SIPART PS2 4/20 mA (6DR50...6DR51...6DR52...6DR53...)
Electropneumatic positioners
08/2017
Edition
Troubleshooting Guide
Page 1: ...SIPART PS2 4 20 mA 6DR50 6DR51 6DR52 6DR53 Electropneumatic positioners 08 2017 Edition Troubleshooting Guide ...
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Page 3: ..._________________ ___________________ ___________________ SIPART PS2 Smart Valve Positioner PS2 Troubleshooting Guide Service Manual 03 2017 A5E36661550 AA Introduction 1 Valve Symptom Guide 2 Troubleshooting Procedures 3 Wiring 4 Appendix A A ...
Page 4: ...ay be operated only by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WAR...
Page 5: ... 9 Basic safety instructions 7 1 10 Customer and Product Support 8 1 11 Device Overview 8 2 Valve Symptom Guide 13 3 Troubleshooting Procedures 15 3 1 Actuator Blow By double acting only 15 3 2 Actuator End Stops 15 3 3 Air Leak 16 3 4 Alarm Parameters 17 3 5 Booster s Not Properly Tuned 18 3 6 Change in Valve Stroke 20 3 7 Change in Tuning Parameters 22 3 8 Deadband Too Large 23 3 9 Deadband Too ...
Page 6: ...t Not Initialized 38 3 29 Valve Block Failure 38 3 30 Valve Does Not Go Fully Closed Open 42 4 Wiring 43 4 1 2 Wire Connection with terminals 6 through 10 43 4 2 2 Wire Connection terminals 2 through 10 44 4 3 Power Specifications 44 4 4 4 to 20 mA Feedback Module Iy Module 46 A Appendix A 49 A 1 Transmission Ratio Slide Bar 49 A 2 Initialization Procedure 50 A 3 NOINI P Manual Mode Troubleshootin...
Page 7: ... that will prevent successful PS2 initialization For mechanical installation of positioner to actuator refer to the specific mounting kit instructions 1 2 Requirements for special applications Due to the large number of possible applications each detail of the described device versions for each possible scenario during commissioning operation maintenance or operation in systems cannot be considere...
Page 8: ...dance with the directives Exception Devices having the type of protection Intrinsic safety Ex i may also be opened in energized state in hazardous areas 1 6 Water in compressed air line WARNING Water in compressed air line Device damage and possibly loss of type of protection The factory setting for the purging air selector is IN In the IN position water from the compressed air line may enter the ...
Page 9: ...ger guaranteed Check the gravity of the error Correct the error If the error still exists Take the device out of operation Prevent renewed commissioning 1 9 Basic safety instructions Qualified personnel for hazardous area applications Persons who install connect commission operate and service the device in a hazardous area must have the following specific qualifications They are authorized trained...
Page 10: ...st http www siemens com automation support request Technical Support 1 800 333 7421 8 a m to 4 45 p m eastern standard time Monday through Friday except holidays Customer Service Returns 1 800 365 8766 warranty and non warranty Public Internet Site http www usa siemens com pi Technical Publications in PDF Click the above link to go to the Siemens Internet site and then click Pro cess Instrumentati...
Page 11: ...ting terminals of option modules Buttons Dummy plug Restrictor Y1 for single acting actuators Cable gland Restrictor Y1 for double acting actuators Wiring diagram on module cover Restrictor Y2 for double acting actuators Purging air selector Exhaust air outlet with a sound absorber 1 for double acting actuators 2 only possible when positioner is open Figure 1 1 View of basic positioner with cover ...
Page 12: ...re Y1 Friction clutch adjustment wheel Display Connecting terminals of option modules Output Actuating pressure Y2 1 Connecting terminals of basic electronics Buttons Safety catch Transmission ratio selector 2 Ground terminal Restrictor Y1 1 for double acting actuators 2 only possible when positioner is open Figure 1 2 View of the positioner in the flameproof enclosure cover opened Note The fricti...
Page 13: ...es MAN Manual Mode Manually move valve with and Does not follow command signal AUT Automatic Mode Unit follows command signal Diagnostics Contains Read only Resettable maintenance data Tuning parameters Leak and current detection Operating Mode Representation in the display Pos Legend P manual mode Potentiometer setting Blinking indicator for the non initialized status Initialization mode Potentio...
Page 14: ...w PS2 Troubleshooting Guide 12 Service Manual 03 2017 A5E36661550 AA Operating Mode Representation in the display Pos Legend Automatic AUT Position Setpoint Fault message Diagnostics Diagnostic value Diagnostic name Diagnostic number ...
Page 15: ... Page 25 Erratic Input Signal Page 26 High Vibration Page 27 Initialization Incomplete Page 27 Insufficient Supply Air Page 28 Loose or Worn Linkage Page 29 Manual Mode Page 31 Mechanical Blockage Page 31 Parameter 1 YFCT Page 31 Parameter 6 SCUR Page 33 Re Initialization Positioner Page 33 Reversing the Action Page 34 Setpoint Ramping Page 35 Stays at 20 mA Position Page 35 Stiction Page 36 Suppl...
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Page 17: ... to move the valve to a new position the two output pressures gauges Y1 Y2 are relatively equal in pressure value 3 2 Actuator End Stops Actuator end stops are adjustable and must be set correctly for each valve application If not set correctly the actuator will drive the valve too far into the valve seat or over rotate the valve in the opening position This can damage the valve and cause poor pro...
Page 18: ...econds PS2 will now be in Diagnostic mode with diagnostic number in lower left hand corner of display Press button to advance through the diagnostic menu Go to diagnostic LEAK Press and hold button for at least 5 seconds Display will flash between test and actual position After one minute the screen will display the leak rate in percent of travel from original positon To return to Automatic mode p...
Page 19: ...s parameter should be set to OFF Use and or to change option Parameters TIM LIM Note These parameters should never be set to zero Continue to press the button until Parameter TIM is reached If unit does not display Auto then use the button to go downward until Auto is reached Repeat same steps with Parameter LIM Parameter XDIAG Continue to press the button until XDIAG is reached This parameter sho...
Page 20: ...valve response Re initialize PS2 after any needle valve adjustments see Initialization Procedure Page 50 see Appendix A volume booster must be setup BEFORE initializing a valve positioner The P manual mode NOINI flashing see display example below can be used to perform this setup The P manual mode will appear once proper electrical power is applied to a new PS2 valve positioner If PS2 is currently...
Page 21: ... adjust needle valve s a quarter turn counter clockwise Repeat above procedure until valve assembly stops when push buttons are released at any travel position If this cannot be accomplished check for air leaks and or replace volume boosters Note When volume booster is at rest neither loading nor exhausting pressure actuator pressure should be isolated from supply and exhaust sources If volume boo...
Page 22: ...lve fully open and fully closed Utilize pressure gauges to determine if PS2 is outputting full supply pressure and exhausting all output pressure For single acting one airline to actuator One end stop position should show full supply pressure The other end stop position will show zero pressure For double acting two airlines to actuator One end stop position should show full supply pressure while t...
Page 23: ...ull supply pressure and exhausting all output pressure For single acting one airline to actuator One end stop position should show full supply pressure The other end stop position will show zero pressure For double acting two airlines to actuator One end stop position should show full supply pressure while the other gauge should show zero pressure Output pressures will be reversed when driving val...
Page 24: ... ms For example if the value is 10 ms the fastest the piezo valves will cycle is 10 ms not any faster Therefore an increase in these values will increase the gain response Range is 2 0 to 160 ms SSUP SSDN Short Step Zone These tuning parameters are similar to integral action Essentially there are two actions of the piezo valves long pulses and quick short pulses The values are in percent of total ...
Page 25: ...to Auto mode 3 8 Deadband Too Large The deadband of the PS2 is the area around setpoint when the PS2 stops working to get closer to setpoint For example if the deadband value is 0 5 and the setpoint is 70 the PS2 will work the piezo valves to get within the following position range 69 5 to 70 5 If the deadband is too large the PS2 may not achieve a desired position There are two settings for the P...
Page 26: ...n for 5 seconds Now observe the parameter name in the lower right corner Continue to press the button until DEBA parameter is reached Use and or buttons to decrease deadband value To return to Automatic mode press and hold the button for 5 seconds The unit will now be in Manual mode Press the button one time to return to Automatic mode 3 9 Deadband Too Small The deadband of the PS2 is the area aro...
Page 27: ...or MAN mode press button for 5 seconds Now observe the parameter name in the lower right corner Continue to press the button until DEBA parameter is reached Use and or buttons to decrease deadband value or change to Auto To return to Automatic mode press and hold the button for 5 seconds The unit will now be in Manual mode Press the button one time to return to Automatic mode 3 10 Erratic Feedback...
Page 28: ...r valves with travel at 25 mm 1 0 inch or more slide bar 90 Reinitialize PS2 See Initialization Procedure Page 50 3 11 Erratic Input Signal There are two ways to identify if the input signal is causing the valve behavior One is placing a current meter in series of the 4 to 20 mA loop The other is using the PS2 s display as a current meter This is found in diagnostic parameter mA While the position...
Page 29: ...e vibration cannot be avoided consider Non Contacting technology Contact Siemens technical support for assistance 1 800 333 7421 3 13 Initialization Incomplete Fault Profile symptoms Possible Cause s Corrective Measures Positioner remains in RUN 1 Waiting time of 1 minute not ac complished Loose or Worn Linkage Page 29 Supply air not connected or Insuffi cient Supply Air Page 28 Valve Block Failur...
Page 30: ...er s Not Properly Tuned Page 18 See Loose or Worn Linkage Page 29 Positioner remains in RUN5 does not go up to FINISH waiting time 7 min Loose or Worn Linkage Page 29 Booster s Not Properly Tuned Page 18 Air Leak Page 16 Part turn actuator verify coupling set screw is secure Linear actuator verify lever arm is secure to input shaft Correct any slack between the actuator and valve Loose or Worn Lin...
Page 31: ...both directions While the valve is moving back and forth inspect the movements of For Rotary Actuator shaft Positioner coupling and Positioner input shaft For Linear Actuator shaft Actuator stem coupling Feedback pin Feedback arm and Positioner input shaft Note Inspect all parts especially the feedback arm for wear Lesser quality feedback arms have been seen with worn pin slots All of these compon...
Page 32: ...rections While the valve is moving back and forth inspect the movements of For Rotary Actuator shaft Positioner coupling Positioner input shaft and Internal Star Linkage For Linear Actuator shaft Actuator stem coupling Feedback pin Feedback arm Positioner input shaft and Internal Star Linkage All of these components must move in unison all together Several back and forth movements will be necessar...
Page 33: ...able to reach full supply pressure then Issue is an air leak somewhere in the output see Air Leak Page 16 If output pressure is unable to exhaust check exhaust port for blockage otherwise replace piezo block If PS2 is satisfied with current position deviation the deadband could be too large see Dead Band Too Large Page 23 3 18 Parameter 1 YFCT The two most common options for parameter 1 are WAY an...
Page 34: ...rrier pin mounted on the lever FWAY FWAY For a linear actuator with a carrier pin mounted on the actuator spindle LWAY LWAY For an external linear potentiometer on a linear actuator ncSt ncSt For an NCS sensor 6DR4004 N 10 and N 40 on a part turn actuator and for an internal NCS module ncSL ncSL For an NCS sensor 6DR4004 N 20 on a linear actuator for strokes 14 mm 0 55 inch ncSLL ncLL For an NCS s...
Page 35: ...From AUT or MAN mode press button for 5 seconds Now observe the parameter name in the lower right corner Continue to press the button until SCUR parameter is reached If it says 0 mA press the button to change this to 4 mA To return to Automatic mode press and hold the button for 5 seconds The unit will now be in Manual mode Press the button one time to return to Automatic mode 3 20 Re Initializati...
Page 36: ...isplays riSE change to FALL or vice versa Use and or buttons to change option To return to Automatic mode press and hold button for 5 seconds The unit will now be in Manual mode Press button one time to return to Automatic mode Note If using the alarm card and or advance diagnostics the alarm thresholds values may not match actual valve position To correct this use the following procedure to rever...
Page 37: ...ignal is shown in the lower right corner of display This value is in percent and should change with a change of input signal Use PS2 diagnostic number mA to convert display to current meter From automatic mode or manual mode press all three buttons down at the same time for 5 seconds Press and release button and go to diagnostic parameter mA The display will show input signal in milliamps If milli...
Page 38: ... identify this symptom Put PS2 in Manual mode from Auto press button once While using the and or buttons try to move valve assembly in the smallest movements for example 0 2 movements If the valve assembly cannot achieve these small movements manually then there is too much stiction The way to quantify how much stiction exists is by how little the valve can move For example if the smallest movemen...
Page 39: ...vel times Press button while times are flashing on display Display will show NOZZL Adjust built in flow restrictor s in clockwise direction with appropriate Allen key Press button again and PS2 will fully stroke the valve and update the display with the current travel times If minimum travel times are not met at least 1 second for both directions then press button again while display is flashing t...
Page 40: ... removes dirt oil moisture and other impurities from instrument air supply In addition exceeding the recommended supply pressure will damage the valve block The maximum pressure rating for the PS2 is 101 psi 7 bar see Supply Air Too High Page 50 It is recommended to install a regulator on the supply line upstream from the positioner and to regulate supply pressure so it does not exceed the maximum...
Page 41: ... the opposite direction reverse the two push button sequence Use the two button method and observe pressure changes on each output gauge Single acting In one direction the output gauge should reach full supply pressure and hold when the buttons are released When going in the opposite direction the output gauge should go to zero psi While it is going to zero air pressure should be blowing out of th...
Page 42: ...ection Does the unit exhaust For double acting the unit should always exhaust during movement For single acting the unit will only exhaust in one direction If one of the output ports does not exhaust check exhaust port for blockage If exhaust port is free from blockage go to Pipe Plug Test at the end of this section If unit always exhausts verify parameter PNEUM is set correctly Std Standard Valve...
Page 43: ...or from fully closing or opening Check valve assembly for mechanical blockage and air leaks Also verify supply is at required pressure for application If PS2 does not exhaust pressure from one of the output ports replace valve block If unit does not hold pressure when buttons are released check for leaks around pipe plug s gauge manifold block and PS2 pneumatic connection block this is a black ano...
Page 44: ... Mode Press and release button once to enter AUTO mode Verify the valve assembly goes to the fully open and or closed position with a 0 or 100 command signal If not The problem may be the input signal Use the PS2 s display as a current meter This is found in Diagnostic parameter mA Verify unit is in Automatic mode Provide a 4 mA input signal Press all three buttons down until display changes Diagn...
Page 45: ...ic electronics HART communicator Requires a regulated current source NOT a voltage source Unit requires at least 3 6 milliamps to power on Do NOT use the 24 volt pair of wires for the feedback card on terminals 6 and 8 if equipped For hazardous areas consult Power Specifications Page 44 and local safety guidelines Connect positive wire for 4 to 20 mA to terminal 6 negative wire to terminal 8 ...
Page 46: ...eedback card on terminals 3 and 8 if equipped Verify jumper wire is installed on terminals 5 6 For hazardous areas consult Power Specifications Page 44 and local safety guidelines Connect positive wire for 4 to 20 mA to terminal 6 negative wire to terminal 8 4 3 Power Specifications 6DR50 and 6DR53 without HART 6DR51 and 6DR52 with HART Basic device without Ex protec tion Basic device with Ex d ex...
Page 47: ... Ω 8 3 V 415 Ω With HART 6DR53 Typical max 7 9 V 395 Ω 8 4 V 420 Ω With HART 6DR51 Typical max 6 6 V 330 Ω 6 72 V 336 Ω 6 6 V 330 Ω 6 72 V 336 Ω With HART 6DR52 Typical max 8 4 V 420 Ω 8 8 V 440 Ω 8 4 V 420 Ω 8 8 V 440 Ω 8 4 V 420 Ω 8 8 V 440 Ω Static destruc tion limit 40 mA 4 mA Effective internal capacitance Ci Without HART 11 nF ic 11 nF With HART 11 nF ic 11 nF Effective internal inductance L...
Page 48: ...ect the positive wire from the analog input card to terminal 62 Connect the negative of the analog input to the negative side of the voltage source Feedback Module Power Specification Chart Basic device without Ex protection Basic device with Ex d explosion protection Basic device with ia explosion protection Basic device with explosion protection ic nA t Position feedback module 6DR4004 8J 6DR400...
Page 49: ... Basic device with explosion protection ic nA t For connecting to circuits with the fol lowing peak values Ui 30 V Ii 100 mA Pi 1 W ic Ui 30 V Ii 100 mA nA t Un 30 V In 100 mA Pn 1 W Effective internal ca pacitance Ci 11 nF Ci 11 nF Effective internal in ductance Li negligibly small Li negligibly small Electrical isolation Electrically isolated from the alarm option and safely isolated from the ba...
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Page 51: ... are two mechanical adjustments for 33 and 90 degrees on the positioner The important information to remember is the order of which the adjustments are completed Verify the Gear Latch is in the neutral positon which is shown with number If not use a flat head screwdriver to move the latch back to neutral as shown above ...
Page 52: ...tween the positioner input shaft and the actuator output shaft Check that there is sufficient supply pressure to operate the actuator valve configuration This is critical on spring return single acting actuators Insufficient air pressure will result in a calibration error Confirm a 4 20 mA source is properly connected to the 2 wire positioner x 0 or 1 or a 2 3 or 4 wire positioner x 2 or 3 Connect...
Page 53: ... rapidly move to one end position If no movement occurs reverse the button sequence Push and hold the button then push and hold the button Once the actuator has reached the end position reverse the push button sequence to rapidly move the actuator to its opposite position To move the actuator slowly push the or only Place the actuator anywhere around mid stroke by using one of the methods describe...
Page 54: ...x A A 2 Initialization Procedure PS2 Troubleshooting Guide 52 Service Manual 03 2017 A5E36661550 AA 3 Verify the Gear Latch is in the neutral positon which is shown by the number in the following illustration ...
Page 55: ...end of the yellow bar so it shows its yellow end on the opposite side from the clutch wheel OR 4B Linear Actuators Verify the transmission bar is set to 33 for a stroke less than or equal to 1 inch 25 mm Confirm the transmission bar is set to 90 for strokes greater than 1 inch 25 mm Using a small screw driver push the end of the yellow bar in to the correct position See previous illustration for p...
Page 56: ...al NCS module In the case of actuators with inverted direction of action use the settings with the minus sign e g turn Meaning of actuator with normal direction of action Part turn rotary actuator closes when the drive shaft positioner shaft or magnet of the NCS sensor rotates in the clockwise direction Linear actuator closes when the actuator spindle rotates downwards and the positioner shaft or ...
Page 57: ...ted just below the knurled thumb wheel inside the housing except Flameproof version with a small screw driver by rotating it TO THE RIGHT This will loosen the friction clutch and allow rotation of the thumb wheel Refer to the diagram in step 4 to locate the thumb wheel Item 6 C Push the button to continue 11 At the end of RUN 3 the display will show the opening and closing speed of the actuator Du...
Page 58: ...tialization 18 Lock the Transmission Ratio Selector according to application 33 or 90 degrees 19 Lock the Friction Clutch Move the slots left to lock see on image above Digital Communication Manual mode can be used for bench testing various positions without the need for a digital network A Profibus unit will also need to have the address set The address can be changed in the configuration menu Fa...
Page 59: ... Parameter 6 From AUT or MAN mode press button for 5 seconds Observe number in the lower left hand corner Continue to press button until Parameter 7 6 is reached If Parameter 7 6 displays rise change to fall or vice versa Use and or to change option Parameter 38 reverses the display and feedback Not needed in Profibus Continue to press button until Parameter 38 is reached If Parameter 38 displays ...
Page 60: ...tton until display changes to no Press and hold button to exit configuration mode Move the Valve While the display is flashing NOINI the valve can be moved with the or buttons To move the valve slowly press either the or button The longer the button is pressed the more air gets delivered Note If the valve is currently at one of the end stops the valve will not move so press the other button To mov...
Page 61: ...upling examples Verify potentiometer s ribbon cable is plugged into MPU board Remove top cover to gain access to MPU board If movement is detected Verify shaft linkage is secure to positioner s input shaft see Loose or Worn Linkage Page 29 section for more details Rotary Applications Verify the coupling setscrew is tight Linear Applications Verify all hardware is tight If feedback solution has a w...
Page 62: ... Air Leak Using the above push button procedure to move the valve move valve to the mid travel position Note Do not use the large number on the display to determine mid travel position use the mechanical indicator on the actuator Once at the mid travel position release push buttons The valve should stay at that position if not Check for air leaks If equipped use pressure gauges to determine which ...
Page 63: ...00 0 1 2 or Number decrements from 3 2 1 0 100 99 98 If numerical value goes through zero then check slide bar setting and slide bar locking mechanism see Transmission Ratio Slide Bar see Appendix A If adjustment was made to the slide bar repeat previous step For linear applications it is possible slide bar is set correctly but feedback pin is too close to positioner s input shaft Therefore secure...
Page 64: ...dback travel should not exceed 100 rotation If necessary secure feedback pin further away from positioner s input shaft or Actuator end stops are set too wide narrow actuator end stop travel Unit is now ready for intiialization procedure See Initialization Procedure A 4 SIPART PS2 Valve Positioner Fail Safe Positions When designing a process loop containing a valve and valve positioner it is wise ...
Page 65: ... and pneumatic power digital positioners require continuous digital communication for proper operation Both Foundation Fieldbus and Profibus power and communicate with the PS2 using a single pair of wires Therefore it is possible to lose digital communication and have device power The following Profibus and Foundation Fieldbus parameters will help you predict actuator position upon loss of digital...
Page 66: ...Appendix A A 4 SIPART PS2 Valve Positioner Fail Safe Positions PS2 Troubleshooting Guide 64 Service Manual 03 2017 A5E36661550 AA Figure A 3 Figure A 3 Reaction to failure of auxiliary powers ...
Page 67: ...Parameters The following safety parameters are accessible using the local pushbuttons or Siemens SIMATIC PDM1 software FSTY Fail Safe Type Determines position of actuator upon loss of digital communication This parameter has three choices FSVL Fail Safe Value Positioner will drive actuator to FSVL position see FSVL parameter FSSP Fail Safe Setpoint Positioner will stay at last known setpoint befor...
Page 68: ...Desired actuator position upon loss of digital communication Faultstate Type must 1 FSTATE_TIME Elapsed time after communication loss before going to safety position Safety Shutdown Profibus only positioners are equipped with an additional input to drive an actuator to the PS2 s factory safety position see Figure A 3 Reaction to failure of auxiliary powers above See Figure A 4 Reaction to failure ...
Page 69: ...Appendix A A 5 Leaflet Operation a concise overview Firmware 4 00 PS2 Troubleshooting Guide Service Manual 03 2017 A5E36661550 AA 67 A 5 Leaflet Operation a concise overview Firmware 4 00 ...
Page 70: ...Appendix A A 5 Leaflet Operation a concise overview Firmware 4 00 PS2 Troubleshooting Guide 68 Service Manual 03 2017 A5E36661550 AA ...
Page 71: ...Appendix A A 6 Leaflet Operation a concise overview Firmware 5 00 PS2 Troubleshooting Guide Service Manual 03 2017 A5E36661550 AA 69 A 6 Leaflet Operation a concise overview Firmware 5 00 ...
Page 72: ...Appendix A A 6 Leaflet Operation a concise overview Firmware 5 00 PS2 Troubleshooting Guide 70 Service Manual 03 2017 A5E36661550 AA ...
Page 73: ...d States 19477 0900 Subject to change without prior notice www siemens com automation support request Siemens Industry Inc Industry Automation Process Instrumentation 1201 Sumneytown Pike Siemens AG 2017 A5E36661550 Rev AA ...
