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POSITIONER, SIPART PS2 6DR5000 OM5510#05.0

Positioner, SIPART PS2 6DR5000

1 General

The electronic pneumatic positioner is used as the final control element of a pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner converts a current output signal (4 to 20 mA) from a process controller or control

system to a set point value and into a corresponding movement. The positioner changes the pressure in a pneumatic actuator chamber or cylinder until the positioncorresponds to the set point value.The positioner can be set up either as a single-action positioner or a double-action

positioner. The single-action positioner is mainly used together with a control valve.The opposite movement for the control valve is supplied by means of springs. Thedouble-action positioner is mainly used to control an air damper via a pneumaticcylinder (actuator). All movements of the pneumatic cylinder are supplied by the

positioner. An illustration of the function diagram for the positioner is shown inigure !. The function diagram is shown with option modules.

1.1 Mode of operation

"omparison of the set point and the actual value ta#es place electronically in a microcontroller. $f the micro controller detects a deviation% it uses a &-way switch

procedure to control the pie'oelectric valves% which in turn regulate the flow of air into the actuating chambers. hen connected in a two-wire system% the $*A+T *2draws its power e,clusively from the 4 to 20 mA set point signal.The pie'oelectric valve converts the command into a pneumatic positionalincrement. The positioner outputs a continuous signal in the area where there is alarge control deviation (high-speed 'one). $n areas of moderate control deviation(slow-speed 'one) it outputs a seuence of pulses. o positioning signals are outputin the case of a small control deviation (adaptive or variable dead 'one)."ommissioning (initialisation) is carried out automatically to a large e,tend. /uring

initialisation% the micro controller automatically determines the 'ero% full-scalevalue% direction of action% and positioning speed of the actuator. $t uses these todetermine the minimum pulse time and dead 'one% thus optimising the control.The positioner can also be operated manually by the pushbuttons and the "/ of the$*A+T *2.The installation of the positioner must be carried out in the following order1 echanic connection

3lectric connection

*neumatic connection

"ommissioning

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Illustration of a function diagram

Figure 1 sips2_5a.tif

2 Mechanic connection of the positioner

ormally the positioner is pre-mounted on the actuator or cylinder. $f not% follow theinstallation guide lines below.

2.1 Mechanic connection to an actator

igure 2 shows the mechanic connection of the positioner to an actuator for a controlvalve.

Step A: ount clamping assembly (8) with he,agon soc#et cap screws (!9) andloc# washers (!7) on the actuator spindle.

Step B: $nsert the pic#-up brac#et (2) into the recesses of the clamping assembly.et the necessary length and tighten the screws so that the pic#-up brac#etcan still be shifted.

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Step C: *ush the roll (&)% spring (!8)% and guide washer (22) onto the pin (4).

Step D: $nsert the pin in the lever (7) and assemble with nut (!:)% spring washer (!4)% and -washer (!2).

Step E: The value of the stro#e range specified on the actuator should be set or if this does not e,ist as a scaling value% the ne,t greatest scaling value should

be set. The centre of the pin must be in line with the scaling value. Thesame value can be set later under parameter ;8.

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2.2 Mechanic connection to a pne!atic c"linder

The positioner is connected to a pneumatic cylinder by means of fi,ing brac#et%lever arm with Allen screw% e,tension arm% and roller.The pneumatic piston is connected to a guide rail with an obliue angle via alin#age. The guide rail moves together with the piston% and the roller6lever connection senses the position of the piston. By operating both sides of the

pneumatic cylinder% the set point is reached. A spring inserted between the fi,ing brac#et and the lever arm secures that the roller is pressed down against the guiderail.

2.# Mechanic connection to a rotar" actator

igure 8 shows the mechanic connection of the positioner to a rotary actuator.Step A: Attach the mounting console (@% actuator specific) onto the rear of the

positioner and secure using the he,agon head screws (!4) and loc# washers(!&).

Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centringhole.

Step C: *ush coupling wheel (2) onto the positioner a,is% pull bac# by about ! mmand tighten the he,agon soc#et head screw (!:) with the Allen #ey

provided.

Step D: *lace the carrier (8) onto the end of the actuator and secure using illister head screw (!7) and washer (!9).

Step E: "arefully place the positioner with mounting console onto the actuator suchthat the pin of the coupling wheel engages in the driver.

Step F: Align the positioner6mounting console assembly in the centre of the actuator and screw tight (screws are not included in the delivery% they are part of theactuator mounting console).

Step : ollow the start-up seuence as described later. /rive the actuator to the

end position and adhere the scale (4.!) onto the coupling wheel (2)according to the direction of rotation and rotary actuator. The scale is self-adhesive.

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%ec'anic connection of t'e positioner rotar0 actuator/

Figure sips2_5c.tif

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# $lectric connection of the positioner

hen the positioner is connected in a two-wire system% the positioner draws its power e,clusively from the 4 to 20 mA set point signal. igure 4 indicates the inputcircuits for the positioner.

ie- of t'e controls and connections

Figure 3 sips2_5d.tif

% Pne!atic connection

3nsure that the air uality is suitable. Crease-free instrumental air with a solidcontent D 80 Em and a pressure dew point 20 5 below the lowest ambienttemperature must be supplied.

4arning: For reasons of safet0 pneumatic po-er ma0 onl0 +e supplied after

assem+l0 -'en t'e positioner is s-itc'ed to operating le)el 67

manual8 operation -it' electrical signal applied.

3.1.1 Selection of 7 manual mode

Before pneumatic power is connected% the positioner must be in * manual mode. Thedisplay must show ;F$$T= in the bottom line.

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3.1.2 7neumatic connections

igure 4 shows a view of the positioner controls and connections.Step A: $f reuired% connect a manometer bloc# for supply air and actuating

pressure.

Step B: The silencer in the e,haust output can be removed if necessary.

Step C: "onnect actuating pressure

Step D: "onnect the supply air (!). The pressure should be between !.4 to 9 bar.

&ote: In order for spring9loaded pneumatic actuators to +e a+le to relia+l0

eploit t'e maimum possi+le actuating pat' t'e suppl0 pressure must

+e sufficientl0 greater t'an t'e maimum re;uired final pressure of t'e

actuator.

3.1. Safet0 position -'en t'e electric po-er suppl0 fails

or a single-action actuator is

3.1.3 3.1.5 7urging air s-itc'o)er

The purging air changeover switch located above the pneumatic terminal bloc# onthe valve manifold can be accessed when the housing is open. hen the switch is in

position ;$= the interior of the housing is purged with very small uantities of clean and dry instrument air. $n position ;FT= the purging air is led directly out of the instrument.

5 &o!!issionin'

"ommissioning (initialisation) is carried out automatically to a large e,tend. /uringinitialisation% the micro controller automatically determines the 'ero value% full-scalevalue% direction of action and positioning speed of the actuator. $t uses these todetermine the minimum pulse time and dead 'one% hereby optimising the control.The positioner can also be operated manually by the pushbuttons and the "/ of the$*A+T *2.

The commissioning of the positioner can be divided into the following steps1 *reparation for initialisation

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Step B: "hec# that the pneumatic supply power (inlet air) is present. The operating

pressure should be at least one bar greater than is necessary for closing6opening the valve during initialisation.

Step C: ithout initialisation the positioner is in ;* manual mode= and ;F$$T=flashes in the display. This level can also be reached by using ;&&.*+T=function (see Table !).

Step D: "hec# the free running of the mechanics in the whole actuating range bymoving the actuator with the #eys ;I= and ;J= and driving to the respectiveend position.

Step E: ith linear actuators drive the actuator to hori'ontal lever position. The

display must indicate 4:K to &2K. $f necessary% correct the value byadLusting the sliding clutch. After the chec# is completed% the actuator must be appro,imately half way along its stro#e. This is due to establishment of the action direction during automatic initialisation.

5.2 Ato!atic initialisation

igure 7 shows the configuration mode including the operation in this mode andTable ! shows the parameter6configuration list. igure 9 shows the initialisation

process of the positioner. The initialisation process is stored in the microprocessor.This means that an additional initialisation only is necessary if any parts of the unit

have been changed.

&ote: ,'e numerical )alues used in Figure 5 Figure > and Figure ? are

eamples.

Step A: "all the configuration mode by pressing the hand symbol #ey for longer than & seconds.

Step B: et the actuator type% linear or part-turn% in the menu item line ;!.

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Initialisation process

Figure ? sips2_5g.cdr

5.# Para!eters

After the initialisation process% the positioner can be configured to meet thereuirements of a specified tas#. The factory settings correspond to the reuirementsfor a typical application. This means that normally only a few parameters will needto be changed.Table ! shows the parameter list for the positioner. The parameter name is written in

plain te,t in the ;menu line= column. The function of the parameter is described

briefly in the ;unction column=. $n addition% the possible parameter values% the physical unit and the factory setting of the parameters are shown.

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P #2.%RUN 1

P #2.%ERROR

Displa" Meanin' Measres

Actator doesnot !o(e

Possi)le !essa'es

Acknowledge me!ge"ng $%e %! nd &m'ol ke&

Se$ $%e ne($ %g%e$ $)!*el*!l"e on $% e l e*e)

Re$!)$ n$ !l!$on

Add$on!ll& +o'le w$% )o$!)&

!c$"!$o)

Ad-"$ "ng "+ !nd down ke&"+ $o d+l! &

on$n"e "ng %!nd &m'ol ke&

Do*n tolerance)and (iolated

Acknowledge me!ge"ng $%e %!nd &m'ol ke&

%eck )e$) c$o) /6 !nd o+en nece!) &

D)*e !c$"!$ o) $o wo)kng )!nge"ng $%e "+ !nd down ke&

Re$!)$ n$ !l!$on

%!nge ge! )ng /

on$n"e "ng "+ ke&

P +2.30435

S $tMIDD

P +.#UP 6

P .%d " IU

O) !d-"$ ldng cl"$c% "+$o d+l!&

T%en onl&on$n"e " ng $%e down ke&

P 6.%d 0 IU

-p tolerance ) and(iolated

P 1+.U7d 8

nce the slipp in'

cltch has )ee nad/sted

ne!) !c$"!$o) e$ +ck7"+le*e) n$o %o)9on$!l +o$on"ng $%e "+ !nd down ke&

on$n"e "ng %!nd &m'ol ke&

Acknowledge me!ge"ng $%e %! nd &m'ol ke&Se$ $%e ne($ lowe$ $)!*el*!l"e on $%e l e*e)

Re$!)$ n$!l!$on

Ad-"$ +o$onng $me "ng)e$)c$o)/

on$n"e " ng $%e"+ o) down ke&

- 1.#NO::

d 1.NO::

Strt; INITA

-pdo*n span(iolated

Actator doesnot !o(e.Positionin'ti!e is possi)l eto ad/st

Ato!atic initial start1p /$!)$#ng w#$% !c$o)& e$$#ng0

Step Meanin'

trn1

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Para!eter list

%enu line Function 7arameter )alues @nit Factor0 settingCustomer

setting

!.

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Para!eter list contined

%enu line Function 7arameter )alues @nit Factor0 settingCustomer

setting

42.B$!4)

unction of B$ !1 oneFnly message (F6" contact)Bloc# configuring (F contact)Bloc# configuring and manual (F contact)/rive valve to pos. up (F6" contact)/rive valve to pos. down (F6" contact)Bloc# movement (F6" contact)

Fon 6 -on boc! boc2u* 6 -u*

don 6 -donto* 6 - to*

F

48.B$24)

unction of B$ 21 one

Fnly message (F6" contact)/rive valve to pos. up (F6" contact)/rive valve to pos. down (F6" contact)Bloc# movement (F6" contact)

F

on 6 -onu* 6 -u*don 6 -don

to* 6 -to*

F

44.A"T&) Alarm function

ithoutA!Pmin. A2Pma,.A!Pmin. A2Pmin.A!Pma,. A2Pma,.

o % A %

A % A

F

4&.A! +esponse threshold of alarm ! 0.0 to !00.0 K !0.047.A2 +esponse threshold of alarm 2 0.0 to !00.0 K @0.0

49.QR"T7)

unction of alarm outputFn faultault S not automaticault S not automatic S B$(;S= means logical F+ operation)

QR

QRnAQRnAb

QR

4:.QRT$ onitoring time for fault message;control deviation=Auto

0 to !00 s Auto

[email protected]$ +esponse threshold for fault message;control deviation=Auto

0.0 to !00.0 K Auto

&0.QRT+5 imit for stro#e integral F! to !.003@ F

&!.QR/"C imit for direction change F! to !.003@ F

&2.QR3+F imit for end stop monitoring% bottom F0.0 to !00.0 K F

&8.QRF*3 imit for end stop monitoring% top F0.0 to !00.0 K F

&4.QR/3BA imit for dead 'one monitoring F

0.0 to !00.0

K F

&&.*+T

*reset (factory setting);no= nothing activated;trt= start of factory setting after pressing#ey for & sec.;o"A

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6 Dia'nosis

$n the diagnostic mode the current operating data (such as number of stro#es%number of changes in direction% number of fault messages% etc.) can be displayed.rom the automatic or manual modes the diagnostic mode can be reached bysimultaneously pressing all three #eys for at least 2 seconds.Table 2 shows an overview of the displayable values. The diagnostic display has asimilar structure as the parameter menu displays. The respective ne,t diagnosticvalue can be selected with the hand symbol #ey. "ertain values can be set to 'ero by

pressing the ;I= #ey for at least & seconds. These are menu item line ;!% 2% 8% and 4=.ome diagnostic values may be greater than @@@@@. $n this case the display switches

to e,ponential display.Dia'nostic list

&o.: A++re)iation %eaning Displa0a+le

)alue

@nit

! T+5 umber of stro#es 0 to 4.2@3@ -2 "/$+ "hanges of direction 0 to 4.2@3@ -8 QR"T ault counter 0 to 4.2@3@ -4 A!"T Alarm counter ! 0 to 4.2@3@ -& A2"T Alarm counter 2 0 to 4.2@3@7 F+ Fperating hours 0 to 4.2@3@ ours9 A< /etermined actuating path 0 to !80 mm or H: T* Travel time up 0 to !000 s@ T/F Travel time down 0 to !000 s!0 3A5 ea#age 0.0 to !00.0 K!! *0 *otentiometer value below stop (0K) 0.0 to !00.0 K!2 *!00 *otentiometer value bottom stop (!00K) 0.0 to !00.0 K!8 $** $mpulse length up 2 to !00 ms!4 $*/ $mpulse length down 2 to !00 ms!& /BF* /ead 'one up 0.! to !00.0 K!7 /B/ /ead 'one down 0.! to !00.0 K!9 * hort step 'one up 0.! to !00.0 K!: / hort step 'one down 0.! to !00.0 K!@ T3* "urrent temperature -4& to :& H"20 T$ inimum temperature -4& to :& H"2! TAV a,imum temperature -4& to :& H"22 T! umber of operating hours in Temperature range ! 0 to 4.2@3@ ours28 T2 umber of operating hours in Temperature range 2 0 to 4.2@3@ ours24 T8 umber of operating hours in Temperature range 8 0 to 4.2@3@ ours2& T4 umber of operating hours in Temperature range 4 0 to 4.2@3@ ours27 T& umber of operating hours in Temperature range & 0 to 4.2@3@ ours29 T7 umber of operating hours in Temperature range 7 0 to 4.2@3@ ours2: T9 umber of operating hours in Temperature range 9 0 to 4.2@3@ ours2@ T: umber of operating hours in Temperature range : 0 to 4.2@3@ ours80 T@ umber of operating hours in Temperature range @ 0 to 4.2@3@ ours8! O3T! umber of cycles pre-control valve ! 0 to 4.2@3@ -82 O3T2 umber of cycles pre-control valve 2 0 to 4.2@3@ -

88 TF+3 tore current values as ;last maintenance=

*ress the up #ey for at least & seconds (store)

- -

,a+le 2

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4 Ser(ice and !aintenance

The positioner is largely maintenance-free. The positioner is fitted with filters in the pneumatic connection as protection against coarse particles of dirt. $f the pneumaticenergy supply contains particles of dirt% the filters may be clog and impair thefunction of the positioner. $n this case the filters can be cleaned as follows1

Step A: witch off the pneumatic power supply and remove the pipes.

Step B: nscrew the cover.

Step C: +emove the three screws from the pneumatic connector strip.

Step D: +emove the filters and F-rings behind the connector strip.

Step E: "lean the filters (e.g. with compressed air).

Step F: After cleaning first insert the filters in the recesses in the housing and then place the F-rings on the filters.

Step : Align the pneumatic connector strip on the two lugs and screw tight withthe three self-tapping screws.

&ote: %a*e sure t'at t'e same t'read is used. ,o do t'is turn t'e scre-s anti9cloc*-ise until t'e0 snap into t'e t'read audi+l0. =nl0 t'en s'ould t'e

scre-s +e tig'tened.

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