SIPART Electropneumatic positioners SIPART PS2 with and without HART communications Introduction 1 General safety notes 2 Description 3 Mounting 4 Installing option modules 5 Connection 6 Operating 7 Functional safety 8 Commissioning 9 Operating Instructions Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 6DR50** - Positioner without HART 6DR51** Positioner with HART, not explosion-protected 6DR52** - Positioner with H
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.
Table of contents 1 2 3 4 Introduction.............................................................................................................................................. 11 1.1 Purpose of this documentation ....................................................................................................11 1.2 History ..........................................................................................................................................11 1.3 Further information......
Table of contents 5 6 6 4.4 Using the positioner in a humid environment.............................................................................. 47 4.5 4.5.1 4.5.2 4.5.3 Positioners exposed to strong acceleration forces or vibrations................................................. 48 Notes on use ............................................................................................................................... 48 Friction clutch ......................................................
Table of contents 7 8 9 10 Operating................................................................................................................................................. 95 7.1 7.1.1 7.1.2 7.1.3 Operating elements......................................................................................................................95 Digital display ...............................................................................................................................95 Buttons ......
Table of contents 10.4.2.4 Description of parameters 10 and 11........................................................................................ 148 10.4.2.5 Description of parameters 12 .................................................................................................... 149 10.4.2.6 Description of parameters 13 through 33.................................................................................. 150 10.4.2.7 Description of parameters 34 ........................................
Table of contents 12 13 14 15 A B Service and maintenance ...................................................................................................................... 205 12.1 Positioner in the metal enclosure and in the flameproof enclosure ...........................................205 12.2 Positioner in the plastic enclosure .............................................................................................205 12.3 Repair/Upgrading..........................................
Table of contents 10 SIPART PS2 with and without HART communications Operating Instructions, 09/2008, A5E00074631-08
1 Introduction 1.1 Purpose of this documentation This programming manual contains all information that you will require to commission and use the device. It is aimed at persons who install the device mechanically, connect it electrically, parameterize and commission it, as well as at service and maintenance engineers. This document also contains special information and safety notes that you will require when using an SIL-certified device in safety-instrumented systems. 1.
Introduction 1.3 Further information Contact person worldwide If you need more information or have particular problems that are not covered sufficiently by this programming manual, please contact your contact person. You can find your regional contact person on the Internet. Product information on the Internet 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.
General safety notes 2.1 2 General information This device left the factory free from safety problems. In order to maintain this status and to ensure safe operation of the device, please observe the safety information and warnings contained in these instructions. 2.2 Correct usage The device may only be used for the purposes specified in these instructions. Insofar as they are not expressly stated in these instructions, all changes to the device are the sole responsibility of the user. 2.
General safety notes 2.4 Measures 2.4 Measures For the sake of safety, the following precautions must be observed: WARNING Type of protection "pressure-proof encapsulation" Devices with "pressure-proof encapsulation" protection may only be opened when off circuit. "Intrinsically safe" protection type "Intrinsically-safe" devices lose their certification as soon as they are operated on circuits which do not correspond with the test certification valid in their country.
General safety notes 2.5 Qualified Personnel 2.5 Qualified Personnel Qualified personnel are people who are familiar with the installation, mounting, commissioning, and operation of the product. These people have the following qualifications: ● They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media.
General safety notes 2.
Description 3.1 3 Function ● The electropneumatic positioner, in combination with the drive, forms a regulation system. The current position of the drive is detected using a servo potentiometer and is sent back as actual value x. The actual and target values are simultaneously displayed on the digital display. ● The setpoint w forms a current applied to the positioner, which in two-wire mode is also used to power the positioner. In 3- and 4-wire mode, power is supplied through a 24-V power input.
Description 3.2 Structure ● NAMUR or IEC 534 ● Integrated addition to ARCA ● Integrated addition to SAMSON in non–explosion-proof housing You can mount the positioner on the usual drives and operate it with the usual drives.
Description 3.
Description 3.3 Operation with natural gas 3.2.2 Structure of the nameplate SIPART PS2 HART Positioner 6DR5210-0EG00-0AA0 II 2 G EEx ia/ib II C T6/T5/T4 Ta = -30 ... 50/65/80°C Uh= 18...30V Iw = 0/4...20mA TÜV 00 ATEX 1654 0044 IP66 NEMA Type 4x p = 1,4 ... 7bar IECEx TUN 04.0018 Ex ia/ib IIC T6..
Description 3.3 Operation with natural gas See also Certificates (http://www.siemens.com/processinstrumentation/certificates) 3.3.2 Natural gas as an actuator medium Introduction Normally, you operate the positioner with compressed air. Natural gas has been approved as an actuator medium for intrinsically safe positioners with the "EEx ia" type of protection. Note Quality of natural gas Only use natural gas which is clean, dry and free from additives.
Description 3.3 Operation with natural gas 6DR5x1x-xExxx 6DR5x2x-xExxx Bleed through the exhaust air outlet E Error case, max. 66.2 91.0 Operation, max. 358.21) 3391), 1.26 1.23 Error case, max. Volume 1) Max. [l] 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.
Description 3.4 Device components 3.4 Device components 3.4.
Description 3.
Description 3.4 Device components ● Buttons ● Terminal strips to connect the optional module to the motherboard 3.4.3 Electrical connections Connecting terminals of the standard controller, the Iy and the alarm optional 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.
Description 3.4 Device components 3.4.4.2 Pneumatic connection in the flameproof enclosure Structure The pneumatic connections are provided on the right side of the positioner.
Description 3.4 Device components 3.4.4.3 Pneumatic connection versions Overview For the integrated attachment for single-action 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.
Description 3.
Description 3.4 Device components 3.4.5 Purge air switching Note Equipment Versions with flameproof enclosures are not equipped with 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.
Description 3.4 Device components 3.4.6 Restrictors Note The exhaust air valve is always open in the de-energized state. ● 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.
Description 3.5 Mode of operation 3.5 Mode of operation 3.5.1 Control loop Control loop The electropneumatic positioner forms a control loop with the pneumatic drive: ● The actual value x represents the position of the drive spindle for linear actuators or the position of the drive shaft for part-turn actuators. ● The control value w represents the positioning current of a closed-loop controller or a manual control station from 0/4 to 20 mA.
Description 3.5 Mode of operation 3.5.2 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.
Description 3.5 Mode of operation 3.5.
Description 3.5 Mode of operation 3.5.4 Mode of operation of the HART function Note • Operation at the positioner has priority over specifications from the HART communicator. • Failure of the auxiliary power to the positioner also interrupts communications. Function The positioner is also available with built-in HART functionality. The HART protocol allows you to communicate with your device through a handheld communicator, PC, or programming unit.
4 Mounting 4.1 Safety notes for installation WARNING Mechanical impact effect Protect the 6DR5**0-*G***-**** version of the positioner from mechanical impact effects that are greater than 1 Joule; this ensure adherence to the IP66 degree of protection. When installing, observe the following sequence imperatively to avoid injuries or mechanical damage to the positioner/mounting kit: 1. Mount the positioner mechanically. 2. Connect the electrical auxiliary power supply. 3.
Mounting 4.2 Installing the linear actuator 4.2 Installing the linear actuator Conditions For linear actuators, use the "linear actuator" mounting kit or the integrated attachment. You require different installation parts depending on the selected actuator type.
Mounting 4.2 Installing the linear actuator 7. Install the mounting bracket ① at the rear side of the positioner. For this purpose, use: – Two hexagon bolts ⑨ – Spring lock washer ⑩ – Flat washer ⑪ 8. Select the row of holes. The selection of the row of holes depends on the yoke width of the actuator. Select the row of holes such that the carrier pin ④ meshes with the pick-up bracket ② near the spindle. Ensure that the pick-up bracket does not touch the clamping pieces. 9.
Mounting 4.
Mounting 4.
Mounting 4.2 Installing the linear actuator "Linear actuator IEC 534 (3 mm to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L Sr. No. ① *) Quantity Name Note 1 NAMUR mounting bracket IEC 534 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.
Mounting 4.3 Installing the part-turn actuator 4.3 Installing the part-turn actuator Conditions 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 scope of delivery of the corresponding actuator. Ensure that the mount has a sheet metal thickness of > 4 mm and reinforcements. Installing the part-turn actuator The position numbers in the text refer to the following illustrations of the assembly procedure. 1.
Mounting 4.
Mounting 4.
Mounting 4.3 Installing the part-turn actuator "Part-turn actuator" mounting kit 6DR4004–8D Sr. No.
Mounting 4.
Mounting 4.3 Installing the part-turn actuator ! PP 0 D E D E 6,5 (0.26) Ø35 (1.38) F05-Lkr.-Ø50 (1.
Mounting 4.4 Using the positioner in a humid environment 4.4 Using the positioner in a humid environment Introduction CAUTION Never clean the positioner with a high pressure cleaner since the IP66 degree of protection is not sufficient for this. 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.
Mounting 4.5 Positioners exposed to strong acceleration forces or vibrations 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.
Mounting 4.
Mounting 4.5 Positioners exposed to strong acceleration forces or vibrations 4.5.2 Friction clutch Procedure NOTICE The following is applicable for the "flameproof enclosure" version: • Move only the outer friction clutch. The inner friction clutch is fixed and may not be moved in case of a flameproof enclosure. • Do not open the flameproof enclosure of the positioner in explosion-prone atmospheres. An additional friction clutch is therefore provided at the outer side of the shaft.
Mounting 4.6 External position displacement sensor 4.6 External position displacement sensor WARNING 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 displacement sensor and the control unit are mounted separately for these applications.
Mounting 4.
Installing option modules 5.1 General information on installing option modules 5.1.1 Safety notes for installing the option modules 5 WARNING Assembling the components For the composition of the components it must be ensured that only positioners and option modules that are certified for the relevant operating range are combined. This condition applies in particular to the safe operation of the positioner in the areas of zone 1, 2 and 22, in which the atmosphere can be potentially explosive.
Installing option modules 5.1 General information on installing option modules 5.1.2 Installing optional modules in the standard and intrinsically safe version The following optional modules are available for the positioner in the standard and intrinsically safe version: ● Iy module ● Alarm unit ● SIA unit ● Mechanical limit switch module ● EMC filter module Preparations for installation Proceed as follows for the preparations for installation: 1. Open the positioner. 2.
Installing option modules 5.
Installing option modules 5.1 General information on installing option modules ⑪ Iy module ⑫ Alarm unit Figure 5-1 ⑳ Wiring diagram Installing the optional modules See also Iy module (Page 59) Alarm unit (Page 60) Installing the slotted initiator alarm unit (Page 63) Installing the mechanical limit switch module (Page 65) EMC filter module (Page 67) 5.1.
Installing option modules 5.
Installing option modules 5.1 General information on installing option modules See also Iy module (Page 59) Alarm unit (Page 60) 5.1.4 Installing the module cover Installing the module cover 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. Proceed as follows to install the module cover: 1. Turn the screws anticlockwise until they noticeably engage in the thread pitch. 2.
Installing option modules 5.2 Iy module 5.2 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 standard controller. 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.
Installing option modules 5.3 Alarm unit 5.3 Alarm unit Function The alarm unit 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.
Installing option modules 5.3 Alarm unit Installation Proceed as follows to install the alarm unit: 1. Slide the alarm unit below the motherboard in the module rack. Ensure that you slide it up to the end stop. 2. Connect the module to the motherboard. For this purpose, use the 8-pole flat ribbon cable provided.
Installing option modules 5.4 Slot initiator alarm module 5.4 Slot initiator alarm module 5.4.1 SIA unit 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.
Installing option modules 5.4 Slot initiator alarm module 5.4.2 Installing the slotted initiator alarm unit Installing the SIA unit Proceed as follows to install the SIA unit: 1. Disconnect all electrical connections of the motherboard. 2. Unlatch both the fixing screws of the motherboard. 3. Disengage the motherboard by carefully bending the four brackets. 4. Insert the SIA unit from the top up to the upper printed circuit board guide of the module rack. 5.
Installing option modules 5.4 Slot initiator alarm module 5.4.3 Setting the limits of the slotted initiator alarm unit Determining the switch status of slotted initiators You will require a suitable display device to determine the switch status. For example, use the initiator tester type 2 / Ex by Pepperl + Fuchs. 1. Connect the display device to the following terminals of the SIA unit: – 41 and 42 – 51 and 52 2. Read the switch status of slotted initiators.
Installing option modules 5.5 Mechanical limit switch module 5.5 Mechanical limit switch module 5.5.1 Installing the mechanical limit switch module WARNING Zone 2 Use of the mechanical limit switch module in zone 2 is only approved in the "nL" type of protection. Function This module is used to report two limits. These limits are reported using galvanic switch contacts.
Installing option modules 5.5 Mechanical limit switch module Installation Proceed as follows to install the mechanical limit switch module: 1. Disconnect all electrical connections of the motherboard. 2. Unlatch both the fixing screws of the motherboard. 3. Disengage the motherboard 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.
Installing option modules 5.6 EMC filter module 5.5.2 Setting the limits of the mechanical limit switch module Setting the L1 and L2 limits Proceed as follows to set the limits: 1. Move the actuator to the first desired mechanical position. 2. Adjust the upper actuating disc 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.
Installing option modules 5.6 EMC filter module Device features Device features include: ● EMC protection ● Connection to motherboard ● Connecting terminals for an external potentiometer Figure 5-7 EMC module Installation Proceed as follows to install the EMC filter module: 1. Remove the module cover. 2. Dismantle all existing optional modules. 3. Unlatch the fixing screws of the module rack that is opposite to the blanking plugs. 4. The EMC filter module has a fastening hole.
Installing option modules 5.7 Accessories See also Installing the module cover (Page 58) Installing optional modules in the standard and intrinsically safe version (Page 54) 5.7 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-action actuators.
Installing option modules 5.8 Set of signs for the non-intrinsically safe version 5.8 Set of signs for the non-intrinsically safe version Warning labels Fasten the included warning label on the side across from the type plate. There are different warning labels depending on the housing material, as described below.
6 Connection 6.1 Electrical connection 6.1.1 Safety notes for electrical connections WARNING Electrical connections in hazardous areas Regulations in the test certificate applicable for your country must be followed. National regulations and laws for hazardous areas applicable in your country must be followed for electrical connections. In Germany, these are, e.g.
Connection 6.1 Electrical connection WARNING Notes on supply cable with auxiliary power The power supply of the device must be guaranteed by safety extra-low voltage (SELV) for Ex "tD" (dust) and Ex "nA". WARNING Laying of cables Connect the devices to be operated in hazardous areas according to the regulations for your country, e.g. secure laying of cables for Ex "d", "nA" and "tD".
Connection 6.1 Electrical connection Two-wire mode Note Never connect the current input (terminals 6 and 7) to a power source; the positioner will probably be destroyed in that case. Always use a current source with a maximum output current of I = 20 mA. To maintain auxiliary power, the input current must be Iw = 3.6 mA. Electromagnetic compatibility The plastic enclosure is metallized from inside to increase the electromagnetic compatibility (EMC) with respect to high-frequency radiation.
Connection 6.1 Electrical connection 6.1.2 Connection for versions "non-intrinsically safe" or "flameproof enclosure" 6.1.2.
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Connection 6.1 Electrical connection 6.1.2.3 Binary inputs and outputs $ODUP PRGXOH '5 $ 9 ื 9 ≥1 9 9 9 9 Fault message . Limit value A1 . 6.1.2.4 9 . Figure 6-6 Digital input 2 Limit value A2 Alarm unit 6DR4004-8A, not Ex SIA unit 6ZLWFKLQJ DPSOLILHU WR (1 6,$ PRGXOH '5 * Figure 6-7 76 .
Connection 6.1 Electrical connection 6.1.2.5 Mechanical limit switch module Safety note for low-voltage supply 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.
Connection 6.1 Electrical connection NOTICE Installing/connecting Only qualified personnel is permitted to install and connect the mechanical limit switch module. NOTICE To observe before connecting Before you connect the mechanical limit switch module, observe the following conditions: • Only qualified personnel is permitted to connect the mechanical limit switch module. • Isolate all wires from power and make sure the device is truly isolated from power.
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Connection 6.1 Electrical connection 5. Tighten the screw ⑱ on the transparent cover ⑲. 6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the provided cable tie ⑳ for this purpose.
Connection 6.1 Electrical connection 6.1.3 Connection for intrinsically safe type of protection 6.1.3.1 Basic device, Ex i Note As auxiliary power, control, and signal circuits, only certified intrinsically safe circuits may be connected.
Connection 6.
Connection 6.1 Electrical connection 6.1.3.2 Split range Note As auxiliary power, control, and signal circuits, only certified intrinsically safe circuits may be connected.
Connection 6.1 Electrical connection 6.1.3.3 Current output, Ex i WARNING Circuits Only the certified circuits may be connected as auxiliary power supply, control and signal circuits.
Connection 6.1 Electrical connection 6.1.3.4 Binary input and output, Ex i WARNING Circuits Only the certified circuits may be connected as auxiliary power supply, control and signal circuits. 1RQ KD]DUGRXV DUHD +D]DUGRXV DUHD ]RQH $ODUP XQLW '5 $ ืb 9 (([ ุ ,QWULQVLFDOO\ VDIH VZLWFKLQJ DPSOLILHU WR (1 Figure 6-15 %( 9 . 9 9 9 (([ . )DXOW PHVVDJH . . /LPLW YDOXH $ (([ . .
Connection 6.1 Electrical connection 6.1.3.5 SIA module, Ex i WARNING Circuits Only the certified circuits may be connected as auxiliary power supply, control and signal circuits. 1RQ KD]DUGRXV DUHD +D]DUGRXV DUHD ]RQH ,QWULQVLFDOO\ VDIH VZLWFKLQJ DPSOLILHU WR (1 6,$ PRGXOH '5 * Figure 6-16 86 . 9 9 /LPLW YDOXH $ 9 /LPLW YDOXH $ (([ (([ (([ .
Connection 6.1 Electrical connection 6.1.3.6 Mechanical limit switch module, Ex i Mechanical limit switch module connection diagram, Ex i WARNING Circuits Only the certified circuits may be connected as auxiliary power supply, control and signal circuits. 1RQ KD]DUGRXV DUHD +D]DUGRXV DUHD ]RQH ,QWULQVLFDOO\ VDIH VZLWFKLQJ DPSOLILHU WR (1 0HFKDQLFDO OLPLW VZLWFK PRGXOH '5 . Figure 6-17 . + '& 9 .
Connection 6.1 Electrical connection 5. Tighten the screw ⑱ on the transparent cover ⑲. 6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the provided cable tie ⑳ for this purpose.
Connection 6.1 Electrical connection 6.1.4 Connection for versions with type of protection "n" 6.1.4.
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Connection 6.1 Electrical connection 6.1.4.5 Mechanical limit switch module, Ex n Mechanical limit switch module wiring diagram, Ex n 1RQ KD]DUGRXV DUHD +D]DUGRXV DUHD ]RQH 6ZLWFKLQJ DPSOLILHU WR (1 0HFKDQLFDO OLPLW VZLWFK PRGXOH '5 . Figure 6-25 . + '& 9 .
Connection 6.1 Electrical connection 5. Tighten the screw ⑱ on the transparent cover ⑲. 6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the provided cable tie ⑳ for this purpose.
Connection 6.2 Pneumatic connection 6.2 Pneumatic connection WARNING 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. NOTICE Observe the specifications regarding the air quality. ● If required, connect the pressure gauge block for supply air and actuating pressure. ● Connect supply air to PZ.
7 Operating 7.1 Operating elements 7.1.1 Digital 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 digital 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.
Operating 7.1 Operating elements Operating mode Representation in the digital display Pos.
Operating 7.1 Operating elements 7.1.2 Buttons ① Digital display ② Operating mode button ③ Decrement button ④ Increment button Figure 7-1 Digital 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.
Operating 7.2 Operating modes Function of buttons: operating mode button is used to select the modes and to forward the ● The parameters. decrement button is used to select parameter values when configuring. You can ● The use this button to move the actuator in the manual mode. increment button is also used to select parameter values when configuring. You ● The can use the increment button to move the actuator in the manual mode.
Operating 7.2 Operating modes 7.2.2 Changing the operating mode The following picture illustrates the available operating modes and switching between the operating modes.
Operating 7.2 Operating modes 7.2.3 Overview of configuration The following figure shows the operation of the configuration and initialization modes. VLPXOWDQHRXV VLPXOWDQHRXV VLPXOWDQHRXV VLPXOWDQHRXV XQWLO Figure 7-4 7.2.4 Overview of configuration Description of operating modes P-manual mode Note The "P-manual mode" is preset for the positioner in the as-delivered condition. The digital display of the positioner shows the current potentiometer position in the upper line.
Operating 7.2 Operating modes Configuration and initialization To get to the "Configuration" mode, press the operating mode 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.
Operating 7.2 Operating modes Diagnostics Proceed as follows to call the "Diagnostics" mode from the "Automatic" or "Manual" modes: 1. 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 The "Automatic" and "Manual" modes remain set when switching to the "Diagnostics" mode.
Operating 7.3 Optimizing the controller data 7.3 Optimizing the controller data Note 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.
Operating 7.3 Optimizing the controller data 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 work as follows: ● 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.
8 Functional safety General safety notes 8.1.1 Safety-instrumented system Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 8.1 This chapter describes the functional safety in general and not specific to a device. The devices in the examples are selected as representative examples. The device-specific information follows in the next chapter.
Functional safety 8.1 General safety notes Functioning of the system as shown in the example See also Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 The transmitter generates a process-specific analog signal. The downstream control system monitors this signal to ensure that it does not fall below or exceed a set limit value. In case of a fault, the control system generates a failure signal of < 3.
Functional safety 8.2 Device-specific safety instructions SFF HFT 0 1 (0) 1) 2 (1) 1) Not permitted SIL 1 SIL 2 60 to 90 % SIL 1 SIL 2 SIL 3 90 to 99 % SIL 2 SIL 3 SIL 4 > 99 % SIL 3 SIL 4 SIL 4 1) Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 < 60 % As per IEC 61511-1, Section 11.4.4 According to IEC 61511-1, Section 11.4.
Functional safety 8.2 Device-specific safety instructions 8.2.2 Safety function Safety function on positioner Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 The safety function on the SIPART PS2 positioner is the depressurizing of the connected valve actuator. 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.
Functional safety 8.2 Device-specific safety instructions 8.2.3 Settings After assembly and commissioning, the following parameter settings should be made for the safety function: Safety parameters Parameter name Function Set parameter value Meaning 2.YAGL Rated angle of rotation of the feedback shaft 33° or 90° to match the setting for the transmission ratio selector Adaptation to the mechanically set range of stroke / rotation angle 6.SCUR Current range of setpoint 4 MA 4...20 mA 7.
Functional safety 8.2 Device-specific safety instructions Checking the safety function To check that the safety configuration is correct, apply a set current of 3.6 mA. 8.2.4 Behavior in case of faults Repairs Chapter 8 is invalid and is replaced by Compact operating instructions "Functional Safety SIPART PS2" A5E00442120-04 In this condition, the valve actuator must bring the valve to the intended safety position.
Functional safety 8.2 Device-specific safety instructions ● 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.
Functional safety 8.
Commissioning 9 NOTICE • 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.
Commissioning 9.1 Sequence of automatic initialization You can use a suitably configured and activated binary input to protect the configured settings against accidental adjustment. See also Overview of operating modes (Page 98) 9.1 Sequence of automatic initialization The automatic initialization takes place in the following phases: Automatic initialization phase Description Start - RUN1 Establishing the direction of action.
Commissioning 9.1 Sequence of automatic initialization Sequence of RUN1 This structured chart describes the process to establish the direction of action.
Commissioning 9.1 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.
Commissioning 9.1 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.
Commissioning 9.
Commissioning 9.
Commissioning 9.2 Commissioning linear actuators 9.2 Commissioning linear actuators 9.2.1 Preparing linear actuators for commissioning Condition You have already installed the positioner using the suitable mounting kit. Setting the transmission ratio selector Note 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 25 ...
Commissioning 9.2 Commissioning linear actuators Setting the actuator 1. Check whether the mechanical unit can be moved freely in the entire actuating range. and buttons. Press both Move the actuator to the respective end position using the the direction buttons simultaneously to 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.
Commissioning 9.2 Commissioning linear actuators 9.2.2 Automatic initialization of linear actuators Conditions 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 positioner automatically Note An ongoing initialization can be interrupted at any time. Press the for this purpose. The settings configured until then are retained.
Commissioning 9.2 Commissioning linear actuators 5. Call the fourth parameter "INITA". Press the operating mode button for a short while for this purpose. The following is shown on the digital display: 6. Start the initialization process. 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 digital display.
Commissioning 9.2 Commissioning linear actuators 9.2.3 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. Conditions The following conditions must be fulfilled before activating the manual initialization: 1.
Commissioning 9.2 Commissioning linear actuators Note Setting parameter 3 Proceed as follows to set parameter 3: 1. On the scale of the lever, read the value marked by the carrier pin. increment or decrement buttons 2. Set the parameter to the read value. Use the for this purpose. 5. Call the "INITM" parameter. Press the operating mode button twice for this purpose. The following is shown on the digital display: 6. Start the initialization process.
Commissioning 9.2 Commissioning linear actuators 9. Determine the end position 2 of the actuator spindle. Move the actuator spindle to the increment or decrement buttons. Accept the desired position by pressing the operating mode button. current position of the actuator spindle by pressing the Note "Set Middl" fault message The lever arm is not in the horizontal position if the "Set Middl" message appears on the digital display. To correct the fault, set the reference point of the sine correction.
Commissioning 9.3 Commissioning part-turn actuators 9.3 Commissioning part-turn actuators 9.3.1 Preparing part-turn actuators for commissioning NOTICE 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°. 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.
Commissioning 9.3 Commissioning part-turn actuators See also External position displacement sensor (Page 51) Pneumatic connection (Page 94) Basic device (Page 74) Transmission ratio selector (Page 50) 9.3.2 Automatic initialization of part-turn actuators Condition 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.
Commissioning 9.3 Commissioning part-turn actuators 5. Start the initialization process. To do this, press the increment button seconds until the digital display shows the following: for at least 5 Note 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 digital display. The initialization process depends on the actuator used, and takes up to 15 minutes. 6.
Commissioning 9.3 Commissioning part-turn actuators 9.3.3 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. Conditions The following conditions must be fulfilled before activating the manual initialization: 1.
Commissioning 9.3 Commissioning part-turn actuators 5. Start the initialization process. Press the increment button the digital display shows the following: for at least 5 seconds until 6. The current potentiometer position is shown on the digital display after 5 seconds. Examples of the displayed potentiometer positions are given below: 7. Determine the end position 1 of the actuator. 8. Move the actuator spindle to the desired position by pressing the increment or decrement buttons. 9.
Commissioning 9.4 Copying the initialization data when replacing a positioner Aborting the manual initialization process 1. Press the operating mode button. The digital display shows the "INITM" parameter. The positioner is in the "Configuration" mode. 2. Exit the "Configuration" mode. To do this, press the operating mode button 5 seconds. for at least 3. The software status is displayed. operating mode button, the positioner is in the "P manual mode", 4. After releasing the i.e.
Commissioning 9.4 Copying the initialization data when replacing a positioner Copying the initialization data Copy the initialization data and the device parameters as follows: 1. Read in the initialization data and the device parameters of the positioner to be replaced. Use a suitable parameterization tool for this purpose. 2. Save the data in the parameterization tool.
Commissioning 9.
Parameterizing/addressing 10.1 10 Parameter chapter In this chapter, how the parameters work is explained in the form of a configuration schematic. Afterwards, there is a tabular overview of all parameters. Finally, the individual parameters and their functionality are described.
Parameterizing/addressing 10.2 Configuration schematic for parameter operating principle 10.
Parameterizing/addressing 10.3 Overview of parameters 10.3 Overview of parameters 10.3.1 Overview of parameters 1 to 5 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.
Parameterizing/addressing 10.3 Overview of parameters 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. 10.3.
Parameterizing/addressing 10.3 Overview of parameters Parameter Function Parameter values Unit 50 : 1 n1 - 50 Freely adjustable 13.SL0 ... 33.SL20 1) 13.SL0 FrEE Setpoint turning point at 0% 14.SL1 .... 5 % ... 32.SL19 95 % 33.SL20 100 % 0.0 ... 100.0 % 34.DEBA Dead zone of closed-loop controller Auto / 0.1 ... 10.0 % 35.YA Start of the manipulated variable limit 0.0 ... 100.0 % 36.YE End of the manipulated variable limit 0.0 ... 100.0 % 37.
Parameterizing/addressing 10.3 Overview of parameters Parameter Function Parameter values Unit A1 = Min, A2 = Max A1 = Min, A2 = Min A1 = Max, A2 = Max 45.A1 Trigger threshold, alarm 1 0.0 ... 10.0 ... 100 % % 46.A2 Trigger threshold, alarm 2 0.0 ... 90.0 ... 100 % % 47. FCT 3) Function for fault message output Normal Inverted Fault Fault + not automatic 4) Fault + not automatic + BE4) 48. TIM Monitoring time for setting of fault message "regulation deviation" Auto / 0 ... 100 s 49.
Parameterizing/addressing 10.3 Overview of parameters 10.3.3 Overview parameters A to P Introduction These parameters are used to set the extended diagnostic functions of the positioner. Note 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". Overview parameter A Parameter A.
Parameterizing/addressing 10.3 Overview of parameters Overview parameter C Parameter C. LEAK Function Parameter values Unit Pneumatic leakage with the following parameters: C1.LIMIT Limit 0.1 ... 30.0 ... 100.0 C2.FACT1 Factor 1 0.1 ... 1.0 ... 100.0 C3.FACT2 Factor 2 0.1 ... 1.5 ... 100.0 C4.FACT3 Factor 3 0.1 ... 2.0 ... 100.0 % Overview parameter d Parameter Function Parameter values d. STIC Friction (slip-stick effect) with the following parameters: d1.LIMIT Limit 0.1 ... 1.0 .
Parameterizing/addressing 10.3 Overview of parameters Overview parameter H Parameter H. TMIN Function Parameter values Unit Monitoring of the lower limit temperature with the following parameters: H1.TUNIT Temperature unit °C °F H2.LEVEL1 Threshold 1 -40 ... -25 ... 90 -40 ... 194 H3.LEVEL2 Threshold 2 -40 ... -30 ... 90 -40 ... 194 H4.LEVEL3 Threshold 3 -40 ... 90 -40 ... 194 °C/°F Overview parameter J Parameter J.
Parameterizing/addressing 10.4 Description of parameters Overview parameter P Parameter Function Parameter values P. PAVG Position mean value calculation with the following parameters: Unit P1.TBASE Time base of the mean value generation P2.STATE State of the position mean value calculation IdLE / rEF / ###.# / Strt P3.LEVEL1 Threshold 1 0.1 ... 2.0 ... 100.0 % P4.LEVEL2 Threshold 2 0.1 ... 5.0 ... 100.0 % P5.LEVEL3 Threshold 3 0.1 ... 10.0 ... 100.0 % 10.
Parameterizing/addressing 10.4 Description of parameters ● YFCT = -ncSt Use this parameter value when you use a non-contacting position sensor on a part-turn actuator with a reverse direction of action. ● YFCT = ncSL Use this parameter value when you use a non-contacting position sensor on a linear actuator. ● YFCT = ncSLL Use this parameter value when you use a non-contacting position sensor on a linear actuator for which the position is transformed into a rotary movement using a lever. Note The "3.
Parameterizing/addressing 10.4 Description of parameters 10.4.1.2 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.
Parameterizing/addressing 10.4 Description of parameters 10.4.2 Description of parameters 6 through 51 10.4.2.1 Description of parameters 6 6.SCUR - Current range of setpoint This parameter is used to set the current range of the setpoint. The selection of the current range depends on the type of connection. Parameter value "0 MA" (0 to 20 mA) is only possible for three-wire and four-wire connections. The factory setting is "4 MA".
Parameterizing/addressing 10.4 Description of parameters 9.SPRE - Split range end With these two parameters in combination with parameter "7.SDIR", you can limit the effective setpoint.
Parameterizing/addressing 10.4 Description of parameters This smooth switching from manual to automatic mode prevents pressure excess in long pipelines. The parameter value "TSUP = Auto" means the slower of the two actuating times determined during initialization is used for the setpoint ramp. Parameter value "TSDO" then has no effect. The factory setting is "0". 10.4.2.5 Description of parameters 12 12.SFCT - Setpoint function This parameter is used to linearize nonlinear valve characteristics.
Parameterizing/addressing 10.4 Description of parameters 10.4.2.6 Description of parameters 13 through 33 13.SL0 bis 33.SL20 - Setpoint interpolation points These parameters are used to assign each setpoint interpolation point a flow metric in units of 5%.
Parameterizing/addressing 10.4 Description of parameters In the other discrete settings, the fixed value for the dead zone is edited. The factory setting is "Auto". 10.4.2.8 Description of parameters 35 and 36 35.YA - Start of the manipulated variable limit The factory setting is "0". and 36.YE - End of the manipulated variable limit These parameters are used to limit the mechanical actuator travel from stop to stop to the configured values.
Parameterizing/addressing 10.
Parameterizing/addressing 10.4 Description of parameters 10.4.2.10 Description of parameters 38 38.YDIR - Direction of manipulated variable for display This parameter is used to set the direction of action of the display and the position feedback IY. The direction can be rising or falling. The factory setting is "riSE". 10.4.2.11 Description of parameters 39 39.
Parameterizing/addressing 10.4 Description of parameters 41.YCUP - Value for "tight closing above" This parameter is used to set the value for "Tight closing below" and "Tight closing above". Note The value in the "40.YCDO" parameter must always be less than that in "41.YCUP". The tight closing function has a fixed hysteresis of 1%. The parameters "40.YCDO" and "41.YCUP" are relative to the mechanical stops. Both parameters are independent of the values set in the "7.SDIR" and "38.YDIR" parameters.
Parameterizing/addressing 10.4 Description of parameters ● BIN1 or BIN2 = PSt or -PSt Using binary inputs 1 or 2, a partial-stroke test can be triggered by actuation of your choice of a normally closed or normally open switch. ● BIN1 or BIN2 = OFF (factory setting) No function Special function of binary input 1: If binary input 1 is activated in "P-manual mode" by means of a jumper between terminals 9 and 10, then when the mode button is pushed the firmware version will be displayed.
Parameterizing/addressing 10.4 Description of parameters Direction of action and hysteresis A1 = 52 /LPLW A2 = 48 $ AFCT = -MIN / -MAX Way =45 Active Way =50 $ ZD\ 0,1 0$; 0,1 0,1 0$; 0$; 0,1 0$; 0,1 0,1 0$; 0$; Way =55 Active Note If the extended diagnostic is activated using parameter "51.XDIAG" with setting "On2" or "On3", then the alarms will not be output through the alarm module. Notification through HART communication is possible at any time, however.
Parameterizing/addressing 10.4 Description of parameters 10.4.2.16 Description of parameters 47 47. FCT - Fault message function 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 in advanced diagnostics See Description of parameters 51 (Page 159), 51.XDIAG activation of advanced diagnostics.
Parameterizing/addressing 10.4 Description of parameters 10.4.2.18 Description of parameters 49 49. LIM - Response threshold of fault message This parameter is used to set a value for the permissible size of the regulation deviation to trigger a fault message. The value is given in percent. If the parameters "48. TIM" and "49. LIM" are set to "Auto", then the fault message is set if the slow motion zone is not reached within a certain period of time. The setting "Auto" is the factory setting.
Parameterizing/addressing 10.4 Description of parameters 10.4.2.20 Description of parameters 51 51.XDIAG - Activation of extended diagnostics This parameter is used to activate extended diagnostics. At the factory, extended diagnostics are deactivated. Parameter "51.XDIAG" is set to "OFF". To activate extended diagnostics, there are three modes available: ● On1: Extended diagnostics are activated. Threshold-3 fault messages will be output over the fault message output.
Parameterizing/addressing 10.4 Description of parameters Figure 10-8 Display of a threshold 3 error message The factory setting is "OFF". 10.4.3 Description of parameters A through P 10.4.3.1 Description of parameter A A. PST - partial stroke test Use this parameter to activate the partial stroke test for cyclic or manual test of up/down and servo solenoid valves. Set the "On" parameter value to activate the test. Sub-parameters are displayed.
Parameterizing/addressing 10.4 Description of parameters A3.STEP - step height Use this sub-parameter to define the step height of the partial stroke test in percent. Set the step height in a range from "0.1" to "100.0". The factory setting is "10.0". A4.STEPD - step direction Use this sub-parameter to set the step direction of the partial stroke test.
Parameterizing/addressing 10.4 Description of parameters Example: An average actuating time of 1.2 seconds is shown in the digital display as "C 1.2", where "C" stands for "calculated". The average actuating time can be used as a reference step time. However, it merely represents a rough standard value. Set the sub-parameters "A1" to "A5" as per your requirements. Then start measuring the increment button for at least five seconds.
Parameterizing/addressing 10.4 Description of parameters 10.4.3.2 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.
Parameterizing/addressing 10.4 Description of parameters 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.
Parameterizing/addressing 10.4 Description of parameters 1. After initializing the positioner automatically, use a calibration device to initiate a ramp movement. 2. Conditions for the ramp movement: – The ramp must cover the normal operating range of the valve. – The steepness of the ramp must match the dynamic requirements of the corresponding application. 3. During the ramp movement, the "15 ONLK" diagnostics parameter provides information about the actual values.
Parameterizing/addressing 10.4 Description of parameters that may occur. Reverse changes in the valve position, the so-called slip jumps, let the positioner close at too large a static friction. If slip jumps are detected, the filtered step height 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.
Parameterizing/addressing 10.4 Description of parameters 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 "10.0". 10.4.3.5 Description of parameter E E. DEBA - dead zone monitoring Use this parameter to activate the "dead zone monitoring" test. This test can be used to monitor the automatic adjustment of dead zones continuously.
Parameterizing/addressing 10.4 Description of parameters 10.4.3.6 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. Use this parameter to activate the test to monitor the zero point displacement.
Parameterizing/addressing 10.4 Description of parameters 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".
Parameterizing/addressing 10.4 Description of parameters 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". 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.
Parameterizing/addressing 10.4 Description of parameters H1.TUNIT - temperature unit Use this sub-parameter to set the temperature unit "°C" or "°F". The selected temperature unit is then also applicable for all other temperature-based parameters. The factory setting is "°C". H2.LEVL1 - threshold 1 Use this sub-parameter to set a threshold in "°C" or "°F". Use threshold 1 to monitor the lower limit temperature. Set the threshold in a range from "-40.0C" to "90.0C" or "-40.0F" to "194.0F".
Parameterizing/addressing 10.4 Description of parameters 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". J1.
Parameterizing/addressing 10.4 Description of parameters 10.4.3.10 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.
Parameterizing/addressing 10.4 Description of parameters 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".
Parameterizing/addressing 10.4 Description of parameters 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 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". O4.
Parameterizing/addressing 10.4 Description of parameters ● 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.
Parameterizing/addressing 10.4 Description of parameters The positioner triggers a fault message if the difference between the position average and the reference average exceeds threshold 3. The process to activate and display this fault message is described in the "XDIAG" parameter. The factory setting is "10.0".
Parameterizing/addressing 10.
11 Alarm, error, and system messages 11.1 Representation of system messages in the digital display 11.1.1 System messages before initialization 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 before initialization (first commissioning) Line Message Up CPUStart X Pnnn.
Alarm, error, and system messages 11.1 Representation of system messages in the digital display 11.1.
Alarm, error, and system messages 11.1 Representation of system messages in the digital display Line ok x The permissible measuring range of end positions is achieved only in case of a manual initialization • Acknowledge with the operating mode button; the remaining steps ("RUN1" to "FINSH") execute automatically RUN1 / ERROR X Error in "RUN1", no movement e.g.
Alarm, error, and system messages 11.1 Representation of system messages in the digital display Line LEAKG nn.n X X %/MIN nn.
Alarm, error, and system messages 11.1 Representation of system messages in the digital display 11.1.
Alarm, error, and system messages 11.2 Diagnosis Line Mode EXTPSt Partial-Stroke-Test was activated, e.g. through binary input InPSt Cyclic Partial-Stroke-Test HTCNF X X X 11.2 Diagnosis 11.2.1 Display of diagnostics values X HART configuration running Structure of the diagnosis display The diagnostics display has similar structure to that of the "Configuration" mode: ● The upper line shows the value of the diagnosis variable.
Alarm, error, and system messages 11.2 Diagnosis 11.2.2 Overview of diagnostics values Explanation about the table The following table provides an overview of values that can be displayed. The third column contains the German meaning and the corresponding English term used to derive the abbreviation if it is not self-explanatory. The last column contains "X" if the value can be set to zero. Overview of diagnostics values No.
Alarm, error, and system messages 11.2 Diagnosis No. Abbreviation Meaning Values that can be displayed Unit Reset possibl e 28 TEMP Current temperature -40 ... 85 °C - 29 TMIN Minimum temperature ("min/max pointer") -40 ... 85 °C - 30 TMAX Maximum temperature ("min/max pointer") -40 ... 85 °C - 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.
Alarm, error, and system messages 11.2 Diagnosis 11.2.3 Meaning of diagnostics values 1 STRKS - stroke number The movements of the actuator in operation are summed up and can be read here as the stroke number. 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 non-volatile memory can be set to increment button.
Alarm, error, and system messages 11.2 Diagnosis 10 LEAK - leakage If a leakage measurement was initiated during the initialization process, the leakage value in %/min can be read here. 11 PST - monitoring of the Partial-Stroke test The measured step time of the last partial stroke test is displayed here. A partial stroke test can be initiated manually or a current partial stroke test can be interrupted by pressing the increment button .
Alarm, error, and system messages 11.2 Diagnosis 12 PRPST - time since the last partial stroke test The time in days elapsed since the last partial stroke test is displayed here. In addition, the following status messages can be displayed: ● notSt - No Test A manual partial stroke test was not yet executed. ● SdtSt - Stopped Test The last Partial-Stroke-Test was interrupted. ● FdtSt - Failed Test The last partial stroke test has failed.
Alarm, error, and system messages 11.2 Diagnosis 19 PAVG - position average The last calculated comparison average is displayed here. 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.
Alarm, error, and system messages 11.2 Diagnosis 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.
Alarm, error, and system messages 11.2 Diagnosis 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 data can be compared with the current data using the PDM.
Alarm, error, and system messages 11.3 Online diagnostics 11.2.4 Meaning of diagnostic value 53 53 mA - setpoint current Here, you can display the current setpoint in mA. Note All diagnostic value are updated every 15 minutes to a non-volatile memory, so that in case of a power failure only the values from the last quarter hour will be lost. 11.3 Online diagnostics 11.3.
Alarm, error, and system messages 11.3 Online diagnostics 11.3.2 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.
Alarm, error, and system messages 11.3 Online diagnostics Error code 8 Threestage Event Parameter setting Fault message disappears when Possible causes No Limit of dead zone 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 the reference step time ...
Alarm, error, and system messages 11.3 Online diagnostics 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.
Alarm, error, and system messages 11.3 Online diagnostics 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.
Alarm, error, and system messages 11.3 Online diagnostics 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.
Alarm, error, and system messages 11.4 Fault correction 11.4 Fault correction 11.4.1 Fault identification Diagnostics guide Fault See fault 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.
Alarm, error, and system messages 11.4 Fault correction 11.4.2 Remedial measures table 1 Fault profile (symptoms) • Positioner remains in "RUN 1". Possible cause(s) A waiting time of up to 1 minute is essential. Do not start initialization from the end position. Provide the network pressure. • • • Transmission ratio selector and parameter 2 "YAGL" and the real stroke do not match. Incorrectly set stroke on the lever. Piezo valve does not activate.
Alarm, error, and system messages 11.4 Fault correction 11.4.3 Remedial measures table 2 Fault profile (symptoms) • • "CPU test" blinks on the digital display approximately every two seconds. Piezo valve does not activate. Possible cause(s) • Remedial measures Water in the pneumatic block (due to wet compressed air) • At an early stage, this fault can be rectified with a subsequent operating using dry air, if required, in a temperature cabinet at 50 to 70°C.
Alarm, error, and system messages 11.4 Fault correction Fault profile (symptoms) • Possible cause A piezo valve activates constantly in • the stationary automatic mode (constant setpoint) and the manual mode. • Remedial measures Pneumatic leakage in the positioner • - actuator system; start the leakage test in "RUN 3" (initialization). • Rectify leakage in the actuator and/or feed line.
Alarm, error, and system messages 11.4 Fault correction 11.4.6 Remedial measures table 5 Fault profile (symptoms) Possible cause(s) Remedial measures • Zero point displaces sporadically (> 3%). • Impact or shock loads result in accelerations so high that the friction clutch moves, e.g. due to "vapor shocks" in vapor lines. • • Rectify the causes for shock loads. Re-initialize the positioner. • The device function has completely failed: no view even on the digital display.
Alarm, error, and system messages 11.
Service and maintenance 12 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. 12.1 Positioner in the metal enclosure and in the flameproof enclosure Dismantling and installation 1.
Service and maintenance 12.3 Repair/Upgrading Installation 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 plastic enclosure. 2. Place the O-rings on the screens. 3.
13 Technical data 13.1 General technical data General data Range of stroke (linear actuator) 3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the feedback shaft 16 to 90°) Angle of rotation (part-turn actuator) 30 ... 100° Installation • 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 534-6 (NAMUR) with a fin, columns, or a plane surface.
Technical data 13.1 General technical data General data Enclosure • 6D5**0-*** (plastic) 6DR5**1-*** (metal) GD AISi12 6DR5**2-*** (stainless steel) Austenitic stainless steel mat. no. 1.4581 6DR5**5-*** (metal, pressure resistant) GK AISi12 Pressure gauge block • Glass fiber reinforced macrolon Aluminum AIMgSi, anodized Vibration resistance • Harmonic vibrations (sine) according to DIN EN 60062-26/05.96 • Bump (half-sine) according to DIN EN 60068-2-29/03.
Technical data 13.1 General technical data Pneumatic data Auxiliary power (air supply) • Pressure 1,4 ... 7 bar (20.3 ... 101.5 psi): sufficiently greater than max. drive pressure (actuating pressure) Air quality in accordance with 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 • • Air supply valve (vent drive) 4) 2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm) 4 bar (58 psi) 7.
Technical data 13.2 Technical data for device version with and without HART 13.
Technical data 13.2 Technical data for device version with and without HART Electrical data Basic device without explosion protection • • Basic device with Ex Basic device with Ex Basic device with Ex ia/ib explosion n/dust explosion d explosion protection protection) protection (flameproof enclosure) With HART (6DR52..) typ. 8.4 V (= 420 Ω) 8.4 V (= 420 Ω) 8.4 V (= 420 Ω) max. 8.8 V (= 440 Ω) 8.8 V (= 440 Ω) 8.
Technical data 13.
Technical data 13.3 Technical data of optional modules 13.3 Technical data of optional modules Additional module Without explosion protection With Ex ia/ib explosion protection With Ex n/dust explosion protection Explosion protection in accordance with ATEX - II 2G Ex ia/ib II C T4/T5/T6 1) Ex n II 3 G Ex nA nL [nL] IIC T6 Dust II 3 D Ex tD A22 IP66 T100°C Installation point - Permissible ambient temperature for operation Zone 1 -30 ... +80°C (-22 ... +176°F) T4: -30 ... +80°C (-22 ...
Technical data 13.3 Technical data of optional modules Additional module Without explosion protection With Ex ia/ib explosion protection With Ex n/dust explosion protection Signal status 0 ≤ 4.5 V or open ≤ 4.5 V or open ≤ 4.
Technical data 13.3 Technical data of optional modules Additional module Without explosion protection Electrical isolation With Ex ia/ib explosion protection With Ex n/dust explosion protection The three outputs are galvanically isolated from the basic device.
Technical data 13.3 Technical data of optional modules Additional module Without explosion protection With Ex ia/ib explosion protection With Ex n/dust explosion protection Temperature influence ≤ 0.1 %/10 K (≤ 0.1 %/18 °F) ≤ 0.1%/10 K (≤ 0.1%/18 °F) ≤ 0.1 %/10 K (≤ 0.
14 Dimension drawings 14.1 Positioner with plastic enclosure 6DR5**0 < $OO DLU FRQQHFWLRQV * RU ಯ 137 GHHS 0 GHHS 3= ( < < [ [ 0 0 [ RU 137 DGDSWHU h9 Ø8 14,5 0.571 7 0.276 38,5 1.516 1 88,5 3.
Dimension drawings 14.2 Terminal strip for positioner with plastic enclosure 14.
Dimension drawings 14.3 Positioner with metal housing 6DR5**1 14.
Dimension drawings 14.
Scope of delivery/spare parts/accessories 15.1 15 Overview WARNING Assembling the components When assembling components, ensure that only those positioners and optional modules are combined with each other that are approved for the corresponding operating range. This condition is particularly applicable for the safe operation of the positioner in the areas where the atmosphere may be potentially explosive (zones 1 and 2).
Scope of delivery/spare parts/accessories 15.1 Overview Accessories ● Pressure gauge block: 2 or 3 pressure gauges for single and double-acting positioners ● Mounting flange (NAMUR) for safety pneumatic block ● Mounting kits for linear and part-turn actuators For separate mounting of positioner and position sensor ● External position detection system Non-contacting position sensor (NCS) Note The version is identified using a special type plate.
Scope of delivery/spare parts/accessories 15.2 Scope of delivery of basic unit 15.
Scope of delivery/spare parts/accessories 15.3 Optional modules 15.
Scope of delivery/spare parts/accessories 15.4 Spare parts 15.4 1 Spare parts Description Order number For version Plastic cover with 4 screws and circumferential sealing ring. C73451-A430-D82 6DR4*** 6DR5*** Metal cover with 4 screws and circumferential sealing ring.
Scope of delivery/spare parts/accessories 15.5 Scope of delivery of small part sets 15.
Scope of delivery/spare parts/accessories 15.5 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.
Scope of delivery/spare parts/accessories 15.6 Accessories 15.6 Accessories Accessories Order number Mounting kit for linear actuator IEC 534 - 6 including a lever for 3 ...
A Appendix A.1 Certificate The certificates can be found on the enclosed CD and on the Internet under: Certificates (http://www.siemens.com/processinstrumentation/certificates) A.2 Literature/catalogs/standards Bibliography and catalogs No. Title Publisher Order number /1/ SIMATIC NET, Ind.
Appendix A.3 Test report (extract) A.3 Test report (extract) FMEDA and Proven-in-use Assessment Project: Electro-pneumatic Positioner SIPART PS2 – single acting shut-down module Customer: SIEMENS AG, A&D PI TQ2 Karlsruhe Germany Contract No.: SIEMENS 04/12-06 Report No.: SIEMENS 04/12-06 R004 Version V1, Revision R1.0, April 2005 Stephan Aschenbrenner The document was prepared using best effort.
Appendix A.3 Test report (extract) Management summary This report summarizes the results of the hardware assessment with proven-in-use consideration according to IEC 61508 / IEC 61511 carried out on the Electro-pneumatic Positioner SIPART PS2 with software version C4 and C5. Table 1 gives an overview of the different configurations that belong to the considered Electro-pneumatic Positioner SIPART PS2. The hardware assessment consists of a Failure Modes, Effects and Diagnostics Analysis (FMEDA).
Appendix A.3 Test report (extract) As the Electro-pneumatic Positioner SIPART PS2 is supposed to be a proven-in-use device, an assessment of the hardware with additional proven-in-use demonstration for the device and its software was carried out. The proven-in-use investigation was based on field return data collected and analyzed by SIEMENS AG, A&D PI TQ2. This data cannot cover the process connection. The proven-in-use justification for the process connection still needs to be done by the end-user.
Appendix A.3 Test report (extract) The assessment has shown that the Electro-pneumatic Positioner SIPART PS2 when used as a single-acting shut-down module ("tight closing bottom") has a PF D AV G within the allowed range for SIL 2 according to table 2 of IEC 61508-1 and table 3.1 of ANSI/ISA– 84.01–1996 and a Safe Failure Fraction (SFF) of more than 84%.
Appendix A.
B Abbreviations Abbreviation Long form Meaning A/D Analog-to-digital converter - AC Alternating current Alternating current AMS Asset Management Solutions Communication software by Emerson Process comparable with the PDM AUT Automatic Operating mode ATEX Atmosphère explosible Product and operation directive of European Commission for explosion protection.
Abbreviations Abbreviation Long form Meaning 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.
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.
Glossary Cornerstone Management software for process instrumentation. Dangerous failure Failure with the potential to switch a safety-instrumented system to a hazardous or nonfunctioning safety status. Decrement From the Latin word decrementare, decrease. Decrement is the defined amount of change when decreasing a variable(s) gradually. In informatics, it is referred to as the stepwise decrease in a numeric value.→Increment.
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 power fail-safe manner. e.g. configuration data or runtime meters. EEx ia/ib protection Types of protection. If potentially explosive mixtures enter the enclosure of a resource, it should not lead to ignition.
Glossary 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.
Glossary HART communicator Connection with a two-wire line is directly established for the parameterization with the HART communicator. For the parameterization 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.
Glossary NEMA 4x The same protection like NEMA 4. Additional protection of the enclosure from corrosion. Parameterization During parameterization, individual parameter settings are specifically changed to adjust the positioner as per the actuator or other requirements. Parameterization is carried out after the complete commissioning of the positioner. Piezoelectric effect Name of a physical phenomenon.
Glossary 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.
Glossary Zone 1 Area in which potentially explosive gaseous atmospheres build up occasionally during the normal operation of a device. Zone 2 Area in which potentially explosive gaseous atmospheres normally never build up or build up for a short while during the 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.
Index A E Accessories, 220 Actuator medium Natural gas, 21 Actuator type Parameter, 144 Angle of rotation of the feedback shaft Parameter, 145 Automatic initialization Parameter, 146 Enclosure, 219 Environmental protection, 12 Exhausted air outlet E, 22 B Bibliography, 227 Bleeding Natural gas, 21 Block circuit diagram Mode of operation, 33 C Catalogs, 227 Certificate, 227 Certification, 227 characteristics Safety, 112 Componentry At electrostatic risk, 14 Connecting terminals Alarm optional module, 25
Index N Natural gas Actuator medium, 21 Bleeding, 21 Operation, 20 O Operation Natural gas, 20 Options, 219 Order number, 20 P Parameters Safety, 111 Parameters 1 and 2 Description, 144 Parameters 1 to 5 Overview, 137 Parameters 3 to 5 Description, 145 Pneumatic actuator, 32 Positioner Double-acting part-turn actuator, 18 Single-acting linear actuator, 19 Positioner Single-acting linear actuator, 18 SIPART PS2 with EEx d protection, 17 SIPART PS2 with EEx ia/ib protection, 17 SIPART PS2 without explosion
