disks ④ and ⑤ are relatively difficult to move. This design prevents
their unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing friction temporarily.
• Move the actuator to and fro while simultaneously holding the actuating disks ④
and ⑤.
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4.7.5
Mechanical limit switch module
4.7.5.1
Mechanical limit switch module - functioning and features
Function
This module is used to report two limits. These limits are reported using galvanic switching
contacts.
Device features
①
Actuating disk bearings
④
②
Special screw
⑤
③
Pin
Figure 4-15
Upper actuating disk for limit L1,
terminals 41/42
Lower actuating disk for limit L2,
terminals 51/52
Mechanical limit switch module
The mechanical limit switch module consists of:
● One binary output to display a collective fault message. Compare with the device features
of the alarm module.
● Two switches to report two mechanically adjustable limits. Both these switches are
electrically independent from the remaining electronic unit.
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4.7.5.2
Installing the mechanical limit switch module
Requirements
You are familiar with the procedure described in the chapter "Installing optional modules in
the standard and intrinsically safe version (Page 53)".
Procedure for installing the mechanical limit switch module
1. Disconnect all electrical connections of the basic electronics.
2. Loosen the two fixing screws of the basic electronics.
3. Disengage the basic electronics by carefully bending the four brackets.
4. Insert the mechanical limit switch module from the top up to the upper printed circuit
board guide of the module rack.
5. Slide the mechanical limit switch module in the printed circuit board of the module rack
approximately 3 mm towards right.
6. Screw in the special screw ② through the mechanical limit switch module into the
positioner shaft. Tighten the special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align the pin ③ before it touches the special screw ②.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that
the pins ③ fit into the special screw ②.
7. Set the limits L1 and L2 as described in the chapter "Setting the limits of the mechanical
limit switch module (Page 67)".
8. An insulating cover is provided over the mechanical limit switch module. Place the
insulating cover on one side under the basic electronics seat on the walls of the rack. The
recesses of the insulating cover must fit in the corresponding webs of the container wall.
9. Place the insulating cover on the mechanical limit switch module by bending the walls of
the rack carefully.
10.Engage the basic electronics into the four brackets.
11.Fix the basic electronics using both the fixing screws.
12.Reestablish all electrical connections between the basic electronics and the option
modules. Connect the basic electronics and the option modules to the ribbon cables
provided. Connect the basic electronics and the potentiometer to the potentiometer cable.
13.Using both the screws, fasten the module cover provided. Do not use the standard
module cover.
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14.Select the labels that already exist on the standard version of the module cover from the
label set provided. Affix the selected labels on the installed module cover as per the
standard version.
15.Establish all electrical connections.
Note
Protective conductor connector
A protective conductor connector is not required for safety reasons and therefore is not
provided.
4.7.5.3
Setting the limits of the mechanical limit switch module
Setting the L1 and L2 limits
To set the limits proceed as follows. The serial numbers refer to the image in the chapter
"Installing the mechanical limit switch module (Page 66)".
1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 41 and 42
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 51 and 52
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
Note
The actuating discs are relatively difficult to move. This design prevents their
unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing friction temporarily. Move the actuator to and fro while
simultaneously holding the actuating discs.
4.7.5.4
Label set for mechanical limit switch module
Fasten the included warning label on the side across from the nameplate. There are different
warning labels depending on the enclosure material, as described below.
Figure 4-16
Warning label for a device with a Macrolon enclosure
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Figure 4-17
Warning label for a device with an aluminum enclosure
Figure 4-18
Warning label for a device with a stainless steel enclosure
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4.7.6
EMC filter module
Requirements
● You have an EMC filter module, order number C73451-A430-D23.
● The module cover is removed.
● Any already installed optional module has been removed.
A description of how to remove the module cover and install the optional modules is provided
in the chapter "General information about the installation of option modules (Page 53)"
Note
Different cable glands
A blue and a gray cable gland are provided to distinguish between explosion-proof and not
explosion-proof devices.
• Use the blue cable gland for explosion-proof devices in "intrinsically safe" protection type.
Use the gray cable gland for all other designs.
Function
You will require the EMC filter module if you use an external position sensor on the
positioner, e.g. a potentiometer or a non-contacting position sensor. The EMC filter module
forms the interface between external position sensors and the basic electronics of the
positioner. This module protects the positioner from electromagnetic effects.
Device features
● EMC protection
● Connection to basic electronics
● Connecting terminals for an external potentiometer
Figure 4-19
EMC filter module
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Procedure for installing the EMC filter module
①
②
③
④
EMC filter module terminals
Positioner
Yellow wheel for locking the position detection
⑤
⑥
⑦
Basic electronics
Screw
EMC filter module C73451-A430-D23
Ribbon cable connector of fitted potentiometer,
or ribbon cable connector of EMC filter module
Figure 4-20
Installation EMC filter module
1. You have performed the steps described in the chapter "General information about the
installation of option modules (Page 53)".
2. Unplug the ribbon cable connector ④ to the fitted potentiometer from the basic
electronics ⑤.
3. Remove the basic electronics ⑤ from the positioner. To this end, remove the two screws
that fix the basic electronics to the pneumatic block.
4. Loosen the screw ⑥ in the connection area of the positioner.
5. Then secure the loose ribbon cable (B) on the container as shown in the following
graphic. To do this, use the cable tie (A) supplied with the EMC filter module
C73451-A430-D23
(A)
Cable tie
(B)
Ribbon cable connector
6. Secure the EMC filter module using the screw ⑥ loosened in the third step.
7. Fit the basic electronics ⑤ back into the positioner.
8. Insert the ribbon cable connector ④ of the EMC filter module onto the positioner basic
electronics.
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9. In non-hazardous environment:
– Stick the supplied nameplate over the nameplate on the external position detection
system.
– Replace the blue cable gland by the supplied gray cable gland.
10.Fasten the module cover. Make sure that the ribbon cable is not trapped.
11.Proceed with the corresponding steps in the chapter "General information about the
installation of option modules (Page 53)".
Refer to section "Scope of delivery of external position detection system (Page 298)", items
"Nameplate for device version without explosion protection" and "Gray cable gland".
See also
Scope of delivery EMC filter module (Page 299)
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4.7.7
Accessories
Pressure gauge block
Pressure gauge blocks that are available as accessories are illustrated below. The gauges
display measured values for the actuating pressure and supply air. The image to the left
shows the pressure gauge block for single-acting actuators. The image to the right shows
the pressure gauge block for double-acting actuators.
Y1
Actuating pressure
PZ
Supply air
Y2
Actuating pressure
Fixing the pressure gauge block
The pressure gauge block is fixed onto the lateral pneumatic connection of the positioner
using the screws provided. Use the provided O-rings as sealing elements.
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5.1
Electric
5.1.1
Basic safety instructions
WARNING
Improper power supply
Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using
direct current instead of alternating current.
• Connect the device in accordance with the specified power supply and signal circuits.
The relevant specifications can be found in the certificates, in Chapter "Technical data
(Page 269)" or on the nameplate.
WARNING
Unsafe extra-low voltage
Danger of explosion in hazardous areas due to voltage flashover.
• Connect the device to an extra-low voltage with safe isolation (SELV).
WARNING
Connecting device in energized state
Danger of explosion in hazardous areas.
• Connect devices in hazardous areas only in a de-energized state.
Exceptions:
• Circuits of limited energy may also be connected in the energized state in hazardous
areas.
• Exceptions for type of protection "Non-sparking nA" (Zone 2) are regulated in the
relevant certificate
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WARNING
Lack of equipotential bonding
Danger of explosion through compensating currents or ignition currents through lack of
equipotential bonding.
• Ensure that the device is potentially equalized.
Exception: It may be permissible to omit connection of the equipotential bonding for devices
with type of protection "Intrinsic safety Ex i".
WARNING
Unprotected cable ends
Danger of explosion through unprotected cable ends in hazardous areas.
• Protect unused cable ends in accordance with IEC/EN 60079-14.
WARNING
Improper laying of shielded cables
Danger of explosion through compensating currents between hazardous area and the nonhazardous area.
• Only ground shielded cables that run into the hazardous area at one end.
• If grounding is required at both ends, use an equipotential bonding conductor.
WARNING
Unsuitable cables and/or cable glands
Danger of explosion in hazardous areas.
• Only use suitable cables and cable glands complying with the requirements specified in
Chapter "Technical data (Page 275)".
• Tighten the cable glands in accordance with the torques specified in Chapter "Technical
data (Page 271)".
• When replacing cable glands use only cable glands of the same type.
• After installation check that the cables are seated firmly.
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WARNING
Incorrect selection of type of protection
Danger of explosion in areas subject to explosion hazard.
This device is approved for several types of protection.
1. Decide in favor of one type of protection.
2. Connect the device in accordance with the selected type of protection.
3. In order to avoid incorrect use at a later point, make the types of protection that are not
used permanently unrecognizable on the nameplate.
NOTICE
Condensation in the device
Damage to device through formation of condensation if the temperature difference between
transportation or storage and the mounting location exceeds 20 °C (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.
Note
Improvement of interference immunity
• Lay signal cables separate from cables with voltages > 60 V.
• Use cables with twisted wires, except for bus cables.
• Avoid getting too close to large electrical process cells.
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Electromagnetic compatibility
The Macrolon enclosure is metalized from inside to increase the electromagnetic
compatibility (EMC) with respect to high-frequency radiation. The shield is connected to the
threaded bush shown in the following picture such that it is electrically conductive.
Note that this protection is effective only if you connect at least one of these bushes to the
earthed control valves through electrically conductive (bare) attachments.
Shield
Figure 5-1
5.1.1.1
Base plate
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.
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5.1.1.2
Interference immunity
If the bus shield is fully effective, the interference immunity and the interference emission
conform to the specifications. The following measures ensure that the bus shield is fully
effective:
● The shields have been connected to the metallic connections of the positioner.
● The shields have been laid up to the terminal boxes, the distributor and the transceiver.
Note
Dissipation of glitch impulses/equipotential bonding
In order to dissipate glitch impulses, the positioner must be connected to an equipotential
bonding cable (earth potential) using a low resistance. The positioner in the Makrolon
enclosure is therefore equipped with an additional cable. Connect the this cable to the
shield of the bus cable and the equipotential bonding cable using a cable clamp.
Devices in the stainless steel or aluminum enclosure have a corresponding terminal on
the outer side of the enclosure. This terminal must also be connected to the equipotential
bonding cable.
For applications in hazardous areas, ensure an adequately suitable equipotential bonding
between the hazardous and non-hazardous areas.
5.1.1.3
Safety shutdown
The positioner is equipped with an additional input (terminal 81 [+] and terminal 82 [-]) to
approach the safety position. After activating this function, this input must be continuously
supplied with +24 V in order to retain the normal control function.
If this auxiliary voltage fails or is switched, the exhaust air valve is forced-opened and the
actuator moves to the defined safety position so that the actuator cannot be moved using the
buttons on the device and the master.
Communication with the master is still possible. The "Jumper" on the basic electronics is
used to activate this function. It can be accessed after removing the module cover, and must
be switched from the right position (delivery state) to the left position.
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5.1.2
Electrical connections
Connecting terminals of the basic device, the Iy module, and the alarm module are provided
at the left front edges, and are arranged in a staircase-shape.
The module cover protects components from being pulled out and prevents an incorrect
assembly.
①
②
Connecting terminals of option modules
Connecting terminals of basic device
Figure 5-2
Connecting terminals of the flameproof enclosure
5.1.3
Bus cable
5.1.3.1
Preparation of bus cable
The following image will help you in preparing the bus cable for the connection:
a
Length in [mm]
80
①
②
Normal version of the device (without Ex and Ex i)
120 Version with flameproof enclosure (Ex d)
Bus cables to be used:
SIMATIC NET, PB FC Process Cable, bus cable for IEC 61158-2
Cable shield
Figure 5-3
Preparation of bus cable
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5.1.3.2
Bus cable for device version without flameproof enclosure
Devices without flameproof enclosure are:
● Normal version of devices
● Intrinsically safe versions
● Versions for zones 2 and 22
Procedure for device versions without flameproof enclosure
①
②
③
④
⑤
⑥
Bus cable
Cable clamp
Basic electronics
Wiring diagram on module cover
Jumper on basic electronics
⑦
⑧
⑨
⑩
⑪
Label
Terminal strip with screw-type terminals
Earth potential
Grounding cable
Cable glands
Module cover
Figure 5-4
Connection of bus cable and grounding cable for device version with Makrolon enclosure
1. Strip the bus cable ①.
2. Open the enclosure of the positioner by unlatching the four cover screws.
3. Insert the prepared bus cable (described in chapter "Preparation of bus cable (Page 78)")
through the cable inlet.
4. Fasten the shield using the clamp ② and the two screws on the enclosure.
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5. Tighten the cable inlet.
6. Connect the red and the green wires to terminals 6 and 7 of the basic electronics as
shown in the following picture. The polarity does not play any role here.
Note
Bus cable and grounding cable for device version with stainless steel/aluminum
enclosure
In the case of the stainless steel or aluminum enclosure, use the grounding terminal
provided on the outside of the device.
5.1.3.3
Bus cable for device version with flameproof enclosure
Procedure for device versions with flameproof enclosure "Ex d"
①
②
③
④
⑤
Basic electronics bus cable
Grounding terminal
Ex d certified cable inlet
Bus cable
Cable clamp/shield
Figure 5-5
Connection of bus cable for versions with flameproof enclosure
1. Strip the bus cable.
2. Open the safety catch and unscrew the screw cap to open the positioner.
3. Insert the prepared bus cable ④ (described in chapter "Preparation of bus cable
(Page 78)") through the Ex d-certified cable inlet ③. Follow the corresponding guidelines
if you are using a conduit piping system.
4. Fasten the shield on the adapter using the clamp ⑤ and the two screws.
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5. Tighten the Ex d-certified cable inlet ③.
6. Connect the red and the green wires to terminals 6 and 7 of the basic electronics as
shown in the following picture. The polarity does not play any role here.
5.1.4
Device without explosion protection/device in flameproof enclosure
5.1.4.1
Basic device without Ex protection / in flameproof enclosure "Ex d"
Connection diagram for order numbers 6DR55..-0N…; 6DR55.5-0E...
①
②
Basic electronics
Input: Safety shutdown
Figure 5-6
③
④
Binary input 1
Power source
Device version 2-wire PROFIBUS PA (without Ex/with Ex d)
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5.1.4.2
Option modules without Ex protection / in flameproof enclosure "Ex d"
Alarm module, without Ex protection / in flameproof enclosure "Ex d"
①
②
③
Alarm module
Binary input 2
Fault message
Figure 5-7
④
⑤
⑥
Limit
Switching amplifier
Switching output
Alarm module 6DR4004-8A (without Ex/with Ex d)
Iy module, without Ex protection / in flameproof enclosure "Ex d"
①
Iy module
Figure 5-8
Iy module 6DR4004-8J, (without Ex/with Ex d)
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SIA module, without Ex protection
①
②
SIA module
Fault message
Figure 5-9
③
④
Limit
Switching amplifier
SIA module 6DR4004-8G (without Ex)
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Limit contact module, without Ex protection
DANGER
Low-voltage supply
When you supply the module in the non-intrinsically safe version with low voltage, you must
be sure to observe the following safety rules before starting work on the device:
1. Isolate the device from power. Use a circuit breaker positioned near the device to do
this.
2. Make sure that the device cannot be switched back on inadvertently.
3. Make sure the device is truly isolated from power.
Note
Maximal values for terminals 41/42 and 51/52
The following maximum values concern only terminals 41, 42, 51, and 52:
• Maximum voltage:
– Not Ex: AC 250 V or DC 24 V
– Ex: 30 V DC
• Maximum current:
– Not Ex: 4 A AC/DC
– Ex: 100 mA DC
• Maximum performance:
– Ex: 750 mW
No safe separation between the terminals can be guaranteed.
Note
To observe before connecting
Before you connect the mechanical limit switch module, observe the following conditions:
• Isolate all wires from power and make sure the device is truly isolated from power.
• Construct the cross-sectional area of the connection cables in such a way that it is
appropriate for the permitted current load.
Note
Preparing the cables or stranded wires
1. Insulate the cables in such a way that the insulation is flush with the terminal when
plugging in the wires.
2. Fit ferrules to the ends of stranded wires.
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Connecting
①
②
Mechanical limit switch module
Fault message
Figure 5-10
③
④
Limit
Switching amplifier
Mechanical limit switch module 6DR4004-8K (without Ex)
Procedure
1. Loosen the screw ① on the transparent cover ②.
2. Pull the transparent cover ② up to the front end stop.
3. Tighten every cable in the corresponding terminal.
4. Slide the transparent cover ② up to the end stop of the basic electronics.
5. Tighten the screw ① on the transparent cover ②.
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5.1 Electric
6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the
provided cable ties ③ for this purpose.
①
②
③
Screw
Cover
Cable tie
Figure 5-11
Connecting the cables
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5.1 Electric
5.1.5
Device with Ex i/Ex n/Ex t type of protection
WARNING
With intrinsically device version (Ex i)
Risk of explosion in hazardous areas.
For intrinsically safe device versions only the certified circuits may be connected as
auxiliary power supply, control and signal circuits.
• Make sure that the power source of the used circuits is marked as intrinsically safe.
5.1.5.1
Basic device Ex i/Ex n/Ex t
Connection diagram for order number 6DR55..-0E/D/F/G/K...
①
②
③
Non-hazardous area
Potentially explosive atmosphere
Basic electronics
Figure 5-12
④
⑤
⑥
Input: Safety shutdown
Binary input 1
Power source
Device version 2-wire with PROFIBUS PA (Ex i/Ex n/Ex t)
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5.1 Electric
5.1.5.2
Option modules Ex i/Ex n/Ex t
Alarm module Ex i/Ex n/Ex t
①
②
③
④
Non-hazardous area
Potentially explosive atmosphere
Alarm module
Binary input 2
Figure 5-13
⑤
⑥
⑦
⑧
Fault message
Limit
Switching amplifier
Switching output
Alarm module 6DR4004-6A and 6DR4004-7A (Ex i/Ex n/Ex t)
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5.1 Electric
Iy module Ex i/Ex n/Ex t
①
②
Non-hazardous area
Potentially explosive atmosphere
Figure 5-14
③
④
Iy module
Feed splitter
Iy module 6DR4004-6J and 6DR4004-7J (Ex i/Ex n/Ex t)
SIA module Ex i/Ex n/Ex t
①
②
③
Non-hazardous area
Potentially explosive atmosphere
SIA module
Figure 5-15
④
⑤
⑥
Fault message
Limit
Switching amplifier
SIA module 6DR4004-6G (Ex i/Ex n/Ex t)
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5.1 Electric
Limit contact module, intrinsic safety "Ex i"
Mechanical limit switch module connection diagram, Ex i
①
②
③
④
Non-hazardous area
Potentially explosive atmosphere
Limit contact module
⑤
⑥
⑦
Limit
Isolation amplifier
Switching amplifier/isolation amplifier
Fault message
Figure 5-16
Limit contact module 6DR4004-6K (Ex i/Ex n/Ex t)
Connecting the limit contact module
Procedure
1. Loosen the screw ① on the transparent cover ②.
2. Pull the transparent cover ② up to the front end stop.
3. Tighten every cable in the corresponding terminal.
4. Slide the transparent cover ② up to the end stop of the basic electronics.
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5.1 Electric
5. Tighten the screw ① on the transparent cover ②.
6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the
provided cable ties ③ for this purpose.
①
②
③
Screw
Cover
Cable tie
Figure 5-17
Connecting the cables
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5.2 Pneumatic
5.2
Pneumatic
5.2.1
Pneumatic connections
5.2.1.1
Pneumatic connection on the standard controller
Structure
The pneumatic connections are provided on the right side of the positioner.
①
②
③
④
⑤
Actuating pressure Y1 for single and double-acting actuators
Positioner axis
Supply air PZ
Actuating pressure Y2 for double-acting actuators
Exhaust air outlet with a sound absorber
Figure 5-18
Pneumatic connection on the standard controller
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5.2 Pneumatic
5.2.1.2
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 5-19
Integrated pneumatic connection
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5.2 Pneumatic
5.2.1.3
Pneumatic connection in the flameproof enclosure
Structure
The pneumatic connections are provided on the right side of the positioner.
①
②
③
④
Restrictor Y2 *)
Restrictor Y1
Actuating pressure Y2
*)
⑤
⑥
⑦
Actuating pressure Y1
Exhaust air outlet
Enclosure ventilation (2x)
Supply air PZ
*) for double-acting actuators
Figure 5-20
Pneumatic connection in the flameproof enclosure
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5.2 Pneumatic
5.2.1.4
Pneumatic connection versions
Overview
For the integrated attachment for single-acting linear actuators, the following pneumatic
connections are provided at the rear side of the standard controller:
● 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.
The following overview diagram shows the pneumatic connection versions for different
actuator types, regulating action and safety position after an auxiliary power supply failure.
CAUTION
Before working on the control valve
Note that before working on the control valve, you must first move it to the safety position.
Make sure that the control valve has reached the safety position. If you only interrupt the
pneumatic auxiliary power supply to the positioner, the safety position may in some cases
only be attained after a certain delay period.
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5.2 Pneumatic
Figure 5-21
Regulating action of pneumatic connection
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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 "Pneumatic data
(Page 270)".
● 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.
See also
Pneumatic connection versions (Page 95)
Changing the operating mode (Page 104)
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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 5-22
Restrictors
See also
Pneumatic connection in the flameproof enclosure (Page 94)
Sequence of automatic initialization (Page 115)
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Operation
6.1
Operating elements
6.1.1
Display
Introduction
Note
Repetition rate display
When operated in temperature ranges below -10°C, the liquid crystal display of the
positioner becomes sluggish and the repetition rate display reduces considerably.
The display has two lines. These two lines are segmented differently. Each element in the
upper line has 7 segments, whereas that in the lower line has 14 segments. Contents of the
display depend on the selected mode.
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6.1 Operating elements
Display options as per the mode
An overview of mode-specific display options is given below.
Operating mode
Representation in the display
P manual mode
Initialization mode
Configuring
Manual mode (MAN)
Automatic (AUT)
Diagnostics
Pos.
Legend
①
Potentiometer setting [%]
②
Blinking indicator for the non-initialized status.
①
Potentiometer setting [%]
②
Display of the current status of initialization or a fault
message.
③
Indicator for ongoing initialization or a fault message.
①
Parameter value
②
Parameter name
③
Parameter number
①
Position [%]
②
Setpoint [%]
③
Fault message
①
Position [%]
②
Setpoint [%]
③
Fault message
①
Diagnostics value
②
Diagnostics name
③
Diagnostics number
See also
System messages before initialization (Page 233)
Changing the operating mode (Page 104)
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6.1 Operating elements
6.1.2
Buttons
①
②
③
④
Display
Operating mode button
Decrement button
Increment button
Figure 6-1
Display and buttons of the positioner
● You can use three buttons to operate the positioner.
● The function of the buttons depends on the mode selected.
● In a positioner with a flameproof enclosure, the buttons are protected with a cover. The
button cover can be opened after unlatching the locking screw.
Note
Key cover
In positioners with flameproof enclosures, the button cover prevents liquids from seeping
through. The IP66/NEMA 4x degree of protection is not ensured when the enclosure or
the button cover is open.
You have to remove the enclosure cover to operate the buttons of the basic device or the
"intrinsically safe" version.
Note
Degree of protection
The IP66/NEMA 4x degree of protection is not ensured as long as the positioner is open.
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6.1 Operating elements
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 5.00.00
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6.2 Operating modes
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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6.2 Operating modes
6.2.2
Changing the operating mode
The following picture illustrates the available operating modes and switching between the
operating modes.
Figure 6-3
Switching between the operating modes
See also
Display (Page 99)
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6.2 Operating modes
6.2.3
Overview of configuration
The following picture illustrates the handling of operating modes such as "Configuration" and
"Initialization mode":
Figure 6-4
6.2.4
Overview of the "Configuration" operating mode
Description of operating modes
P manual mode
Note
Delivery state
The "P manual mode" is preset for the positioner in the delivery state.
The display of the positioner shows the current potentiometer position in the upper line.
"NOINI" blinks in the second line of the display.
Move to the actuator with the
or
buttons.
Switch to "Configuration" and "Initialization mode" to adapt the actuator as per the positioner.
Alarms or position feedbacks can be triggered after initializing the positioner completely.
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6.2 Operating modes
Configuration and initialization
To get to the "Configuration" mode, press the
button for at least 5 seconds.
You can use the "Configuration" mode to adjust the positioner individually as per your
actuator and start commissioning or initialization.
The positioner reports the "Configuration" mode with a configurable fault message. A
position feedback or display of limits A1 and A2 is not possible.
Note
Failure of electrical auxiliary power
If electrical auxiliary power supply fails when configuring, the positioner responds as follows
until the power supply is reestablished:
• The positioner switches to the first parameter.
• Settings of the values already configured are retained.
In order to save the changed parameter values, exit the "Configuration" mode or switch to
another parameter. When "Configuration" mode is restarted, the output in the display
switches to the last activated parameter.
Manual mode (MAN)
In this mode, you move the actuator with
or . The setting selected here is retained
irrespective of the setpoint current and leakages, if any.
Note
Accelerating the actuator movement
Proceed as follows if you wish to accelerate the actuator movement:
1. Keep one of the two direction buttons pressed.
2. Press the remaining direction button simultaneously.
Note
Failure of power supply
When the power supply is reestablished after a failure, the positioner switches to the
"Automatic" mode.
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6.2 Operating modes
Automatic (AUT)
Automatic is the standard mode. In this mode, the positioner compares the setpoint position
with the actual position. The positioner moves the actuator until the control deviation reaches
the configurable deadband. A fault message is displayed if the deadband cannot be reached.
Display
Mode
Meaning
OS
OOS
out of service; reaction: last position is retained.
IMN
IMAN
initialization manual mode
LO
LO
local override
MM
MAN
manual mode
AUT
AUTO
automatic mode
CAS
CAS
cascade mode
RCS
RCAS
remote cascade
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.:
● 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.
See also
Commissioning (Page 111)
Description of parameters A to P (Page 172)
Overview of diagnostics values (Page 242)
Meaning of the diagnostics values (Page 244)
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6.3 Optimizing the controller data
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 301)"
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.
22 lmpulse length up / 23 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.
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6.3 Optimizing the controller data
26 Slow step zone up / 27 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 chapter "Control algorithm (Page 27)".
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.
43 Prediction up / 44 Prediction down
These parameters work similar to attenuation factors. These parameters are used to set the
control dynamics. The parameter settings have the following results:
● Small values result in quick adjustments with overshoots.
● Large values result in slow adjustments without overshoots.
Note
Reference variable
It is advantageous to use a fixed reference variable to optimize the control data.
Therefore, change the deadband parameter from auto to a fixed value.
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6.3 Optimizing the controller data
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7.1
7
Basic safety instructions
WARNING
Improper commissioning in hazardous areas
Device failure or danger of explosion in hazardous areas.
• Do not commission the device until it has been mounted completely and connected in
accordance with the information in Chapter "Technical data (Page 269)".
• Before commissioning take the effect on other devices in the system into account.
WARNING
Loss of explosion protection
Danger of explosion in hazardous areas if the device is open or not properly closed.
• Close the device as described in Chapter "Installing/mounting (Page 35)".
WARNING
Opening device in energized state
Danger of explosion in areas subject to explosion hazard.
• Only open the device in a de-energized state.
• Check prior to commissioning that the cover, cover locks, and cable inlets are
assembled in accordance with the directives.
Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened
in energized state in hazardous areas.
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Commissioning
7.1 Basic safety instructions
WARNING
Water in compressed air line
Device damage and possibly loss of type of protection. The factory setting for the purging
air selector is "IN". In the "IN" position, water from the compressed air line may enter the
device from the pneumatics during initial commissioning.
• Before commissioning, make sure that no water is present in the compressed air line.
If you cannot be sure that there is no water in the compressed air line:
• Set the purging air selector to "OUT". In this way, you prevent water from the
compressed air line from penetrating the device.
• Only set the purging air selector to "IN" again when all water has been discharged from
the compressed air line.
CAUTION
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection
specified on the nameplate or in Chapter "Technical data (Page 269)" 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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7.1 Basic safety instructions
7.1.1
Safety notes for operation with natural gas
When operating the positioner with natural gas, you must follow and adhere to the following
safety notes:
WARNING
Operation with natural gas
1. Only the "Ex ia" version of the positioner and option modules with the "Ex ia" type of
protection may be operated with natural gas. Positioners with other types of protection,
e.g. flameproof enclosure or versions for zones 2 and 22 are not permitted.
2. Do not operate the positioner with natural gas in closed spaces.
3. Natural gas is continuously blown off in the servo-drive depending on the model. Special
care must therefore be taken during maintenance activities near the positioner. Always
ensure that the immediate surroundings of the positioner are adequately ventilated.
The maximum values for ventilation are listed in section "Technical data for natural gas
as actuator medium (Page 277)".
4. The limit contact module may not be used when operating the positioner with natural
gas.
5. Depressurize the devices operated with natural gas adequately during maintenance
activities. Open the cover in an explosion-free atmosphere and depressurize the device
for at least two minutes.
Note
Quality of natural gas
Only use natural gas which is clean, dry and free from additives.
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7.2 Overview
7.2
Overview
Note
• During the initialization process, the operating pressure must be at least one bar more
than that required to close or open the valve. However, the operating pressure should not
be greater than the maximum permissible operating pressure for the actuator.
• The transmission ratio selector can be set only when the positioner is open. Therefore,
check this setting before closing the enclosure.
General information about commissioning
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.
● Copying the initialization data when replacing a positioner:
the initialization data of a positioner can be read and copied into another positioner. A
defective device can thus be replaced without interrupting an ongoing process through
initialization.
You have to define a few parameters for the positioner before initialization. Owing to the
preset values, you cannot adjust further parameters for initialization.
You can use a suitably configured and activated binary input to protect the configured
settings against accidental adjustment.
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7.3 Sequence of automatic initialization
See also
Overview of operating modes (Page 103)
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:
● Establishing and display of the actuating time/leak monitoring 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 the linear actuators
7.5
Commissioning the linear actuators
7.5.1
Preparing linear actuators for commissioning
Requirements
You have already installed the positioner using the suitable mounting kit.
Setting the transmission ratio selector
Note
Commissioning
The setting of the transmission ratio selector is extremely important to commission the
positioner.
Stroke [mm]
Lever
Position of the transmission ratio selector
In [°]
Position
5 ... 20
Short
33
Down
15 ... 35
Short
90
Up
30 ... 130
Long
90
Up
1. Move the carrier pin on the lever. Select the scale position equal to the nominal stroke or
a next-higher position.
2. Tighten the carrier pin using the M6 hexagon nut.
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.
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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.
Note
The following is applicable for the flameproof enclosure version:
The inner friction clutch is fixed. Therefore, only move the outer friction clutch.
See also
Device components (Page 24)
Installing the optional modules (Page 53)
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7.5 Commissioning the linear actuators
7.5.2
Automatic initialization of linear actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The actuator spindle can be moved completely.
2. The actuator spindle is at a central position after moving.
Initializing the linear actuator automatically
Note
Interrupting initialization
An ongoing initialization can be interrupted at any time. To do this, press
configured until then are retained.
. The settings
All parameters are reset to factory settings only if you have explicitly activated the preset
settings in the "PRST" parameter.
1. Switch to the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The display shows the following:
2. Call the "2.YAGL" parameter. To do this, briefly press the
button. The following is
shown on the display depending on the setting:
3. Check whether the value displayed in the "2.YAGL" parameter matches the setting of the
transmission ratio selector. If required, change the setting of the transmission ratio
selector to 33° or 90°.
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4. Set the "3.WAY" parameter to determine the total stroke in mm. The setting of parameter
3 is optional. The display shows the determined total stroke only at the end of the
initialization phase.
– Briefly press the
button if you do not require any information about the total stroke
in mm. You are then directed to parameter 4.
– Call the "3.YWAY" parameter. To do this, briefly press the
button. The display
shows the following:
Note
Set the "3.YWAY" parameter
Proceed as follows to set parameter 3:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter with the buttons or to the read value.
5. Call the "4.INITA" parameter. To do this, briefly press the
button. The display shows
the following:
6. Start the initialization process. To do this, press the
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.
7. The following display indicates that the automatic initialization is complete:
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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.
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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.
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 "2.YAGL" parameter. To do this, briefly press the
button. The following is
shown on the display depending on the setting:
3. Check whether the value displayed of the "2.YAGL" parameter matches with the setting
of the transmission ratio selector. If required, change the setting of the transmission ratio
selector to 33° or 90°.
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4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of the
"3.YWAY" parameter is optional. The display shows the determined total stroke only at
the end of the initialization phase.
– Briefly press the
button if you do not require any information about the total stroke
in mm. You are then directed to parameter 4.
button. The display
– Call the "3.YWAY" parameter. To do this, briefly press the
shows the following:
Note
Set the "3.YWAY" parameter
To set the "3.YWAY" parameter proceed as follows:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter to the read value with the
or
5. Call the "5.INITM" parameter. To do this, press the
button.
button twice. The display shows
the following:
6. Start the initialization process. To do this, press the
the display shows the following:
button for at least 5 seconds until
The current potentiometer position is output on the display after 5 seconds. Examples of
the displayed potentiometer positions are given below:
7. Determine the end position 1 of the actuator spindle.
8. Move the actuator to the desired position using the
or
button.
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9. Press the
button. The current position of the actuator is applied. The display shows the
following:
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
2. Press the
button.
3. Move the actuator to another position using the
or
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.
10.Determine the end position 2 of the actuator spindle. Move the actuator to the desired
or button.
position using the
11.Press the
button. The current position of the actuator is applied.
Note
Fault message "Set Middl"
The lever arm is not in the horizontal position if the "Set Middl" message is output on the
display. To correct the fault, set the reference point of the sine correction. Proceed as
follows:
1. Move the lever arm to the horizontal position using the
2. Press the
or
button.
button.
12.The initialization process is automatically resumed. Initialization steps "RUN1" to "RUN5"
are output in the bottom line of the display. The following is displayed when the
initialization has been completed successfully:
Note
Total stroke
If the "3.YWAY" parameter has been set, the display shows the total stroke in mm.
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Aborting the manual initialization process
1. Press the
button. The display shows the "5.INITM" parameter. The positioner is in the
"Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
software status is displayed. After releasing the
button for at least 5 seconds. The
button, the positioner is in "P manual
mode". The positioner is not initialized.
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7.6 Commissioning the part-turn actuators
7.6
Commissioning the part-turn actuators
7.6.1
Preparing part-turn actuators for commissioning
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°.
• Set the transmission ratio selector in the positioner to 90°.
Condition
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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See also
Device components (Page 24)
Installing the optional modules (Page 53)
7.6.2
Automatic initialization of part-turn actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The 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.YAGL" parameter. To do this, briefly press the
button. This parameter has
already been set to 90° automatically. The display shows the following:
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4. Call the "4.INITA" parameter. To do this, briefly press the
button. The display shows
the following:
5. Start the initialization process. To do this, press the
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.
6. The following display indicates that the automatic initialization is complete. The total angle
of rotation of the actuator is shown on the upper line on the display:
Aborting the automatic initialization process
1. Press the
button. The display shows the following:
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
The software status is displayed.
After releasing the
button, the positioner is in "P manual mode". The part-turn actuator
is not initialized.
See also
Sequence of automatic initialization (Page 115)
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7.6 Commissioning the part-turn actuators
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.
Requirements
The following requirements must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on part-turn actuators.
2. The actuator can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°. Accordingly set the
transmission ratio selector in the positioner to 90°.
Initializing the positioner manually
1. Switch to the "Configuration" mode. To do this, press the
button for at least 5 seconds
until the display shows the following:
2. Set the "YFCT" parameter to "turn". To do this, press
. The display shows the following:
3. Call the second parameter "YAGL". To do this, press
. The display shows the following:
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4. Call the "INITM" parameter. To do this, press the
button twice. The display shows the
following:
5. Start the initialization process. Press the
shows the following:
button for at least 5 seconds until the display
6. The current potentiometer position is output on the display after 5 seconds:
7. Determine the end position 1 of the actuator.
8. Move the actuator to the desired position using the
9. Press the
or
button.
button. The current position of the actuator is applied. The display shows the
following:
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
2. Press the
button.
3. Move the actuator to another position using the
or
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.
10.Determine the end position 2 of the actuator. Move the actuator to the desired position
or button.
using the
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11.Press the
button. The current position of the actuator is applied.
12.The initialization process is automatically resumed. Initialization steps "RUN1" to "RUN5"
are output in the bottom line of the display. The following display indicates that the
initialization has been completed successfully:
Aborting the manual initialization process
1. Press the
button. The display shows the "INITM" parameter. The positioner is in the
"Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the
button for at least 5 seconds.
3. The software status is displayed.
4. After releasing the
button, the positioner is in "P manual mode". "P manual mode"
means that the positioner has not been initialized.
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7.7 Device replacement
7.7
Device replacement
Introduction
Note
Initialization
The positioner can be replaced without having to interrupt ongoing processes. However,
copying and pasting of the initialization parameters only allows an approximate adjustment of
the positioner to your actuator. Following initialization, the positioner initially works with the
manually defined parameters.
• For this reason, an automatic or manual initialization should be carried out as soon as
possible.
Note
Deferred initialization
Initialize the new positioner as soon as possible. The following properties can be ensured
only after initializing:
• Optimum adjustment of the positioner as per the mechanical and dynamic properties of
the actuator.
• Non-deviating position of end stops
• Correctness of the maintenance data
There are two ways of replacing a positioner when the equipment is in operation, without
having to interrupt the process. The two options depend on whether your positioner has
communication.
First possibility - with communication
1. Read the initialization parameters from the previous positioner. Use the parameter
assignment tools suitable for this purpose.
2. Read the initialization parameters from Point 1 into the new positioner.
3. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
4. Determine the actual position value. To do this, read the actual position value from the
display of the previous positioner. Note down the read value.
5. Dismount the previous positioner from the actuator.
6. Attach the lever arm of the previous positioner to the new positioner.
7. Mount the new positioner on the actuator.
8. Set the transmission ratio selector of the new positioner to the same position as that of
the previous positioner.
9. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
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7.7 Device replacement
10.The new positioner is ready for operation when the displayed and noted values match.
11.Release the fixing of the actuator.
Second possibility - without communication
1. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
2. Determine the actual position value. To do this, read the actual position value on the
display of the previous positioner. Note down the read value.
Note
Electronics defect
If the positioner's electronics is defective, measure the actual position value with a ruler or
protractor at the actuator or valve. Convert the read value into %. Note down the
converted value.
3. Dismount the previous positioner from the actuator.
4. Attach the lever arm of the previous positioner to the new positioner.
5. To prevent interference with the ongoing process, initialize the new positioner on an
actuator with a similar stroke or swivel range. Attach the new positioner to this actuator.
Initialize the new positioner.
6. Then dismount the new, initialized positioner from this actuator.
7. Mount the new, initialized positioner on the fixed actuator.
8. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
9. Use the buttons on the positioner to enter the parameters which deviate from the factory
setting, such as type of actuator or tight closing.
10.Change to the measured value view using the mode button (manual button), see section
"Description of operating modes (Page 105)".
11.Release the fixing of the actuator.
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8.1
8
Range of applications for functional safety
The positioner is suitable for use on valves that satisfy the special requirements in terms of
functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511. The 6DR5.1.-0........-Z C20 versions are available for this.
These are single-acting positioners for mounting on pneumatic actuators with spring return.
The positioner automatically depressurizes the valve actuator on demand or in case of faults,
which thus switches the valve to the specified safety position.
This positioner meets the following requirement:
● Functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511 for safe venting
See also
Functional safety in process instrumentation (http://www.siemens.com/SIL)
8.2
Safety function
Safety function on positioner
Depressurizing of the connected actuator is the safety function for the positioner. The built-in
spring brings the valve to the required safety position. Depending on the direction of action of
this spring, the valve is completely opened or closed.
This safety function can be triggered by:
● The signal at the input for the safety shutdown (terminals 81 and 82) is < 4.5 V.
This function is also referred to as "safety shutdown" in the device documentation.
● Failure of the auxiliary power supply via the bus connection.
The safety function is not effected by other device functions, particularly the microcontroller,
software and communication interface. With respect to this safety function, the positioner
must therefore be considered as a type A subsystem in accordance with EN 61508-2.
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8.2 Safety function
Situations in which it is not possible to depressurize the actuator on demand or in the case of
a fault represent a dangerous failure.
WARNING
Disregarding conditions for fulfilling the safety function
Disregarding conditions can result in a malfunction of the process system or application, for
example, process pressure too high, maximum level exceeded.
The mandatory settings and conditions are listed in chapters "Settings (Page 142)" and
"Safety characteristics (Page 143)".
• These conditions must be met in order to fulfill the safety function.
The pneumatic block of the positioner pressurizes and depressurizes the actuator. The
pneumatic block contains two pilot valves. The characteristic service life of the pneumatic
block depends on the load. On average it is approx. 200 million switching operations for
each of the two pilot valves with symmetrical load. The number of control procedures for the
switching operations is called in the local display or via HART communication. Refer to the
diagnostics parameters "40 VENT1" and "41 VENT2" under the following "see also" link.
See also
Meaning of the diagnostics values (Page 244)
Safety-instrumented system in single-channel operation (SIL 2)
Figure 8-1
Safety-instrumented system in single-channel operation
The combination of transmitter, automation system and final controlling element forms a
safety-instrumented system that performs a safety function.
The transmitter generates a process-related measured value that is transferred to the
automation system. The automation system monitors this measured value. If the measured
value exceeds the range of the high or low limit, the automation system generates a
shutdown signal for the connected final controlling element, which switches the associated
valve to the specified safety position.
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8.3 Safety Integrity Level (SIL)
8.3
Safety Integrity Level (SIL)
The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from
SIL 1 to SIL 4. Every level corresponds to a probability range for the failure of a safety
function.
Description
The following table shows the dependency of the SIL on the "average probability of
dangerous failures of a safety function of the entire safety-instrumented system" (PFDAVG).
The table deals with "Low demand mode", i.e. the safety function is required a maximum of
once per year on average.
Table 8- 1
Safety Integrity Level
SIL
Interval
4
10-5 ≤ PFDAVG < 10-4
3
10-4 ≤ PFDAVG < 10-3
2
10-3 ≤ PFDAVG < 10-2
1
10-2 ≤ PFDAVG < 10-1
The "average probability of dangerous failures of the entire safety-instrumented system"
(PFDAVG) is normally split between the following three components:
Figure 8-2
PFD distribution
The following table shows the achievable Safety Integrity Level (SIL) for the entire safetyinstrumented system for type A devices depending on the safe failure fraction (SFF) and the
hardware fault tolerance (HFT).
● Type A devices include analog transmitters and shut-off valves without complex
components, e.g. microprocessors (see also IEC 61508, Section 2).
● The specific values for your device are listed in the manufacturer's declaration
(Declaration of Conformity, Functional Safety according to IEC 61508 and IEC 61511):
Certificates (http://www.siemens.com/processinstrumentation/certificates).
SFF
HFT for type A devices
0
1
2
< 60 %
SIL 1
SIL 2
SIL 3
60 to 90 %
SIL 2
SIL 3
SIL 4
90 to 99 %
SIL 3
SIL 4
SIL 4
> 99 %
SIL 3
SIL 4
SIL 4
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8.4 Settings
8.4
Settings
WARNING
Safety function: Positioning "Jumper" on the basic electronics
The safety function is not activated in the delivered state; the "Jumper" is in the "Normal"
position. "Normal" means: Without safety function, no depressurizing of the connected
actuator. To activate the safety function, proceed as follows:
• Insert the "Jumper" in the left position facing the terminals. This corresponds to the
position "Shut Down enabled" on the wiring diagram present on the module cover, see
"Auto-Hotspot".
Or
• Remove the "Jumper" from the basic electronics.
Special parameter settings are not necessary.
Protection against configuration changes
You should attach the housing cover so that the device is protected against unwanted and
unauthorized changes/operation.
Checking the safety function
Prerequisite for checking the safety function
● Positioner is in operation.
● The actuator belonging to the positioner is not in the safety position.
Procedure
1. In order to test the safety shutdown, apply a LOW level, i.e. a voltage of maximum 4.5 V,
to the input for the safety shutdown.
2. Verify that the valve returns to the safety position.
3. In order to test the response of the actuator, apply a HIGH level, i.e. a voltage >13 V, to
the input for the safety shutdown.
4. Set the setpoint to 50% using a local operation (manual operation) or bus communication.
5. Reduce the intake pressure (Pz) to a third of the maximum supply pressure.
6. Verify that the valve returns to the safety position.
7. Check the filters in the pneumatic connections for contamination and clean them if
necessary.
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8.5 Safety characteristics
8.5
Safety characteristics
The safety characteristics necessary for use of the system are listed in the SIL declaration of
conformity. These values apply under the following conditions:
● The positioner is only used in applications with low demand rate for the "Low demand
mode".
● "Jumper" on the basic electronic system was plugged into the left position facing the
terminals at position "Shut Down enabled" or removed completely.
● The positioner is blocked against unwanted and unauthorized changes/operation.
● The shut-off signal for the positioner is generated at the input for the safety shutdown
(terminals 81 and 82) by a safe system which meets at least SIL 2. The LOW level has a
maximum of 4.5 V at the input terminals.
● The connected actuator must be singe-acting and return the valve to the safe end
position by spring force in the following scenario:
– At a chamber pressure (Y1 connection) up to a third of the maximum available intake
pressure (Pz connection)
● The air outlet does not contain any additional cross-sectional contractions leading to an
increased dynamic pressure. In particular, a silencer is only allowed if icing or other
contamination is ruled out.
● The restrictor in the Y1 circuit may not be completely closed during operation.
● The auxiliary pneumatic power is free of oil, water and dirt in line with:
DIN/ISO 8573-1, maximum class 2
● The average temperature viewed over a long period is 40 °C.
● Fault rates are calculated on the basis of a mean time to repair (MTTR) of 8 hours.
● In case of a fault, the pneumatic outlet of the positioner is depressurized. A spring in the
pneumatic actuator must move the valve to the pre-defined, safe end position.
● A dangerous failure of the positioner is when the pressure outlet is not depressurized, or
the safety position is not reached, with a LOW level of maximum 4.5 V at the input for the
safety shutdown.
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Functional safety
8.5 Safety characteristics
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9.1
Overview of the parameters
9.1.1
Overview of parameters 1 to 5
9
Introduction
Parameters 1 to 5 are the same for all versions of positioner. 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
Note
Factory-set parameter values are printed in bold in the following table.
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9.1 Overview of the parameters
Overview
Parameter
Function
1.YFCT
Type of position actuator
Parameter values
Unit
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator without sine correction)
ncSt (part-turn actuator with NCS)
-ncSt (part-turn actuator with NCS, inverse
direction of action)
ncSL (linear actuator with NCS)
ncSLL (linear actuator with NCS and lever)
2.YAGL
Nominal angle of rotation of the feedback message 1)
33°
Degrees
90°
3.YWAY2)
Range of stroke (optional setting) 3)
OFF
mm
5 | 10 | 15 | 20
(Short lever 33°)
25 | 30 | 35
(Short lever 90°)
40 | 50 | 60 | 70 | 90 | 110 | 130
(Long lever 90°)
4.INITA
Initialization (automatic)
NOINI | no / ###.# | Strt
5.INITM
Initialization (manual)
NOINI | no / ###.# | Strt
1)
Set the transmission ratio selector accordingly.
2)
The parameter only appears for "WAY" and for "ncSLL".
3)
When used the value must correspond with the set range of stroke on the actuator.
Carriers must be scaled to the actuator's stroke value,or if this is not scaled they then must be set to the next
largest scaled value.
See also
Commissioning (Page 111)
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9.1 Overview of the parameters
9.1.2
Overview of parameters 6 to 53
Note
The following table contains the parameters required to operate the positioner. Factory-set
parameter values are printed in bold.
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9.1 Overview of the parameters
Overview of parameters 6 to 53
Overview of the positioner parameters 6 to 53
Parameter
Function
Parameter values
6.SDIR
Setpoint direction
Ascending
riSE
Decreasing
FALL
7.TSUP
Setpoint ramp OPEN
8.TSDO
Setpoint ramp CLOSED
9.SFCT
Setpoint function
Linear
Equal percentage
Inverse equal percentage
10.SL0
s
0 ... 400
s
1 : 25
1 - 25
1 : 33
1 - 33
1 : 50
1 - 50
25 : 1
n1 - 25
33 : 1
n1 - 33
50 : 1
n1 - 50
FrEE
Setpoint turning points with free characteristic
at
0%
11.SL1 ....
5 % ...
29.SL19
95 %
30.SL20
Auto / 0 ... 400
Lin
Freely adjustable
10.SL0 ...
30.SL20 1)
Unit
0 ... 100.0
%
Auto / 0.1 ... 10.0
%
100 %
31.DEBA
Controller dead zone
32.YA
Beginning of manipulated variable limiting
0.0 ... 100.0
%
33.YE
End of manipulated variable limiting
0.0 ... 100.0
%
34.YNRM
Standardization of manipulated variable
35.YCLS
To mechanical travel
MPOS
At flow
FLOW
Tight closing manipulated variables
None
no
Above only
uP
Below only
Above and below
do
uP do
36.YCDO
Value for tight closing below
0.0 ... 100
%
37.YCUP
Value for tight closing above
0.0 ... 100
%
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9.1 Overview of the parameters
Overview of the positioner parameters 6 to 53
Parameter
Function
Parameter values
38.BIN1 2)
Function of the BE1
Normally open contact
None
Message only
OFF
on
Block configuring
bloc1
Block configuring and manual
operation
bloc2
-on
Move valve to position YE
uP
-uP
Move valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Partial stroke test
39.BIN2 2)
Function of the BE2
PST
-PST
Normally open contact
Normally closed
contact
None
Message only
OFF
on
-on
Move valve to position YE
uP
-uP
Move valve to position YA
doWn
-doWn
Block movement
StoP
-StoP
Partial-Stroke-Test
40.AFCT 3)
Unit
Normally closed
contact
Alarm function
PST
-PST
Normal
Inverted
none
OFF
A1 = Min, A2 = Max
A1 = Min, A2 = Min
A1 = Max, A2 = Max
41.A1
Response threshold alarm 1
42.A2
Response threshold alarm 2
43. FCT 3)
Fault message output function
0.0 ... 10.0 ... 100
%
0.0 ... 90.0 ... 100
%
Normal
Inverted
Fault
Fault + not automatic 4)
Fault + not automatic + BE4)
44. TIM
Monitoring period for setting the fault message
"Control deviation"
Auto / 0 ... 100
s
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9.1 Overview of the parameters
Overview of the positioner parameters 6 to 53
Parameter
Function
45. LIM
Response threshold of the fault message
"Control deviation"
46. STRK
Limit for path integral
47.PRST
Preset (factory setting) 5)
48.XDIAG
49.FSTY
Parameter values
Unit
Auto / 0 ... 100
%
0 ... 1.00E9
no
Nothing activated
no
Strt
Start of the factory setting
Strt
oCAY
Display after the button has been
pressed for 5 seconds
oCAY
Activation of advanced diagnostics
Off
OFF
Single stage message
On1
Two stage message
On2
Three stage message
On3
Safety setting.
Parameterized safety setpoint
FSVL
Last setpoint
FSSP
Open vent valve
FSAC
50.FSTI
Monitoring period for setting the safety setting
0 ... 100
s
51.FSVL
52.STNR
Safety setpoint
0.0 ... 100.0
%
Station number
0 ... 126
53.IDENT
Device operating mode (ID No.)
Independent of manufacturer
0
Full functionality
1
1)
Setpoint turning points only appear when "9.SFCT = FrEE" is selected.
2)
"Normally closed" means: Operation when a switch is open or Low level
"Normally open" means: Operation when a switch is closed or High level
3)
"Normal" means: High level, no fault message
"Inverse" means: Low level, no fault message
4)
"+" means: OR logic combination
5)
Preset effects "NOINI"!
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9.1 Overview of the parameters
9.1.3
Overview parameters A to P
Introduction
These parameters are used to set the extended diagnostic functions of the positioner.
Note
Factory setting
Factory-set parameter values are printed in bold in the following table.
Note
Display
Parameters A to P and their sub-parameters are only displayed when the extended
diagnostics has been activated using parameter "XDIAG" with parameter value "On1", "On2"
or "On3".
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9.1 Overview of the parameters
Overview parameter A
Parameter
Function
Parameter values
A. PST
Partial stroke test with the following parameters:
Unit
A1.STPOS
Starting position
0.0 ... 100.0
%
A2.STTOL
Starting tolerance
0.1 ... 2.0 ... 10.0
%
A3.STEP
Stroke magnitude
0.1 ... 10.0 ... 100.0
%
A4.STEPD
Stroke direction
uP / do / uP do
A5.INTRV
Test interval
OFF / 1 ... 365
Days
A6.PSTIN
Reference stroke time for partial stroke test
NOINI / (C)##.# / Fdini / rEAL
s
A7.FACT1
Factor 1
0.1 ... 1.5 ... 100.0
A8.FACT2
Factor 2
0.1 ... 3.0 ... 100.0
A9.FACT3
Factor 3
0.1 ... 5.0 ... 100.0
Overview parameter b
Parameter
Function
Parameter values
b. DEVI
General control valve fault with the following parameters:
Unit
b1.TIM
Time constant
Auto / 1 ... 400
s
b2.LIMIT
Limit
0.1 ... 1.0 ... 100.0
%
b3.FACT1
Factor 1
0.1 ... 5.0 ... 100.0
b4.FACT2
Factor 2
0.1 ... 10.0 ... 100.0
b5.FACT3
Factor 3
0.1 ... 15.0 ... 100.0
Overview parameter C
Parameter
Function
C. LEAK
Pneumatic leakage with the following parameters:
Parameter values
C1.LIMIT
Limit
0.1 ... 30.0 ... 100.0
C2.FACT1
Factor 1
0.1 ... 1.0 ... 100.0
C3.FACT2
Factor 2
0.1 ... 1.5 ... 100.0
C4.FACT3
Factor 3
0.1 ... 2.0 ... 100.0
Unit
%
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9.1 Overview of the parameters
Overview parameter d
Parameter
Function
Parameter values
d. STIC
Friction (slip-stick effect) with the following parameters:
d1.LIMIT
Limit
0.1 ... 1.0 ... 100.0
d2.FACT1
Factor 1
0.1 ... 2.0 ... 100.0
d3.FACT2
Factor 2
0.1 ... 5.0 ... 100.0
d4.FACT3
Factor 3
0.1 ... 10.0 ... 100.0
Unit
%
Overview parameter E
Parameter
Function
E. DEBA
Deadband monitoring with the following parameters:
E1.LEVL3
Threshold
Parameter values
Unit
0.1 ... 2.0 ... 10.0
%
Parameter values
Unit
Overview parameter F
Parameter
Function
F. ZERO
Zero point monitoring with the following parameters:
F1.LEVL1
Threshold 1
0.1 ... 1.0 ... 10.0
F2.LEVL2
Threshold 2
0.1 ... 2.0 ... 10.0
F3.LEVL3
Threshold 3
0.1 ... 4.0 ... 10.0
%
Overview parameter G
Parameter
Function
Parameter values
G. OPEN
Displacement of the upper stop with the following parameters:
G1.LEVL1
Threshold 1
0.1 ... 1.0 ... 10.0
G2.LEVL2
Threshold 2
0.1 ... 2.0 ... 10.0
G3.LEVL3
Threshold 3
0.1 ... 4.0 ... 10.0
Unit
%
Overview parameter H
Parameter
Function
Parameter values
H. TMIN
Monitoring of the lower limit temperature with the following parameters:
Unit
H1.TUNIT
Temperature unit
°C
°F
H2.LEVL1
Threshold 1
-40 ... -25 ... 90
-40 ... 194
H3.LEVL2
Threshold 2
-40 ... -30 ... 90
-40 ... 194
H4.LEVL3
Threshold 3
-40 ... 90
-40 ... 194
°C/°F
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9.1 Overview of the parameters
Overview parameter J
Parameter
Function
Parameter values
J. TMAX
Monitoring of the upper limit temperature with the following parameters:
Unit
J1.TUNIT
Temperature unit
°C
°F
°C/°F
J2.LEVL1
Threshold 1
-40 ... 75 ... 90
-40 ... 194
J3.LEVL2
Threshold 2
-40 ... 80 ... 90
-40 ... 194
J4.LEVL3
Threshold 3
-40 ... 90
-40 ... 194
Overview parameter L
Parameter
Function
Parameter values
L. STRK
Monitoring the path integral with the following parameters:
L1. LIMIT
Limit for the number of changes of direction
1 ... 1E6 ... 1E8
L2.FACT1
Factor 1
0.1 ... 1.0 ... 40.0
L3.FACT2
Factor 2
0.1 ... 2.0 ... 40.0
L4.FACT3
Factor 3
0.1 ... 5.0 ... 40.0
Unit
Overview parameter O
Parameter
Function
Parameter values
O. DCHG
Monitoring the changes in direction with the following parameters:
O1.LIMIT
Limit for the number of changes of direction
1 ... 1E6 ... 1E8
O2.FACT1
Factor 1
0.1 ... 1.0 ... 40.0
O3.FACT2
Factor 2
0.1 ... 2.0 ... 40.0
O4.FACT3
Factor 3
0.1 ... 5.0 ... 40.0
Unit
Overview parameter P
Parameter
Function
P. PAVG
Position mean value calculation with the following parameters:
Parameter values
Unit
P1.TBASE
Time base of the mean value generation
0.5h / 8h / 5d / 60d / 2.5y
P2.STATE
State of the position mean value calculation
IdLE / rEF / ###.# / Strt
P3.LEVL1
Threshold 1
0.1 ... 2.0 ... 100.0
%
P4.LEVL2
Threshold 2
0.1 ... 5.0 ... 100.0
%
P5.LEVL3
Threshold 3
0.1 ... 10.0 ... 100.0
%
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9.2 Description of parameters
9.2
Description of parameters
9.2.1
Description of parameters 1 to 5
1.YFCT - actuator type
You can use this parameter to adjust the positioner as per the respective actuator and, if
required, as per the position sensor used. The following parameter values are available:
● YFCT = turn
Use this parameter value for a part-turn actuator.
The subsequent parameter "2.YAGL" is automatically set to 90° and cannot be changed.
● YFCT = WAY (factory setting)
Use this parameter value for a linear actuator. The positioner compensates the nonlinearity 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.
● YFCT = LWAY
Use this parameter value for:
– An external linear potentiometer on a linear actuator.
– An external linear potentiometer on a part-turn actuator with a reverse direction of
action.
● YFCT = ncSt
Use this parameter value when you use a non contacting sensor on a part-turn actuator.
● YFCT = -ncSt
Use this parameter value when you use a non contacting sensor on a part-turn actuator
with a reverse direction of action.
● YFCT = ncSL
Use this parameter value when you use a non contacting sensor on a linear actuator.
● YFCT = ncSLL
Use this parameter value when you use a non contacting sensor on a linear actuator for
which the position is transformed by a lever into a rotary movement.
Note
The "3.YWAY" parameter is displayed only for "WAY" and "ncSLL".
The factory setting is "WAY".
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9.2 Description of parameters
2.YAGL - angle of rotation of the feedback shaft
Use this parameter for a linear actuator. For a linear actuator, set an angle of 33° or 90°
depending on the range of stroke. The following is applicable:
● 33° for strokes ≤ 20 m
● 90° for strokes > 20 m
Both angles are possible if the lever up to 35 mm stroke is used. The long lever with a stroke
greater than 35 mm is intended for an angle of 90°. The long lever is not part of the mounting
kit 6DR4004-8V. Order the long lever separately using order number 6DR4004-8L.
The "YFCT = turn" parameter value sets an angle of 90° automatically for part-turn actuators.
Note
Matching the angles
Ensure that the values set in the transmission ratio selector and the "2.YAGL" parameter
match. If not, the value shown on the display does not match the actual position.
The factory setting is "33°".
9.2.1.1
Description of parameters 3 to 5
3.YWAY - display of the range of stroke
Use this parameter to set the value for the real range of stroke. This parameter is optional.
You must set this parameter only if the determined value in mm is to be displayed at the end
of the initialization process of a linear actuator.
Determine the value for the range of stroke as follows:
Fix the carrier pin on the lever at the desired position. This position on the lever has a
specific scaled value, e.g. 25. Set this scaled value in the "YWAY" parameter.
If you select the "OFF" parameter value, the real stroke is not displayed after initialization.
Note
The value set in the "YWAY" parameter must match with the mechanical range of stroke. Set
the carrier to the value of the actuator stroke. If the actuator stroke is not scaled, set it to the
next higher scaled value.
The factory setting is "OFF".
4.INITA - automatic initialization
Use this parameter to start the automatic initialization process. Select the "Strt" parameter
button for at least 5 seconds. The sequence of the initialization
value. Then press the
process from "RUN1" to "RUN5" is output in the bottom line of the display.
The factory setting is "NOINI".
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9.2 Description of parameters
5.INITM - manual initialization
Use this parameter to start the manual initialization process. Select the "Strt" parameter
button for at least 5 seconds.
value. Then press the
Note
If the positioner has already been initialized and if the "INITA" and "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.
The factory setting is "NOINI".
9.2.2
Description of parameters 6 to 53
9.2.2.1
Description of parameter 6
6.SDIR - setpoint direction
Use this parameter to set the setpoint direction. The setpoint direction is used to reverse the
direction of action of the setpoint. The setpoint direction is mainly used for single-acting
actuators with the "uP" safety position.
The factory setting is "riSE".
See also
Description of parameters 7 and 8 (Page 157)
9.2.2.2
Description of parameters 7 and 8
7.TSUP - setpoint ramp up
and
8.TSDO - setpoint ramp down
The setpoint ramp is effective in the automatic mode and restricts the modification speed of
the effective setpoint. When switching over from the manual to the automatic mode, the
setpoint ramp is used to adjust the effective setpoint to the setpoint of the positioner.
The shock-free switchover from the manual to the automatic mode prevents excessive
increase in pressure in long pipelines.
Two actuating times are determined during the initialization process. In the "TSUP = Auto"
position, the slower of the two actuating times is used for the setpoint ramp. The "TSDO"
parameter then has no effect.
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9.2 Description of parameters
The factory setting is "0".
9.2.2.3
Description of parameter 9
9.SFCT - setpoint function
Use this parameter to linearize the non-linear valve characteristic curves. Any flow
characteristics can be simulated in case of linear valve characteristic curves. Refer to the
pictures you can find in chapter "Description of parameters 10 to 30 (Page 159)".
Seven valve characteristic curves are stored in the positioner and are set using the "SFCT"
parameter:
Valve characteristic curve
Setting with parameter value
Linear
Lin
Equal percentage
1:25
1-25
Equal percentage
1:33
1-33
Equal percentage
1:50
1-50
Inverse equal percentage
25:1
n1-25
Inverse equal percentage
33:1
n1-33
Inverse equal percentage
50:1
n1-50
Freely adjustable
FrEE
The factory setting is "Lin".
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9.2 Description of parameters
9.2.2.4
Description of parameters 10 to 30
10.SL0 to 30.SL20 - setpoint support points
Use these parameters to allocate a characteristic flow value at a distance of 5% to the
corresponding setpoint support point. These points lead to a polyline with 20 linear sections
which form a valve characteristic line:
Setpoint characteristic curves, standardization of manipulated variable and tight closing
function
Setpoint support points can be entered only for "9.SFCT = FrEE". You may only enter a
monotonously rising characteristic curve, and two successive support values must differ by
at least 0.2%.
The factory setting is "0", "5" ... "95", "100".
See also
Description of parameter 9 (Page 158)
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9.2 Description of parameters
9.2.2.5
Description of parameter 31
31.DEBA - dead zone of the controller
In the automatic mode, use this parameter and the "Auto" parameter value to adjust the
dead zone continuously as per the requirements of the control loop in an adaptive manner. If
a control deviation is detected, the dead zone is increased stepwise. A time criterion is used
for the reverse adaptation.
The fixed set value is used for the dead zones in other discrete settings.
The factory setting is "Auto".
9.2.2.6
Description of parameters 32 and 33
32.YA - start of the manipulated variable limit
The factory setting is "0".
and
33.YE - end of the manipulated variable limit
Use these parameters to limit the mechanical actuator travel between the end stops to the
set values. This helps in limiting the mechanical actuating range of the actuator to the
effective flow rate and in preventing the integral saturation of the guiding controller. For this
purpose, see the picture below the also-see link.
Note
Setting
"YE" must always be set greater than "YA".
The factory setting is "100".
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9.2 Description of parameters
9.2.2.7
Description of parameter 34
YNRM - Normalization of manipulated variable
Using the "YA" and "YE" parameters, you can limit the manipulated variable. This limitation
causes two different scaling types, MPOS or FLOW, for the display and for the position
feedback through the current output. See the figure below.
The MPOS scaling type shows the mechanical position from 0 to 100% between the hard
stops of the initialization. The position is not influenced by the "YA" or "YE" parameters. The
parameters "YA" and "YE" are shown in the MPOS scale.
The FLOW scale is the standardization from 0 to 100% in the range between the "YA" and
"YE" parameters. Over this range, the setpoint w is also always 0 to 100%. This results in a
more or less flow-proportional display and position feedback "IY". The flow-proportional
display and position feedback "IY" also results from the use of valve characteristics.
In order to calculate the control deviation, the setpoint in the display is also shown in the
corresponding scale.
The following uses the example of an 80-mm linear actuator to illustrate the dependence of
the stroke on the scaling as well as the parameters "YA" and "YE".
Figure 9-1
YNRM = MPOS or YNRM = FLOW; default: YA = 0 % and YE = 100 %
Figure 9-2
Example: YNRM = MPOS with YA = 10 % and YE = 80 %
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9.2 Description of parameters
Figure 9-3
Example: YNRM = FLOW with YA = 10 % and YE = 80 %
The factory setting is "MPOS".
See also
Description of parameters 32 and 33 (Page 160)
Description of parameter 35 (Page 162)
9.2.2.8
Description of parameter 35
35.YCLS - tight closing manipulated variables
Use this parameter to move the valve using the maximum torque of the actuator (permanent
contact of piezo valves) into the seat. The tight closing function can be activated on one side
or for both end positions. "35.YCLS" becomes effective when the effective setpoint is at or
below "36.YCDO" or at or above "37.YCUP". See the picture in chapter "Description of
parameters 10 to 30 (Page 159)".
Note
Activated tight closing function
If the tight closing function is activated, then for parameter "45. LIM" the monitoring of
regulation deviation is turned off in the appropriate overflow direction. "YCDO: < 0 %" and
"YCUP: > 100 %" are applicable in such a case. This function is mainly advantageous for the
valves with soft seats. In order to monitor the end positions for a long time, we recommend
activating the "F. ZERO" and "G. OPEN" parameters.
The factory setting is "no".
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9.2 Description of parameters
9.2.2.9
Description of parameters 36 and 37
36.YCDO - value "down tight closing"
The factory setting is "0".
and
37.YCUP- value "up tight closing"
Note
"36.YCDO" must always be set greater than "37.YCUP". The tight closing function has a
fixed hysteresis of 1%. "36.YCDO" and "37.YCUP" refer to mechanical end stops.
Mechanical end stops are independent of the setting of "6.SDIR".
The factory setting is "100".
See also
Description of parameter 35 (Page 162)
9.2.2.10
Description of parameters 38 and 39
38.BIN1 - function binary input 1
and
39.BIN2 - function binary input 2
Use these parameters to determine the function of binary inputs. The possible functions are
described below. The direction of action can be adjusted as per a normally open contact or a
normally closed contact.
● BIN1 or BIN2 = on or -on
Binary messages of peripherals (e.g. pressure or temperature switch) can be read
through the communication interface, or they lead to the response of the fault message
output through a logical OR combination with other messages.
● BIN1 = bLoc1
Use this parameter value to interlock the "Configuration" mode against adjustment. For
example, a wire jumper between terminals 9 and 10 is used for interlocking.
● BIN1 = bLoc2
If binary input 1 has been activated, the "Manual" as well as "Configuration" modes are
blocked.
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9.2 Description of parameters
● BIN1 or BIN2 = uP and doWn (contact closed) or -uP and -doWn (contact open).
If the binary input is activated, the actuator uses the value defined by "YA" and "YE" for
controlling in the "Automatic" mode.
● BIN1 or BIN2 (contact closed) = StoP or -StoP (contact open).
In "Automatic" operating mode the piezo valves are blocked when the binary input is
activated. The actuator remains in the last position. Leakage measurements can then be
taken without the initialization function.
● BIN1 or BIN2 = PSt or -PSt
Binary inputs 1 or 2 can be used to initiate a partial stroke test by pressing either a
normally closed or a normally open contact depending on the choice.
● BIN1 or BIN2 = OFF (factory setting)
No function
The following is applicable if one of the aforementioned functions has been activated
simultaneously using the "BIN1" and "BIN2" parameters: "Blocking" has priority over "uP"
and "uP" has priority over "doWn".
The factory setting is "OFF".
9.2.2.11
Description of parameter 40
40.AFCT - alarm function
Six setting options are available:
1. Min Max
2. Min Min
3. Max Max
4. -Min -Max (inverting message)
5. -Min -Min (inverting message)
6. -Max -Max (inverting message)
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9.2 Description of parameters
Direction of action and hysteresis
Alarm unit
Examples:
A1 = 48
A1
A2
A2 = 52
AFCT = MIN / MAX
Path = 45
Active
Path = 50
Path = 55
A1 = 48
A2 = 52
Active
AFCT = -MIN / -MAX
Path = 45
Active
Path = 50
Active
Path = 55
Active
A1 = 52
Active
A2 = 48
AFCT = MIN / MAX
Path = 45
Active
Path = 50
Active
Path = 55
A1 = 52
A2 = 48
Active
Active
AFCT = -MIN / -MAX
Path = 45
Active
Path = 50
Path = 55
Active
Note that:
● Both limits can be evaluated separately in the control system only for settings 1 or 4 since
both the limits, A1 and A2 are connected to each other through a logical OR combination
in the "READBACK" and "POS_D" status messages.
● The response of both limits cannot be detected in the "READBACK" and "POS_D" status
reports if the positioner is in the manual mode.
● The direction of action shown reverses for an alarm unit.
● The direction of action also reverses when the setting of the response threshold of alarms
in the "41.A1" parameter is greater than that in the "42.A2" parameter.
● The hysteresis of the limit is 1% by default.
● In the factory setting "OFF", the output of both alarms "41.A1" and "42.A2" is deactivated.
The factory setting is "OFF".
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9.2 Description of parameters
See also
Description of parameter 48 (Page 169)
9.2.2.12
Description of parameters 41 and 42
41.A1 - response threshold of alarm 1
The factory setting is "10.0".
and
42.A2 - response threshold of alarm 2
Use these parameters to set the alarm thresholds that are used to trigger an alarm. The
response thresholds of the "41.A1" and "42.A2" alarms refer to the MPOS scale that
corresponds to the mechanical path.
The factory setting is "90.0".
9.2.2.13
Description of parameter 43
43. FCT - function of the fault message output
The fault message in the form of monitoring of control deviation over time can also be
triggered due to the following events:
● Power failure
● Processor fault
● Actuator fault
● Valve fault
● Compressed air failure
● Threshold 3 error message of advanced diagnostics.
See Description of parameter 48 (Page 169) , 48.XDIAG - Activating advanced
diagnostics.
Note that the fault message cannot be switched off. It can however be suppressed (factory
setting) when you switch over to "No automatic mode". If you also want to generate a fault
message here, you will need to set the "43.FCT" parameter to "nA".
You also have an option to connect the fault message with the status of binary inputs using a
logical OR combination. For this purpose, set the "32.FCT" parameter to "nAb".
Select the "- " setting if you want the fault message output inverted on the alarm or SIA
module.
The factory setting is " ".
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9.2 Description of parameters
9.2.2.14
Description of parameter 44
44. TIM - monitoring time to set the fault messages
Use this parameter to set the value in seconds before which the positioner must attain the
corrected status. The corresponding response threshold is defined using the "45. LIM"
parameter.
The fault message output is set when the set time is exceeded.
Note
Activated tight closing function
If the tight closing function is activated, the monitoring of control deviation in the
corresponding overrun direction is switched off for the "45. LIM" parameter. "YCDO: < 0 %"
and "YCUP: > 100 %" are applicable in such a case. This function is mainly advantageous
for the valves with soft seats. In order to monitor the end positions for a long time, we
recommend activating the "F. ZERO" and "G. OPEN" parameters.
The factory setting is "Auto".
9.2.2.15
Description of parameter 45
45. LIM - response threshold of fault message
Use this parameter to set a value for the permissible extent of the control deviation to trigger
a fault message. The value is specified in percent.
If the "44. TIM" and "45. LIM" parameters have been set to "Auto", the fault message is set
when the slow step zone is not reached within a specific time. The "Auto" setting is the
factory setting. Within 5 to 95% of the actuator travel, this time is two times the initialization
time, and outside 10 to 90% it is ten times the initialization time.
Note
Activated tight closing function
If the tight closing function is activated, the monitoring of control deviation in the
corresponding overrun direction is switched off for the "45. LIM" parameter. "YCDO: < 0 %"
and "YCUP: > 100 %" are applicable in such a case. This function is mainly advantageous
for the valves with soft seats. In order to monitor the end positions for a long time, we
recommend activating the ""F. ZERO" and "G. OPEN" parameters.
The factory setting is "Auto".
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9.2 Description of parameters
9.2.2.16
Description of parameter 46
46. STRK - limit for monitoring the path integral (number of strokes)
Use this parameter to set the limit for the path integral. This parameter corresponds to the
profile parameter "TOTAL_VALVE_TRAVEL_LIMIT" and was applied for compatibility
reasons.
If the configured limit is exceeded, the bit "CB_TOT_VALVE_TRAV" is set in the profile
parameter "CHECK_BACK".
This function enables preventive maintenance of the control valve.
Note
Path integral
The path integral can also be monitored by the advanced diagnostics. Refer to chapter
"Description of parameter 48 (Page 169).XDIAG - activation of advanced diagnostics" and
chapter "Description of parameter L (Page 186) .STRK - monitoring the path integral".
The factory setting is "1E9".
9.2.2.17
Description of parameter 47
47.PRST - Preset
Use this parameter to restore the factory settings. To do this, press the
5 seconds.
button for at least
In particular when the positioner was already used previously on a different actuator, you
must always restore factory settings before a fresh initialization. This is the only way to
ensure known start conditions. The "PRST" parameter is available for this purpose.
We recommend that you restore factory settings when you have changed many parameters
at once without being able to predict their effect and undesired reactions have occurred as a
result.
Not all parameters are set to the factory setting if "no" is shown on the display. All
parameters are set to the factory setting if "oCAY" is shown on the display.
Note
If you have activated the "Preset" parameter value for the factory setting, you must reinitialize the positioner. All previously configured maintenance
parameters will be deleted.
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9.2 Description of parameters
9.2.2.18
Description of parameter 48
48.XDIAG - activation of advanced diagnostics
This parameter is used to activate advanced diagnostics. Advanced diagnostics is
deactivated by default. The "48.XDIAG" parameter is set to "OFF". Three operating modes
are available to activate advanced diagnostics:
● On1: Advanced diagnostics is activated. Threshold 3 error messages are output via the
fault message output.
● On2: advanced diagnostics is activated. The threshold 2 error messages are activated via
alarm output 2. Threshold 3 error messages are also output via the fault message output.
● On3: advanced diagnostics is activated. Threshold 1 error messages are activated via
alarm output 1. Threshold 2 error messages are activated via alarm output 2. Threshold 3
error messages are also output via the fault message output.
Note
Activation of advanced diagnostics
Please note that the parameters of advanced diagnostics from "A. PST" to "P. PAVG"
will only be shown on the display after one of the modes "On1" to "On3" has been
selected.
In the factory settings, parameters "A. PST" to "P. PST" are deactivated by default.
Parameter "48.XDIAG" is set to "OFF". The corresponding parameters are only displayed
after you activate the appropriate menu item with "On".
In advanced diagnostics, the threshold of the fault message is displayed using columns in
addition to the error code. These columns are shown on the display as follows:
Figure 9-4
Display of a threshold 1 fault message
Figure 9-5
Display of a threshold 2 fault message
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9.2 Description of parameters
Figure 9-6
Display of a threshold 3 fault message
The factory setting is "OFF".
See also
Description of parameter A (Page 172)
XDIAG parameter (Page 253)
9.2.2.19
Description of parameter 49
49.FSTY - safety position
Use this parameter to move the actuator to a defined safety position when communication
fails. Three settings are available:
● FSVL:
the actuator is controlled using the configured safety setpoint. This value also becomes
effective following failure of the auxiliary power supply.
● FSSP:
the actuator is controlled using the last effective setpoint.
● FSAC:
the positioner responds in the same way as when the auxiliary power supply fails, see
Figure 5-21 Regulating action of pneumatic connection (Page 96).
The factory setting is "FSAC".
See also
Pneumatic connection versions (Page 95)
9.2.2.20
Description of parameter 50
50.FSTI - monitoring time to set the safety position
If communication fails, the positioner switches to the safety position after the set value
expires.
The factory setting is "0".
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9.2 Description of parameters
9.2.2.21
Description of parameter 51
51.FSVL - safety setpoint
Default value of the safety position.
Note that the "FSVL" safety setpoint of 0% always refers to the mechanical position in which
the actuator is depressurized. The mechanical position is especially important if you have set
the "6.SDIR" parameter to "FALL" and expect 100% mechanical position at 0% setpoint
default. The "6.SDIR = FALL" setting corresponds a declining characteristic curve of the
setpoint.
The factory setting is "0.0".
See also
Description of parameter 6 (Page 157)
9.2.2.22
Description of parameter 52
52.STNR - station number
A separate station number must be set on each device in order to address the devices on
the bus separately.
The factory setting is "126".
9.2.2.23
Description of parameter 53
53.IDENT - device operating mode
The positioner identifies two device operating modes with respect to the response to the DP
master of class 1:
● [0] profile-compliant:
can be replaced with positioners of other manufacturers complying with PROFIBUS PA
profile 3.0.
● [1] profile-compliant with extensions:
complete functional range of the positioner (condition at delivery).
Note
A specific GSD file is allocated to every device operating mode.
If the configuration of your PROFIBUS PA path does not match the set device operating
mode, the device cannot accept the cyclic data exchange. The station number and the
device operating mode cannot be modified during ongoing communication with a master
of class 1.
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9.2 Description of parameters
A successfully established connection with a cyclic master can be detected when the
positioner responds to the setpoint of the master.
A blinking decimal point in the upper line of the positioner display indicates communication
with an acyclic master.
The factory setting is "1".
See also
Cyclic data transfer (Page 206)
9.2.3
Description of parameters A to P
9.2.3.1
Description of parameter A
A. PST - partial stroke test
Use this parameter to activate the partial stroke test for cyclic or manual testing of
open/closed and control valves. Set the "On" parameter value to activate the test. Subparameters are displayed. If the sub-parameters are set to the desired parameter values,
initiate the partial stroke test using:
● Buttons on the device
● A binary input
● Communication
● A cyclic test interval
Sub-parameters are described below.
The factory setting is "OFF".
A1.STPOS - starting position
Use this sub-parameter to define the starting position of the partial stroke test in percent. To
this end, set the starting position within a range from "0.0" to "100.0".
The factory setting is "100.0".
A2.STTOL - starting tolerance
Use this sub-parameter to define the starting tolerance of the partial stroke test in percent.
Set the starting tolerance relative to the starting position in a range from "0.1" to "10.0".
Example: You have set 50% as a starting position and 2% as a starting tolerance. In this
case, a partial stroke test is initiated during operation only between a current position of 48
and 52%.
The factory setting is "2.0".
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9.2 Description of parameters
A3.STEP - stroke magnitude
Use this sub-parameter to define the stroke magnitude of the partial stroke test in percent.
To this end, set the stroke magnitude within a range from "0.1" to "100.0".
The factory setting is "10.0".
A4.STEPD - stroke direction
Use this sub-parameter to set the stroke direction of the partial stroke test. The following
parameter values are available:
● "uP" for up
● "do" for down
● "uP do" for up and down
If you select the "uP" parameter value, it leads to the following:
● The actuator moves from the starting position to the target position without control.
● After reaching the target position, the actuator moves back to the starting position in a
controlled manner.
The target position is determined from the starting position plus the stroke magnitude.
The same procedure in the reverse order is applicable for the "do" parameter value.
If you select the "uP do" parameter value, it leads to the following:
● The actuator first moves from its starting position to the upper target position without
control.
● Then, the actuator moves from the upper target position to the lower target position
without control.
● After reaching the lower target position, the actuator moves back to the starting position in
a controlled manner.
The upper target position is determined from the starting position plus the stroke magnitude.
The lower target position is determined from the starting position minus the stroke
magnitude.
The factory setting is "do".
A5.INTRV - test interval
Use this sub-parameter to enter the interval time for the cyclic partial stroke test in days. Set
the test interval in a range from 1 to 365.
The factory setting is "OFF".
A6.PSTIN - partial stroke test reference stroke time (PSTIN = partial stroke test initialization)
Use this sub-parameter to measure the reference stroke time for the partial stroke test. The
unit is seconds. The reference stroke time corresponds to the controlled movement from the
starting position to the target position.
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9.2 Description of parameters
The positioner must be initialized in order to measure a reference stroke time. If the
positioner is not yet initialized, the display shows "NOINI". If the positioner has already been
initialized, the calculated average travel time of the control valve is displayed as a reference
value.
Example: An average travel time of 1.2 seconds is shown in the display as "C 1.2", where
"C" stands for "calculated". The average travel time can be used as a reference stroke time.
However, it merely represents a rough default value.
Set the sub-parameters "A1" to "A5" as per your requirements. Then start measuring the
button for at least 5 seconds. The display shows
reference stroke time by pressing the
"rEAL" during these 5 seconds.
The device then moves to the configured starting position automatically and executes the
desired stroke. The current position in percent is continuously shown on the display. "inPST"
for "initialize partial stroke test" appears in the lower line of the display. When the test is
completed, the measured reference stroke time in seconds is shown. "Fdini" is displayed if
the starting position cannot be approached or the stroke target cannot be achieved. "Fdini"
stands for "failed PST initialization".
The factory setting is "NOINI".
A7.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of the reference stroke time
and "A7.FACT1". The process to determine the reference stroke time is described under
"A6.PSTIN".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "1.5".
A8.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of the reference stroke time
and "A8.FACT2". The process to determine the reference stroke time is described under
"A6.PSTIN".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "3.0".
A9.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of the reference stroke time
and "A9.FACT3". The process to determine the reference stroke time is described under
"A6.PSTIN".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
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9.2 Description of parameters
If the time threshold is exceeded, the control signal of the actuator is simultaneously
cancelled to prevent a sticky or rusty valve, if any, from breaking off and overshooting.
The partial stroke test is then interrupted temporarily, a threshold 3 error message is
reported, and the actuator is moved back to its starting position.
The factory setting is "5.0".
See also
Description of parameter 48 (Page 169)
9.2.3.2
Description of parameter b
b. DEVI - general control valve fault
Use this parameter to activate the general control valve fault test for dynamic monitoring of
the control valve response. The actual position course is compared with the expected
position course for this purpose. This comparison helps in drawing a conclusion about the
correct operational response of the control valve. Set the "On" parameter value to activate
the test. Sub-parameters are displayed. Sub-parameters are described below.
The current value is displayed in the "14 DEVI" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds one of the three configurable limit
thresholds.
The factory setting is "OFF".
b1.TIM - time constant of the low-pass filter
Use this sub-parameter to define the attenuation effect of the low-pass filter. The unit is
seconds. This sub-parameter is set to "Auto" if the device is initialized automatically. The
"b1.TIM" time constant is determined from the initialization parameters such as "uP" and
"doWn" actuating times.
If the time constant is not adequate, the setting of "b1.TIM" can be changed manually. Set
the time constant in a range from "1" to "400". In this case:
● Setting "1" indicates too weak an attenuation.
● Setting "400" indicates too strong an attenuation.
The current value is displayed in the "14 DEVI" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds one of the three configurable limit
thresholds.
The factory setting is "Auto".
b2.LIMIT - limit of the general control valve fault
Use this sub-parameter to set a base limit in percent. The base limit defines the magnitude
of the permissible deviation from the expected position course. The limit serves as a
reference variable for the fault message factors.
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9.2 Description of parameters
Set the base limit in a range from "0.1" to "100.0".
The factory setting is "1.0".
b3.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "b2.LIMIT" and
"b3.FACT1".
The threshold 1 fault message is displayed when the limit threshold 1 is exceeded. The
process to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "5.0".
b4.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "b2.LIMIT" and
"b4.FACT2".
The threshold 2 fault message is displayed when the limit threshold 2 is exceeded. The
process to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "10.0".
b5.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "b2.LIMIT" and
"b5.FACT3".
The threshold 3 fault message is displayed when the limit threshold 3 is exceeded. The
process to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "15.0".
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9.2 Description of parameters
9.2.3.3
Description of parameter C
C. LEAK - pneumatic leakage
Use this parameter to activate the pneumatic leakage test. This test can be used to
determine possible pneumatic leakages. Depending on the direction, changes in the position
and the internal manipulated variable used for it are continuously recorded and filtered for
this purpose. The filter result is used to form an indicator, which allows drawing a conclusion
about a possible leakage.
Note
Accuracy of results
Note that this test delivers unambiguous results only in the case of single-acting, springloaded actuators.
Set the "On" parameter value to activate the test. Sub-parameters are displayed. Subparameters are described below.
The current value is displayed in the "15 ONLK" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds one of the three configurable limit
thresholds.
The factory setting is "OFF".
C1.LIMIT - limit of the leakage indicator
Use this sub-parameter to set the limit of the leakage indicator in percent. Set the limit in a
range from "0.1" to "100.0". If no leakage exists, the leakage detection is automatically
calibrated in such a way during the initialization (see chapter "Commissioning (Page 111)")
that the leakage indicator remains below the value 30. If a value above 30 is displayed, this
means that a leakage exists. "30.0" is therefore an advisable setting for the parameter. After
a certain time this limit can be varied slightly depending on the application. To optimize the
sensitivity of the leakage detection to your specific application, follow these steps:
1. After initializing the positioner automatically, use a calibration device to initiate a ramp
movement.
2. Conditions for the ramp movement:
– The ramp covers the normal operating range of the valve.
– The steepness of the ramp matches the dynamic requirements of the corresponding
application.
– The characteristic of the ramp corresponds to the characteristic of the setpoint that
actually occurs.
3. During the ramp movement, the "15 ONLK" diagnostics parameter provides information
about the actual values. Define the limit of the leakage indicator accordingly.
The positioner triggers a fault message if the current value exceeds one of the three
configurable limit thresholds. How to set the three limit thresholds is described below.
The factory setting is "30.0".
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9.2 Description of parameters
C2.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "C1.LIMIT" and
"C2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
procedure to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "1.0".
C3.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "C1.LIMIT" and
"C3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
procedure to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "1.5".
C4.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "C1.LIMIT" and
"C4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
procedure to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "2.0".
9.2.3.4
Description of parameter d
d. STIC - static friction/slipstick effect
Use this parameter to continuously monitor the current static friction of the final controlling
element (slipstick). If the parameter is activated, the positioner detects the slipstick effects
that may occur. Sudden changes in the valve position, so-called slip jumps, indicate
excessive friction. If slip jumps are detected, the filtered stroke magnitude is saved as a
slipstick value. If slip jumps no longer exist, the slipstick value is reduced slowly.
Set the parameter value to "On" to activate the test. Sub-parameters are displayed. Subparameters are described below.
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9.2 Description of parameters
The current value is displayed in the "16 STIC" diagnostics parameter. The positioner
triggers an error message if the current value exceeds a limit threshold.
Note
Incorrect interpretation in case of actuating times below one second
If the actuating times are less than one second, the positioner does not accurately
differentiate between a normal movement of the actuator and a reverse change. Therefore,
increase the actuating time if required.
The factory setting is "OFF".
d1.LIMIT - limit for slipstick detection
Use this sub-parameter to set the base limit for slipstick detection in percent. Set the base
limit in a range from "0.1" to "100.0".
The factory setting is "1.0".
d2.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "d1.LIMIT" and
"d2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
process to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "2.0".
d3.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "d1.LIMIT" and
"d3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
process to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "5.0".
d4.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "100.0". The limit threshold is the product of "d1.LIMIT" and
"d4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
process to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "10.0".
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9.2 Description of parameters
9.2.3.5
Description of parameter E
E. DEBA - deadband monitoring
Use this parameter to activate the "deadband monitoring" test. This test can be used to
monitor the automatic adjustment of deadbands continuously.
Configure the following settings to activate the test:
1. Ensure that the "34.DEBA" parameter is set to "Auto".
2. Set the "E. DEBA" parameter to "On". The sub-menu to set the threshold value is
displayed. The test is activated.
3. Change the parameter in the sub-menu if required. The setting option is described below.
The positioner triggers a fault message if the current deadband exceeds the configured limit
threshold during the test.
The factory setting is "OFF".
E1.LEVL3 - threshold for monitoring the deadband adjustment
Use this sub-parameter to set the factor limit threshold to monitor the deadband adjustment.
Set the threshold in a range from "0.1" to "10.0".
The threshold 3 fault message is displayed when the current deadband exceeds the
threshold limit during the test. The procedure to activate and display this error message is
described in the "XDIAG" parameter.
Note
Fault message display
A three-stage fault message display has not been implemented for deadband monitoring.
The positioner triggers only threshold 3 fault messages depending on the setting.
The factory setting is "2.0".
9.2.3.6
Description of parameter F
F. ZERO - zero point displacement
Note
Fault detection
The monitoring unit for the zero point displacement responds to the fault in the valve. If the
limit thresholds of the zero point displacement are exceeded due to misalignment of the
position feedback, the misalignment also triggers a diagnostics message.
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9.2 Description of parameters
Use this parameter to activate the test to monitor the zero point displacement. The test is
executed whenever the valve is in the "down tight closing" position. The test checks whether
the value of the lower end stop has changed with respect to its value at the time of
initialization (zero point P0).
Configure the following settings to activate the test:
1. Ensure that the parameter "YCLS" manipulated variable tight closing parameter is set to
values "do" or "uP do".
2. Set the "F. ZERO" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
3. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The current zero point displacement is displayed in the "17 ZERO" diagnostics parameter.
The positioner triggers a fault message if the current value undershoots a threshold.
If the value undershoots a threshold, the fault message is saved in a power fail-safe manner
until:
● No fault occurs during a repeat test.
● The device is re-initialized.
● The "F. ZERO" parameter is deactivated.
The factory setting is "OFF".
F1.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in percent. Use threshold 1 to monitor the lower
hard end stop. Set the threshold in a range from "0.1" to "10.0".
The positioner triggers a fault message if the difference between the lower hard end stop
and the initialization value undershoots threshold 1. The process to activate and display this
fault message is described in the "XDIAG" parameter.
The factory setting is "1.0".
F2.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in percent. Use threshold 2 to monitor the lower
hard end stop. Set the threshold in a range from "0.1" to "10.0".
The positioner triggers a fault message if the difference between the lower hard end stop
and the initialization value undershoots threshold 2. The process to activate and display this
fault message is described in the "XDIAG" parameter.
The factory setting is "2.0".
F3.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in percent. Use threshold 3 to monitor the lower
hard end stop. Set the threshold in a range from "0.1" to "10.0".
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The positioner triggers a fault message if the difference between the lower hard end stop
and the initialization value undershoots threshold 3. The process to activate and display this
fault message is described in the "XDIAG" parameter.
The factory setting is "4.0".
9.2.3.7
Description of parameter G
G. OPEN - displacement of upper end stop
Note
Fault detection
The monitoring unit for the displacement of the upper end stops does not only respond to the
fault in the valve. If the limit thresholds of the displacement of the upper end stop are
exceeded due to the misalignment of position feedback, the misalignment also triggers a
diagnostics message.
Use this parameter to activate the test to monitor the displacement of the upper end stop.
The test is executed whenever the valve is in the "up tight closing" position. The test checks
whether the value of the upper hard end stop has changed with respect to its value at the
time of initialization (end stop P100).
Configure the following settings to activate the test:
1. Ensure that the parameter "YCLS" manipulated variable tight closing parameter is set to
values "uP" or "do uP".
2. Set the "G. OPEN" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
3. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The current displacement of the upper end stop is displayed in the "18 OPEN" diagnostics
parameter. The positioner triggers a fault message if the current value exceeds a threshold.
If the value exceeds a threshold, the fault message is saved in a power fail-safe manner
until:
● No fault occurs during a repeat test.
● The device is re-initialized.
● The "G. OPEN" parameter is deactivated.
The factory setting is "OFF".
G1.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in percent. Use threshold 1 to monitor the upper
hard end stop. Set the threshold in a range from "0.1" to "10.0".
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The positioner triggers a fault message if the difference between the upper hard end stop
and the initialization value exceeds threshold 1. The process to activate and display this fault
message is described in the "XDIAG" parameter.
The factory setting is "1.0".
G2.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in percent. Use threshold 2 to monitor the upper
hard end stop. Set the threshold in a range from "0.1" to "10.0".
The positioner triggers a fault message if the difference between the upper hard end stop
and the initialization value exceeds threshold 2. The process to activate and display this fault
message is described in the "XDIAG" parameter.
The factory setting is "2.0".
G3.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in percent. Use threshold 3 to monitor the upper
hard end stop. Set the threshold in a range from "0.1" to "10.0".
The positioner triggers a fault message if the difference between the upper hard end stop
and the initialization value exceeds threshold 3. The process to activate and display this fault
message is described in the "XDIAG" parameter.
The factory setting is "4.0".
9.2.3.8
Description of parameter H
H. TMIN - monitoring the lower limit temperature
Use this parameter to activate the test to continuously monitor the lower limit temperature
inside the enclosure. The current temperature in the enclosure is recorded by a sensor on
the electronic printed circuit board. The limit temperature is monitored in three stages.
Configure the following settings to activate the test:
1. Set the "H. TMIN" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The positioner triggers a fault message if the lower limit temperature undershoots a
threshold during the test.
The factory setting is "OFF".
H1.TUNIT - temperature unit
Use this sub-parameter to set the temperature unit "°C" or "°F". The selected temperature
unit is then also applicable for all other temperature-based parameters.
The factory setting is "°C".
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H2.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 1 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 1. The process to activate and display this fault message is described
in the "XDIAG" parameter.
The factory setting is "-25.0C".
H3.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 2 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 2. The process to activate and display this fault message is described
in the "XDIAG" parameter.
The factory setting is "-30.0C".
H4.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 3 to monitor the
lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
undershoots threshold 3. The process to activate and display this fault message is described
in the "XDIAG" parameter.
The factory setting is "-40.0C".
9.2.3.9
Description of parameter J
J. TMAX - monitoring the upper limit temperature
Use this parameter to activate the test to continuously monitor the upper limit temperature
inside the enclosure. The current temperature in the enclosure is recorded by a sensor on
the electronic printed circuit board. The limit temperature is monitored in three stages.
Configure the following settings to activate the test:
1. Set the "J. TMAX" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The positioner generates a fault message if the upper limit temperature exceeds a threshold
during the test.
The factory setting is "OFF".
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9.2 Description of parameters
J1.TUNIT - temperature unit
Use this sub-parameter to set the temperature unit "°C" or "°F". The selected temperature
unit is then also applicable for all other temperature-based parameters.
The factory setting is "°C".
J2.LEVL1 - threshold 1
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 1 to monitor the
upper limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 1. The process to activate and display this fault message is described in
the "XDIAG" parameter.
The factory setting is "75.0C".
J3.LEVL2 - threshold 2
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 2 to monitor the
upper limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 2. The process to activate and display this fault message is described in
the "XDIAG" parameter.
The factory setting is "80.0C".
J4.LEVL3 - threshold 3
Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 3 to monitor the
upper limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to
"194.0F".
The positioner triggers a fault message if the current temperature inside the enclosure
exceeds threshold 3. The process to activate and display this fault message is described in
the "XDIAG" parameter.
The factory setting is "90.0C".
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9.2 Description of parameters
9.2.3.10
Description of parameter L
L. STRK - monitoring the path integral
Use this parameter to monitor the entire path covered by the final controlling element
continuously.
Configure the following settings to activate the test:
1. Set the "L. STRK" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The following is applicable for the version with PROFIBUS communication: This test
determines the actuator movements in 100% strokes. In this case, a 100% stroke is equal to
twice the complete path, e.g. from ON→OFF and OFF→ON.
The following is applicable for the standard version and the version with
FOUNDATION fieldbus communication: This test determines the actuator movements in
100% strokes. In this case, a 100% stroke is equal to the complete path, e.g. from ON→OFF
or OFF→ON.
The current value is displayed in the "1 STRKS" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds a limit threshold.
The factory setting is "OFF".
L1.LIMIT - limit for the number of strokes
Use this sub-parameter to set the base limit for the number of strokes. Set the base limit in a
range from "1" to "1.00E8".
The factory setting is "1.00E6".
L2.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L2.FACT1".
The threshold 1 fault message is displayed when the limit threshold 1 exceeds. The process
to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "1.0".
L3.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L3.FACT2".
The threshold 2 fault message is displayed when the limit threshold 2 exceeds. The process
to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "2.0".
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L4.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "L1.LIMIT" and "L4.FACT3".
The threshold 3 fault message is displayed when the limit threshold 3 exceeds. The process
to activate and display this fault message is described in the "XDIAG" parameter.
The factory setting is "5.0".
See also
Display of diagnostics values (Page 241)
9.2.3.11
Description of parameter O
O. DCHG - monitoring the change of direction
Use this parameter to continuously monitor the number of changes of direction of the
actuator caused in the deadband.
Configure the following settings to activate the test:
1. Set the "O. DCHG" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
The current value is displayed in the "2 CHDIR" diagnostics parameter. The positioner
triggers a fault message if the current value exceeds a limit threshold.
The factory setting is "OFF".
O1.LIMIT - limit for the change of direction
Use this sub-parameter to set the base limit for the number of changes of direction of the
actuator. Set the base limit in a range from "1" to "1.00E8".
The factory setting is "1.00E6".
O2.FACT1 - factor 1
Use this sub-parameter to set the factor for the formation of limit threshold 1. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O2.FACT1".
The threshold 1 error message is displayed when the limit threshold 1 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "1.0".
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O3.FACT2 - factor 2
Use this sub-parameter to set the factor for the formation of limit threshold 2. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O3.FACT2".
The threshold 2 error message is displayed when the limit threshold 2 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "2.0".
O4.FACT3 - factor 3
Use this sub-parameter to set the factor for the formation of limit threshold 3. Set the factor in
a range from "0.1" to "40.0". The limit threshold is the product of "O1.LIMIT" and
"O4.FACT3".
The threshold 3 error message is displayed when the limit threshold 3 is exceeded. The
procedure to activate and display this error message is described in the "XDIAG" parameter.
The factory setting is "5.0".
See also
Display of diagnostics values (Page 241)
9.2.3.12
Description of parameter P
P. PAVG - calculation of position average
Use this parameter to activate the test to calculate and monitor the position average.
Configure the following settings to activate the test:
1. Set the "P. PAVG" parameter to "On". Sub-parameters to set the test parameters are
displayed. The test is activated.
2. Set the suitable parameter values in sub-parameters. The setting options available in
sub-parameters are described below.
During the test, the position and reference average values are always compared at the end
of a time interval. The positioner triggers an error message if the current position average
exceeds a threshold.
The factory setting is "OFF".
P1.TBASE - time base for averaging
Use this sub-parameter to set the time interval to calculate the position average.
The following values are available to define the time intervals:
● 30 minutes
● 8 hours
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9.2 Description of parameters
● 5 days
● 60 days
● 2.5 years
After starting the reference average calculation and the expiry of the time interval, a position
average over the interval period is determined and compared with the reference average.
The test is then restarted.
The factory setting is "0.5 h".
P2.STATE - status of the position average calculation
Use this sub-parameter to start the calculation of the position average. If a reference
average has never been determined, the parameter value is "IdLE".
Then start the calculation by pressing the
button for 5 seconds. The value in the display
changes from "IdLE" to "rEF". The reference average is calculated.
When the time interval expires, the calculated reference average is shown on the display.
Note
Current position average
The respective current position average is displayed in the "19.PAVG" diagnostics
parameter. If no position average has been calculated, "COMP" is displayed in the
"19.PAVG" diagnostics parameter.
The factory setting is "IdLE".
P3.LEVL1 - threshold 1
Use this sub-parameter to set threshold 1 for the maximum deviation of the current position
average from the reference average. Set the threshold in a range from "0.1" to "100.0".
The positioner triggers an error message if the difference between the position average and
the reference average exceeds threshold 1. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
The factory setting is "2.0".
P4.LEVL2 - threshold 2
Use this sub-parameter to set threshold 2 for the maximum deviation of the current position
average from the reference average. Set the threshold in a range from "0.1" to "100.0".
The positioner triggers an error message if the difference between the position average and
the reference average exceeds threshold 2. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
The factory setting is "5.0".
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P5.LEVL3 - threshold 3
Use this sub-parameter to set threshold 3 for the maximum deviation of the current position
average from the reference average. Set the threshold in a range from "0.1" to "100.0".
The positioner triggers an error message if the difference between the position average and
the reference average exceeds threshold 3. The procedure to activate and display this error
message is described in the "XDIAG" parameter.
The factory setting is "10.0".
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10.1
10
System integration
A control system (master) uses acyclic and cyclic data transfer to operate and monitor the
positioner. You must set an address of the positioner in advance so that it can communicate
with the master as a slave.
The PROFIBUS address is set to 126 in the as-delivered condition. You set the PROFIBUS
address on the device or use a configuration tool like SIMATIC PDM to set the address
through the bus.
10.2
Acyclic data transfer
10.2.1
Acyclic data transfer using SIMATIC PDM
SIMATIC PDM
The acyclic data transfer is mainly used to transfer parameters during commissioning and
maintenance, for batch processes or to display other measured variables that do not
participate in the cyclic transmission of useful data.
The data is transferred between a class 2 master and a field device using the so-called C2
connections. The device supports up to four C2 connections, so the multiple class 2 masters
can access the same positioner simultaneously.
SIMATIC PDM is preferably used for the acyclic data transfer. It is a software package for
project planning, parameterization, commissioning, diagnostics and maintenance of the
positioner and other field devices.
SIMATIC PDM enables access to process values, alarms, status and diagnostics information
of the device. You can use SIMATIC PDM to execute the following functions for field
devices:
● Display
● Set
● Change
● Compare
● Check for plausibility
● Manage and simulate
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10.2 Acyclic data transfer
Procedure for acyclic data transfer:
We recommend the following general procedure:
1. First read the current settings from the device using the "Load into PG/PC" menu item.
2. Check the current settings.
3. Configure the necessary settings.
4. Load the parameter settings into the device using the "Load into devices" menu item.
5. Save the settings in the PDM as well.
The menu bar of SIMATIC PDM contains the "File", "Device", "View", "Extras" and "Help"
menus. The "Device" and "View" menus, which also contain other sub-menus, are described
below in detail.
10.2.2
"Device" menu
10.2.2.1
Communication path
Call this sub-menu to display the communication path. It normally deals with a
PROFIBUS DP.
10.2.2.2
Load into devices
Use this sub-menu to load the parameters from the offline display of SIMATIC PDM into the
corresponding device. This function can also be called using the following icon.
Figure 10-1
10.2.2.3
Load into devices
Load into PG/PC
Use this sub-menu to read the parameters from the positioner. These parameters are then
displayed using SIMATIC PDM. This function can also be called using the following icon.
Figure 10-2
10.2.2.4
Load into PG/PC
Update diagnostics status
Use this sub-menu to update the diagnostics status in SIMATIC PDM that is visualized using
symbols. Symbols are shown before the device name.
The following table contains the symbols and the corresponding diagnostics status
represented by these symbols:
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10.2 Acyclic data transfer
Meaning
Symbols
Out of service
Priority
Highest
Manual mode
Simulation or substitute value
Maintenance requirement
Maintenance demand
Maintenance requirement
Configuration error
Configuration warning
Configuration changed
Erroneous process value
Process value uncertain
Process value out of tolerance
Normal operation
10.2.2.5
Lowest
Set address
Use this sub-menu to allocate a new address to the positioner. Note that, this is possible
only if the slave is not yet integrated into the cyclic service.
10.2.2.6
Operation
Target modes
The following target modes (operating modes) are possible:
● Automatic
● Manual
● Out of service (OS)
Note that the target modes refer to the operating modes of function blocks of the
PROFIBUS PA block model, and should not be mistaken for with the "Automatic" and
"Manual" operating modes of the positioner.
The above target modes are effective when the positioner is in the automatic mode (AUT). If
the positioner is in the manual mode (MAN), they are effective only after an on-site
switchover to the automatic mode (AUT).
These target modes are saved in the positioner in the power failure-safe manner.
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10.2 Acyclic data transfer
Automatic mode
As long as the positioner is not integrated into the cyclic service as a slave, SIMATIC PDM
can be used to send a setpoint to it in a cyclic manner.
Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Automatic".
3. Enter a value between 0 and 100% for the desired setpoint, quality as "Good" and the
status as "OK".
4. Transfer these settings to the positioner.
The positioner is controlled using the desired setpoint until a cyclic master starts
communication with a slave or you switch over the positioner to the "Manual" mode on-site.
Note
Note that the positioner responds with the "Poor" quality and the "Constant value" status
after sending the data.
If you exit this target mode and no other master sends a setpoint to the positioner, it is
controlled using the configured fail-safe value after the set monitoring time expires.
Manual mode
You can use SIMATIC PDM to send a setpoint to the positioner even when cyclic
communication is active. To do this, you need only set priority over the cyclic master
beforehand.
Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Manual".
3. Enter a value between 0 and 100% as a starting value, "Good" as the quality and "OK" as
the status.
4. Transfer these settings to the positioner.
The positioner is now controlled using the desired starting value and reports this manual
mode through "MM" on the display.
Note that the starting value entered in the manual mode is directly written in the starting
block of the positioner without scaling.
You can switch the positioner to the manual mode on-site and move the actuator using
buttons. The setpoint is tracked as per the current actual value. The manual mode and the
current position are retained after switching back to the automatic mode.
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10.2 Acyclic data transfer
After a power failure, the positioner is controlled in the manual mode depending on the
direction of action of the actuator using the value set in the "YA" or "YE" parameters.
Note
You must set the target mode to "Automatic" to reactivate the setpoints of the cyclic master.
Out of service (O/S)
You can use SIMATIC PDM to put the positioner out of service irrespective of the cyclic
communication.
CAUTION
Depressurize
In order to prevent physical injuries and material damage, you must ensure that the
actuator is depressurized when it is put out of service.
Make the following settings:
1. Go to the "Operating mode" tab.
2. Set the target mode to "Out of service (O/S)".
3. Transfer these settings to the positioner.
The successful transmission is reported by "OS--" on the display of the positioner.
You can switch the positioner to the manual mode on-site and move the actuator using
buttons in this target mode also. "MAN--" is then shown on the display.
The "Out of service (O/S)" mode is retained after switching back to the automatic mode. The
actuator remains depressurized after a power failure.
Note
You must set the target mode to "Automatic" to reactivate the setpoints of the cyclic master.
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10.2.2.7
Simulation
Tab
Use this sub-menu to access the "Simulation" online menu that is split into the following four
tabs:
● Simulation of actual value
● Simulation of device status
● Simulation of device diagnostics 1
● Simulation of device diagnostics 2
Simulation of actual value
You can activate the actual value simulation in this tab and also define the actual value to be
simulated and its quality and status. The following feedback values are available:
● Setpoint
● Actual value
● Setpoint deviation
● Checkback bits in the checkback field.
Changes become effective as soon as the Transfer button is pressed.
Simulation of device status
You can activate the simulation of device status in this tab and can then select the
diagnostics messages to be simulated. It concerns the content of the "DIAGNOSTICS
physical block parameters" that generates different diagnostics messages depending on
whether the condensed status has been activated or deactivated. Changes become effective
as soon as the Transfer button is pressed.
Simulation of device diagnostics 1
You can activate the simulation of device diagnostics in this tab. It is applicable for device
diagnostics 1 and 2.
You can then select the desired diagnostics events in the simulation of device diagnostics 1,
and use device diagnostics 1 and message text to obtain the feedback indicating that the
corresponding event has been triggered in the device. Changes become effective as soon as
the Transfer button is pressed.
Simulation of device diagnostics 2
You can activate the simulation of device diagnostics in this tab. It is applicable for device
diagnostics 2 and 1. You can then select the desired diagnostics events in the simulation of
device diagnostics 2, and use device diagnostics 2 and message text to obtain the feedback
indicating that the corresponding event has been triggered in the device. Changes become
effective as soon as the Transfer button is pressed.
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10.2.2.8
Partial stroke test (PST)
Availability
This menu item is available only if the advanced diagnostics has been activated in the
parameter list in advance. You can then activate and parameterize the partial stroke test.
Functions
Use the Partial stroke test button to access the functions of the partial stroke test:
● Start the partial stroke test.
● Stop the partial stroke test.
● Initialize the partial stroke test.
Changes become effective as soon as the Transfer button is pressed.
10.2.2.9
PST trace characteristic
Availability
This menu item is available only if the advanced diagnostics has been activated in the
parameter list in advance. Use this menu item to call the following sub-menus:
● Read in the trace data
● Save the trace data
● PST trace characteristic
Read in the trace data
When executing a partial stroke test, the temporal course of the actual value is scanned in
the background and saved in the RAM of the positioner with a maximum of 1000 data points.
Use this menu item to read in the saved data in the PDM. The end of the reading process is
displayed in the PDM status bar.
Save the trace data
Use this menu item to save the currently read in temporal course of the partial stroke test in
the PDM as a reference in the PDM.
PST trace characteristic
Use this to call the characteristic display of the actual value course during the partial stroke
test. If you have already saved the trace data once, the saved and the currently read in
courses are displayed simultaneously.
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10.2.2.10
Status monitoring
Availability
This menu item is available only if the advanced diagnosis has been activated in the
parameter list in advance. You can then activate and parameterize the following diagnostic
functions:
● General control valve fault
● Pneumatic leakage
● Static friction/slipstick
● Dead zone monitoring
● Lower end stop
● Upper end stop
● Lower limit temperature
● Upper limit temperature
● Path integral/number of strokes
● Change of direction
● Temporal position average
Changes become effective as soon as the Transfer button is pressed.
10.2.2.11
Initialization parameters
Use
Not only you can display the initialization parameters in this menu, but also change them
specifically. Allow only specialists to change the initialization parameters.
You also need this function if you need to replace the electronic unit. However you cannot
initialize at the moment.
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10.2.2.12
Initialization
Use
With SIMATIC PDM, you have the option to initialize the positioner for the first time.
First initialization
WARNING
You are not located on-site. In order to prevent personal injuries and material damage, take
in-house precautionary measures before starting the initialization process.
Note
Also ensure that you always start the initialization process from the acyclic master even if the
positioner is in the automatic mode and contains setpoints of a cyclic master.
If required, you can interrupt the ongoing initialization by pressing the "Stop initialization"
button. You can also press the operating mode button or disconnect the power supply to
interrupt the initialization process on the device.
Proceed as follows to initialize the positioner using SIMATIC PDM for the first time:
1. For this purpose, go to the "Device" menu and then to the "Initialization" sub-menu. A
window containing an overview of initialization-relevant device parameters, checkback,
device status, diagnostics and initialization status then opens.
2. Press the "Start initialization" button. A warning is then displayed. Follow this warning
without fail to prevent personal injuries and damage to the system.
3. Acknowledge the warning.
The initialization process starts once you acknowledge the warning. You can monitor the
progress in the "Status (initialization)" field in the open window of the initialization menu. As
soon as the initialization is completed successfully, the positioner continues working in the
operating mode from which the initialization process was started. If a fault message appears,
an on-site correction is required.
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10.2.2.13
Reset PDM parameters
Use
Use this menu item to open a dialog box to reset all PDM parameters to their factory settings
(default values).
PDM parameters are reset when you press the "OK" button. You can then transfer the
parameters to the PDM memory using "File->Save".
Select "Device->Load into devices" to transfer the reset parameters to the positioner as well.
10.2.2.14
Reset the field device
Reset the positioner to the as-delivered condition
If the positioner has been moved such that it can no longer perform its control task, you can
use the "Reset" function to restore the as-delivered condition. This function resets all
parameters to their factory settings except for the PROFIBUS address.
The reset action is indicated by the "Restart executed" diagnostics message. You must then
reset all parameters and execute the initialization process.
Warm restart
Use the warm restart to exit the positioner, shut it down and restart. The communication is
interrupted and restored while doing so.
This warm restart is indicated by the "Warm restart executed" diagnostics message. If no
measured value result is available, the automation or control system reads in the
"Uncertain, initial value, constant value" status.
Reset the PROFIBUS address to 126
If no device in your system has the preset address 126, you can add your positioner to the
PROFIBUS path during the ongoing operation of the automation or control system. You must
then change the address of the newly integrated device to another value.
If you remove a positioner from the PROFIBUS path, you must reset its address to 126 using
this function, so that you can re-integrate a positioner in this or another system depending on
the requirement.
The address cannot be reset if a cyclic master is already communicating with the positioner.
Reset message
You can use the "Reset message" tab to reset the messages regarding the checkback,
device status and unfiltered device diagnostics 1 in the PDM. Since it concerns an online
menu, messages that have been reset in the PDM may be set again in the next cycle as the
corresponding events still exist in the device.
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10.2.2.15
Write lock
Use
After completing the commissioning, you can set the write lock to prevent undesired changes
through an acyclic master.
You can however change the parameters of the positioner on-site as before.
Activate the write lock
1. Call the "Write lock" sub-menu.
2. Enter "ON" in the "Write lock" sub-menu in the positioner.
If you still try to write, the PDM displays the "Connection terminated" message.
Note
If "Hardware protection" equal to "ON" is displayed in this mask, the binary input 1 in the
positioner has been parameterized at "bLoc1" or "bLoc2" and activated. Writing through the
PDM is this blocked.
10.2.3
"View" menu
10.2.3.1
Measured value display
"Measured value" tab
This tab contains:
● Bar graph displays of actual value and setpoint.
● Further information about the quality of values.
● Information about the valve position.
● Information about setpoint deviation.
● Information about checkback.
"Output" tab
The "Output" tab contains:
● A bar graph display of the output value
● Information about the quality of the output value
● Information about checkback.
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10.2.3.2
Characteristic
Characteristic (setpoint/actual value)
In this online menu, the actual value and setpoint are displayed as bar graphs and a
characteristic curve over time.
Characteristic (characteristic curve)
Device characteristic curves are displayed in this characteristic if it has been set to "free
(user-defined)".
If tight closing is active, the tight closing limits are also displayed irrespective of the setting of
the characteristic curve.
10.2.3.3
Device status
Available tabs
In this online menu, information about the device status is processed in the following four
tabs:
● General
● Profile
● Status/Messages
● Device diagnostics
"General" tab
The "General" tab contains information about the unique identification of the device, e.g.
TAG or the device serial number.
"Profile" tab
The "Profile" tan contains profile-relevant information, e.g. profile revision or revision
numbers of blocks.
"Status/Messages" tab
The "Status/Messages" tab contains an overview of the device status (DIAGNOSTICS
physical block parameter), the checkback (CHECK_BACK analog output block parameter)
and the limit status. As far as the limit status is concerned, all three-stage diagnostics events
are handled by a collective message. This means that, if any threshold of a diagnostics
event has exceeded, a corresponding limit status message is displayed here.
You will also obtain information about the statuses of:
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● "Fault message output"
● "Alarm output 1"
● "Alarm output 2"
● "Binary input 1"
● "Binary input 2".
"Device diagnostics" tab
Diagnostics events of the devices are displayed in the "Device diagnostics 1" "Device
diagnostics 2" fields of the "Device diagnostics" tab. It also contains information about the
communication, the quality and the status of the actual value as well as a message text. The
message text contains notes regarding the currently active diagnostics event.
10.2.3.4
Maintenance information
Available tabs
The maintenance information is processed in the following six tabs:
● "Current maintenance information" tab
● "Maintenance information (last maintenance)" tab
● "Maintenance counter" tab
● "Operating temperature" tab
● "Operating times" tab
● "Static revision numbers" counter
Use
The "Maintenance information (current)" tab contains an overview of the values determined
by the positioner during the last initialization process. Use the "Save maintenance
information (last maintenance)" button to transfer the current values to the memory of the
positioner. You can use these values in the "Maintenance information (last maintenance)"
tab as the reference values for comparison at the time of a subsequent re-initialization of the
device. When saving the current values, you will be prompted to enter the maintenance date.
Use the "Reset maintenance information" button to reset the maintenance date to
01.01.2000. This date indicates the positioner that no maintenance has been carried out as
yet.
The saved values are then hidden in the next "Maintenance information (last maintenance)"
tab.
The "Maintenance counter" contains an overview of the number of:
● Strokes,
● Changes of direction
● Fault messages
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● Alarms
● switching cycles of piezo valves.
Press the "Reset maintenance counter" button to access a selection menu to reset all
maintenance counters at one go or individually.
The "Operating temperature" tab displays the minimum, current and maximum temperatures
in the pointer instruments.
The "Operating times" tab contains the number of operating hours of the positioner and the
time elapsed since the last initialization.
The "Static revision numbers" tab gives an overview of the status of the revision numbers of
PROFIBUS blocks. Revision numbers of a block are incremented whenever a parameter in
the corresponding block is changed.
10.2.3.5
Trend characteristic
Versions
Use this menu item to access the following trend characteristics:
● Actual value
● Control deviation
● Leakage
● Static friction
● Lower end stop
● Upper end stop
● Temperature
● Dead zone
Use
The temporal course of the corresponding measured variable over the selected interval is
shown in a trend characteristic. The trend characteristic gives an overview of the previous
development of the measured value and can be used as the basis to estimate the future
course. If adequate measured values are available, trends over the last 30 minutes, eight
hours, five days, two months and 30 months can always be processed.
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10.2.3.6
Histograms
Versions
Use this menu item to access the following histograms:
● Position
● Control deviation
● Temperature
Use
A class division over the entire measuring range of a variable is included in a histogram. The
time spent by the measured variable within different classes is also displayed. You can use
the position histogram to assess whether a servo solenoid valve has been designed
practically and whether it was essentially in the expected operating point during its use so
far.
10.2.3.7
Adjusting the view of SIMATIC PDM
Function bar
With this you can show or hide the function bar containing the color icons in the top margin
of SIMATIC PDM.
Status bar
With this you can show or hide the status bar in the lower margin of SIMATIC PDM. Note
that, important information is sometimes displayed in the status bar, e.g. end of data upload
for the PST trace characteristic.
Update
Use this menu item to update the view in the open working window. After every entry in the
table, the values of all parameters dependent on the changed parameter are automatically
updated; however, their visibility is not updated.
The visibility of all parameters in the table is updated by clicking this menu line or by
pressing the F5 function key. You can use the menu item Extras > Settings > Table to define
whether this update should be executed immediately after changing any value. In addition,
the diagnostics status in the PDM that is visualized using symbols before the device name is
updated.
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10.3
Cyclic data transfer
10.3.1
Cyclic data transfer
The cyclic data transfer is used to transfer the useful data relevant for the process
automation between the class 1 master (control or automation system) and the positioner.
10.3.2
Configuration
Configuring with the GSD
Information about input and output ranges as well as the consistency of the cyclically
transferred data is defined in the GSD file that is used by the device to check the
configuration telegram and to declare it as valid if required.
The useful data to be transferred in the cyclic operation is determined during the projecting
planning. The data volume to be transferred can thus be optimized. The GSD files of all
common devices are already stored in the Siemens control systems. GSD files can be
imported later. You can download the GSD files from:
www.siemens.de/sipartps2
Under "More Info", click on "→ Downloads".
Configuring the useful data
The useful data made available to the control system or the controller through PROFIBUS
depends on the selected desired configuration.
Note
Configuration tool
In case of STEP 7, the configuration tool used is HW config.
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Figure 10-3
①
②
③
④
⑤
⑥
Example of a small PROFIBUS DP/PA system
PC or PG (master class 2)
Power supply
PROFIBUS DP
PROFIBUS PA
Splitter
⑦
⑧
⑨
⑩
PA devices
DP/PA coupler/link
CPU SIMATIC S7 (master class 1)
MPI cable (required for commissioning
and monitoring)
Bus terminator
A small STEP 7 program that establishes cyclic exchange with the positioner using
PROFIBUS PA (positioner) is given below.
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Figure 10-4
STEP 7 sample program
In this example, all data in the input and output directions supported by the device are
transferred. The selected peripheral starting address is 256 (W#16#100).
Note
Only the older SIMATIC CPUs require the SFC14 and SFC16 modules for consistent
reading and writing.
Legend of the sample program
Byte
Function
Composition
Number of bytes
Byte 15
Input data
READBACK
5
RCAS_OUT
5
CHECKBACK
3
POS_D
2
SP
5
RCAS_IN
5
Byte 10
Output data
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10.3.3
Useful data through PROFIBUS
Cyclic useful data
The positioner can exchange a combination of the following cyclic useful data through
PROFIBUS:
Name
Abbreviation
Direction from the
positioner's point of
view
Length in
byte
Comprising:
German
English
Setpoint
Setpoint
SP
Input
5
Value/Status
Readback
Readback
RB
Output
5
Value/Status
Position discrete
Position discrete
POS_D
Output
2
Value/Status
Checkback
Checkback
CB
Output
3
Value
Remote Cascade Input
Remote Cascade Input
RCAS_IN
Input
5
Value/Status
Remote Cascade
Output
Remote Cascade
Output
RCAS_OUT
Output
5
Value/Status
Setpoint
The setpoint is divided into a floating point value (4 bytes) and the corresponding status (1
byte, see further below).
Actual value
The actual value indicates the valve position. The actual value is divided into a floating point
value (4 bytes) and the corresponding status (1 byte).
Position discrete
The discrete valve position is displayed as a value (1 byte) having the following meaning:
0 = not initialized
1 = valve closed
2 = valve open
3 = valve in the intermediate position: Even this value has a status (1 byte).
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Checkback
The checkback is displayed in 3 bytes in a bit-coded format:
Bit
0
1
2
Meaning of "1"
Remarks
0
Device in the fail safe position
The position is determined by the "49.FSTY"
parameter.
1
Request for on-site operation
Reports that a button has been pressed.
2
The device is operated on-site.
The device is parameterized on-site, e.g. using the
"1.YFCT" parameter or is not initialized.
3
Emergency operation active
The device is in the manual mode. Representation on
the display: MAN or P
4
Deviation of the movement direction
Not required for the positioner.
5
End stop reached (valve completely open)
Not required for the positioner.
6
End stop reached (valve completely closed)
Not required for the positioner.
7
Run time overshoot
The device could not be adjusted. Monitoring time and
threshold in the "44.TIM" and "45.LIM" parameters
exceeded, e.g. due to the lack of compressed air
0
The valve is opened.
The "Ventilate actuator" command issued
1
The valve is closed.
The "Depressurize actuator" command issued
2
Parameters were changed.
Set temporarily after switching back from the
"Configuration" mode if one or more parameters were
changed.
3
Simulation mode
The simulation mode was released. Master class 2
can overwrite the current actual value, e.g., to test the
response of limits in the control system.
4
Not occupied in profile 3.
-
5
Fault in the closed-loop control.
Not required for the positioner.
6
Closed-loop control inactive
Not required for the positioner.
7
Self-monitoring active
Not required for the positioner.
0
Path integral exceeded
Set if the set limit for the path integral has exceeded
1
Additional input active
Binary 1 was activated.
2
Additional input active
Binary 2 was activated.
Remote cascade input
The remote cascade input is used as a setpoint in the remote cascade mode (actual mode =
remote cascade). The remote cascade input comprises the floating point value (4 bytes) and
the status (1 byte).
Remote cascade output
This output delivers the current setpoint in the AUTO and Remote cascade modes. The
status is specially used for the transfer from AUTO to Remote cascade.
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In combination with the input variable parameter (primary value scale), not only you can
define the setpoints as a percentage of the valve position, but also in terms of physical
variables such as cubic meter per day or liter per minute. Even the actual values are
adjusted as per this scale.
10.3.3.1
Possible combinations of the useful data
Useful data and position in the address room
You can select a combination of values for the communication of cyclic useful data between
the master and the positioner:
SP
Setpoint:
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
0
RCAS_OUT - floating point number
RCAS_OUT, RCAS_IN
Remote cascade output, remote cascade input:
Input (master view)
Starting address
1
2
3
4
RCAS_OUT - status
0
RCAS_IN - floating point number
Output (master view)
Starting address
1
2
3
4
RCAS_IN - status
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READBACK, POS_D, SP
Actual value, discrete position, setpoint:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
POS_D
6
POS_D - status
0
SP - floating point number
Output (master view)
Starting address
1
2
3
4
SP - status
0
CHECKBACK
Checkback, SP
Checkback, setpoint:
Input (master view)
Starting address
1
2
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
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READBACK, CHECKBACK, POS_D, SP
Actual value, discrete position, checkback, setpoint:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
POS_D
6
POS_D - status
7
CHECKBACK
8
9
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
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RCAS_OUT, CHECKBACK, RCAS_IN
Remote cascade output, checkback, remote cascade input:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
POS_D
6
POS_D - status
0
RCAS_IN - floating point number
Output (master view)
Starting address
1
2
3
4
RCAS_IN - status
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READBACK, RCAS_OUT, POS_D, CHECKBACK, SP, RCAS_IN
Actual value, remote cascade output, discrete position, checkback, setpoint, remote cascade
input:
Input (master view)
Starting address
0
READBACK - floating point number
1
2
3
4
READBACK - status
5
RCAS_OUT - floating point number
6
7
8
9
RCAS_OUT - status
10
POS_D
11
POS_D - status
12
CHECKBACK
13
14
Output (master view)
Starting address
0
SP - floating point number
1
2
3
4
SP - status
5
RCAS_IN - floating point number
6
7
8
9
RCAS_IN - status
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10.3.3.2
Diagnostics
Function
The positioner can report active information about its device status. These diagnoses are
important information that can be used by an automation system to initiate remedial
measures.
Standard mechanisms of PROFIBUS-DP are used to transfer the diagnostics information
and report it actively to the class 1 master. PROFIBUS-DP has a protocol to transfer the
information that has higher priority than the useful data to the class 1 master.
The contents of the "Device status" parameter from the physical block are reported along
with the information whether a status change (event received/event sent) has occurred.
Diagnostics as per PROFIBUS DP (DDLM_Slave_Diag)
The positioner delivers the diagnostics data in the following format:
Input (master view)
Starting address
0
Station_status_1
1
Station_status_2
2
Station_status_3
3
Diag_Master_Add
4
Ident_Number
5
Ident_Number
6
Header
7
Status_Type
8
Slot_Number
9
Specifier
10
Diagnostics (0)
11
Diagnostics (1)
12
Diagnostics (2)
13
Diagnostics (3)
Standard DP - diagnostics
Status coding as per DP/V1
Diagnostics object of the physical block
Specifier
The following specifiers are available:
1: Incoming event
2: Outgoing event
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10.3.4
Adjustable status (condensed status)
Diagnostics messages are generated in the DIAGNOSTICS physical block parameter
depending on the diagnostics events in the device. At the same time, the statuses of three
PowerTags (FEEDBACK_VALUE, READBACK and POS_D) that are sent to the master by
the SIPART PS2 PA positioner are affected.
In the device, there is now an option to use diagnostics messages and predefined status
messages that are permanently associated with the triggering diagnostics events. The
condensed status must be deactivated for this purpose.
If the condensed status is activated, the diagnostics messages in a specific frame can be
allocated to a smaller number of collective diagnostics messages and selectable status
messages. This "routing" of diagnostics events is shown in the following picture.
Figure 10-5
Routing of a diagnostics event
Note
Please note that the condensed status cannot be changed using the SIMATIC PDM when
the device is in a cyclic operation with a master class 1.
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10.3 Cyclic data transfer
Figure 10-6
Activating the condensed status for the device parameterization - with an example of HW configuration with
SIMATIC S7
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10.3 Cyclic data transfer
Figure 10-7
Activating the condensed status for the device parameterization - with an example of SIMATIC PDM
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10.3 Cyclic data transfer
10.3.4.1
Diagnostics messages in case of deactivated condensed status
The diagnostics messages of the DIAGNOSTICS physical block parameter in case of the
deactivated condensed status are shown in the following table:
Byte
Bit
0
0 ... 2
1
Name and meaning
Cause
Measure
Not used
-
-
3
DIA_TEMP_ELECTR
Electronic unit temperature too
high
The temperature measured at
the device electronic unit has
exceeded one or more set
thresholds.
Check why the temperature is
beyond the specified range.
4
DIA_MEM_CHKSUM
Memory error
During operation, the memory is
constantly checked for the
checksum and write/read errors.
This message is generated in
case of an error.
Replace the electronic unit.
5
Not used
-
-
6
DIA_NOT_INIT
Device not initialized
The initialization process
required for the device
functioning has not yet been
carried out successfully.
Carry out the device initialization
process.
7
DIA_INIT_ERR
Error in initialization
Values obtained during the
initialization process cannot be
used.
Carry out the device initialization
process again. Check the
relevant parameter settings.
0
DIA_ZERO_ERR
Lower end stop beyond the
tolerance
The lower end stop is beyond the Check the valve. Flow restrictors
and/or the seat ring are probably
set tolerance.
worn out.
1
DIA_SUPPLY
Error in the compressed air
supply
A run time overshoot was
detected. In all probability, the
energy (compressed air) is not
available.
Establish the compressed air
supply and check the feed lines.
2
Not used
-
-
3
DIA_WARMSTART
Warm restart executed (goes to
"0" after 10 s)
Power was fed to the device.
Check the cabling and the supply
unit.
SIMATIC PDM was used to
trigger a warm restart.
The internal watchdog has
responded.
4
DIA_COLDSTART
Restart executed
(goes to "0" after 10 s)
The device was reset to factory
settings.
-
5
DIA_MAINTENANCE
Maintenance required
To determine the cause, check in Depends on the triggering
DIAGNOSTICS_EXTENSION
diagnostics event.
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
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10.3 Cyclic data transfer
Byte
Bit
Name and meaning
Cause
Measure
6
DIA_CHARACT
Characteristic curve invalid
The parameterized characteristic
curve does not have the required
monotony, number of support
points, or the x values are not
arranged in 5% distances. The
original characteristic curve is
used further.
Modify the configuration data
(change the GSD) such that it is
consistent with the identification
number set in the device.
7
IDENT_NUMBER_VIOLATION
Identification number changed
You have changed the
PROFIBUS identification number
parameter during the active
cyclic operation. The device
reports the identification number
violation and displays a failure
warning. In case of a warm
restart, the device no longer
participates in the cyclic transfer
of useful data without changing
the system configuration.
Modify the configuration data
(change the GSD) such that it is
consistent with the identification
number set in the device.
2
0 ... 7
Reserved
-
-
3
0 ... 6
Reserved
-
-
EXTENSION_AVAILABLE
Extension available
Further information about the
triggering diagnostics event is
available in
DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2.
-
7
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10.3 Cyclic data transfer
10.3.4.2
Diagnostics messages in case of activated condensed status
Thematic classification
Collective diagnostics messages of the DIAGNOSTICS physical block parameter when the
condensed status is activated are given below. The Group column contains a thematic
classification of diagnostics messages. The same meaning is also used for status messages:
Maintenance:
M1
MAINTENANCE REQUIRED
M12
MAINTENANCE REQUIRED,
MAINTENANCE DEMAND
M
MAINTENANCE REQUIRED,
MAINTENANCE DEMAND,
MAINTENANCE ALARM
Process-dependant:
P
PROCESS RELATED
Functional check:
F
FUNCTION CHECK
Collective diagnostics messages
Collective diagnostics messages in the case of the activated condensed status are shown in
the following table:
Byte
0
Bit
0
... 7
Name and meaning
Cause
Measure
Group
Reserved
Power was fed to the device.
-
-
Or:
SIMATIC PDM was used to
trigger a warm restart,
Or:
The internal watchdog has
responded.
1
0
... 2
Reserved
The device was reset to factory
settings.
-
-
3
DIA_WARMSTART
Warm restart executed (goes to "0"
after 10 s)
To determine the cause, check
in DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
Check the cabling
and the supply
unit.
-
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10.3 Cyclic data transfer
Byte
2
Name and meaning
Cause
Measure
Group
4
Bit
DIA_COLDSTART
Restart executed
(goes to "0" after 10 s)
-
-
-
5
DIA_MAINTENANCE
Maintenance required
You have changed the
Depends on the
PROFIBUS identification number triggering
parameter during the active
diagnostics event.
cyclic operation. The device
reports the identification number
violation and displays a failure
warning. In case of a warm
restart, the device will no longer
participate in the cyclic transfer
of useful data without changing
the system configuration.
M1, M12,
M
6
Reserved
-
-
-
7
IDENT_NUMBER_VIOLATION
Identification number changed
To determine the cause, check
in DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
Modify the
configuration data
(change the GSD)
such that it is
consistent with the
identification
number set in the
device.
-
0
DIA_MAINTENANCE_ALARM
Maintenance alarm
To determine the cause, check
in DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
Depends on the
triggering
diagnostics event.
M
1
DIA_MAINTENANCE_DEMANDED
Maintenance demand
To determine the cause, check
in DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
Depends on the
triggering
diagnostics event.
M12, M
2
DIA_FUNCTION_CHECK
Functional check
The device is in the on-site
operation or
FEEDBACK_VALUE is
simulated
-
F
3
DIA_INV_PRO_COND
Invalid process conditions
To determine the cause, check
in DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2
which diagnostics event has
triggered the message.
Depends on the
triggering
diagnostics event.
P
4
... 7
Reserved
-
-
-
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10.3 Cyclic data transfer
Byte
3
Name and meaning
Cause
Measure
Group
0
... 6
Bit
Reserved
-
-
-
7
EXTENSION_AVAILABLE
Extension available
Further information about the
triggering diagnostics event is
available in
DIAGNOSTICS_EXTENSION
and
DIAGNOSTICS_EXTENSION_2.
-
10.3.4.3
Definition of the status
Status byte
The status is used to provide information about the quality of the input and output values.
This information is classified into four stages. Quality stages such as "Bad", "Uncertain",
"Good" and "Good (cascade)" are accompanied with further information. In this case, it deals
with the sub-status and the limit bits. The status byte has the following structure:
Status byte structure
7
6
5
4
Quality
Quality
Limit bits
3
Sub-status
2
1
0
Limit bits
00
Bad
01
Uncertain
10
Good
11
Good (cascade)
00
Good
01
Lower limit reached
10
Upper limit reached
11
Value is constant.
The meaning of the sub-status depends on whether the condensed status is activated or not.
The sub-status is therefore specified separately for both the cases.
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10.3 Cyclic data transfer
10.3.4.4
Sub-status for deactivated condensed status
Bit
Name profile
German name
7
6
5
4
3
2
1
0
0
0
0
0
0
0
x
x
Bad, non specific
Schlecht
0
0
0
0
0
1
x
x
Bad, configuration error
Schlecht, Konfigurationsfehler
0
0
0
0
1
0
x
x
Bad, not connected
Schlecht, keine Verbindung
0
0
0
0
1
1
x
x
Bad, device failure
Schlecht, Gerätefehler
0
0
0
1
0
0
x
x
Bad, sensor failure
Schlecht, Sensorfehler
0
0
0
1
1
1
x
x
Bad, out of service
Schlecht, Außer Betrieb
0
1
0
0
0
0
x
x
Uncertain, non specific
Unsicher
0
1
0
1
0
0
x
x
Uncertain, sensor conversion not
accurate
Unsicher, Wert ungenau
0
1
0
1
1
1
x
x
Uncertain, configuration error
Unsicher, Konfigurationsfehler
0
1
1
0
0
0
x
x
Uncertain, simulated value
Unsicher, Simulationswert
1
0
0
0
0
0
x
x
Good, ok
Gut, Ok
1
0
0
0
0
1
x
x
Good, update event
Gut, Aktiver Blockalarm
1
0
1
0
0
1
x
x
Good, maintenance required
Gut, Instandhaltungsbedarf
1
1
0
0
0
0
x
x
Good (Cascade), ok
Gut (Kaskade), Ok
1
1
0
0
0
1
x
x
Good (Cascade), initialisation
acknowledged
Gut (Kaskade), Initialisierung bestätigt
1
1
0
0
1
0
x
x
Good (Cascade), initialisation request
Gut (Kaskade), Initialisierung angefordert
1
1
0
0
1
1
x
x
Good (Cascade), not invited
Gut (Kaskade), Nicht eingeladen
1
1
0
1
1
0
x
x
Good (Cascade), local override
Gut (Kaskade), Vor-Ort-Bedienung
1
1
1
0
0
0
x
x
Good (Cascade), initiate fail safe
Gut (Kaskade), Sicherheitsstellung
anfahren
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10.3 Cyclic data transfer
10.3.4.5
Sub-status for activated condensed status
Bits
Name
Group
7
6
5
4
3
2
1
0
0
0
1
0
0
1
x
x
Bad, maintenance alarm
Schlecht, Instandhaltungsalarm
M
0
0
1
0
1
0
x
x
Bad, process related, no
maintenance
Schlecht, Prozess-Störung, kein
Wartungsbedarf
P
0
0
1
1
1
1
x
x
Bad, function check /local override;
value not usable
Schlecht, Funktion überprüfen /
Handbetrieb
F
0
1
1
0
1
0
x
x
Uncertain, maintenance demand
Uncertain, maintenance demand
M
0
1
1
1
1
0
x
x
Uncertain, process related, no
maintenance
Unsicher, Prozess-Störung, kein
Wartungsbedarf
P
1
0
0
0
0
0
x
x
Good, ok
Gut, Ok
1
0
1
0
0
1
x
x
Good, maintenance required
Gut, Instandhaltungsbedarf
1
0
1
0
1
0
x
x
Good, maintenance demand
Good, maintenance requirement
1
0
1
1
1
1
x
x
Good, function check
Gut, Funktion überprüfen /
Handbetrieb
10.3.4.6
Profile
German
M1, M12,
M
M12, M
F
List of diagnostics events with status and diagnostics message for deactivated
condensed status
A list of diagnostics events with status and diagnostics message for deactivated condensed
status is given in the following table. DIAGNOSTICS_EXTENSION and
DIAGNOSTICS_EXTENSION_2 are physical block parameters.
DIAGNOSTICS_EXTENSION physical block parameter
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
0
1
Run time error of the actuator
Bad, maintenance requirement DIA_SUPPLY
1
2
The device is not in the
"Automatic mode"
Uncertain, simulation value
None
2
3
Binary 1 is active (only
message)
Good, maintenance required
DIA_MAINTENANCE
3
4
Action triggered by binary
input 1
Uncertain, simulation value
None
4
5
Binary 2 is active (only
message)
Good, maintenance required
DIA_MAINTENANCE
5
6
Action triggered by binary
input 2
Uncertain, simulation value
None
7 ... 21
2
DIAGNOSTICS bit
0
Reserved
-
-
5
22
Limit for alarm A1 exceeded
Good, maintenance required
DIA_MAINTENANCE
6
23
Limit for alarm A2 exceeded
Good, maintenance required
DIA_MAINTENANCE
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10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
3
DIAGNOSTICS bit
7
24
Error in the device electronic
unit
Bad, device error
DIA_MEM_CHKSUM
0
25
The device is not yet ready for
operation (not initialized)
Bad, configuration error
DIA_NOT_INIT
1
26
The device is not yet ready for
operation (initialization error)
Bad, configuration error
DIA_INIT_ERR
3
27
Reserved
-
-
3
28
Reserved
-
-
4
29
Device in the Manual mode
(FB in the Manual mode)
Depends on the set status
None
5
30
Device in the Simulation mode
(FEEDBACK is simulated)
Depends on the simulated
status
None
6
31
Device in the TRACE mode
-
None
7
32
Diagnostics simulation
(diagnostics events are
simulated)
Depends on the simulated
diagnostics event
Depends on the simulated
diagnostics event
Reserved
-
-
33 ... 48
DIAGNOSTICS_EXTENSION_2 physical block parameter
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
0
1
DIAGNOSTICS bit
0
49
General control valve fault
(limit 1)
Good, maintenance required
DIA_MAINTENANCE
1
50
General control valve fault
(limit 2)
Good, maintenance required
DIA_MAINTENANCE
2
51
General control valve fault
(limit 3)
Good, maintenance required
DIA_MAINTENANCE
3
52
Pneumatic leakage (limit 1)
Good, maintenance required
DIA_MAINTENANCE
4
53
Pneumatic leakage (limit 2)
Good, maintenance required
DIA_MAINTENANCE
5
54
Pneumatic leakage (limit 3)
Good, maintenance required
DIA_MAINTENANCE
6
55
Static friction (limit 1)
Good, maintenance required
DIA_MAINTENANCE
7
56
Static friction (limit 2)
Good, maintenance required
DIA_MAINTENANCE
0
57
Static friction (limit 3)
Good, maintenance required
DIA_MAINTENANCE
1
58
Lower end stop monitoring
(limit 1)
Good, maintenance required
DIA_ZERO_ERR
2
59
Lower end stop monitoring
(limit 2)
Good, maintenance required
DIA_ZERO_ERR
3
60
Lower end stop monitoring
(limit 3)
Good, maintenance required
DIA_ZERO_ERR
4
61
Upper end stop monitoring
(limit 1)
Good, maintenance required
DIA_ZERO_ERR
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10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Hard-coded effect of a diagnostics event
Quality status code
2
3
62
Upper end stop monitoring
(limit 2)
Good, maintenance required
DIA_MAINTENANCE
6
63
Upper end stop monitoring
(limit 3)
Good, maintenance required
DIA_MAINTENANCE
7
64
Limit 1 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
0
65
Limit 2 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
1
66
Limit 3 for path integral (100%
strokes) exceeded
Good, maintenance required
DIA_MAINTENANCE
2
67
Limit 1 for changes of direction Good, maintenance required
exceeded
DIA_MAINTENANCE
3
68
Limit 2 for changes of direction Good, maintenance required
exceeded
DIA_MAINTENANCE
4
69
Limit 3 for changes of direction Good, maintenance required
exceeded
DIA_MAINTENANCE
5
70
Limit 1 for position average
exceeded
Good, maintenance required
DIA_MAINTENANCE
6
71
Limit 2 for position average
exceeded
Good, maintenance required
DIA_MAINTENANCE
7
72
Limit 3 for position average
exceeded
Good, maintenance required
DIA_MAINTENANCE
0
73
PST reference time exceeded
(limit 1)
Good, maintenance required
DIA_MAINTENANCE
1
74
PST reference time exceeded
(limit 2)
Good, maintenance required
DIA_MAINTENANCE
2
75
PST reference time exceeded
(limit 3)
Good, maintenance required
DIA_MAINTENANCE
Reserved
-
-
76 ... 80
4
DIAGNOSTICS bit
5
0
81
Permissible device
Good, maintenance required
temperature exceeded (limit 1)
DIA_TEMP_ELECTR
1
82
Permissible device
Good, maintenance required
temperature exceeded (limit 2)
DIA_TEMP_ELECTR
2
83
Permissible device
Good, maintenance required
temperature exceeded (limit 3)
DIA_TEMP_ELECTR
3
84
Permissible device
Good, maintenance required
temperature undershot (limit 1)
DIA_TEMP_ELECTR
4
85
Permissible device
Good, maintenance required
temperature undershot (limit 2)
DIA_TEMP_ELECTR
5
86
Permissible device
Good, maintenance required
temperature undershot (limit 3)
DIA_TEMP_ELECTR
6
87
Limit for dead zone monitoring
exceeded
Good, maintenance required
DIA_TEMP_ELECTR
Reserved
-
-
88 ... 96
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10.3 Cyclic data transfer
10.3.4.7
List of diagnostics events with status and diagnostics message for activated
condensed status
A list of diagnostics events with status and diagnostics message for activated condensed
status is given in the following table. DIAGNOSTICS_EXTENSION and
DIAGNOSTICS_EXTENSION_2 are physical block parameters.
Different status and diagnostics messages can be allocated to individual diagnostics events
as per the following tables. The frame in which an allocation is possible is defined by the
group in the selection column. The following principle is used: in case of three-stage
diagnostics events of the MAINTENANCE group, the effect of the higher lever events can be
downgraded, but that of the lower level events cannot be upgraded.
DIAGNOSTICS_EXTENSION physical block parameter
Byte
Bit
No.
Diagnostics events
Effect of the event1)
0
1
Run time error of the
actuator
Good, Ok
DIA_MAINTENANCE_ALARM
M
1
2
The device is not in the
"Automatic mode"
Good, check function /
manual mode
DIA_FUNCTION_CHECK
F
2
3
Binary 1 is active (only
message)
Good, Ok
DIA_MAINTENANCE_DEMAND M, F, P
ED
3
4
Action triggered by
binary input 1
Good, Ok
DIA_FUNCTION_CHECK
4
5
Binary 2 is active (only
message)
Good, Ok
DIA_MAINTENANCE_DEMAND M, F, P
ED
5
6
Action triggered by
binary input 2
Good, Ok
DIA_FUNCTION_CHECK
M, F, P
7 ... Reserved
21
-
-
-
5
22
Limit for alarm A1
exceeded
Good, maintenance
requirement
DIA_MAINTENANCE
None, hardcoded
6
23
Limit for alarm A2
exceeded
Good, maintenance
requirement
DIA_MAINTENANCE
None, hardcoded
7
24
Error in the device
electronic unit
Bad, maintenance
requirement
DIA_MAINTENANCE_ALARM
None, hardcoded
0
25
The device is not yet
ready for operation (not
initialized)
Bad, maintenance
requirement
DIA_MAINTENANCE_ALARM
None, hardcoded
1
26
The device is not yet
ready for operation
(initialization error)
Bad, maintenance
requirement
DIA_MAINTENANCE_ALARM
None, hardcoded
3
27
Reserved
-
-
-
3
28
Reserved
-
-
-
4
29
Device in the Manual
mode (FB in the Manual
mode)
DIA_FUNCTION_CHECK
None, hardcoded
Quality status code
0
2
3
Group
DIAGNOSTICS bit
M, F, P
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10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Effect of the event1)
5
30
Device in the Simulation Depends on the
mode (FEEDBACK is
simulated status
simulated)
DIA_FUNCTION_CHECK
None, hardcoded
6
31
Device in the TRACE
mode
-
DIA_FUNCTION_CHECK
None, hardcoded
7
32
Diagnostics simulation
(diagnostics events are
simulated)
Depends on the
simulated diagnostics
event
Depends on the simulated
diagnostics event
-
33
...
48
Reserved
-
-
-
Quality status code
Group
DIAGNOSTICS bit
Effects of the event can be set using the DIAG_EVENT_SWITCH or DIAG_EVENT_SWITCH_2 parameters (default
settings in this case)
1)
DIAGNOSTICS_EXTENSION_2 physical block parameter
Byte
Bit
No.
Diagnostics events
Effect of the event1)
Quality status code
0
1
DIAGNOSTICS bit
Group
0
49
General control valve
fault (limit 1)
Good, maintenance
requirement
DIA_MAINTENANCE
1
50
General control valve
fault (limit 2)
Good, maintenance
requirement
DIA_MAINTENANCE_DEMAND M12
ED
2
51
General control valve
fault (limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
3
52
Pneumatic leakage
(limit 1)
Good, maintenance
requirement
DIA_MAINTENANCE
M1
4
53
Pneumatic leakage
(limit 2)
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
5
54
Pneumatic leakage
(limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
6
55
Static friction (limit 1)
Good, maintenance
requirement
DIA_MAINTENANCE
M1
7
56
Static friction (limit 2)
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
0
57
Static friction (limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
1
58
Lower end stop
monitoring (limit 1)
Good, maintenance
requirement
DIA_MAINTENANCE
M1
2
59
Lower end stop
monitoring (limit 2)
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
3
60
Lower end stop
monitoring (limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
4
61
Upper end stop
monitoring (limit 1)
Good, maintenance
requirement
M1
DIA_MAINTENANCE
M1
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10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Effect of the event1)
Quality status code
2
3
Group
62
Upper end stop
monitoring (limit 2)
Good, maintenance
demand
6
63
Upper end stop
monitoring (limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
7
64
Limit 1 for path integral
(100% strokes)
exceeded
Good, maintenance
requirement
DIA_MAINTENANCE
M1
0
65
Limit 2 for path integral
(100% strokes)
exceeded
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
1
66
Limit 3 for path integral
(100% strokes)
exceeded
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
2
67
Limit 1 for changes in
direction exceeded
Good, maintenance
requirement
DIA_MAINTENANCE
M1
3
68
Limit 2 for changes of
direction exceeded
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
4
69
Limit 3 for changes of
direction exceeded
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
5
70
Limit 1 for position
average exceeded
Good, maintenance
requirement
DIA_MAINTENANCE
M1, P
6
71
Limit 2 for position
average exceeded
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12, P
ED
7
72
Limit 3 for position
average exceeded
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M, P
0
73
PST reference time
exceeded (limit 1)
Good, maintenance
requirement
DIA_MAINTENANCE
M1
1
74
PST reference time
exceeded (limit 2)
Good, maintenance
demand
DIA_MAINTENANCE_DEMAND M12
ED
2
75
PST reference time
exceeded (limit 3)
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
Reserved
-
-
-
76 ...
80
4
DIAGNOSTICS bit
5
DIA_MAINTENANCE_DEMAND M12
ED
0
81
Permissible device
temperature exceeded
(limit 1)
Uncertain, process
fault, no maintenance
required
DIA_INV_PRO_COND
M1, P
1
82
Permissible device
temperature exceeded
(limit 2)
Uncertain, process
fault, no maintenance
required
DIA_INV_PRO_COND
M12, P
2
83
Permissible device
temperature exceeded
(limit 3)
Uncertain, process
fault, no maintenance
required
DIA_INV_PRO_COND
M, P
3
84
Permissible device
temperature undershot
(limit 1)
Uncertain, process
fault, no maintenance
required
DIA_INV_PRO_COND
M1, P
4
85
Permissible device
temperature undershot
(limit 2)
Uncertain, process
fault, no maintenance
required
DIA_INV_PRO_COND
M12, P
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10.3 Cyclic data transfer
Byte
Bit
No.
Diagnostics events
Effect of the event1)
Quality status code
DIA_INV_PRO_COND
Group
86
Permissible device
temperature undershot
(limit 3)
Uncertain, process
fault, no maintenance
required
6
87
Limit for dead zone
monitoring exceeded
Uncertain, maintenance DIA_MAINTENANCE_ALARM
demand
M
Reserved
-
-
88 ...
96
1)
DIAGNOSTICS bit
5
-
M, P
Effects of the event can be set using the DIAG_EVENT_SWITCH or DIAG_EVENT_SWITCH_2 parameters (default
settings in this case)
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Alarm, fault and system messages
11.1
Representation of system messages on the display
11.1.1
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
CPUStart
P---
NOINI
Remedy
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 entire actuator travel
can be covered using the "+" and "-"
buttons and "P---" is never displayed
•
Execute the initialization process
Measuring range was exceeded, the
potentiometer is in the inactive zone, the
transmission ratio selectors or the effective
lever arm are not adjusted as per the
actuator travel
•
Switch the transmission ratio selector to
90° especially in case of part-turn
actuators
•
Adjust the effective lever length of linear
actuators as per the measuring range
Positioner is not initialized
•
Start initialization
Down
X
X
Pnnn.n
Meaning / cause
X
X
X
See also
Display (Page 99)
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11.1 Representation of system messages on the display
11.1.2
System messages during initialization
Remarks about the tables:
nn
stands for variable numeric values
Error symbol
/
(slash): the texts on the left and right of the slash flash alternately
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11.1 Representation of system messages on the display
Messages during initialization
Message
Line
Up
P--
Meaning / cause
Remedy
Measuring range was exceeded, the
potentiometer is in the inactive zone, the
transmission ratio selectors or the effective
lever arm are not adjusted as per the
actuator travel
•
Switch the transmission ratio selector to
90° especially in case of part-turn
actuators
•
Adjust the effective lever length of linear
actuators as per the measuring range
Down
X
RUN1
X
Initialization was started, part 1 is active (the
direction of action is determined)
•
Maintenance
RUN2
X
Initialization part 2 is active (actuator travel
check and determination of end stops)
•
Maintenance
RUN3
X
Initialization part 3 is active (determination
and display of travel times)
•
Maintenance
RUN4
X
Initialization part 4 is active (determination of
the minimum controller increment length)
•
Maintenance
RUN5
X
Initialization part 5 is active (optimization of
the transient response)
•
Wait until "FINSH" is displayed
(initialization completed successfully)
•
Acknowledge by pressing the operating
mode button briefly and exit the
configuration level by pressing it longer
•
Approach the first end position using the
"+" or "-" button
•
Acknowledge using the operating mode
button
•
Approach the second end position using
the "+" or "-" button
•
Acknowledge using the operating mode
button
•
Approach another end position using the
"+" and "-" buttons and acknowledge with
the operating mode button, or
•
Move the friction clutch until "ok" is
displayed, and then acknowledge with
the operating mode button, or
•
Terminate the initialization process by
pressing the operating mode button,
switch to the P-manual mode and correct
the actuator travel and the position
displacement sensor
•
Acknowledge with the operating mode
button; the remaining steps ("RUN1" to
"FINSH") execute automatically
YEND1
YEND2
RANGE
ok
X
X
X
x
The first end position can be approached
only in case of a manual initialization
The second end position can be approached
only in case of a manual initialization
The end position or the measuring span is
beyond the permissible measuring range
only in case of a manual initialization
The permissible measuring range of end
positions is achieved only in case of a
manual initialization
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Alarm, fault and system messages
11.1 Representation of system messages on 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
U->d
Remedy
Error in "RUN1", no movement e.g. due to
the lack of compressed air
•
Down
X
d___U
Meaning / cause
Bar graph display of the zero point; zero
point is beyond the tolerance range
Friction clutch was moved; "P 50.0" not
displayed when the lever is horizontal
"UP" tolerance range was exceeded or the
inactive zone of the potentiometer was
covered
Open the restrictor(s)
Restart the initialization process
•
Set between "P 4.0" and "P .9" ( >0< )
using a friction clutch
•
Continue with the "+" or "-" button
•
In case of linear actuators, use the "+"
and "-" buttons to bring the lever
perpendicular to the spindle
•
Press the operating mode button slightly
to acknowledge (the initialization process
is continued)
•
Increase the effective lever length of the
linear actuators or switch the
transmission ratio selector to 90°
•
Press the operating mode button slightly
to acknowledge
•
Restart the initialization process
Use the "+" and "-" buttons to move it in
the range between 90 and 95%
"Up-Down" measuring span was undershot
•
Decrease the effective lever length of the
linear actuators or switch the
transmission ratio selector to 33°
•
Press the operating mode button slightly
to acknowledge
•
Restart the initialization process
•
Wait, or
•
To change the travel time, interrupt the
initialization process with the "-" button,
or
•
Activate the leakage test with the "+"
button
•
Wait, or
•
To change the travel time, interrupt the
initialization process with the "-" button,
or
•
Activate the leakage test with the "+"
button
X
Display of the "Down" travel time
X
•
•
Possible only in case of part-turn actuators:
•
actuator travel is not in the range between 90
and 95%
•
Display of the "Up" travel time
X
Provide adequate compressed air
Press the operating mode button slightly
to acknowledge
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11.1 Representation of system messages on the display
Message
Line
Up
X
X
LEAKG
nn.n
X
X
%/MIN
nn.n
Remedy
Actuator stops (the initialization process was
interrupted using the "-" button when the
actuation speed display was active)
•
The travel time can be changed by
adjusting the restrictor(s)
•
Redetermine the speed of shifting using
the "-" button
•
Continue with the "+" button
Leakage test active (the "+" button was
pressed when the actuation speed display
was active)
•
Wait for 1 minute
•
Continue with the "+" button
Value and unit of the result after the leakage
test
•
Rectify the leakage if the value is too
large
•
Continue with the "+" button
•
Acknowledge by pressing the operating
mode button briefly and exit the
configuration level by pressing it longer
Down
NOZZL
TESt
Meaning / cause
X
X
FINISH
Initialization completed successfully with the
display of actuator travel or the actuator
angle
X
See also
System messages before initialization (Page 233)
11.1.3
System messages when exiting the Configuration mode
Remarks about the tables:
nn
stands for variable numeric values
Error symbol
/
(slash): the text to the left and right of the slash blink interchangeably.
Messages when exiting the configuration mode:
Message
Goals
Up
n.nn.nnV
ER
X
ErrorSLn
n
X
Down
Operating mode
Automatic
Manual mode
Meaning / Cause
Measure
Software version
•
P Manual mode
X
X
Monotony interruption •
of the free
characteristic on the
setpoint turning point
n
Wait
Correct value
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11.1 Representation of system messages on the display
11.1.4
System messages during operation
Remarks about the tables:
nn
stands for variable numeric values
Error symbol
/
(Slash): texts to the left and the right of the slash blink alternately
Messages during operation:
Message
Line
Meaning / cause
Measure
•
X
Message after connecting
the electrical auxiliary
power supply
Wait
HW /
ERROR
X
Error in the hardware
•
Replace the
electronic unit
NOINI
X
Positioner is not initialized
•
Start the
initialization
process
•
Correct the station
address
•
Set the target
mode with class 2
master to
"Automatic"
•
Send the "0x80"
status (good)
Up
CPUSTA
RT
nnn.n
Down
Operating mode
Automatic
Manual
mode
P-manual
mode
X
X
X
X
X
Actual position value [in
%] of the initialized
positioner. Blinking
decimal point indicates
communication with a
class 2 master
AUnn
X
X
Automatic mode (nn =
setpoint)
FS -- --
X
X
Failsafe (the exhaust air
valve is opened). Possible
causes:
FS nn
X
X
•
No communication
connection with the
master
•
Target mode is at "MA"
•
Master sends a wrong
status
Controlled using the
See above
configured failsafe position
(Cause: see above)
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11.1 Representation of system messages on the display
Message
Line
Up
MM nn
Operating mode
Down
Automatic
X
X
MAnn
X
LO nn
OS --
Manual
mode
X
X
X
X
X
oFL /
127.9
Meaning / cause
Measure
Positioner is in the
"manual mode"
•
Set the target
mode with class 2
master to
"Automatic"
•
Send the "0x80"
status (good)
Manual mode
(nn = setpoint)
•
Switch to the
automatic mode
using the
operating mode
button
Positioner is in the "local
override mode"
•
Set the target
mode with class 2
master to
"Automatic"
•
Send the "0x80"
status (good)
•
Set the target
mode with class 2
master to
"Automatic"
•
Send the "0x80"
status (good)
•
Move the friction
clutch such that
the actual value
display remains
within 0.0 to 100.0
when moving the
actuator or
•
Adjust the
transmission ratio
selector or
•
Set the factory
setting (preset)
and execute the
initialization
process
P-manual
mode
Positioner is in the "out of
service mode"
Display range was
exceeded.
Possible causes:
EXSTP
X
X
•
Friction clutch or
•
Transmission ratio
selector were moved
or
•
The positioner was
attached to another
actuator without reinitializing it
Actuator was stopped
using a binary input
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11.1 Representation of system messages on the display
Message
Line
Up
Operating mode
Manual
mode
Meaning / cause
Measure
Down
Automatic
P-manual
mode
EX UP
X
X
Actuator is moved to the
upper end stop using a
binary input
EXDWN
X
X
Actuator is moved to the
lower end stop using a
binary input
EXTPSt
The partial stroke test was
activated, e.g. using a
binary input
inPSt
Cyclic
partial stroke test
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Alarm, fault and system messages
11.2 Diagnostics
11.2
Diagnostics
11.2.1
Display of diagnostics values
Structure of the diagnostics display
The diagnostics display has similar structure to that of the "Configuration" mode:
● The upper line shows the value of the diagnostics variable.
● The lower line shows the number and the abbreviation of the displayed variable.
Some diagnostics value can be greater than 99999. In such a case, the display switches
over to the exponential view. Example: The value "1234567" is shown as "1.23E6".
General procedure
1. Press all three buttons at the same time for at least 2 seconds. You are now in the
diagnostics display.
2. Use the
3. Press the
button to select the next diagnostics value.
button for at least 2 seconds in order to exit the diagnostics display.
How to show the diagnostics values in reverse order
Press the
and
buttons simultaneously.
How to set values to zero
Specific values can be set to zero by pressing the
button for at least 5 seconds.
See also
System messages before initialization (Page 233)
Description of parameters 10 to 30 (Page 159)
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11.2 Diagnostics
11.2.2
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
possible
1
STRKS
Number of strokes
0 ... 4.29E9
-
X
2
CHDIR
Number of changes of direction
0 ... 4.29E9
-
X
3
CNT
Number of fault messages
0 ... 4.29E9
-
X
4
A1CNT
Number of alarms 1
0 ... 4.29E9
-
X
5
A2CNT
Number of alarms 2
0 ... 4.29E9
-
X
6
HOURS
Operating hours
0 ... 4.29E9
Hours
-
7
WAY
Determined actuator travel
0 ... 130
mm or °
-
8
TUP
Travel time up
0 ... 1000
s
-
9
TDOWN
Travel time down
0 ... 1000
s
-
10
LEAK
Leakage
P 0.0 ... 100.0
%
-
11
PST
Monitoring of the partial stroke test
OFF / ###.#, fdini, notSt, s for ###.#
SdtSt, fdtSt, notd, Strt,
StoP
-
12
PRPST
time since the last partial stroke test
###, notSt, Sdtst, fdtSt
Days
-
13
NXPST
time until the next partial stroke test
OFF / ###
Days
-
14
DEVI
General control valve fault
OFF, 0.0 ... 100.0
%
-
15
ONLK
Pneumatic leakage
OFF, 0.0 ... 100.0
-
-
16
STIC
Stiction
OFF, 0.0 ... 100.0
%
-
17
ZERO
Zero point displacement
OFF, 0.0 .. 100.0
%
-
18
OPEN
Displacement of upper end stop
OFF, 0.0 ... 100.0
%
-
19
PAVG
Position average
0.0 ... 100.0
%
-
20
P0
Potentiometer value of lower end stop (0%)
0.0 ... 100.0
%
-
21
P100
Potentiometer value of upper end stop (100%) 0.0 ... 100.0
%
-
22
IMPUP
impulse length up
6 ... 160
ms
-
23
IMPDN
impulse length down
6 ... 160
ms
-
24
DBUP
deadband up
0.1 ... 10.0
%
-
25
DBDN
deadband down
0.1 ... 10.0
%
-
26
SSUP
slow step zone up
0.1 ... 100.0
%
-
27
SSDN
slow step zone down
0.1 ... 100.0
%
-
28
TEMP
Current temperature
-50 ... 100
-58 ... 212
°C
°F
-
29
TMIN
Minimum temperature ("min/max pointer")
-50 ... 100
-58 ... 212
°C
°F
-
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11.2 Diagnostics
No.
Abbreviation
Meaning
Values that can be
displayed
Unit
Reset
possible
30
TMAX
Maximum temperature ("min/max pointer")
-50 ... 100
-58 ... 212
°C
°F
-
31
T1
Number of operating hours in temperature
range 1
0 ... 4.29E9
Hours
-
32
T2
Number of operating hours in temperature
range 2
0 ... 4.29E9
Hours
-
33
T3
Number of operating hours in temperature
range 3
0 ... 4.29E9
Hours
-
34
T4
Number of operating hours in temperature
range 4
0 ... 4.29E9
Hours
-
35
T5
Number of operating hours in temperature
range 5
0 ... 4.29E9
Hours
-
36
T6
Number of operating hours in temperature
range 6
0 ... 4.29E9
Hours
-
37
T7
Number of operating hours in temperature
range 7
0 ... 4.29E9
Hours
-
38
T8
Number of operating hours in temperature
range 8
0 ... 4.29E9
Hours
-
39
T9
Number of operating hours in temperature
range 9
0 ... 4.29E9
Hours
-
40
VENT1
Counter for pilot valve 1
0 ... 4.29E9
-
-
41
VENT2
Counter for pilot valve 2
0 ... 4.29E9
-
-
42
STORE
Save the current values as "last maintenance" (press the increment button for 5 s)
-
-
43
PRUP
Prediction up
1 ... 40
-
-
44
PRDN
Prediction down
1 ... 40
-
-
45
WT00
Number of operating hours in the actuating
range WT00
0 ... 4.29E9
Hours
X
46
WT05
Number of operating hours in the actuating
range WT05
0 ... 4.29E9
Hours
X
47
WT10
Number of operating hours in the actuating
range WT10
0 ... 4.29E9
Hours
X
48
WT30
Number of operating hours in the actuating
range WT30
0 ... 4.29E9
Hours
X
49
WT50
Number of operating hours in the actuating
range WT50
0 ... 4.29E9
Hours
X
50
WT70
Number of operating hours in the actuating
range WT70
0 ... 4.29E9
Hours
X
51
WT90
Number of operating hours in the actuating
range WT90
0 ... 4.29E9
Hours
X
52
WT95
Number of operating hours in the actuating
range WT95
0 ... 4.29E9
Hours
X
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11.2 Diagnostics
11.2.3
Meaning of the diagnostics values
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. The value is written in a non-volatile memory every 15 minutes. The nonbutton.
volatile memory can be set to zero using the
2 CHDIR - number of changes of 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.
The value is written in a non-volatile memory every 15 minutes. The non-volatile memory
button.
can be set to zero using the
3 CNT - number of fault messages
Every fault is noted in the closed-loop controller and added to the number of fault messages.
button.
The counter can be set to zero using the
4 A1CNT - Number of alarms 1 and
5 A2CNT - Number of alarms 2
These two counters indicate how often alarms 1 and 2 have been triggered. Activation of
alarms using the "AFCT" parameter is a requirement for this. The counters can be set to
button.
zero using the
6 HOURS - operating hours
The runtime meter is incremented every hour as soon as electric auxiliary power is supplied
to the positioner.
7 WAY - determined actuator travel
This value indicates the actuator travel determined during the initialization process as per the
display at the end of an initialization process. Requirement for linear actuators: Specification
of the lever arm using the "YWAY" parameter.
8 TUP - Response time open and
9 TDOWN - Response time closed
These values indicate the actuating times determined during the initialization process. The
unit is seconds.
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11.2 Diagnostics
10 LEAK - leakage
If a leakage measurement was initiated during the initialization process, the leakage value in
%/min can be read in this parameter.
11 PST - monitoring of the Partial-Stroke test
This parameter indicates the stroke time measured during the last partial stroke test. A
partial stroke test can be initiated manually or a current partial stroke test can be interrupted
button.
by pressing the
The following states are output in the display:
● OFF
The partial stroke test function is deactivated in the configuration menu.
● FdIni - Failed PST Initialization
The reference stroke time measurement of the partial stroke test has failed.
● notSt - No Test
A manual partial stroke test has not yet been executed.
● ###.# (measured stroke time in seconds)
The last partial stroke test was successfully executed.
● SdtSt - Stopped Test
The last partial stroke test was interrupted.
● FdtSt - Failed Test
The last partial stroke test has failed.
The following status messages appear when you press the
button:
● notoL - No Tolerance
The control valve is beyond the tolerance range to start the partial stroke test. A manual
partial stroke test is not started.
● Strt - Start
A manual partial stroke test is started five seconds after pressing the button.
● StoP - Stop
The current partial stroke test is interrupted.
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11.2 Diagnostics
12 PRPST - time since the last partial stroke test
This parameter shows the elapsed time in days since the last partial stroke test. In addition,
the following status messages can be displayed:
● notSt - No Test
A manual partial stroke test has not yet been executed.
● SdtSt - Stopped Test
The last Partial-Stroke-Test was interrupted.
● FdtSt - Failed Test
The last partial stroke test has failed.
13 NXPST - time until the next partial stroke test
This parameter shows the time in days until the next partial stroke test. The requirements are
that the partial stroke test is activated in the configuration menu and a test interval is set. If
one of the above-mentioned conditions is not met, "OFF" is shown on the display.
14 DEVI - general control valve fault
This value provides information about the present dynamically determined deviation from the
model response. If the underlying function is deactivated in the configuration menu, "OFF" is
displayed.
15 ONLK - pneumatic leakage
This parameter shows the current leakage indicator. If the leakage detection is deactivated in
the configuration menu, "OFF" is displayed.
16 STIC - static friction/slipstick effect
This parameter shows the filtered value of the stroke magnitude in percent resulting from the
static friction. If the function is deactivated in the configuration menu, "OFF" is displayed.
17 ZERO - zero point displacement
Display of the current displacement of the lower hard end stop with respect to its initialization
value. The activation of the "down tight closing function" is a condition to determine this.
Activate using the "YCLS" parameter in the configuration menu. If the underlying function is
deactivated in the configuration menu, "OFF" is displayed.
18 OPEN - displacement of upper end stop
Display of the current displacement of the upper hard end stop with respect to its initialization
value. The activation of the "up tight closing function" is a condition to determine this.
Activate using the "YCLS" parameter in the configuration menu. If the underlying function is
deactivated in the configuration menu, "OFF" is displayed.
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19 PAVG - position average
This value shows the last calculated comparison average. The following status messages
are also available:
● OFF
The underlying function is deactivated in the configuration menu.
● IdLE (inactive)
The function has not been started yet.
● rEF (the reference average is calculated)
The function was started, and the reference interval is in progress at the moment.
● COMP (the comparison average is calculated)
The function was started, and the comparison interval is in progress at the moment.
20 P0 - Potentiometer value of bottom end stop and
21 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.
22 IMPUP - impulse length up
This parameter can be set for special applications.
23 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.
24 DBUP - Deadband open and
25 DBDN - Deadband closed
This parameter shows the deadbands of the controller in the "Open" and "Closed" directions.
The values correspond either to the manually configured value of the "DEBA" parameter or
to the value automatically adapted by the device if "DEBA" was set to "Auto".
26 SSUP - slow step zone up
This parameter can be set for special applications.
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27 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.
28 TEMP - current temperature
Current temperature in the positioner enclosure. The sensor is provided on the electronic
printed circuit board.
In order to switch over the temperature display between °C and °F, press the
button.
29 TMIN - Minimum temperature (slave pointer) and
30 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.
31 T1 ... 39 T9 - number of operating hours in temperature ranges T1 to T9
Statistics about the duration of operation in different temperature ranges is maintained in the
device. An average of the measured temperature is taken every hour and the counter
assigned to the corresponding temperature range is incremented. This helps in drawing
conclusions about the past operating conditions of the device and the entire control valve.
The temperature ranges are classified as follows:
Temperature range [°C]
T1
T2
T3
T4
T5
T6
T7
T8
T9
-
≥ -30
≥ -15
≥0
≥ 15
≥ 30
≥ 45
≥ 60
≥ 75
≥ -30
< -15
<0
< 15
< 30
< 45
< 60
< 75
-
Operating hours in temperature ranges T1 to T2
40 VENT1 - Counter for pilot valve 1 and
41 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. On average it is approx. 200 million switching operations for
each of the two pilot valves with symmetrical load. The number of control procedures for the
switching operations serves to assess the switching frequency of the pneumatic block.
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Counting procedure for single-acting actuators:
● Pressurize => 40 VENT1
● Depressurize => 41 VENT2
Counting procedure for double-acting actuators:
● Pressurize (Y2) / Depressurize (Y1) => 40 VENT1
● Depressurize (Y1) / Pressurize (Y2) => 41 VENT2
42 STORE - save maintenance data
Press the
button for at least 5 seconds in order to exit the save function. The diagnostics
data 7 to 10 and 20 to 27 is saved in the non-volatile memory as "data of last maintenance".
This diagnostics data contains selected values whose changes can give information about
mechanical wear and tear of the valve.
This function is normally operated through the PDM, menu command "Device-> Save
maintenance info". The data of the last maintenance operation can be compared with the
current data using SIMATIC PDM.
43 PRUP - Prediction open and
44 PRDN - Prediction closed
Refer to chapter "Optimizing the controller data (Page 108)"
45 WT00 bis 52 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.
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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.
See also
Safety function (Page 139)
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11.3 Online diagnostics
11.3
Online diagnostics
11.3.1
Overview of online diagnostics
Online diagnostics means diagnostics during ongoing operation. A few important variables
and parameters are continuously monitored during the operation of the positioner. In
"Configuration" mode, you can configure this monitoring in such a way that the fault
message output will be activated if, for instance, a limit is exceeded.
Information about what events can activate the fault message output can be found in the
table in chapter "Overview of error codes (Page 251)".
This chapter contains information about the following situations in particular:
● Possible causes of the fault message.
● Events which activate the fault message output or alarm outputs.
● Setting of parameters needed for event monitoring.
● Canceling a fault message
When the fault message output is triggered in automatic or manual mode, the display shows
which fault triggered the message. Both digits at bottom-left indicate the corresponding error
code. If multiple triggers occur at the same time, they are displayed one after the other
cyclically.
See also
Description of parameter 48 (Page 169)
11.3.2
Overview of error codes
Overview of error codes that activate the fault message output
Error
code
Threestage
Event
Parameter setting
Error message disappears
when
Possible causes
1
No
Remaining control
deviation
Always active
... the control deviation
disappears again.
Compressed air failure,
actuator fault, valve fault (e.g.
blockade).
2
No
Device not in the
automatic mode
**. FCT1)
... the device is switched to
the automatic mode.
The device has been
configured or is in the manual
mode
Binary input BE1
or BE2 active
**. FCT1)
... the binary input is no
longer active.
The contact connected to the
binary input was active (e.g.
packing gland monitoring,
overpressure, temperature
switch).
3
No
= nA or = nAB
= nAB and binary
function BIN1 or
BIN2 on "On"
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Error
code
Threestage
Event
Parameter setting
Error message disappears
when
Possible causes
4
Yes
The limit of stroke
number exceeded
L. STRK≠OFF
... the stroke counter is reset
or the thresholds are
increased
The total path covered by the
actuator exceeds one of the
configured thresholds.
5
Yes
Limit of changes of O. DCHG≠OFF
direction exceeded
... the counter for changes of
direction is reset or the
thresholds are increased.
The number of changes of
direction exceeds one of the
configured thresholds.
6
Yes
Limit of the lower
hard end stop
exceeded
F. ZERO≠OFF
... the deviation of the end
**.YCLS = do or up stop disappears or the device
do
is re-initialized.
Wear and tear of the valve
seat, deposits or foreign
bodies in the valve seat,
mechanical misalignment,
friction clutch moved.
7
Yes
Limit of the upper
hard end stop
exceeded
G. OPEN≠OFF
**.YCLS1) = do or
up do
... the deviation of the end
stop disappears or the device
is re-initialized.
Wear and tear of the valve
seat, deposits or foreign
bodies in the valve seat,
mechanical misalignment,
friction clutch moved.
8
No
Limit of deadband
adjustment
exceeded
E. DEBA≠OFF
... the limit is undershot again
Increased packing gland
friction, mechanical gap in the
position feedback.
**.DEBA1) = Auto
9
Yes
Partial-Stroke-Test A. PST≠OFF
exceeds reference
stroke time
... a Partial-Stroke-Test is
successfully executed within
the reference stroke time or
the function is deactivated.
Valve jams or has rusted,
increased friction
10
Yes
General control
valve fault
b. DEVI≠OFF
... the position is again in a
narrow corridor between the
reference variable and the
model, or the function is
deactivated.
Actuator fault, valve fault,
valve jams, increased friction,
decreased compressed air
11
Yes
Pneumatic
leakage
C. LEAK≠OFF
... the leakage drops below
the configured thresholds, or
the function is deactivated.
Pneumatic leakage
12
Yes
Static friction/
Slipstick effect
occurs
d. STIC≠OFF
... Slipjumps can no longer be Increased static friction, valve
detected, or the function is
no longer moves smoothly,
deactivated.
but with jerks
13
Yes
Temperature
undershot
H. TMIN≠OFF
... the lower temperature
thresholds are no longer
undershot.
Ambient temperature too low
14
Yes
Temperature
overshot
J. TMAX≠OFF
... the upper thresholds are
no longer overshot.
Ambient temperature too high
15
Yes
Position average
deviates from the
reference value
P. PAVG≠OFF
... the position average
calculated after a comparison
interval is again within the
thresholds for the reference
value, or the function is
deactivated.
In the last comparison
interval, the valve trajectory
was changed so severely that
a deviating position average
was calculated.
1)
Refer to the corresponding parameter descriptions for additional information about parameters
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See also
Description of parameters (Page 155)
11.3.3
XDIAG parameter
You can use the advance diagnostics parameters to display fault messages in one, two or
three stages. In addition to the fault message output, alarm outputs 1 and 2 are then used.
For this purpose, set the "XDIAG" parameter as described in the following table:
Settings of XDIAG
Message due to
OFF
Advanced diagnostics not activated
On 1
Fault message output for threshold 3 fault messages (one-stage)
On 2
Fault message output for threshold 3 fault messages and alarm output 2 for threshold 2
fault messages (two-stage)
On 3
Fault message output for threshold 3 fault messages and alarm output 2 for threshold 2
fault messages and alarm output 1 for threshold 1 fault messages (three-stage)
Possible settings of the "XDIAG" parameter
See also
Description of parameter 48 (Page 169)
11.3.4
Meaning of error codes
1 Monitoring of control deviation
The deviation between the setpoint and the actual value is continuously monitored in the
automatic mode. The fault message for the remaining control deviation is activated
depending on the setting of the " TIM" parameter, monitoring time for setting the fault
messages and " LIM" and the response threshold. The fault message is cancelled as soon
as the control deviation drops below the response threshold.
2 Automatic mode monitoring
When the device is not in automatic mode, a fault message is generated if the " FCT"
parameter (function of fault message output) is set correctly. A warning is then sent to the
control system if the device was switched to manual or configuration mode on-site.
3 Binary input BE1 or BE2 active
If the binary input is activated, a fault message is generated when the " FCT" parameter
(function of fault message output) and the "BIN1" parameter (function of binary input 1) are
set correctly. For example, it can be a switch to monitor the packing glands, a temperature
switch or a limit switch (e.g. for pressure).
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Binary input 2 (in the optional alarm module) can be configured in a similar manner.
4 Monitoring of the stroke number
5 Monitoring of the number of changes of direction
Both the values, namely the stroke number and the number of changes of direction are
constantly compared with the thresholds that are determined from the parameters "L1.LIMIT"
to "L4.FACT3" and "O1.LIMIT" to "O4.FACT3". If the thresholds are exceeded, the fault
message output or the alarm outputs respond depending on the mode of the extended
diagnostics. Both these functions can be deactivated using the parameter setting "OFF" for
"L. STRK" and "O. DCHG".
6 Monitoring of the lower hard end stop (valve seat)
7 Monitoring of the upper hard end stop
If the parameter "F. ZERO" is set to "ON", monitoring of the lower hard end stop is activated.
This function can be used to detect the errors in the valve seat. An overshot limit indicates
the possibility of deposits or foreign bodies in the valve seat. An undershot limit indicates
probable wear and tear of the valve seat or flow restrictor. Even a mechanical misalignment
of the position feedback can trigger this fault message.
Monitoring is always carried out whenever the valve is in the "down tight closing" position.
The current position is compared with the position that was determined as the lower end stop
at the time of initialization. The activation of "down tight closing" ("YCLS" parameter) is
therefore the condition.
Example: A value of 3% is set. The position is normally adopted for "down tight closing". A
fault is reported if a value > 3% or < -3% is determined instead.
The fault message remains activated until either a subsequent monitoring remains within the
tolerance or a re-initialization process is executed. Even the deactivation of monitoring ("F.
ZERO"=OFF) may trigger a fault message.
This monitoring function does not deliver any utilizable results if the end stops were not
determined automatically at the time of initialization, but the limits were set manually (manual
initialization, "5.INITM").
A similar diagnostics is carried out for the upper hard end stop. The "G. OPEN" parameter is
used to set the limit for this. The activation of "up tight closing" ("YCLS" parameter) is
therefore the condition.
8 Monitoring of deadband adjustment
If the deadband increases disproportionately when adjusting it automatically ("DEBA"=Auto
parameter), it indicates an error in the system (e.g. severely increased packing gland friction,
play in the position displacement sensor, leakage). A limit can therefore be entered for this
value ("E1.LEVL3", threshold for deadband monitoring). A fault message output is activated
when this value is exceeded.
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9 Partial stroke test exceeds the reference stroke time
On the one hand, this fault message appears when a manual or cyclic partial stroke test is
initiated and the test cannot be started since the valve is not within the starting tolerance. On
the other hand, this fault message appears when one of the three thresholds of the partial
stroke test that are determined from the "A6.PSTIN" reference stroke time multiplied by
factors "A7.FACT1" to "A9.FACT3" is violated. The degree of the fault message is shown in
the number of columns on the display. The degree of the fault message is simultaneously
displayed using the fault message output or alarm outputs depending on the mode of the
extended diagnostics.
10 General control valve fault
The monitoring of the operational response responds when the actual valve position shifts
from a narrow corridor between the reference variable and the expected position course. In
this case, the deviation between the expected and actual position course is filtered,
displayed and compared with the configured thresholds that are determined from the
"b2.LIMIT" limit multiplied by the factors "b3.FACT1" to "b5.FACT3".
11 Pneumatic leakage
This fault message appears when the leakage indicator exceeds the configured thresholds.
Keep in mind that the complete sensitivity of this function can be used only if a ramp
movement was initiated after initialization to set the leakage indicator (see explanations for
"C1.LIMIT").
12 Static friction/slipstick effect is too large
If the static friction of the control valve increases during operation or more Slipjumps are
detected, it may exceed the corresponding limits and lead to this fault message.
13 Temperature undershot
This fault message appears when the lower limit temperature thresholds are undershot.
14 Temperature overshot
This fault message appears when the upper limit temperature thresholds are overshot.
15 Monitoring of the position average
This fault message appears when a position value calculated after the expiry of a
comparison interval deviates from the reference value by more than the configured
thresholds.
See also
Description of parameter C (Page 177)
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11.4
Fault correction
11.4.1
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
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11.4 Fault correction
11.4.2
Remedial measures table 1
Fault profile (symptoms)
•
•
•
•
Positioner remains in "RUN 1".
Positioner remains in "RUN 2".
Positioner remains in "RUN 3".
Positioner remains "RUN 5", does
not go up to "FINISH" (waiting time
> 5 min).
Possible cause(s)
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.
•
Network pressure not connected or
it is too low.
•
Provide the network pressure.
•
Transmission ratio selector and
parameter 2
•
•
"YAGL" and the real stroke do not
match.
Check settings: see leaflet: "Device
view (7)" picture as well as
parameters 2 and 3
•
Check the stroke setting on the
lever. See table 2
•
Open the restrictor completely
and/or set the pressure PZ (1) to
the highest permissible value.
•
Use a booster if required.
•
Part-turn actuator: check for the
firmness of the grub screw of the
coupling wheel
•
Linear actuator: check for the
firmness of the lever on the
positioning shaft.
•
Remove any play between the
actuator and the control valve.
•
Incorrectly set stroke on the lever.
•
Piezo valve does not activate.
•
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
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11.4.3
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.)
•
•
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
The screw between the shrouding
cover and the pneumatic block has
not been tightened firmly or the
cover got stuck.
•
Tighten the screw firmly; if required,
rectify the deadlock.
•
Dirt (swarf, particles) in the
pneumatic block
•
Repair or a new device; clean
and/or replace the built-in fine
screens.
•
Deposits on the contacts between
the electronic printed circuit board
and the pneumatic block may
develop due to abrasion owing to
continuous loads resulting from
strong vibrations.
•
Clean all contact surfaces with
spirit; if required, bend the
pneumatic block contact springs.
•
Water in the pneumatic block (due
to wet compressed air)
Fault table 2
See also
Repair/Upgrading (Page 266)
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11.4.4
Remedial measures table 3
Fault profile (symptoms)
Possible cause
Remedial measures
•
Actuator does not move.
•
Compressed air < 1.4 bar
•
Set the supply air pressure to
> 1.4 bar.
•
Piezo valve does not activate (a
gentle click sound is however
audible when the "+" or "-" buttons
are pressed in the manual mode.)
•
Restrictor valve turned off (screw at
the right end stop)
•
Open the restrictor screw by turning
it anticlockwise, see leaflet, "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 activates constantly in •
the stationary automatic mode
(constant setpoint) and the manual
mode.
•
Dirt in the pneumatic block, see
above
•
In case of an intact actuator and
tight feed line: Repair or new device
See above
Fault table 3
See also
Repair/Upgrading (Page 266)
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11.4.5
Remedial measures table 4
Symptoms
•
Possible cause(s)
In stationary automatic mode
(constant setpoint) and in manual
mode, both piezo valves continually
switch alternately, and the actuator
oscillates around a mean value.
•
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
•
Select 3/4-wire mode
•
•
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
11.4.6
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, fault and system messages
11.4 Fault correction
See also
Repair/Upgrading (Page 266)
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Alarm, fault and system messages
11.4 Fault correction
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Service and maintenance
12.1
12
Basic safety instructions
WARNING
Impermissible repair of the device
• Repair must be carried out by Siemens authorized personnel only.
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
• Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
WARNING
Improper connection after maintenance
Danger of explosion in areas subject to explosion hazard.
• Connect the device correctly after maintenance.
• Close the device after maintenance work.
Refer to Chapter "Connect (Page 73)".
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
12.1 Basic safety instructions
CAUTION
Releasing key lock
Improper modification of parameters could influence process safety.
• Make sure that only authorized personnel may cancel the key locking of devices for
safety-related applications.
WARNING
Electrostatic charge
Danger of explosion in hazardous areas if electrostatic charges develop, for example, when
cleaning plastic enclosures with a dry cloth.
• Prevent electrostatic charging in hazardous areas.
WARNING
Dust layers above 5 mm
Danger of explosion in hazardous areas. Device may overheat du to dust build up.
• Remove any dust layers in excess of 5 mm.
Cleaning the enclosure
● Clean the outside of the enclosure and the display window using a cloth moistened with
water or a mild detergent.
● Do not use aggressive cleaning agents or solvents. Plastic components or painted
surfaces could be damaged.
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12.2 Cleaning of the screens
12.2
Cleaning of the screens
The positioner is maintenance-free to a large extent. Screens are installed in the pneumatic
connections of the positioners to protect them from rough dirt particles. If there are dirt
particles in the pneumatic auxiliary power supply, they damage the screens and hamper the
function of the positioner. Clean the screens as described in the following two chapters.
12.2.1
Positioner in macrolon enclosure
DANGER
Risk of explosion due to electrostatic charge
Electrostatic charges develop when cleaning the positioner in the macrolon enclosure with
a dry cloth, for example.
It is imperative you avoid electrostatic charges in the hazardous environment.
Removal and cleaning of the screens
1. Disconnect the pneumatic auxiliary power supply.
2. Remove the lines.
3. Unscrew the cover.
4. Unscrew the three self-tapping 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
CAUTION
Damage to the enclosure
• The enclosure is damaged due to screwing in the self-tapping screws improperly.
• Ensure that the available thread pitches are used.
• Turn the screws anticlockwise until they engage noticeably in the thread pitch.
• Tighten the self-tapping screws only after they have engaged.
1. Insert the screens into the recesses of the macrolon 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-on the three self-tapping screws.
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12.3 Repair/Upgrading
5. Place the cover and tighten it.
6. Reconnect the pipelines and feed the pneumatic power supply.
12.2.2
Positioner in stainless steel, aluminum and flameproof aluminum enclosure
Removal, cleaning and installation of the screens
1. Disconnect the pneumatic auxiliary power supply.
2. Remove the pipelines.
3. Remove the metal screen from the bores carefully.
4. Clean the metal screens, e.g. using compressed air.
5. Insert the screens.
6. Connect the pipelines again.
7. Feed the pneumatic auxiliary power supply.
12.3
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
provide the serial number of the original device. You can find the serial number on the
nameplate.
See also
Nameplate layout (Page 22)
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Service and maintenance
12.4 Return procedure
12.4
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.
Any devices/replacement parts returned without a decontamination declaration will be
cleaned at your expense before further processing.
The forms can be found on the Internet as well as in the documentation which comes with
the device.
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12.4 Return procedure
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Technical data
13.1
Rated conditions
Rated conditions
Ambient temperature
•
Permissible ambient temperature for operation
In hazardous areas, observe the maximum permissible
ambient temperature corresponding to the temperature
class.
-30 ... +80 °C (-22 ... +176°F)
Degree of protection 1)
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/axle
•
Bumping (half-sine) according to EN 60068-2-27/02.2010
150 m/s² (492 ft/s²), 6 ms, 1000 shocks/axle
•
Noise (digitally controlled) according to EN 60068-264/04.2009
10 ... 200 Hz; 1 (m/s²)²/Hz (3.28 (ft/s²)²/Hz)
•
98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axle
200 ... 500 Hz; 0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz)
4 hours/axle
•
Recommended range of continuous operation of the entire ≤ 30 m/s² (98.4 ft/s²) without resonance peak
control valve
Climate class
According to DIN EN 60721-3-4
•
Storage
1K5, but -40 ... +80°C (1K5, but -40 ... +176°F)
•
Transport
2K4, but -40 ... +80°C (2K4, but -40 ... +176°F)
•
Operation 2)
4K3, but -30 to +80 °C (4K3, but -22 to +176 °F) 3)
1)
Max. impact energy 1 Joule for enclosure with inspection window 6DR5..0 and 6DR5..1.
2)
At ≤ -10 °C (≤ 14 °F), the display refresh rate is limited. In the case of use with Iy module, only T4 is permissible.
3)
-20 to +80 °C (-4 to +176 °F) for 6DR55..-0G ..., 6DR56..-0G ..., 6DR55..-0D ... and 6DR56..-0D...
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Technical data
13.2 Pneumatic data
13.2
Pneumatic data
Pneumatic data
Auxiliary power (air supply)
Compressed air, carbon dioxide (CO2), nitrogen (N), noble
gases or cleaned natural gas
1,4 ... 7 bar (20.3 ... 101.5 psi)
Pressure
•
Air quality to ISO 8573-1
•
Solid particulate size and density
Class 2
•
Pressure dew point
Class 2 (min. 20 K (36°F) below ambient temperature)
•
Oil content
Class 2
Unrestricted flow (DIN 1945)
Inlet air valve (ventilate actuator) 1)
•
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)
Air exhaust valve (depressurize
•
9.8 Nm³/h (43.1 USgpm)
drive) 1)
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)
1)
When using device version Ex d (6DR5..5-...), values are reduced by approximately 20%.
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Technical data
13.3 Construction
13.3
Construction
Construction
How does it work?
•
Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 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
•
Glass-fiber reinforced polycarbonate housing
Approx. 0.9 kg (1.98 lb)
•
Aluminum enclosure
Approx. 1.3 kg (2.86 lb)
•
Stainless steel enclosure
Approx. 3.9 kg (8.6 lb)
•
Flameproof aluminum enclosure
Approx. 5.2 kg (11.46 lb)
Material
•
Enclosure
6DR5..0-... (Makrolon)
Glass-fiber reinforced polycarbonate
(PC)
6DR5..1-... (aluminum)
GD AISi12
6DR5..2-... (stainless steel)
Austenitic stainless steel mat. No.
1.4581
6DR5..5-... (aluminum, flameproof)
•
Pressure gauge block
GK AISi12
Aluminum AIMgSi, anodized
Versions
•
In Makrolon enclosure
Single-acting and double-acting
•
In the aluminum enclosure
Single-acting
•
In flameproof aluminum enclosure
Single-acting and double-acting
•
In the stainless steel enclosure
Single-acting and double-acting
Torques
•
Part-turn actuator fixing screws DIN 933 M6x12-A2
5 Nm (3.7 ft lb)
•
Linear actuator fixing screws DIN 933 M8x16-A2
12 Nm (8.9 ft lb)
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Technical data
13.3 Construction
Construction
•
Gland pneumatic G¼
•
Gland pneumatic ¼ NPT
•
15 Nm (11.1 ft lb)
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 8 Nm (5.9 ft lb)
enclosure
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
13.4 Controller
13.4
Controller
Controller
Control unit
•
Five-point controller
•
Dead zone
Adaptive
dEbA = auto
Adaptive or can be preset
dEbA = 0.1 ... 10 %
Adaptive or can be preset
Analog-to-digital converter
•
Scanning time
10 ms
•
Resolution
≤ 0.05 %
•
Transmission error
≤ 0.2 %
•
Temperature influence
≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
Cycle time
•
20 mA/HART device
20 ms
•
PA device
60 ms
•
FF device
60 ms (min. loop time)
13.5
Certificates, approvals, explosion protection for all device versions
Certificates and approvals
Classification according to pressure
equipment directive (PED 97/23/EC)
For fluid group 1 gases; fulfills requirements in article 3, paragraph 3 (good
engineering practice SEP)
CE conformity
The applicable directives and standards applied with their revision levels can
be found in the EC declaration of conformity on the Internet.
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Technical data
13.5 Certificates, approvals, explosion protection for all device versions
Explosion protection
Ex markings
Explosion protection in accordance with
ATEX/IECEx
Flameproof enclosure "d"
Zone 1:
II 2 G Ex d IIC T6/T4 Gb
FM/CSA
FM:
XP, Class I, Division 1, ABCD
XP, Class I, Zone 1, AEx d, IIC,T6/T4
CSA:
Class I, Division 1, Groups CD
Class II/III, Division 1, Groups EFG
Intrinsic safety "ia"
Zone 1:
II 2 G Ex ia IIC T6/T4 Gb
II 2 D Ex ia IIIC 110°C Db
Intrinsic safety "ic"
Zone 2:
FM:
IS, Class I, Division 1, ABCD
Class I, Zone 1, AEx ib, IIC,T6/T4
CSA:
Class I, Division 1, ABCD
Class I, Zone 1, Ex ib, IIC
-
II 3 G Ex ic IIC T6/T4 Gc
Non-sparking "nA"
Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
FM:
NI, Class I, Division 2, ABCD
NI, Class I, Zone 2, IIC,T6/T4
CSA:
Class I, Division 2, ABCD
Class I, Zone 2, IIC
Dust, protection by enclosure "t"
Zone 22:
II 3 D Ex tb IIIC T100°C Dc
CSA:
Class II, Division 1
IP66
Permissible ambient temperature
•
For operation with or without HART 1)
Zones 1, 2 and 22
T4: -30 ... +80 °C (-22 ... +176 °F)
T6: -30 ... +50 °C (-22 ... +122 °F)
•
For operation with PROFIBUS PA or
with FOUNDATION Fieldbus 1)
Zones 1, 2 and 22
T4: -20 ... +75 °C (-4 ... +103 °F)
T6: -20 ... +50 °C (-4 ... +122 °F)
1)
At ≤ -10 °C (+14 °F), the display refresh rate of the display is limited. For basic devices with explosion protection: When
using Iy module, only T4 is permissible.
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Technical data
13.6 Electrical specifications
13.6
Electrical specifications
Basic device without Basic device with
explosion protection explosion protection
Ex d
Auxiliary power supply bus
circuit
(terminals 6 and 7)
Bus voltage
Basic device with
explosion protection
Ex "ia"
Basic device with
explosion protection
Ex "ic", "nA", "t"
Bus-powered
9 ... 32 V
9 ... 32 V
9 ... 24 V
9 ... 32 V
-
-
Ui = 17.5 V DC
Ii = 380 mA
Pi = 5.32 W
"ic":
Ui = 17.5 VDC
Ii = 570 mA
For connecting to circuits with
the following peak values
•
Bus connector with FISCO
supply unit
"nA"/"t":
Un ≤ DC 32 V
•
Bus connector with barrier
Ui = DC 24 V
Ii = 250 mA
Pi = 1.2 W
"ic":
Ui = DC 32 V
"nA"/"t":
Un ≤ DC 32 V
Effective inner capacitance Ci
-
-
Negligible
Negligible
Effective inner inductance Li
-
-
8 μH
"ic":
8 μH
Current consumption
11.5 mA ± 10 %
Additional fault current
0 mA
Safety shutdown can be
activated using "Jumper"
(terminals 81 and 82)
Electrically isolated from bus circuit and binary input
> 20 kΩ
•
Input resistance
•
Signal status "0" (shutdown
active)
0 ... 4.5 V or no switch
•
Signal status "1" (shutdown
inactive)
13 ... 30 V
•
For connecting to power
source with the following
peak values
•
-
Effective internal
capacitance and inductance
-
Ui = DC 30 V
Ii = 100 mA
Pi = 1 W
"nA":
Un ≤ DC 30 V
In ≤ 100 mA
"ic":
Ui = DC 30 V
Ii = 100 mA
-
Negligible
Negligible
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Technical data
13.6 Electrical specifications
Basic device without Basic device with
explosion protection explosion protection
Ex d
Binary input BE1
(terminals 9 and 10) electrically
connected to the bus circuit
Basic device with
explosion protection
Ex "ia"
Basic device with
explosion protection
Ex "ic", "nA", "t"
Jumpered or connection to switch contact.
Suitable only for floating contact; max. contact load
< 5 μA with 3 V
Galvanic isolation
•
For basic device without Ex
protection and for basic
device with Ex d
Galvanic isolation between the basic device and the input for safety shutdown and the
outputs of option modules.
•
For basic device Ex "ia"
The basic device, the input for safety shutdown, and the outputs of option modules are
individual intrinsically safe circuits.
•
For basic device Ex "ic",
"nA", "t"
Galvanic isolation between the basic device and the input for safety shutdown and the
outputs of option modules.
Test voltage
DC 840 V, 1 s
Basic device without Basic device with
explosion protection explosion protection
Ex d
Basic device with
explosion protection
Ex "ia"
Basic device with
explosion protection
Ex "ic", "nA", "t"
Connections, electrical
•
Screw terminals
•
Cable gland
Connections, pneumatic
2.5 AWG28-12
M20x1.5 or
½-14 NPT
Ex d certified
M20x1.5;
½-14 NPT or
M25x1.5
M20x1.5 or
½-14 NPT
M20x1.5 or
½-14 NPT
Female thread G¼ or ¼-18 NPT
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Technical data
13.7 Technical data for natural gas as actuator medium
13.7
Technical data for natural gas as actuator medium
Introduction
Note when using an actuator with natural gas that this can escape at the following points:
● At the exhaust air outlet with a sound absorber at the bottom of the device.
● At the enclosure ventilation at the bottom of the device.
● At the control air outlet near the pneumatic connections.
Note
Exhaust air outlet with a sound absorber at the bottom of the device
The positioner is delivered as standard with a sound absorber at the bottom of the device.
To provide an outlet for the exhaust air, replace the sound absorber by a G¼ pipe
coupling.
Enclosure ventilation and control air outlet
Enclosure ventilation and control air outlet cannot be collected and channeled off.
Please refer to the following table for the maximum bleeding values.
Maximum values for escaping natural gas
Bleeding process
Ventilation of enclosure volume via bottom of
device. Purge air switch is at "IN":
Bleed through the control air outlet near the
pneumatic connections:
Ventilation via the exhaust air outlet with a
sound absorber at the bottom of the device
Operating
mode
6DR5.1.-.E...
6DR5.2.-.E...
Single-acting
Double-acting
[Nl/min]
[Nl/min]
Operation,
typical
0.14
0.14
Operation,
max.
0.60
0.60
Error case,
max.
60.0
60.0
Operation,
typical
1.0
2.0
Operation,
max.
8.9
9.9
Error case,
max.
66.2
91.0
Operation,
max.
358.21)
3391),
1.26
1.23
Error case,
max.
Volume
Max. [l]
1) Depending on the actuating pressure and volume of the actuator as well as the frequency of
control. The maximum flow rate is 470 Nl/min at a differential pressure of 7 bar.
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Technical data
13.8 Option modules
See also
Safety notes for operation with natural gas (Page 113)
Pneumatic connection on the standard controller (Page 92)
13.8
Option modules
13.8.1
Alarm module
Without Ex protection/
with Ex protection Ex d
With Ex protection Ex "ia"
With Ex protection
Ex "ic", "nA", "t"
6DR4004-8A
6DR4004-6A
6DR4004-6A
≤ 35 V
-
-
High (not addressed)
Conductive, R = 1 kΩ,
+3/-1 % *)
≥ 2.1 mA
≥ 2.1 mA
Low *) (addressed)
Deactivated, IR < 60 µA
≤ 1.2 mA
≤ 1.2 mA
Switching thresholds for
supply as per EN 609475-6:
UH = 8.2 V, Ri = 1 kΩ
Switching thresholds for
supply as per EN 609475-6:
UH = 8.2 V, Ri = 1 kΩ
Ui = DC 15.5 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = DC 15.5 V
I i = 25 mA
Alarm module
3 binary output circuits
•
Alarm output A1: Terminals 41 and 42
•
Alarm output A2: Terminals 51 and 52
•
Fault message output: Terminals 31 and 32
•
Auxiliary voltage UH
•
Signal status
*) The status is also Low if the *) When using in the
basic device is faulty or without flameproof housing, the
a auxiliary power.
current consumption must
be restricted to 10 mA per
output.
•
For connecting to circuits with the
following peak values
-
"nA"/"t":
Un ≤ DC 15.5 V
Effective internal capacitance
-
Ci = 5.2 nF
Ci = 5.2 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
1 binary input circuit
•
Binary input BE2: Terminals 11 and 12, terminals 21 and 22 (jumper)
•
Galvanically connected with the
basic device
Signal status 0
Floating contact, open
Signal status 1
Floating contact, closed
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Technical data
13.8 Option modules
Without Ex protection/
with Ex protection Ex d
With Ex protection Ex "ia"
Contact load
•
With Ex protection
Ex "ic", "nA", "t"
3 V, 5 μA
Electrically isolated from the basic
device
Signal status 0
≤ 4.5 V or open
Signal status 1
≥ 13 V
Internal resistance
≥ 25 kΩ
•
Static destruction limit
± 35 V
-
-
•
Connecting to circuits with the
following peak values
-
Ui = DC 25.2 V
"ic":
Ui = DC 25.2 V
"n"/"t":
Un ≤ DC 25.5 V
Effective internal capacitance
-
Ci = negligibly small
Ci = negligibly small
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
The three outputs, the BE2 input and the basic device are galvanically isolated
from each other.
Test voltage
DC 840 V, 1 s
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Technical data
13.8 Option modules
13.8.2
Iy module
Iy module
Without Ex protection/
with Ex protection Ex d
With Ex protection Ex ia
(only in temperature class
T4)
With Ex protection
Ex "ic", "nA", "t"
6DR4004-8J
6DR4004-6J
6DR4004-6J
Direct current output for position
feedback
1 current output, terminals 61 and 62
2-wire connection
Rated signal range
4 ... 20 mA, short-circuit proof
Dynamic range
Auxiliary voltage UH
3.6 ... 20.5 mA
+12 ... +35 V
External load RB [kΩ]
+12 ... +30 V
+12 ... +30 V
≤ (UH [V] - 12 V)/i [mA]
Transmission error
≤ 0.3%
Temperature influence
≤ 0.1%/10 K (≤ 0.1%/18 °F)
Resolution
≤ 0.1%
Residual ripple
≤1%
For connecting to circuits with the
following peak values
Ui = DC 30 V
Ii = 100 mA
Pi = 1 W
"ic":
Ui = DC 30 V
Ii = 100 mA
"nA"/"t":
Un ≤ DC 30 V
In ≤ 100 mA
Pn ≤ 1 W
Effective internal capacitance
-
Ci = 11 nF
Ci = 11 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
Test voltage
Safe galvanic isolation from alarm option and basic device
DC 840 V, 1 s
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Technical data
13.8 Option modules
13.8.3
SIA module
SIA module
Without Ex protection
With Ex protection Ex "ia"
With Ex protection Ex "ic",
"nA", "t"
6DR4004-8G
6DR4004-6G
6DR4004-6G
Limit encoder with slotted initiators
and fault message output
2 slotted initiators
•
Binary output (limit transmitter) A1: Terminals 41 and 42
•
Binary output (limit transmitter) A2: Terminals 51 and 52
2-wire connection
•
Connection
•
Signal state Low (triggered)
•
2 slotted initiators
•
Function
•
Connecting to circuits with the
following peak values
2 wire technology in accordance with EN 60947-5-6 (NAMUR), for switching
amplifiers connected on load side
< 1.2 mA
Type SJ2-SN
NC contact (NC, normally closed)
Nominal voltage 8 V;
current consumption:
≥ 3 mA (limit not
activated),
≤ 1 mA (limit activated)
Ui = DC 15 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = DC 15 V
Ii = 25 mA
"nA":
Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance
-
Ci = 41 nF
Ci = 41 nF
Effective internal inductance
-
Li = 100 μH
Li = 100 μH
1 fault message output
•
Binary output: Terminals 31 and 32
•
Connection
At switching amplifier in accordance with EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri =
1 kΩ).
•
Signal state High
(not triggered)
R = 1.1 kΩ
> 2.1 mA
> 2.1 mA
•
Signal state Low (triggered)
R = 10 kΩ
< 1.2 mA
< 1.2 mA
•
Auxiliary power supply UH
UH ≤ DC 35 V
I ≤ 20 mA
-
-
•
Connecting to circuits with the
following peak values
-
Ui = DC 15 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = DC 15 V
Ii = 25 mA
"nA":
Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance
-
Effective internal inductance
-
Galvanic isolation
Test voltage
Ci = 5.2 nF
Ci = 5.2 nF
Li = negligibly small
Li = negligibly small
The 3 outputs are galvanically isolated from the basic device.
DC 840 V, 1 s
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Technical data
13.8 Option modules
13.8.4
Limit value contact module
Mechanical limit switch module
Without Ex protection
With Ex protection Ex ia
With Ex protection Ex "ic",
"nA", "t"
6DR4004-8K
6DR4004-6K
6DR4004-6K
Limit encoder with mechanical
switching contacts
2 limit contacts
•
1 binary output: Terminals 41 and 42
•
2 binary output: Terminals 51 and 52
•
Max. switching current AC/DC
4A
-
-
•
For connecting to circuits with the
following peak values
-
Ui = DC 30 V
Ii = 100 mA
Pi = 750 mW
"ic":
Ui = 30 V DC
Ii = 100 mA
Effective internal capacitance
-
Ci = negligibly small
Ci = negligibly small
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
250 V/24 V
DC 30 V
DC 30 V
"nA": Un ≤ 15 V DC
•
Max. switching voltage AC/DC
1 fault message output
•
Binary output: Terminals 31 and 32
•
Connection
At switching amplifier in accordance with EN 60947-5- 6: (NAMUR),
UH = 8.2 V, Ri = 1 kΩ).
•
Signal state High
(not triggered)
R = 1.1 kΩ
> 2.1 mA
> 2.1 mA
•
Signal state Low (triggered)
R = 10 kΩ
< 1.2 mA
< 1.2 mA
•
Auxiliary power
UH ≤ DC 35 V
I ≤ 20 mA
-
-
•
Connecting to circuits with the
following peak values
-
Ui = 15 V
Ii = 25 mA
Pi = 64 mW
"ic":
Ui = 15 V
Ii = 25 mA
Effective internal capacitance
-
Ci = 5.2 nF
Ci = 5.2 nF
Effective internal inductance
-
Li = negligibly small
Li = negligibly small
Galvanic isolation
The 3 outputs are galvanically isolated from the basic device
Test voltage
Rated condition height
DC 3150 V, 2 s
Max. 2 000 m mean sea
level
Use a suitable power
supply at an altitude of
more than 2 000 m (6,562
ft.) above sea level.
-
-
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Technical data
13.8 Option modules
13.8.5
EMC filter module
Without Ex protection With Ex protection Ex ia
With Ex protection
Ex "ic", "nA", "t"
EMC filter module type C73451-A430-L8 is required for NCS sensor or an external potentiometer.
External position sensor (potentiometer or NCS; option) with the following maximum values
Resistance of the external potentiometer
10 kΩ
Maximum values when powered by the
PROFIBUS basic device
-
Uo = 5 V
Io = 75 mA static
Io = 160 mA short-term
Po = 120 mW
Uo = 5 V
Io = 75 mA
Po = 120 mW
Maximum values when powered by other
basic devices
-
Uo = 5 V
Io = 100 mA
Po = 33 mW
Co = 1 μF
Lo = 1 mH
Uo = 5 V
Io = 75 mA
Po = 120 mW
Co = 1 μF
Lo = 1 mH
Galvanic isolation
Test voltage
Galvanically connected with the basic device
DC 840 V, 1 s
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Technical data
13.8 Option modules
13.8.6
Non-contacting position sensor
Additional modules
Without Ex protection
With Ex protection
Ex "ia"
With Ex protection
Ex "ic", "nA"
Actuating range
•
Linear actuator 6DR4004-.N.20
3 to 14 mm (0.12 ... 0.55")
•
Linear actuator 6DR4004-.N.30
10 ... 130 mm (0.39 ... 5.12"); up to 200 mm (7.87") on request
•
Part-turn actuator
30 ... 100°
Linearity (after corrections made by
positioner)
±1%
Hysteresis
± 0.2%
Temperature influence (range:
rotation angle 120° or stroke
14 mm)
≤ 0.1%/10 K (≤ 0.1%/18 °F) for -20 to 90 °C (-4 to 194 °F)
≤ 0.2%/10 K (≤ 0.2%/18 °F) for -40 to -20 °C (-40 to -4 °F)
Climate class
According to DIN EN 60721-3-4
•
Storage
1K5, but -40 to +90 °C (1K5, but -40 to +176 °F)
•
Transport
2K4, but -40 to +90 °C (2K4, but -40 to +176 °F)
Vibration resistance
•
Harmonic oscillations
(sine wave) according to
IEC 60068-2-6
•
Permanent shocks according to
IEC 60068-2-29
3.5 mm (0.14"), 2 ... 27 Hz, 3 cycles/axis
98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axis
300 m/s2(984 ft/s2), 6 ms, 4000 shocks/axis
Torque for cable gland nut made of Plastic
2.5 Nm (1.8 ft lb)
Housing protection type
Metal
Stainless steel
4.2 Nm (3.1 ft lb)
4.2 Nm (3.1 ft lb)
IP68 according to EN 60529; NEMA 4X / Encl. Type 4X
For connecting to circuits with the
following peak values
-
Ui = 5 V
Ii = 160 mA
Pi = 120 mW
Ui = 5 V
Effective internal capacitance
-
Ci = 180 nF
Ci = 180 nF
Effective internal inductance
-
Li = 922 μH
Li = 922 μH
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Technical data
13.8 Option modules
Certificates and approvals
CE conformity
The applicable directives and standards applied with their revision levels can be
found in the EC declaration of conformity on the Internet.
Explosion protection
Types of protection
Ex markings
•
Intrinsic safety "ia"
ATEX/IECEx
FM
Zone 1:
IS, Class I, Divison 1, ABCD
IS, Class I, Zone 1, AEx ib, IIC
II 2 G Ex ia IIC T6/T4 Gb
•
Intrinsic safety "ic"
-
Zone 2:
II 3 G Ex ic IIC T6/T4 Gc
•
Non-sparking "nA"
Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
Permissible ambient temperature
T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)
13.8.7
External position sensing system
13.8.7.1
Operating conditions for all device versions
Ambient temperature
•
1
Permissible ambient temperature for operation
NI, Class I, Divison 2, ABCD
NI, Class I, Zone 2, AEx nA, IIC
T4: -40 ... +85 °C (-40 ... +185 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)
In hazardous areas, observe the maximum permissible
ambient temperature corresponding to the temperature
class.
-40 ... +90 °C (-40 ... +194°F)
Degree of protection 1)
IP66 according to EN 60529 / NEMA 4X
Climate class
According to DIN EN 60721-3-4
•
Storage
1K5, but -40 ... +90 °C (1K5, but -40 ... +194 °F)
•
Transport
2K4, but -40 ... +90 °C (2K4, but -40 ... +194 °F)
•
Operation
4K3, but -40 ... +90 °C (4K3, but -40 ... +194 °F)
) Impact energy max. 1 joule.
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Technical data
13.8 Option modules
13.8.7.2
Constructional design for all device versions
How does it work?
•
Range of stroke (linear actuator)
3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the
positioner axis 16 to 90°)
•
Angle of rotation (part-turn actuator)
30 ... 100°
Mounting method
•
On the linear actuator
Using the mounting kit 6DR4004-8V and, if required, an
additional lever arm 6DR4004-8L on the actuators as per
IEC 60534-6-1 (NAMUR) with a fin, columns, or a plane
surface.
•
On the part-turn actuator
Using the mounting kit 6DR4004-8D on the actuators with
fastening plane as per VDI/VDE 3845 and IEC 60534-6-2:
The required mount must be provided on the actuatorside.
Material
•
Makrolon® glass-fiber reinforced polycarbonate (PC)
Enclosure
Weight, basic device
Approximately 0.9 kg (1.98 lb)
Torque for plastic cable gland nut
2.5 Nm
13.8.7.3
Certificates, approvals, explosion protection for all device versions
Electrical data
For connecting to circuits with the
following peak values
Ui = 5 V
Ii = 100 mA
Pi = 160 mW
Ci = negligibly small
Li = negligibly small
Certificates and approvals
CE conformity
The applicable directives and standards applied with their revision levels can
be found in the EC declaration of conformity on the Internet.
Explosion protection
Ex markings
Explosion protection in accordance with
ATEX
Intrinsic safety "ia"
Zone 1:
II 2 G Ex ia IIC T6/T4 Gb
Zone 21:
II 2 D Ex ia IIIC 110°C Db
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Technical data
13.8 Option modules
Explosion protection
Intrinsic safety "ic"
Ex markings
Zone 2:
II 3 G Ex ic IIC T6/T4 Gc
Non-sparking "nA"
Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
Permissible ambient temperature
T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +60 °C (-40 ... +140 °F)
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Technical data
13.8 Option modules
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Dimension drawings
14.1
①
②
③
14
Positioner with Makrolon enclosure 6DR5..0 and stainless steel
enclosure 6DR5..2
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
Dimensions of stainless steel version (see superscript footnotes in the graphic)
1)
99 mm (3.89 inch)
2)
74 mm (2.91 inch)
3)
98 mm (3.86 inch)
Figure 14-1
Macrolon enclosure version, dimensions in mm (inch)
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Dimension drawings
14.2 Terminal strip for positioner with Macrolon enclosure
14.2
Terminal strip for positioner with Macrolon enclosure
①
Thread depth
Figure 14-2
Terminal strip for positioner with Macrolon enclosure, dimensions in mm (inch)
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Dimension drawings
14.3 Positioner with aluminum enclosure 6DR5..1
14.3
①
②
③
Positioner with aluminum enclosure 6DR5..1
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 14-3
Aluminum enclosure version, dimensions in mm (inch)
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Dimension drawings
14.4 Positioner with flameproof enclosure 6DR5..5
14.4
①
②
Positioner with flameproof enclosure 6DR5..5
All air connections G¼ or ¼ NPT
Air connection Y2, only with double-acting version
Figure 14-4
Version with flameproof enclosure, dimensions in mm (inch)
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Spare parts/accessories/scope of delivery
15.1
15
Overview
WARNING
Assembling the components
When assembling components, ensure that only those positioners and option modules are
combined with each other that are approved for the corresponding operating range.
This condition particularly applies to safe operation of the positioner in Zones 1, 2 and 22. It
is imperative to observe categories 2 and 3 of the device itself and of its option modules.
Basic version
The positioner can be delivered for:
● Double-acting actuators
● Single-acting actuators
The positioner and its option modules are delivered as separate units and with different
versions for the operation in:
● Hazardous environments and atmospheres
● Non-hazardous environments and atmospheres
Enclosure
The electronic unit with display, the position feedback, and the pneumatic block are
integrated in the enclosure.
The enclosure is available in the following versions:
● Makrolon enclosure for single and double-acting actuators
● Aluminum enclosure for single-acting actuators
● Stainless steel enclosure for single and double-actuators
● Flameproof enclosure for single and double-acting actuators
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Spare parts/accessories/scope of delivery
15.1 Overview
Options
The positioner can be equipped with different option modules. The following modules are
normally available:
● Iy module: two-wire current output 4 to 20 mA for position feedback
● Alarm module: 3 binary outputs and 1 binary input
● SIA module: one binary output for fault messages, two binary outputs for limit monitors
● Mechanical limit switch module with two switches and one alarm output.
The mechanical limit switch module cannot be used in device versions with flameproof
enclosure. Likewise, its use in zones 2 or 22 is not permitted.
Accessories
● Pressure gauge block: 2 or 3 pressure gauges for single and double-acting positioners
● Mounting flange (NAMUR) for safety pneumatic block
● Mounting kits for linear and part-turn actuators
For separate mounting of positioner and position sensor
● External position sensing system
● Non contacting sensor (NCS)
Note
The version is identified using a special nameplate.
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Spare parts/accessories/scope of delivery
15.2 Spare parts
15.2
Spare parts
Description
Order no.
For version
Plastic cover with 4 screws and circumferential
sealing ring
C73451-A430-D82
6DR5...
Aluminum cover with 4 screws and
circumferential sealing ring
C73451-A430-D83
6DR5...
Basic electronics, 2-wire, not Ex, without HART
A5E00082459
6DR50..-.N
Basic electronics 2-wire, Ex, without HART
A5E00082457
6DR50..-.E
Basic electronics, 2-wire, not Ex, with HART
A5E00082458
6DR51..-.N
Basic electronics, 2/3/4-wire, Ex, with HART
A5E00082456
6DR52..
Basic electronics, 2/3/4-wire, not Ex, without
HART
A5E00102018
6DR53..-.N
Basic electronics, PROFIBUS PA, not Ex
A5E00141523
6DR55..-.N
Basic electronics, PROFIBUS PA, Ex
A5E00141550
6DR55..-.E
Basic electronics, FOUNDATION fieldbus, not Ex A5E00215467
6DR56..
Basic electronics, FOUNDATION fieldbus, Ex
A5E00215466
6DR56..
Pneumatic block, single-acting, with seal and
screws
C73451-A430-D80
6DR5...
Pneumatic block, double-acting, with seal and
screws
C73451-A430-D81
6DR5...
Potentiometer (complete)
C73451-A430-D84
6DR5...
Magnet holder made of fiberglass reinforced
polyester including magnet for non contacting
position detection for part-turn actuators
A5E00078030
6DR4004-.N.10
Magnet holder made of anodized aluminum
including magnet for non contacting position
detection for part-turn actuators
A5E00524070
6DR4004-.N.40
Note
See Catalog "Field devices for process automation" for additives and possible modules".
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Spare parts/accessories/scope of delivery
15.3 Scope of delivery of small part sets
15.3
Scope of delivery of small part sets
Small part set 1
The small part set 1 with the order number C73451-A430-D85 contains the following items:
Position
Quantity
[unit]
Clamping piece
2
Pick-up bracket
1
Screw DIN 7984 M6x25-A2
2
Spring lock washer DIN 127 B6-SN06031
2
Screw SN 62217 G4x45-/16WN1452-TX-ST
5
Screw SN 62217 G4x14-combi-Torx-TX-ST
5
Screw SN 62217 G5x18-WN1452-T20-A2
3
Screw SN 62217 H5x8-WN1451-TX-A2
2
Screw DIN 7964 M4x16x6-A4-70-F
4
Cable gland MET 20-GR
3
Cable gland MET 20-BL
3
Blind plug M20 SW
3
Slide switch
1
Leaf spring
1
Sign, printed
1
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15.3 Scope of delivery of small part sets
Small part set 2
The small part set 2 with the order number C73451-A430-D86 contains the following items:
Position
Terminal strip C73451-A430-C21
Quantity
[unit]
1
Terminal strip C73451-A430-C22
1
Screen, molded
10
O-ring 14-P431ANBR75 (black)
10
O-ring 5.5-P431ANBR75 (black)
6
Screw SN 62217 G5x18-WN1452-T20-A2
3
Attenuator
5
Lip non-return valve
3
Plug 12 PE
10
Seal
3
Installation instructions
1
Sign, printed
1
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15.4 Scope of delivery of external position detection system
15.4
Scope of delivery of external position detection system
Scope of delivery of external position detection system C73451-A430-D78
Quanti Designation
ty
15.5
1
DVD
with the complete documentation for all variants and accessories
1
External position detection system
1
Gray cable gland
1
Sealing set 2x5 mm for cable gland
1
Plug for sealing set
1
Nameplate for device version without explosion protection
Scope of delivery of mechanical limit switch module
If the mechanical limit switch module was ordered for later installation, then the following
components are included in the scope of delivery:
● One mechanical limit switch module with accessories
● DVD with product documentation
● One housing cover with enlarged aperture
● One insulating cover
● Two cable ties
● One set of signs; how these are to be attached depends on the version.
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15.6 Scope of delivery EMC filter module
15.6
Scope of delivery EMC filter module
Cable glands and adapters
The EMC filter module is supplied with various cable glands and adapters. The following
diagram shows the different variants.
Connections ① to ③ for power supply
①
Adapter M20 ½-14 NPT for macrolon
enclosure
•
②
③
6DR5...-0.G../ -0.M..
Figure 15-1
Cable gland for connection thread
M20x1.5 with seal insert
•
⑤
6DR55..-0.R../ -0.R..
Cable gland for connection thread
M20x1.5
•
④
6DR5..0-0.N../ -0.P..
M12 connector for device version with
PROFIBUS communication (optional)
•
Connections ④ to ⑥ for optional modules
Dummy plug for device version without
optional modules
•
⑥
6DR5...-0...1/ -0...2/ -0...3
6DR5...-0...0
Adapter M20 ½-14 NPT for macrolon
enclosure with connection thread and
cover
•
6DR5..0-0.N../ -0.P..
Positioner with the different cable glands and adapter
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15.7 Accessories
Scope of delivery EMC filter module
Legend numbers refer to the graphic
Description
EMC filter module C73451-A430-L8
Seal ring
Cable tie I = 200 mm
①
Adapter M20 ½-14 NPT for macrolon enclosure
②
M12 connector for device version with PROFIBUS communication
③
Cable gland for connection thread M20x1.5
④
Cable gland for connection thread M20x1.5 with seal insert
⑤
Dummy plug for device version without optional modules
⑥
Adapter M20 ½-14 NPT for macrolon enclosure with connection thread and cover
Adhesive label 9x37 ws
15.7
Accessories
For accessories, refer to Catalog FI 01 "Field devices for process automation", for example:
● Option modules
● Non-contacting position sensor (NCS)
● Mounting kits
● Operating software
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A
Appendix
A.1
Operation with boosters
Introduction
In order to shorten the 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
Make sure that the booster does not result in pressure variations in the supply air Pz on the
positioner.
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 section Optimizing the controller data (Page 108).
See also
Sequence of automatic initialization (Page 115)
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Appendix
A.2 Certificates
A.2
Certificates
The certificates can be found on the DVD supplied and on the Internet at: Certificates
(http://www.siemens.com/processinstrumentation/certificates)
A.3
Literature and catalogs
Table A- 1
No.
Title
Publisher
Order no.
/1/
PNO guidelines
PROFIBUS PA
PNO
Technologiefabrik
2.091
Haid-und-Neu-Str. 7
D-76131 Karlsruhe
/2/
Catalog ST 70 SIMATIC
Products for Totally
Integrated Automation
Siemens AG
E86060-K4670-A111-B1
/3/
Catalog ST 70 NSIMATIC
News
Products for Totally
Integrated Automation
Siemens AG
E86060-K4670-A151-A3
/4/
Catalog ST 80 SIMATIC
HMI operation and
observation products
Siemens AG
E86060-K4680-A101-B4
/5/
Catalog IK PI
Industrial Communication
Siemens AG
Internet address:
IK PI Catalog
(http://www.automation.siemens.com/net/
html_76/support/printkatalog.htm)
E86060-K6710-A101-B5
See also
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
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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: +49 (0) 911 895 7 222
● Fax: +49 (0) 911 895 7 223
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 documentation, we offer a comprehensive knowledge base on the Internet
at:
Service&Support (http://www.siemens.com/automation/service&support)
There you will find:
● The latest product information, FAQs, downloads, tips and tricks.
● Our newsletter with the latest information about our products.
● A Knowledge Manager to find the right documents for you.
● Our bulletin board, where users and specialists share their knowledge worldwide.
● Your local contact partner for Industry Automation and Drives Technologies in our partner
database.
● Information about field service, repairs, spare parts and lots more under "Services."
Additional Support
Please contact your local Siemens representative and offices if you have any questions
about the products described in this manual and do not find the right answers.
Find your contact partner at:
Partner (http://www.automation.siemens.com/partner)
Documentation for various products and systems is available at:
Instructions and manuals (http://www.siemens.com/processinstrumentation/documentation)
See also
SIPART PS2 product information (http://www.siemens.com/sipartps2)
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
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A.4 Technical support
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B
Abbreviations
B.1
Abbreviations for PS2 positioners
Abbreviation
Long form
Meaning
A/D
Analog-to-digital converter
-
AC
Alternating current
Alternating current
AMS
Asset Management Solutions
Communication software from Emerson Process comparable
with the PDM
AUT
Automatic
Operating mode
ATEX
Atmosphère explosible
Product and operation directive of European Commission for
explosion protection.
CENELEC
Comité Européen de Normalisation
Electrotechnique
European committee for electrotechnical standardization
CPU
Central processing unit
Master processor
DC
Direct current
Direct current
DI
Digital Input
Digital input
DIN
Deutsche Industrie Norm
-
DO
Digital Output
Digital output
DTM
Device Type Manager
-
EDD
Electronic Device Description
-
Ex
Explosion protection
-
EMC
Electromagnetic compatibility
-
FDT
Field Device Tool
-
FF
FOUNDATION Fieldbus
Fieldbus of the Fieldbus Foundation
FM
Factory Mutual
American testing agency/insurance company
FW
Firmware
Device-specific software
GSD
Device master data
-
HART®
Highway Addressable Remote
Transducer
Communication system for the development of industrial field
busses.
IP
International Protection
International protection types (long form as per DIN)
Ingress Protection
Seepage protection (long form as used in US)
LC
Liquid crystal
Liquid crystal
MAN
Manual
Operating mode
NAMUR
Standards working group for
measurement and control technology
in the chemicals industry
Association of users in process conductor technology
µC
Microcontroller
One-Chip computer system
NCS
Non-Contacting Position Sensor
No-contact position sensor
NEMA
National Electrical Manufacturers
Association
US standards institution
National Electrical Manufacturers Association
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Abbreviations
B.1 Abbreviations for PS2 positioners
Abbreviation
Long form
Meaning
NPT
National Pipe Thread Taper
Pipe threading for self-sealing threads as per ANSI B.1.20.1
Open Positioner Interface
Standard interface for the connection between a positioner
and a pneumatic linear or part-turn actuator
PA
Process Automation
Process automation
PDM
Process Device Manager
Siemens communication software / Engineering tool
PROFIBUS
Process Field Bus
Fieldbus
PTB
Physical Technical Federal Institution -
SIA
Slit initiator alarm unit
-
SIL
Safety Integrity Level
Safety requirement level as per IEC 61508/IEC 61511
VDE
Verband der Elektrotechnik,
Elektronik und Informationstechnik
e. V.
Industrial and professional association
VDI
Verein Deutscher Ingenieure e. V.
Technical/scientific association
OPOS
interface®
Abbreviation
Full term in English
Meaning
FIT
Failure in Time
Frequency of failure
Number of faults within 109 hours
HFT
Hardware Fault Tolerance
Hardware fault tolerance:
Capability of a function unit to continue executing a required
function in the presence of faults or deviations.
MooN
"M out of N" voting
Classification and description of the safety-instrumented system
in terms of redundancy and the selection procedures used.
A safety-instrumented system or part that consists of "N"
independent channels. The channels are connected to each
other in such a way that "M" channels are in each case
sufficient for the device to perform the safety instrumented
function.
Example:
Pressure measurement: 1oo2 architecture. A safetyinstrumented system decides that a specified pressure limit has
been exceeded if one out of two pressure sensors reaches this
limit. In a 1oo1 architecture, there is only one pressure sensor.
MTBF
Mean Time Between Failures
Average period between two failures
MTTR
Mean Time To Restoration
Average period between the occurrence of a fault in a device or
system and restoration of functionality
PFD
Probability of Dangerous Failure on
Demand
Probability of dangerous failures of a safety function on demand
PFDAVG
Average Probability of Dangerous
Failure on Demand
Average probability of dangerous failures of a safety function on
demand
SFF
Safe Failure Fraction
Proportion of safe failures:
Proportion of failures without the potential to bring the safetyinstrumented system into a dangerous or non-permissible
functional status.
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Abbreviations
B.1 Abbreviations for PS2 positioners
Abbreviation
Full term in English
Meaning
SIL
Safety Integrity Level
The international standard IEC 61508 defines four discrete
Safety Integrity Levels (SIL 1 to SIL 4). Each level corresponds
to a range of probability for failure of a safety function. The
higher the Safety Integrity Level of the safety-instrumented
system, the lower the probability that it will not execute the
required safety functions.
SIS
Safety Instrumented System
A safety-instrumented system (SIS) executes the safety
functions that are required to achieve or maintain a safe status
in a system. It consists of sensors, logic unit/control system and
final controlling elements.
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Abbreviations
B.1 Abbreviations for PS2 positioners
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Glossary
Analog
A signal type which represents data using continuously varying, measurable and physical
quantities, e.g. current or voltage. Opposite to digital. The range between 4 and 20 mA is
often used to transfer analog signals.
Analog-to-digital converter
An analog-to-digital converter is an interface between the analog environment and the
digitally working computers. Only then can the computers be used for measurement and
control tasks.
Analog-to-digital converters convert analog input signals to digital signals. Analog
measurement data is thus converted into digital information. On the other hand, a digital-toanalog converter coverts digital information into analog signals.
Asset Management Solution (AMS)
Software package by Emerson Process. The AMS Device Manager, which is somewhat
similar to the PDM, is a part of the package.
ATEX
ATEX is the abbreviation of the French term "Atmosphère explosible". ATEX stands for both
the directives of the European Community for the field of explosion protection: the ATEX
product directive 94/9/EC and the ATEX operation directive 1999/92/EC.
Auxiliary voltage
Auxiliary voltage is an electric supply or reference voltage that is required by many electric
circuits in addition to the standard supply. The auxiliary voltage can be extremely stabilized,
have a specific level or polarity and/or other properties having decisive significance for the
correct functioning of parts in the circuit. Auxiliary voltage is used, for example, with four-wire
systems.
Conduit piping system
A piping system for the American market, wherein the electric and pneumatic lines are
protected by a casing.
Configuring
See parameter assignment.
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Glossary
Cornerstone
Management software for process instrumentation.
Decrement
From the Latin word decrementare, decrease. Decrement is the defined amount of change
when decreasing a variable(s) gradually. IT term that refers to a step-by-step decrease in a
numeric value.→Increment.
Degree of protection
The degree of protection of a device indicates the extent of protection. The extent of
protection includes the safety of persons against coming in contact with live or rotating parts,
and the protection of electric resources against the penetration of water, foreign bodies and
dust. The degrees of protection of electric machines are indicated by an abbreviation
comprising two letters and two numbers (e.g. IP55). The degree of protection is coded using
the IP code. The degrees of protection are standardized in DIN EN 60529.
Device category 1
Category 1 devices must be procured such that they ensure an extremely high degree of
safety. Devices in this category must ensure an extremely high degree of safety even for
faults that occur rarely. Even if two faults occur in the device, it should not lead to ignition.
Devices in this category are suitable for use in zone 0.
Device category 2
Category 2 devices must be procured such that they ensure a high degree of safety. Devices
in this category must ensure the required degree of safety in case of frequent faults or ones
that can be normally expected, e.g. defects in the device, and avoid ignition sources.
Devices in this category are suitable for use in zone 1.
Device category 3
Category 3 devices must be procured such that they ensure a normal degree of safety.
Devices in this category must ensure the required degree of safety in case of frequent faults
or ones that can be normally expected, e.g. defects in the device, and avoid ignition sources.
Devices in this category are suitable for use in zone 2.
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".
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Glossary
EEPROM
EEPROM (Electrically Erasable Programmable Read-Only Memory; literally: elektrisch
löschbarer, programmierbarer Nur-Lese-Speicher in German) is a non-volatile electronic
memory. EEPROMs are often used when individual data bytes change over long time
periods and need to be saved in a manner protected against power failure, e.g. configuration
data or operating hours counters.
Electromagnetic compatibility
Definition as per the EMC law: EMC is the capability of a device to work satisfactorily in the
electromagnetic environment without causing electromagnetic interferences that are
unacceptable for other devices present in this environment.
Ex d protection
Type of protection for versions with flameproof enclosures. When the potentially explosive
mixtures enter the enclosure of a resource and an ignition source exists in the enclosure.
The transfer of the explosion inside the enclosure to the surrounding space must be ruled
out.
● d: flameproof enclosure
Ex ia/ib protection
Types of protection. If potentially explosive mixtures enter the enclosure of a resource, it
should not lead to ignition. Demarcation of sparks and increased temperatures.
● ia: intrinsic safety, as per special requirements compliant with EN 50020
● ib: intrinsic safety, as per EN 50020
Factory Mutual
Industrial property insurer and certification agency in the USA. FM Global is one of the
largest industrial insurers in the world who are specialized in the field of technicallysupported property insurance. It offers services like product research, testing and
certification.
Failure that causes a dangerous situation
Failure with the potential to switch a safety-instrumented system to a hazardous or nonfunctioning safety status.
Fieldbus
A fieldbus is an industrial communication system used to connect a number of field devices
with a control device. Field devices include measuring sensors, final controlling elements
and actuators.
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Glossary
Fieldbus Foundation
Syndicate of manufacturers of measurement and control systems. The syndicate develops
the open fieldbus specifications of the FOUNDATION Fieldbus.
Final controlling element
Converter that converts electric signals into mechanical or other non-electric variables.
Firmware
Firmware (FW) is the software embedded in a chip in electronic devices. It is not like
software that is stored on hard disks, CD-ROMs or other mediums. These days, the firmware
is mostly stored in a flash memory or an EEPROM. Firmware is software in the hardware,
and is thus an intermediate between the software and the hardware. Firmware is normally
model-specific. This means that it does not function on other device models and is delivered
by the manufacturing company. The corresponding devices cannot function without the
firmware. The firmware mostly contains elementary functions to control the device, as well as
input and output routines.
FOUNDATION Fieldbus
Fieldbus to connect sensors and final control elements in hazardous areas in accordance
with IEC 61158-2. The FOUNDATION Fieldbus uses a common 2-wire cable for data
communication and power supply. Data communication and power supply. The
FOUNDATION Fieldbus uses bus types such as High Speed Ethernet and Foundation H1.
Frequency shifting process
ENGLISH: Frequency shift keying (FSK)
The frequency shifting process is a simple modulation format in which digital values 0 and 1
are represented by two different frequencies.
GSD file
The file that describes the properties of a PROFIBUS DP slave or a PROFINET IO device.
The GSD file is a database file for PROFIBUS devices. The device manufacturer provides
the corresponding GSD file containing the description of device properties. The information
in the file can be read using Engineering Tools.
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Glossary
HART
HART (Highway Addressable Remote Transducer) is a standardized and widely used
communication system for erecting industrial fieldbuses. This communication system
enables digital communication of multiple participants (field devices) using a common data
bus. HART implements the widely used 4/20 mA standard to transfer analog sensor signals.
Existing cables of the old system can be used directly and both systems can be operated
simultaneously. HART specifies several protocol levels in the OSI model. HART enables
transfer of process and diagnostics information and control signals between field devices
and superordinated control system. Standardized parameter sets can be used for
manufacturer-independent operation of all HART devices.
HART communicator
Connection with a two-wire line is directly established for the parameter assignment with the
HART communicator. For the parameter assignment with a laptop or a PC, a HART modem
is connected in between.
Increment
From the Latin word incrementare, increase. Increment is the defined amount of change
when increasing a variable(s) gradually. In informatics, it is referred to as the stepwise
increase in a numeric value.→Decrement.
Initialization
Setting the most important basic parameters. Requirement for commissioning the positioner.
IP code
The abbreviation IP stands for International Protection as per DIN. In English-speaking
countries, IP stands for Ingress Protection.
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.
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Glossary
NEMA
National Electrical Manufacturers Association. NEMA is a standardization institute in the
USA. NEMA was formed in 1926 with the merger of Associated Manufacturers of Electrical
Supplies and the Electric Power Club.
NEMA 4
An enclosure standard of the National Electrical Manufacturers Association. The NEMA 4
compliant devices are suitable for use in indoor and outdoor applications. Protection is
provided against dust particles, rain as well as spray and splash water.
NEMA 4x
The same protection like NEMA 4. Additional protection of the enclosure from corrosion.
Parameter assignment
Individual parameter settings are specifically changed to adjust the positioner as per the
actuator or other requirements. Parameter assignment is carried out after the complete
commissioning of the positioner.
Piezoelectric effect
Name of a physical phenomenon. Due to mechanical compression loads on a crystal, an
electric potential develops on specific crystal surfaces. In a reverse case, applying an electric
field to specific crystal surfaces leads to crystal deformation.
Potentially explosive gaseous atmosphere
Mixture of air, combustible gases, vapors, mists or dusts.
Process device manager
PDM is a Siemens software package for project planning, parameter assignment,
commissioning and maintenance of network configuration and field devices. Part of SIMATIC
Step7. Is used for configuration and diagnostics.
PROFIBUS
PROFIBUS stands for process fieldbus. PROFIBUS is a vendor-independent standard for
networking field devices (e.g. PLCs, actuators, final control elements, and sensors).
PROFIBUS is compatible with protocols such as DP (decentralized peripherals), FMS
(fieldbus message specification) and PA (process automation).
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Glossary
PROFIBUS PA
PA is an abbreviation of process automation. PROFIBUS PA is used in process engineering.
This fieldbus is used to control the measuring devices using a process control system. This
version of PROFIBUS is suitable for hazardous areas of zones 0 and 1. Only a weak current
flows through an intrinsically safe circuit in the bus cables, and hence sparks are not
generated even in case of a fault.
PA enhances PROFIBUS DP with an intrinsically safe transmission technique compliant with
the international standard IEC 61158-2.
Protocols
Protocols contain information about data formats, time sequences and error handling when
exchanging data between computers.
A protocol is a convention about establishing, monitoring and terminating a connection.
Different protocols are required for a data connection. Protocols can be assigned to every
layer of the reference model. Transport protocols are used for the lower four layers of the
reference mode and higher protocols are used for control, data provision and application.
Safety function
Defined function executed by a safety-instrumented system with the objective of attaining or
maintaining a safe status of the system by taking a defined hazardous incident into account.
Example: limit pressure monitoring
Safety-instrumented system
A safety-instrumented system (SIS) executes safety functions that are required to attain or
maintain the safe status in a system. It consists of sensors, logic unit/control system and final
controlling elements.
Example: a safety-instrumented system consists of a pressure transmitter, a limit signal
indicator and a servo valve.
Sensor
Converter that converts mechanical or other non-electric variables into electric signals.
SIL
The international standard IEC 61508 defines four discrete safety integrity levels (SIL) from
SIL 1 to SIL 4. Every level indicates a probability range for the failure of the safety function.
The higher the SIL of the safety-instrumented system, the higher the probability that the
required safety function works. The achievable SIL is determined by the following safetyinstrumented characteristics:
● Average probability of dangerous failures of a safety function on demand (PFDAVG)
● Hardware fault tolerance (HFT)
● Safe failure fraction (SFF)
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Glossary
SIMATIC software
Programs for process automation (e.g. PCS7, WinCC, WinAC, PDM, Step7).
Zone 0
Area in which hazardous potentially explosive gaseous atmospheres build up often, regularly
or over long durations during the normal operation of a device.
Zone 1
Area in which potentially explosive gaseous atmospheres build up occasionally during the
normal operation of a device.
Zone 2
Area in which a potentially explosive gaseous atmosphere normally never builds up or builds
up only for a short while during normal operation of a device.
Zone 22
Zone 22 is an area in which a potentially explosive gaseous atmosphere in the form of a
cloud of combustible dust in air never develops or develops only for a short while during
normal operation.
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Index
6
0B
6DR4004-6A (ATEX/IEC),
6DR4004-6G (ATEX/IEC/FM/CSA),
6DR4004-6J (ATEX/IEC),
6DR4004-6K (with Ex),
6DR4004-7A (FM/CSA),
6DR4004-7J (FM/CSA),
6DR4004-8A (without Ex),
6DR4004-8G (without Ex),
6DR4004-8J (without Ex),
6DR4004-8K (without Ex),
A
1B
Accessories, 294
Actuating disk bearings
Position, 54
Actuating pressure, 24
Adapter, 299
Position, 57
Additional Support, 303
Advanced diagnostics, 169
Alarm function
Parameter, 164
Alarm module
Connecting, 82, 88
Installation, 60
Position, 54, 57
Amplifier,
Appendix, 302
B
2B
Basic electronics, 295
Graphic, 26, 57
Position, 54
Binary input/output,
Booster, 301
Bus cable, 24
Connecting, 79
C
3B
Cable gland, 299
Carrier, 44, 146, 156
Carrier pin, 122, 125, 128, 156
Certificates, 15, 302
characteristics
Safety, 143
Commissioning
Cancel, 126
Interrupting, 124
Manual, 127, 134
Compressed air, 36
Connecting
Alarm module, 82, 88
Iy module, 89
Limit contact module, 90
Mechanical limit switch module, 85
SIA module, 83, 89
Connecting terminals, 78
Connection
Pneumatic, 92, 121
Control air outlet, 277
Control system, 19, 140
Correct usage,
Coupler, 32
Current output,
Customer Support Hotline, 303
D
4B
Dead zone of the controller, 160
Device operating mode
Parameter, 171
Diagnostics, 241
Advanced, 169
During ongoing operation, 251
Extended, 151
Diagnostics guide, 256
Documentation
Edition, 11
E
5B
EMC filter module
Installation, 70
Scope of delivery, 300
Enclosure, 293
Enclosure ventilation, 277
End of the manipulated variable limit
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Index
Parameter, 160
Ex markings, 274, 285, 286
Exhaust air outlet, 24, 277
Extended diagnostics
Parameter, 151
F
6B
Factory setting
Resetting to ~, 124, 132
Fault identification, 256
Fault message
Setting the ~, 167
Feedback lever bracket
Position, 57
Feedback shaft
Parameter 2.YAGL, 156
Position, 57
Final controlling element, 140
Firmware, 11
FISCO, 32
Five-point controller, 19
Flow rate, 277
Friction clutch, 19, 51
Position, 55, 57
Friction clutch, 19, 51
Function binary input 1
Parameter, 163
Function binary input 2
Parameter, 163
Function of the fault message output
Parameter, 166
G
Initialization,
Automatically, 115
Cancel, 133
Interrupting, 132
Installation
Alarm module, 60
Iy module, 59
SIA module, 63
Internet, 303
Iy module
Connecting, 82, 89
Installation, 59
Position, 54, 57
L
10B
Label set, 67
Limit contact module, 113
Connecting, 90
Position, 54
Linear actuator
Angle of rotation parameter (2.YAGL), 156
Automatic commissioning, 124
Automatic commissioning (sequence diagram), 116
Automatic initialization parameter (4.INITA), 156
Automatic initialization parameter (5.INITM), 157
Manual commissioning, 127
Mounting, 38
Pneumatic connection, integrated, 93
Range of stroke display parameters (3.YWAY), 156
Single-acting, 20
Link, 32
M
7B
11B
Gear
switchable, 19
GSD file
Device operating mode, 171
Manometer
Mounting, 72
Manufacturer serial number, 22
Master
Class-1 master, 30
Class-2 master, 30
Mechanical limit switch module, 65
Connecting, 85
Module cover, 78
Position, 54, 57
Monitoring the path integral
Parameter, 168
Motherboard,
Mount
Dimensions, 47
Mounting kit
H
8B
Hazardous area
Laws and directives, 15
History, 11
Hotline, 303
I
9B
Improper device modifications, 16
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Linear actuator, 38
N
12B
Nameplate
Position, 55
Natural gas
Maximum values for ventilation, 277
Operation, 113
NCS, 69
O
13B
Online diagnostics, 251
Operation
Natural gas, 113
Option module
Terminal, 24
Option modules, 294
Installation, 55
Order no., 22
Ordering supplement, 22
P
14B
Parameters 1 to 5
Actuator (1.YFCT), 155
Angle of rotation of feedback shaft (2.YAGL), 156
Automatic initialization (4.INITA), 156
Description, 155
Manual initialization (5.INITM), 157
Overview, 146
Range of stroke display (3.YWAY), 156
Parameters 6 to 53
Description, 157
Overview, 148
Parameters 7 and 8
Description, 157
Parameters A to P
Overview, 152
Partial stroke test (PST)
Extended diagnostics, 172
Part-turn actuator
Automatic commissioning, 132
Automatic commissioning (sequence diagram), 116
Automatic initialization parameter (4.INITA), 156
Automatic initialization parameter (5.INITM), 157
Double-acting, 21
Manual commissioning, 134
Mounting, 44
Pin (feedback lever bracket)
Position, 57
Pneumatic actuator, 27
Pneumatic block,
Position, 54
Purging air selector, 121
Pneumatic connections, 121
Position feedback module,
Positioner
Replacing, 137
With linear actuator, 20
Potentiometer, 69
Preset
Parameter, 168
Pressure gauge block, 20
Printed circuit board,
Product name, 22
PROFIBUS, 29
Automation system, 30
Connection, 31
DP, 29
Eigenschaft, 31
PA, 29
Profile, 31
Strand, 31
Topology, 29
Purge air switch, 277
Purging air selector, 24, 121
Pz, 143
Q
15B
Qualified personnel, 17
R
16B
Reading initialization parameters, 137
Reference stroke time
Extended diagnostics, 173
Response threshold of fault message
Parameter, 167
Ribbon cable
Graphic, 54
Position, 57
Ring gear
Position, 57
S
17B
Safety catch
Position, 57
Safety function, 139
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Index
Safety position
Parameter, 170
Safety setpoint
Parameter, 171
Safety shutdown, 139
Scope of delivery, 12
EMC filter module, 300
Screen
Cleaning of~, 265
Screw terminal, 79
SELV, 32
Service, 303
servo valve
Integrated, 19
Setpoint direction
Parameter, 157
Setpoint function
Parameter, 158
Setpoint ramp down
Parameter, 157
Setpoint ramp up
Parameter, 157
Setpoint support points
Parameter, 159
Setting the safety position
Parameter, 170
Shield connection, 24
SIA module
Connecting, 83, 89
Installation, 62, 63
Position, 54
SIL 2, 140
Single-channel operation, 140
Slot initiator,
Sound absorber, 24, 277
Start of the manipulated variable limit
Parameter, 160
Starting position
Extended diagnostics, 172
Starting tolerance
Extended diagnostics, 172
Station number
Parameter, 171
Step direction,
Step magnitude,
Stroke direction
Extended diagnostics, 173
Stroke magnitude
Extended diagnostics, 173
Support, 303
Symbols,
System integration
PDM, 11
T
18B
Terminal strip, 121
Without flameproof enclosure, 79
Terminating resistor, 32
Terminating resistor T, 31
Test certificates, 15
Test interval
Extended diagnostics, 173
Tight closing, 139
Tight closing manipulated variables
Parameter,
Transmission ratio selector, 24
Position, 54, 57
Transmitter, 140
V
19B
Value for, 163
W
20B
Warning label,
Warning symbols, 15
Wiring diagram
Position, 55
Y
21B
Y1, 143
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Operating Instructions • 10/2013
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SIPART
Electropneumatic positioners
SIPART PS2 with PROFIBUS PA
Operating Instructions
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Subject to change without prior notice
A5E00127926-09
© Siemens AG 2013
A5E00127926-09
www.siemens.com/automation
A5E00127926-09
A5E00127926-09
GN: 30020_SIPART PS2_neu
Edition
10/2013
Answers for industry.
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