SIEMIENS SIPART PS2 (6DR5...) Electrical Positioner Operation Guide

SIEMIENS SIPART PS2 (6DR5...) Electrical Positioner Operation Guide

Basic and Product Overview

Overview

The compact operation guide for SIPART PS2 (6DR5...) electric pneumatic positioner covers core contents such as product introduction, safety instructions, installation and mounting, connection, debugging, maintenance, technical parameters, and appendices. It is clear that the positioner is suitable for continuous control of process valves in multiple industries such as chemical, oil and gas, and energy. It emphasizes that the use in hazardous areas must comply with explosion-proof standards (such as ATEX, IECEx), and installation and debugging must follow specific steps (such as automatic/manual initialization). At the same time, detailed technical data (such as working temperature -30~+80 ° C, protection level IP66) and adaptation information for each module (alarm, position feedback, etc.) are provided to ensure safe and compliant operation of the equipment.

Product Usage and Compatibility

Usage: Used in 8 major industries including chemical, oil and gas, energy, food and beverage, papermaking, water supply and drainage, pharmaceuticals, and offshore platforms to achieve continuous control of valves in pneumatic drive processes

Compatibility: Different document versions need to match specific device firmware (FW) and integrated software versions, as shown in the table below:

Communication protocol document version, device firmware requirements, compatible with integrated software (including EDD version)

HART 05/2018 FW: 5.01.00 and above; Device version 6 and above  SIMATIC PDM V9.0（EDD:23.00.00+）、AMS Device Manager V12.5（EDD:23.00.00+） wait

PROFIBUS PA 05/2018 FW: 6.00.00 and above SIMATIC PDM V9.0 (EDD: 22.00.00+), SITRANS DTM V4.1 (EDD: 22.00.01+), etc

FOUNDATION Fieldbus 05/2018 FW: 3.00.00 and above; Device version 3  SITRANS DTM V4.1（EDD:3.00.00+）、AMS Device Manager V12.5（EDD:3.00.00+） wait

Goods inspection and nameplate

Goods inspection: After receiving the goods, it is necessary to check whether the packaging/items are damaged and verify the consistency between the order and the shipping documents; Prohibit the use of damaged or incomplete equipment (there is a risk of explosion in hazardous areas)

Nameplate information: including key information such as manufacturer, protection level (e.g. IP66), software and hardware versions, explosion-proof identification (e.g. Ex d IIC T6/T4), serial number, etc. The explosion-proof nameplate needs to be additionally labeled with ATEX/IECEx/FM/CSA certification information

Safety instructions (core risk prevention and control)

Warning level system

DANGER: Failure to take preventive measures may result in death or serious personal injury

Warning: Failure to take preventive measures may result in death or serious personal injury

CAUTION: Failure to take preventive measures may result in minor personal injury

NOTICE: Failure to take preventive measures may result in property damage

Requirements for use in hazardous areas

Operator: Must have the qualification to operate equipment in hazardous areas and be familiar with electrical, high-voltage, and hazardous medium safety regulations

Explosion proof requirements: Only use equipment labeled with the corresponding explosion-proof level (such as II 2 G Ex d IIC T6/T4 Gb), and prohibit the use of equipment suitable for non hazardous areas; If the equipment has been used in non hazardous areas, its explosion-proof label must be permanently removed

Special Warning: The pneumatic terminal board of 6DR5. 6 locator is a safety component of explosion-proof shell, and its fixing screws must not be loosened

Other safety regulations

Equipment modification: Only modifications are allowed according to the document instructions. Unauthorized modifications will cancel the warranty and certification

Power requirements: It is necessary to connect a safety isolated Extra Low Voltage (SELV) to avoid voltage flashover; Dangerous area connection equipment must be carried out in a power-off state (except for Ex i version)

Cable requirements: Use cable glands/plugs that meet explosion-proof standards. Unused cable entrances must be sealed, and shielded cables are only allowed to be grounded at one end (when crossing hazardous areas)

Installation and mounting

Basic security prerequisites

Pneumatic actuators have high operating force and must follow their safety instructions; The mounting kit with position detection lever poses a risk of compression, and it is prohibited to insert limbs into the range of motion of the lever

Only use Siemens original accessories/spare parts to avoid the risk of explosion in hazardous areas; Before installation, confirm that there is no visible damage to the equipment and that the sealing gasket is correctly positioned to avoid damage during cover installation

Different mounting methods for actuators

Linear actuator: Use 6DR4004-8V mounting kit, suitable for stroke 3-35mm; for stroke exceeding 35mm, an additional 6DR4004-8L lever needs to be ordered

Angular stroke actuator: VDI/VDE 3845 mounting surface (thickness>4mm with reinforcement) needs to be provided on the actuator side, paired with 6DR4004-8D kit or TGX: 16300-1556 stainless steel coupling

Vibration/acceleration environment treatment

The equipment is equipped with a friction clutch and a gear lock with a transmission ratio selector to cope with strong vibrations/accelerations (such as emergency shut-off valves, steam shock scenarios)

Locking steps: Ensure that the gear lock is in the neutral position → Confirm the gear ratio selector (33 ° or 90 °) → Lock the gear lock with a 4mm screwdriver → Secure the friction clutch (non explosion proof shell version), ensuring that the gear ratio selector is set to the same position as the gear lock (to avoid position detection delay)

Optional module installation

Optional modules for standard/intrinsic safety versions: position feedback module, alarm module, SIA module, mechanical limit switch module, EMC filtering module, NCS sensor, internal NCS module

Optional modules for explosion-proof shell version: only supports position feedback module, alarm module, and internal NCS module; The internal NCS module is used for wear free position detection and is installed in the same slot as the position feedback module

Connection (electrical and pneumatic)

electrical connection

Basic requirement: When the environmental temperature difference exceeds 20 ° C, it should be left to stand for several hours before being powered on (to avoid condensation); When the ambient temperature is ≥ 60 ° C, cables with a temperature resistance of ≥ 80 ° C must be used; The 2-wire version prohibits connecting the voltage source to the current input terminal (I2w, terminals 6/7) and requires the use of a high impedance power supply

Wiring for different communication versions:

With/without HART: Supports 2/3/4 wire system, 2-wire current input 4-20mA (terminals 6+, 7-)

PROFIBUS PA: Bus circuit connection terminals 6/7, equipped with safety shutdown input (terminals 81+, 82-)

FOUNDATION Fieldbus: Bus circuit connection terminals 6/7, supporting simulation enable function

M12 connector adaptation: The M12 pins of different modules correspond to different functions, such as the 61+pin 1 (brown) and 62- pin 3 (blue) of the position feedback module 6DR4004-6J/8J

Pneumatic connection

Interface specifications: All are G ¼ or ¼ "NPT internal threads, Y1 is the driving pressure for single/double acting actuators 1, Y2 is the driving pressure for double acting actuators 2

Interface positions for different models:

6DR5. 0/1/2/3: The pneumatic interface is located on the right side of the locator, including Y1, Y2, air source PZ, and exhaust port with muffler

6DR5. 5/6 (Explosion proof enclosure): The pneumatic interface is on the right side, including Y1/Y2 flow restrictor, enclosure ventilation port, and exhaust port

Safe location settings:

When power is off: single acting actuator Y1 releases pressure; Double acting actuator Y1 applies pressure (maximum driving pressure) and Y2 releases pressure; Fail in Place actuator maintains the current pressure of Y1/Y2

Usage of flow restrictor: When the actuator travel time T>1.5s, rotate the Y1/Y2 flow restrictor clockwise to reduce the air output. It is recommended to close it first and then slowly open it. The double acting valve should ensure that the two flow restrictors are set close to each other

Debugging (Commissioning)

Basic safety precautions

Installation and connection must be completed before debugging in hazardous areas, and equipment must be turned off (except for Ex i version); If there may be water in the compressed air pipeline, the purge air selector should be set to "OUT" (then set to "IN" after drainage)

Special requirements for natural gas operation: Only intrinsically safe (Ex ia) equipment can be used; Prohibited from operating in enclosed spaces; Adequate ventilation is required (see technical data for maximum ventilation capacity); Prohibit the use of mechanical limit switch modules; Relieve pressure for at least 2 minutes before maintenance

Initialization type and process

Initialization type:

Automatic initialization: Automatically detect the direction of action, actuator stroke/rotation angle, stroke time, and adapt control parameters, with a time consumption of ≤ 15 minutes

Manual initialization: manually set stroke/rotation angle, and automatically detect other parameters (applicable to PTFE lined valves)

Data replication: Copy the initialization data of the original device when replacing it to avoid process interruption

Core parameters (1-5):

Parameter function applicable to actuators, optional parameter value units

1. YFCT action direction/detection type linear/angular stroke linear: WAY/- WAY/FWAY/- FWAY/LWAY; Angular travel: turn/- turn; NCS adaptation: ncSt/ncSL/ncSLL, etc-

2. YAGL locator shaft rated rotation angle stroke 33, 90 degrees

3. YWAY travel range (optional) Linear (WAY/- WAY/ncSLL/- ncLL) OFF, 5, 10, 15, 20 (33 ° short lever); 25, 30, 35 (90 ° short leverage); 40~130 (90 ° long lever) mm

4. InitiatA automatically initializes all NOINI (uninitialized) and Strt (start)-

5. InitiatM manually initializes all NOINI (uninitialized) and Strt (start)-

Automatic initialization steps for linear actuators:

Press and hold the button for 5 seconds to enter configuration mode → Call 2. YAGL to confirm consistency with the transmission ratio selector → Set 3. YWAY (optional) → Call 4. InitiatA and press and hold for 5 seconds to start → Display "FINSH" after completion

Automatic initialization of angular actuator: Similar to linear actuator, default 2. YAGL=90 °, and display the total rotation angle after initialization

Maintenance and upkeep

Basic security requirements

Only authorized personnel from Siemens are authorized to perform repairs; The surface area of equipment in hazardous areas with dust exceeding 5mm needs to be cleaned (to avoid overheating); When cleaning, use a damp cloth or neutral cleaner, and do not use solvents such as acetone (to avoid damaging the plastic/paint surface)

After maintenance, it is necessary to correctly connect the equipment and close the casing to ensure the explosion-proof level; Button lock only allows authorized personnel to cancel (to avoid parameter errors affecting process safety)

Filter cleaning (core maintenance item)

Cleaning methods for different shell materials:

Polycarbonate (6DR5. 0), Aluminum Shell (6DR5. 3), Explosion proof Aluminum Shell (6DR5. 5): Disconnect the air source → Remove the pipeline → Open the cover → Unscrew the 3 screws of the pneumatic terminal board → Remove the filter screen/O-ring → Clean with compressed air → Reinstall in the original order (polycarbonate shell screws are self tapping screws, need to first find the thread counterclockwise before tightening)

Stainless steel shell (6DR5. 2), explosion-proof stainless steel shell (6DR5. 6), single acting aluminum shell (6DR5. 1): Disconnect the air source → remove the pipeline → remove the metal filter → clean and reinstall

Repair and Disposal

Repair: The faulty equipment needs to be sent for repair along with the fault information, and the original equipment serial number needs to be provided when ordering replacement equipment; Prohibition of unauthorized repairs (cancellation of warranty and certification)

Return: Please provide the waybill, return documents, and proof of cleaning. If there is no proof of cleaning, a cleaning fee will be charged

Disposal: Compliant with the WEEE Directive (2012/19/EC), municipal waste disposal is prohibited and must be returned to the supplier or local compliant recycling agency

Technical data

General Parameters

Working conditions: temperature -30~+80 ° C (-40~+80 ° C with Z M40 order code), altitude ≤ 2000m, humidity 0~100%, protection level IP66 (NEMA 4X), anti vibration (2~27Hz: 3.5mm amplitude); 27~300Hz: 98.1m/s ² acceleration

Pneumatic data: Air source pressure of 1.4~7 bar (fault holding double acting 3~7 bar), air quality meets ISO 8573-1 (solid particle Class3, pressure dew point Class3, oil content Class3), valve leakage<6 × 10 ⁻⁴ Nm ³/h, controlled air consumption<3.6 × 10 ⁻² Nm ³/h

Various versions of electrical data (excerpt)

With/without HART: 2-wire system maintaining current ≥ 3.6mA; without HART version (6DR50.) typical load voltage 6.36V (318 Ω), maximum 6.48V (324 Ω); The typical load voltage for the HART version (6DR52.) is 8.4V (420 Ω), with a maximum of 8.8V (440 Ω)

PROFIBUS PA/Foundation Fieldbus: Bus voltage 9~32V (intrinsic safety type 9~24V), current consumption 11.5mA ± 10%, safe shutdown input (terminal 81/82) electrically isolated from the bus circuit

Optional module parameters (excerpt)

Alarm module (6DR4004-6A/8A): 3-channel binary output, intrinsically safe maximum input 30V/100mA/1W, signal high level>2.1mA, low level<1.2mA

Position feedback module (6DR4004-6J/8J): 4-20mA current output (2-wire system), transmission error ≤ 0.3%, temperature impact 0.1%/10K, intrinsic safety type only applicable to T4 temperature level

Mechanical limit switch module (6DR4004-6K/8K): 2 limit contacts, maximum switch current 4A (AC/DC), intrinsic safety maximum voltage 30V, UL certified version (6DR4004-6K) maximum voltage 30V AC/DC, 8K version without UL certification