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Siemens PROFIBUS PA SIPART PS2 Manual

Electropneumatic positioner for linear and rotary actuators
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Manual Edition 07/2003
sipart ps2
Electropneumatic positioner
for linear and rotary actuators
6DR55xx

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  • Page 1 Manual Edition 07/2003 sipart ps2 Electropneumatic positioner for linear and rotary actuators 6DR55xx...
  • Page 3 SIPART PS2 PA 6DR55xx Edition 07/2003 Manual Electropneumatic Positioner for Linear and Rotary Actuators SIPART PS2 PA Manual A5E00127926-03...
  • Page 4 D--76181 Karlsruhe Trademarks SIMATICe, SIPARTe, SIRECe, SITRANSe are registered trademarks of the Siemens AG Third parties using for their own purposes any other names in this document which refer to trade- marks might infringe upon the rights of the trademark owners.

  • Page 5: Table Of Contents

    Contents Information for the Operator ..........General information .
  • Page 6 3.3.4 Assembly procedure (see figure 3-7, page 48) ....3.3.5 Mounting kit ”Rotary actuator” 6DR4004-8D ..... . 3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) .
  • Page 7 5.3.2.2 Diagnostics ..........5.3.3 Diagnostics acc.
  • Page 8 SIPART PS2 PA Manual A5E00127926-03...

  • Page 9: Information For The Operator

    Information for the Operator Information for the Operator Dear customer, Please read this manual before starting work! It contains important information and data which, when observed, ensure full availability of the equipment and save service costs. This simplifies handling of this control instrument considerably and provides accurate measuring results.

  • Page 10: Classification Of Safety-Related Notices

    Siemens office or the office responsible for you. Functionality, commissioning and operation are described in this manual.

  • Page 11: Qualified Personnel

    Information for the Operator CAUTION used with the safety alert symbol indicates a potentially hazardous si- tuation which, if not avoided, may result in minor or moderate injury. CAUTION used without safety alert symbol indicates a potentially hazardous si- tuation which, if not avoided, may result in property damage. NOTICE used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesireable result or state.
  • Page 12 Information for the Operator WARNING The instrument must only be installed and commissioned by qualified personnel. The instrument is designed for connection to functional and safety extra low voltage. The instrument is designed for connection to operate voltage or safety extra--low voltage.

  • Page 13: Use As Intended

    Operating instructions German/English A5E00120717 Operating instructions French/Italian/Spanish A5E00120711 Leaflet German A5E00120712 Leaflet English A5E00120713 Leaflet French A5E00120714 Leaflet Spanish A5E00120715 Leaflet Italian This document is also available in electronic form on the Internet under the address www.siemens.com/fielddevices SIPART PS2 PA Manual A5E00127926-03...

  • Page 14: Warranty Information

    We should like to point out that the content of this manual is not part of and does not modify a previous or current agreement, undertaking or legal relationship. Siemens is bound solely by the contract of sale, which also contains the complete and exclusive warranty. The contractual warranty conditions are neither extended nor restricted by this document.

  • Page 15: Introduction

    Introduction Introduction General information about the positioner The positioner is used to adjust and control pneumatic actuators. The controller operates electropneumatically with compressed air as an energy supply. The positioner together with the PROFIBUS PA communications inter- face are components in a digital process automation system. It commu- nicates with the master as a slave via the PROFIBUS PS field bus.
  • Page 16 Introduction The housing is available in three versions: Plastic housing for single- and double-acting actuators Metal housing for single-acting actuators Explosion-proof metal housing for single and double-acting actua- tors The device is designed with IP65/NEMA4x degree of protection. Degree of protection Explosion The intrinsically safe version can be used in hazardous areas in zone 1...
  • Page 17 Introduction Actuator Positioner, single-acting in metal housing Lantern Manometer block, single-acting Valve Figure 1-1 Positioner mounted on linear actuator (single-acting) Positioner in plastic housing Rotary actuator Manometer block, double-acting Figure 1-2 Positioner mounted on rotary actuator (double-acting) SIPART PS2 PA Manual A5E00127926-03...
  • Page 18 Introduction Actuator Positioner, single-acting in explosion proof metal housing Lantern Manometer block, single-acting Figure 1-3 Explosion proof positioner mounted on linear actuator (single-acting) Positioner double-acting in explosion proof metal housing Rotary actuator Manometer block, double-acting Figure 1-4 Explosion proof positioner mounted on rotary actuator (double-acting) SIPART PS2 PA Manual A5E00127926-03...

  • Page 19: General Information Regarding Profibus

    Introduction General information regarding PROFIBUS The PROFIBUS-PA(PA = Process Automation) is a variant of the PRO- FIBUS DP (DP = Decentral Peripheral) which is widely used in manufacturing engineering. The PROFIBUS (Process Field Bus) is an open communication sys- tem for automation engineering and thousands are used all over the world.

  • Page 20: Properties Of The Profibus Pa

    (GS*) files (available on the Internet at http://www.ad.siemens.de/csi_e/gsd). One or more class 2 masters can access the field devices acyclically in addition to the cyclic mode. With this communication type further infor- mation can be fetched from the devices or settings made in the de- vices.

  • Page 21: Profile

    Introduction 1.2.4 Profile Supplementary to the EN standard 50170, the PNO (PROFIBUS User- organisation) has defined the functionality of the individual field device types in a so-called profile description. This profile defines minimum functional requirements and optional extensions. The device-internal Device Management supplies all the basic information necessary for finding the profile parameters to the control system configuration tool.
  • Page 22 Introduction An additional terminating resistor T must be fitted at the far end of the bus for transmission-technical reasons. When using the recommended bus cable, the theoretically possible line length (sum of all line sections) is a maximum of 1900 mm. In addition, the voltage drop over the lines supplying the field devices must be taken into account in the planning.
  • Page 23 Introduction Before operation make sure that the positioner addresses of two or more field devices are set on the bus. So that the addresses are unique, each address must only be assigned once. In principle, an address range from 1 to 125 is possible. In its as-supplied state, address 126 is set.
  • Page 24 Introduction SIPART PS2 PA Manual A5E00127926-03...

  • Page 25: Design And Method Of Operation

    Design and Functional Principle Design and Method of Operation The following chapter describes the mechanical and electrical design, the instrument components and method of operation of the positioner. Overview The electropneumatic positioner forms a control system in connection Introduction with an actuator. The current position of the positioner is detected by a servo potentiometer and fed back as actual value x.

  • Page 26: Instrument Components

    Design and Functional Principle The limit value alarms are output by the alarm option module which can monitor and report the function of the positioner and the actuator addi- tionally through a fault message output. The value of the control differ- ence dependent on the travel time is monitored in automatic mode.

  • Page 27: Motherboard

    Design and Functional Principle -- -- Input: Supply air Transmission ratio selector Output: Actuating pressure Y1 (only possible with positioner open) Display Adjustment wheel for friction clutch Output: Actuating pressure Y2 Terminals standard controller Operating keys Terminals options modules Restrictor Y1 Safety catch Restrictor Y2 in double-acting actuators...

  • Page 28: Pneumatic Connections

    Design and Functional Principle 2.2.3 Pneumatic Connections The pneumatic connections are on the right hand side of the positioner (figure 2-3 and figure 2-4). Actuating pressure Y1 in single- and double-acting actuators Feedback shaft Supply air P Actuating pressure Y2 in double-acting actuators Exhaust air output E with silencer on the bottom of the instrument Figure 2-3 Pneumatic connection in normal version...
  • Page 29 Design and Functional Principle The exhaust air output E can be provided for supplying dry instrument air to the tapping chamber and spring chamber to prevent corrosion. Figure 2-5, page 27 shows the pneumatic connection variants for the different actuator types, the positioning acting and the safety position after power failure.

  • Page 30: Mounting Kit

    Design and Functional Principle 2.2.4 Mounting Kit The positioner can be mounted on almost all actuators with the ap- propriate mounting kit. 2.2.5 Purge air switching (not in the explosion-proof version) The purge air switch is accessible above the pneumatic terminal strip with the housing open (figure 2-6).

  • Page 31: Method Of Operation

    Design and Functional Principle Method of Operation The electropneumatic positioner forms a control circuit with the pneumatic actuator in which the actual value x is the position of the actuator bar in linear actuators or the position of the actuator shaft in rotary actuators and the command variable w is supplied digitally via the PROFIBUS.

  • Page 32: State As Supplied

    Design and Functional Principle NOTE The exhaust air valve is always open when there is no current. Figure 2-8 Method of operation five-point switch State as supplied There are no mechanical mounting accessories on the controller in the state as supplied These must be ordered and installed according to the “operating instructions”...
  • Page 33 Design and Functional Principle Opening the To open the positioner, the four screws of the housing cover must be instrument loosened with a Phillips screwdriver. Disconnect or isolate the power supply cables. Remove the module cover (1). To do this, the two screws (1.1) must be removed with a screwdriver.
  • Page 34 Design and Functional Principle Place the insulating cover (10) over the SIA module underneath the surface of the basic electronics board at the container wall on one side. The recesses in the insulating cover must slot into the corresponding lugs on the container wall. Place the insulating cover on the SIA module by carefully bending the container walls.
  • Page 35 Design and Functional Principle EMC filter module The positioner can also be driven by an external position sensor (po- for connection of tentiometer or NCS) (see page 44). An EMC filter module, order num- external position ber C73451--A430--D23, is required for this. sensor Module cover Fixing screws...

  • Page 36: Options Modules In Explosion-Proof Version

    Design and Functional Principle 2.5.2 Options modules in explosion-proof version The options modules are protected and mechanically fixed by a module cover ((1), see figure 2-10, page 35). NOTE The housing must be opened to install the options modules. The degree of protection IP65/NEMA4x is not guaranteed as long as the positioner is open.
  • Page 37 Design and Functional Principle 13.1 13.1 Module cover Fixing screws PA module module with ribbon cable Alarm module with ribbon cable Ribbon cable for alarm module Ribbon cable for J module Transmission ratio selector Adjusting wheel for slipping clutch Housing Screw-on cover Safety catch Rack...

  • Page 38: Alarm Module

    Design and Functional Principle 2.5.3 Alarm module Function The alarm module contains 3 digital outputs and 1 digital input The digital outputs serve to output fault messages and alarms. The configuration is described in chapter 4.4, page 89, with the parameters 44 to 54.

  • Page 39: Sia Module

    Design and Functional Principle Installation The J - module is pushed in to the bottom compartment of the module rack up to the stop and connected by the enclosed 6-wire ribbon cable (6) to the motherboard (see figure 2-9, page 33). 2.5.5 SIA module The SIA module contains: a digital output for outputting a group fault message (see alarm...
  • Page 40 Design and Functional Principle SIPART PS2 PA Manual A5E00127926-03...

  • Page 41: Preparing For Operation

    Preparing for Operation Preparing for Operation This chapter describes all the preparations necessary for operating the positioner. Instrument identification (type key) The order number of the positioner is printed on the rating plate and on the packaging. Compare this with the order number in chapter 8.1, page 148.
  • Page 42 Preparing for Operation 79,5 G 1/4 or 20,5 1/4” NPT 2xM6 29,5 58,75 Thread depth 5.5 Figure 3-2 Dimensional drawing terminal strip for plastic housing 50 x 4 x M6 9 deep M8, 9 deep All air connections 11,2 G 1/4 or 1/4” NPT M20 x 1.5 or NPT-adapter 14,5 38,5...

  • Page 43: Assembly

    Preparing for Operation All air connections ”NPT M8, 14 deep (4x) M6, 11 deep (4x) M6, 8 deep (2x) 87,2 M20, M25 or 14,3 25,7 ”NPT (2x) 129,5 Connection 238/Y2 only in double-acting version 235,3 ∅ 8 h9 Figure 3-4 Dimensional drawing for positioner with metal housing in explosion-proof version 6DR5xx5 Assembly General...

  • Page 44: Instructions For Using Positioners In A Wet Environment

    Preparing for Operation NOTE The positioner will be equipped at the factory and delivered complete with the necessary options at the customer’s request. Options modules may only be retrofitted by our service technicians. The positioner must be assembled – especially in a moist environment –...
  • Page 45 Preparing for Operation Figure 3-5 Favorable and unfavorable installation positions If conditions oblige you to operate the positioner in a unfavorable installation position, you can take additional precautionary measures to prevent penetration by water. NOTE Never clean the positioner with a high pressure water jet because the IP65 degree of protection is inadequate protection for this.

  • Page 46: Instructions For Using Positioners Which Are Exposed To Great Accelerations Or Vibrations

    Preparing for Operation Assembly of the screw-type gland with plastic hose Unscrew the sinter bronze silencer from the exhaust air opening on the underside of the housing. Screw the screw-type gland mentioned above into the exhaust air opening. Mount the above mentioned plastic hose on the screw-type gland and check the good fit.
  • Page 47 Preparing for Operation I P65 NEMA D--76181 Karlsruhe Type4x SIP ARTPS2 i/p Positioner 6DR5010-- 0 NG00-- 0 AA0 Iw = 4...20mA Ta = -- 30... +80 module p = 1,4 ... 7bar module Alarm module F-- N r. N1-- P 212-- 1234567 MadeinFrance Fixing device for the slip clutch Figure 3-6...

  • Page 48: Mounting Kit "Linear Actuator" 6Dr4004-8V And 6Dr4004-8L

    Preparing for Operation 3.3.3 Mounting kit ”linear actuator” 6DR4004-8V and 6DR4004-8L The scope of delivery of the mounting kit” linear actuator IEC 534 (3 mm to 35 mm)” are contained (ser. no. see figure 3-7, page 48): Ser. no. pieces Designation Note NAMUR mounting kit bracket...
  • Page 49 Preparing for Operation Selection of the row of holes depends on the width of the actuator yoke. The roll (5) should engage in the pick-up bracket (2) as close as possible to the spindle but may not touch the clamping assembly.
  • Page 50 Preparing for Operation Without explosion-proof version Explosion-proof version: Figure 3-7 Assembly procedure (linear actuator) SIPART PS2 PA Manual A5E00127926-03...

  • Page 51: Mounting Kit "Rotary Actuator" 6Dr4004-8D

    Preparing for Operation Mounting on yoke Mounting on yoke with plane surface with ledge Mounting on yoke with columns as required Figure 3-7 Assembly procedure (linear actuator) continued 3.3.5 Mounting kit ”Rotary actuator” 6DR4004-8D The scope of delivery of the mounting kit ”Rotary actuator” contains (ser. no. see figures 3-8 and 3-9): Ser.

  • Page 52: Assembly Procedure (See Figure 3-8 And Figure 3-9)

    Preparing for Operation 3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) Attach VDI/VDE 3845 mounting console ((9), actuator-specific, scope of delivery actuator manufacturer) onto rear of positioner and secure using hexagon head screws (14) and lock washers (15). Adhere pointer (4.2) onto mounting console in the center of the centering hole.
  • Page 53 Preparing for Operation 0%20 40 60 80 100% Figure 3-8 Assembly procedure (rotary actuator) SIPART PS2 PA Manual A5E00127926-03...
  • Page 54 Preparing for Operation 0%20 40 60 80 100% Figure 3-9 Assembly procedure for explosion-proof version (rotary actuator) SIPART PS2 PA Manual A5E00127926-03...
  • Page 55 Preparing for Operation CUT A -- B 14,15 Positioner Rotary actuators Clutch wheel Feedback shaft Driver Hexagon-head screw M6×12 Multiple-purpose plate Retaining washer S6 Scale Round-head screw M6×12 Pointer mark Washer VDI/VDE 3845 mounting bracket Socket-head cap screw Figure 3-10 Mounted positioner for rotary actuators SIPART PS2 PA Manual A5E00127926-03...
  • Page 56 Preparing for Operation fastening level Befestigungsebene Stellungsregler positioner 4 mm +0,1 Schwenkantrieb rotary actuator F05-Lkr.- Figure 3-11 Attachment of rotary actuator, mounting console (scope of delivery actuator manufacturer), dimensions SIPART PS2 PA Manual A5E00127926-03...

  • Page 57: Electrical Connection

    Preparing for Operation Electrical Connection NOTE Any necessary options modules must be installed before electrical connection (see chapter 2.5, page 30). N.B.: The transmission ratio selector can only be set when the positioner is open. Therefore check this setting before closing the positioner.
  • Page 58 Preparing for Operation CAUTION To discharge impulses under fault conditions, the positioner must be connected via a low resistance to an equipotential bonding (ground potential). For this the positioner in plastic housing is provided with an additional cable. Connect this cable using the cable clip to the PROFI- BUS--PA cable shield and to the equipotential bonding.
  • Page 59 Preparing for Operation 5. Tighten the cable gland. 5. Tighten the Ex--d--certified cable gland. *) 6. Connect the red and green wires as 6. Connect the red and green wires as shown in figure 3-14, page 58 to terminals shown in figure 3-16, page 59 to terminals 3 and 7 of the motherboard (the polarity is 3 and 7 of the motherboard (the polarity is immaterial).
  • Page 60 Preparing for Operation for positioner in normal version: Bus cable Cable clip Basic PCB Module cover Plate Terminal block Ground potential Cable glands Figure 3-14 Bus cable connection for positioner in explosion-proof version Base plate Cable shield Cable clip EEx d certified cable inlets Bus cable Figure 3-15 Bus cable connection for positioner in explosion-proof version...
  • Page 61 Preparing for Operation Approved associated apparatus or barrier ≤ 30 V Input: Safe position Positioner PROFIBUS PA ≤ 24 V DP/PA coupling Digital input 1 Hazardous area zone 1 Non-hazardous area Figure 3-16 Electric connection of basic device with in intrinsically safe version ≤...

  • Page 62: Connection Variant: Options In Positioner In Non-Intrinsically Safe And Explo- Sion-Proof Version

    Preparing for Operation This function is activated by the coding bridge on the motherboard. This is accessible after removing the module cover and must be moved from the right position (as delivered) to the left position. 3.4.1 Connection variant: Options in positioner in non-intrinsically safe and explosion-proof version Current output ≤...

  • Page 63: Connection Variant: Options In The Positioner In Intrinsically Safe Version

    Preparing for Operation SIA module SIA module: 6DR4004-8G 8.2 V Fault message 8.2 V Limit value A1 8.2 V Limit value A2 Figure 3-20 SIA module 6DR4004-8G, non Ex 3.4.2 Connection variant: Options in the positioner in intrinsically safe version Current output Hazardous area zone 1 or zone 2 Non-hazardous area...
  • Page 64 Preparing for Operation Digital inputs and outputs Alarm module 6DR4004-6A ≤ 25.2 V Digital ≥1 input 2 Intrinsically safe 8.2 V Fault Switching message amplifier to EN 50227 8.2 V Limit value A1 8.2 V Limit value A2 Non-hazardous area Hazardous area zone 1 or zone 2 Figure 3-22 Alarm module 6DR4004-6A, EEx i...

  • Page 65: Connection Variant: Options In The Positioner In Type Of Protection "N" Version

    Preparing for Operation 3.4.3 Connection variant: Options in the positioner in type of protection “n” version Current output Non-hazardous area Hazardous area zone 2 ≤ 30 V module 6DR4004-6J Figure 3-24 module 6DR4004-6J, EEx n Digital inputs and outputs Alarm module 6DR4004-6A ≤...
  • Page 66 Preparing for Operation SIA module SIA module 6DR4004-6G 8.2 V Alarm 8.2 V Limit A1 8.2 V Limit A2 Non-hazardous area Hazardous area zone 2 Figure 3-26 SIA module 6DR4004-6G, EEx n SIPART PS2 PA Manual A5E00127926-03...

  • Page 67: Pneumatic Connection

    Preparing for Operation Pneumatic Connection WARNING For reasons of safety, the pneumatic power may only be supplied after assembly when the positioner is switched to operating mode P manual operation with electrical signal applied (as-delivered state, see figure 4-4, page 86). NOTE Note the air quality! Oil-free industrial air, solid content <...

  • Page 68: Commissioning

    Preparing for Operation Commissioning Once the positioner has been fitted to a pneumatic actuator, it must be provided with electrical and pneumatic auxiliary power. The electrical auxiliary power can be provided via a bus interface or separate power source with 15 to 30 V DC. Then you can then adapt the position controller to the respective actuator by parameterizing and initializing it and setting the bus address.

  • Page 69: Preparations For Linear Actuators

    Preparing for Operation 3.6.1 Preparations for linear actuators Assemble the positioner with the appropriate mounting kit (see chapter 3.3.3, page 39). NOTE Particularly important is the position of the transmission ratio selector (7, figure 2-1, page 24) in the positioner: Stroke Lever Position of the transmission ratio se-...

  • Page 70: Automatic Initialization Of Linear Actuator

    Preparing for Operation 3.6.2 Automatic initialization of linear actuator If you can move the actuator correctly, leave it standing in a central po- sition and start automatic initialization: Press the operation mode key for longer than 5 s. This brings you to the Configuration operating mode.
  • Page 71 Preparing for Operation Start initialization by pressing the key for longer than 5 s. Display: During the initialization phase ”RUN1” to ”RUN5” appear one after an- other in the bottom display (see also structograms figures 3-28, page 78 to figure 3-31, page 81). NOTE The initialization process may last up to 15 minutes depending on the actuator.

  • Page 72: Manual Initialization Of Linear Actuator

    Preparing for Operation 3.6.3 Manual initialization of linear actuator The positioner can be initialized with this function without the actuator being driven hard against the limit stop. The start and end positions of the stem path are set manually. The other initialization steps (optimiza- tion of the control parameters) run automatically as in automatic initiali- zation.
  • Page 73 Preparing for Operation Switch on to the following display by pressing the operation mode key twice: Start initialization by pressing the increment key for longer than 5 s. Display: After 5 s the display changes to: (The display of the potentiometer setting is shown here and below as an example only).
  • Page 74 Preparing for Operation If step 7 was successful, the following display appears: Now move the actuator to the position which you want to define as the second end position with the increment and decre- ment key. Then press the operation mode key .

  • Page 75: Preparations For Rotary Actuator

    Preparing for Operation 3.6.4 Preparations for rotary actuator NOTE Very important: Switch the transmission ratio selector in the positioner (8, figure 2-1, page 24) to position 90° (normal angle for rotary actuator). Mount the positioner with the appropriate mounting kit (see chapter 3.3.5, page 49).
  • Page 76 Preparing for Operation Set the parameter with the -key to ”turn” Display: Switch to the second parameter by pressing the operation mode briefly. This has set automatically to 90°. Display: Switch on to the following display with the operation mode key Start initialization by pressing the key for longer than 5 s.
  • Page 77 Preparing for Operation The following display appears after pressing the operation mode key briefly: To exit the Configuration mode, press the operation mode key longer than 5 s. The software version is displayed after about 5 s. The instrument is in manual operation after releasing the operation mode key.

  • Page 78: Manual Initialization Of Rotary Actuators

    Preparing for Operation 3.6.6 Manual initialization of rotary actuators The positioner can be initialized with this function without the actuator being driven hard against the limit stop. The start and end positions of the displacement path are set manually. The other initialization steps (optimization of the control parameters) run automatically as in automa- tic initialization.
  • Page 79 Preparing for Operation After successful initialization the determined rotary range appears in the top display. “5.INITM” appears in the bottom line again after pressing the ope- ration mode key briefly. This brings you back to the Configura- tion operating mode. To exit the Configuration mode, press the operation mode key for longer than 5 seconds.

  • Page 80: Automatic Initialization (Structograms)

    Preparing for Operation 3.6.7 Automatic initialization (structograms) Linear actuator Rotary actuator Down Open Closed Figure 3-27 Direction of action of the actuators The initialization procedure should be taken from the following structo- gram (figure 3-28 to figure 3-31). The terms Open/Closed and up/down in the structogram refer to the direction of action of the actuators as illustrated in figure 3-27.
  • Page 81 Preparing for Operation actuator moves into closed position turn slip clutch until 0 appears in the bottom line tolerance band of the display 4% < dw < 10% continue with: actuator moves into open position hard stop up < 97 % ? continue with: check mechanics...
  • Page 82 Preparing for Operation set lever vertical to stem with: continue with: actuator moves continue with: into closed position has slip clutch been moved? continue with: correct height adjustment or turn slip clutch until 0 appears tolerance band in the bottom line 4% <...
  • Page 83 Preparing for Operation continue with: determine travel times set restrictor(s) to display travel times change the travel flashes times if setting of travel alternating times is desired flashes within alternating 5 s ? display of travel times in s actuator comes to standstill after display of leakage within...

  • Page 84: Copying Initialization Data (Positioner Exchange)

    Preparing for Operation Copying initialization data (positioner exchange) With this function you have the possibility of starting up a positioner without running the initialization routine. This allows for example a posi- tioner to be changed on a running system in which automatic or manual initialization cannot be performed without disturbing the process.

  • Page 85: Operation

    Operation Operation The following chapter describes the operation of the positioner. Display The LC display has two lines whereby the lines have different segmentation. The elements of the top line consist of 7, those of the bottom line of 14 segments. The display depends on the selected operating mode (see chapter 4.3, page 86) NOTE If the positioner is operated in ranges with temperatures below --10 °C...
  • Page 86 Operation Figure 4-1 Meaning of the various display options SIPART PS2 PA Manual A5E00127926-03...
  • Page 87 Operation Display Operation mode key Decrement key Increment key Figure 4-2 Display and input keys of the positioner Explanations of the input keys The operation mode key (manual key) serves to switch over the operating mode and pass on parameters. NOTE By pressing and holding the operation mode key and additionally pressing the decrement key, you can select the parameters in reverse...

  • Page 88: Operating Modes

    Operation Operating modes The positioner can be operated in five operating modes. P-manual mode (ex-factory state) Configuration and initialization Manual mode (MAN) Automatic (AUT) Diagnostic display Figure 4-4 gives you an overview of the possible operating modes and the change between them. Figure 4-4 Change between the operating modes SIPART PS2 PA Manual...
  • Page 89 Operation P-manual mode The display of the positioner shows you the current potentiometer (ex-factory state) setting in the top line and ”NOINI” flashes in the second line. You can move the actuator with the decrement and increment key . In order to adapt the positioner to your actuator, you have to change to the Configuration menu.

  • Page 90: Parameters

    Operation NOTE You can move the actuator quickly by pressing the other direction key additionally whilst keeping the direction key selected first pressed. The manual mode can be reported by outputting a parameterizable fault message, a position feedback or output of limit values A1 and A2 is only possible in automatic mode.
  • Page 91 Operation ■ SIPART PS2 PA configurations (PROFIBUS version) Parameter- Function Parameter values Dimen- name sion Parameter- Function Parameter values Dimen- 39. BIN2 Function of binary input 2 name sion None 1. YFCT Type of actuator: rotary/linear - Rotary actuator Only signal turn Drive valve to ye - Linear actuator...
  • Page 92 Operation setpoint t ight closing processing function setpoint SDIR YCLS TSUF YCDO TSDO master YCUP SFCT SLO..SL20 actual value adaptive processing five-point position switch YFCT DEBA YAGL YWAY INIT A valve 1 INIT M PRST valve 2 SFCT YNRM alarm digital signal detection processing...
  • Page 93 Operation NOTE In particular if the positioner has previously been operated using a different actuator, it must always be reinitialized in order to restore the factory settings. Only in this way can the positioner matching process start from known conditions. The parameter ”51 PRST” is provided for this purpose.
  • Page 94 Operation NOTE After ”LWAY, ncSt, --ncSt or ncSL, ncSLL” have been adjusted, both the following parameters ”2. YAGL” and ”3. YWAY” will not be displayed. 2.YAGL Rated angle of rotation of the feedback shaft In rotary actuators, an angle of 90° is preset automatically by 1.YFCT = turn (see above).
  • Page 95 Operation 4.INITA Automatic initialization (see chapter 3.6, page 66) By selecting “Strt” and pressing the increment key for at least 5 seconds, automatic initialization is started. The initialization process is displayed by “RUN 1” to “RUN 5” (see figure 3-28, page 78 to figure 3-31, page 81).
  • Page 96 Operation Six valve characteristics are stored in the positioner linear (9.SFCT = Lin, factory setting) equal percentage 1 : 25 (9.SFCT = 1 : 25) equal percentage 1 : 33 (9.SFCT = 1 : 33) equal percentage 1 : 50 (9.SFCT = 1 : 50) inverse equal percentage 25 : 1...
  • Page 97 Operation The setpoint turning point can only be input at You may only enter a strictly monotonous characteristic, and two consecutive vertex values must differ by at least 0.2 %. 31.DEBA Dead zone of the controller At dEbA = AUto the dead zone in automatic operation is adapted con- tinuously to the requirements of the control circuit.
  • Page 98 Operation YNRM = MPOS or YNRM = FLOW Presetting: YA = 0% and YE = 100% Input current (setpoint) 7.2mA 10.4mA 13.6mA 16.8mA 20mA X display W display 100% Mechan. Stroke (actual value) 16mm 32mm 48mm 64mm 80mm YA = 0% YE = 100% Example: YNRM = MPOS with YA = 10 % and YE = 80 %...
  • Page 99 Operation NOTE YCDO must always be set to less than YCUP. The tight closing function has a fixed hysteresis of 1 %. 38.BIN1 Function digital input 1 39.BIN2 Function digital input 2 The parameters “BIN1” and “BIN2” can be set individually depending on the purpose.
  • Page 100 Operation 40.AFCT Alarm function There are 6 setting capabilities available: 1. Min 2. Min 3. Max 4. --Min --Max (inverted reporting) 5. --Min --Min (inverted reporting) 6. --Max --Max (inverted reporting) Limit Alarm module SIMATIC A1 = 48 AFCT = MIN / MAX A2 = 52 Travel = 45 Activated...
  • Page 101 Operation 43. FCT Function of the fault message output If fault messages are used as a monitor for control non-conformities over a period of time, they will be triggered in addition by the following events also: Power failure Processor fault Actuator fault Valve fault Compressed air failure...
  • Page 102 Operation This function enables a preventive maintenance of the fitting, see also chapter 4.5 “Diagnostics”, page 103. This monitoring function can be deactivated with the OFF setting (factory setting). 48. ZERO Tolerance value for monitoring the bottom hard stop With this value a limit value (in percent related to the total mechanical distance) can be preset for the monitoring of the bottom hard stop.
  • Page 103 Operation 50. DEBA Limit value for monitoring the dead zone adaptation The automatic adaptation of the dead zone can be monitored with this value (%). If the dead zone exceeds the set value, the fault message output is activated. Prerequisite for this function is the setting of the parameter“31.DEBA” = Auto.
  • Page 104 Operation 55.STNR Station number So that the devices on the bus can be addressed separately, a sepa- rate station number must be set on each device. 56.IDENT Device operating mode The SIPART PS2 PA positioner recognizes two device operating modes for its behavior in relation to DP masters class1: [0] profile conformity: exchangeable for positioners from other suppliers to PROFIBUS--PA profile 3.0 [1] profile conformity with extensions: full scope of function of SIPART...

  • Page 105: Diagnosis

    Operation Diagnosis 4.5.1 Diagnostic display You go to the diagnostic display from automatic or manual operation by simultaneously pressing all three keys for at least two seconds. The following table shows an overview of the displayable values. In the third column the corresponding English term from which the abbrevi- ation is derived is shown next to the German meaning unless this is self explanatory.

  • Page 106: Meaning Of The Diagnostic Values

    Operation Abbrevia- Meaning Displayable va- Unit Rest tion lues poss. Number of operating hours in Temperature range 7 0 to 4.29E9 Hours Number of operating hours in Temperature range 8 0 to 4.29E9 Hours Number of operating hours in Temperature range 9 0 to 4.29E9 Hours VENT1...
  • Page 107 Operation 4 A1CNT Alarm counter 1 5 A2CNT Alarm counter 2 Responses of alarm 1 and alarm 2 are counted with these two counters. The prerequisite is the activation of the alarms with the parameter “40.AFCT”. The counters can be reset to zero with the increment key 6 HOURS Operating hours...
  • Page 108 Operation 13 IMPUP Impulse length up 14 IMPDN Impulse length down During initialization the smallest impulse lengths are determined with which a movement of the actuator can be achieved. They are deter- mined and displayed here for the “Up”-direction and the “Down”-direc- tion.
  • Page 109 Operation 22 T1 to Number of operating hours in temperature range T1 to T9 30 T9 Statistics how long operation takes place in which temperature ranges is kept in the instrument. To do this, the measured temperature over one hour respectively is averaged and incremented in the counter which is assigned to the corresponding temperature range every hour.

  • Page 110: Online-Diagnosis

    Operation 36 WT00 to Number of operating hours in distance class WT00 to WT95 43 WT95 If the positioner is in automatic mode, statistics are constantly kept for how long a valve or a flap has been operated in which section of the setting range.
  • Page 111 Operation Error Event Parameter Fault message dis- Possible causes code setting appears when ... Limit value ... the change of direction The number of changes of 47. DCHG¸OFF change of di- counter is reset or the limit direction exceeded the set rection excee- value increased limit value.
  • Page 112 Operation 4 Monitoring of number of strokes 5 Monitoring of number of changes of direction The two values number of strokes and number of changes of direction are compared continuously with the limit values which are specified with the parameters “46. STRK” and “47. DCHG”. The fault message output responds when exceeded.

  • Page 113: Meanings Of Other Display Texts

    Operation Meanings of other display texts Notes on the tables: stands for variable numerical values Fault symbol (slash): the texts to the left and right of the slash flash alternately Reports before initializing (first commissioning): Meaning/Cause Actions Report after connecting the electrical S·...
  • Page 114 Operation Meaning/Cause Actions YEND2 only during manual initialization Move to second end position using second end position can be moved the ”+” or ”--” key Press ”operating mode” key to ack- nowledge RANGE only during manual initialization Using ”+” and ”--” keys move to the End position or measurement span other end position and press ”operat- are outwith the permitted measure-...
  • Page 115 Operation Meaning/Cause Actions d nn.n Display the positioning time ”Down” Wait, or U-->d To change the positioning time inter- rupt initialization with the ”--” key, Activate the leakage test with the ”+” NOZZL Actuator stationary (initialization inter- Positioning time can be adjusted by rupted with the ”--”...
  • Page 116 Operation Meaning/Cause Actions FS ---- ---- Fail safe (air discharge valve opened). Possible causes No communication Correct station address with master Set target mode to ”au- Target mode set to tomatic” with class 2 ”MA” master Send status ”0x80” Master sending incor- (good) rect status FS nn...

  • Page 117: Optimization Of The Control Data

    Operation Optimization of the control data The data automatically determined during initialization for control qual- ity are optimized for short duration commands with small overshoots. In special cases (e.g. extremely small and specially quick actuators or when operating with boosters) it can however occur that these data need to be revised to achieve quick responses or heavy damping.

  • Page 118: Fault Correction

    Operation Fault correction Diagnostics indicator Table In which operating mode did the fault occur? Initialization • Manual mode and automatic mode • Under which circumstances and conditions did the fault occur? Wet environment (e.g. heavy rain or constant condensation) • Vibrating fittings •...
  • Page 119 Operation Fault description (symp- Possible cause(s) Corrective actions toms) CPU test blinks in the Water in the valve manifold At the early stages the fault can be • • • display of the SIPART (from wet compressed air) corrected by subsequent operation PS2 (ca.
  • Page 120 Prevention: Mount the SIPART • shaken loose PS2 on rubber metal Table 5 CSC address (Customer Support Center) Siemens Production Automatisation S. A. CSC 1, chemin de la Sandlach B. P. 189 F--67506 Haguenau CEDEX -- France -- Tel. 0033--38890--6677 Fax 0033--38890--6688 e-mail: Hotline.ADPA1--2@khe.siemens.de...

  • Page 121: Functions/Operation Via Profibus Pa

    Care and Maintenance Functions/Operation via PROFIBUS PA System integration The positioner can be controlled and monitored by acyclic and cyclic data transmission by a control system (master). So that the positioner can be in communication as slave with the master, its address must be set up in advance.

  • Page 122: Allocate Address

    Care and Maintenance With SIMATIC PDM the process device data can be displayed, adjusted, changed, compared, checked for plausibility administered and simulated In general, we recommend the following procedure: First of all read the current settings from the device, by initiating the action “Load to PG/PC”, Check the current settings, Check the required settings,...

  • Page 123: Set Maintenance Information

    Care and Maintenance To see the values displayed, open the ”Device” menu and open the ”Read maintenance information” sub-menu. Because there is so much information, these are divided amongst several registers: Maintenance information 1 and 2 here the initialization values such as zero point P0, end value P100, positioning times etc.

  • Page 124: Operation

    Care and Maintenance Only by confirming the register ”Reset counter” by pressing the ”Reset maintenance counter” key will the following maintenance counters be reset: Number of 100% strokes (STRKS) Number of changes of direction (CHDIR) Number of fault messages (\CNT) Number of alarms 1 and 2 (A1CNT / A2CNT) 5.2.1.6 Operation...
  • Page 125 Care and Maintenance NOTE Note that the positioner will respond after the transmission with the quality ”Bad” and the status ”value constant”. On leaving this target mode and if no further master sends a setpoint to the positioner, the positioner after the set monitoring period will adopt the parameterized fail safe value.
  • Page 126 Care and Maintenance Local Overlay (LO) To allow the drive to insist on maintaining the current position, the posi- tioner can be set using the PDM to ”Local Overlay”. In this mode the positioner valves will not be activated, although they can detect any leakage.

  • Page 127: Reset

    Care and Maintenance Simulation of Simulation functions are of assistance during commissioning pieces of readbacks equipment and positioner. Process values can be generated without output of real positional values. Equally the outputs from the alarm modules and the position value of the Iy module will not be affected by them.

  • Page 128: Initialization Parameters

    Care and Maintenance To remove an positioner from the PROFIBUS line, its address should be restored to 126 using this function, so that in future it can be linked into this or another system if necessary. If a cyclic master is already in communication with the positioner, the address cannot be reset.

  • Page 129: Cyclic Data Transmission

    This means that it is pos- sible to optimise the quantity of data to be transmitted. The DMD files for all common devices are already stored in the Siemens control sys- tem, however they are also accessible over the Internet (www.ad.siemens.de/csi_e/gsd) and can be subsequently imported.
  • Page 130 Care and Maintenance PC or PG (Master class 2) Power supply PROFIBUS DP Bus termination PROFIBUS PA DP/PA Coupler DP/PA Link Splitters MPI cable (is required for commission- ing and monitoring) SIMATIC S7 (Master class 1) PA devices Figure 5-1 Example of a small PROFIBUS DP/PA system Here is a small STEP 7 program that established cyclic data transmis- sion with the positioner with PROFIBUS PA.

  • Page 131: User Data Via Profibus

    Care and Maintenance In this example all fies supported by the device are transmitted in the input or output direction. 256 (W#16#100) is selected as the initial I/O address. Legend Byte 15 15 bytes of input data consisting of the following: READBACK 5 Byte RCAS_OUT...
  • Page 132 Care and Maintenance Checkback The checkback is displayed bit-coded in 3 bytes: Meaning for ”1” Notes Device in failsafe position Position determined by parameter 46 (FSTY) Request for local operation Reports that a key has been pressed Device is operated locally Device locally parameterized (e.g.
  • Page 133 Care and Maintenance Status The status provides information about the quality of the input or output value. The format of the status is always Quality Additional information Limit value bits Quality 0: bad 1: uncertain 2: good 3: good (cascade) Grenzwertbit 0: good 1: lower limit value reached, exceeded or limited to lower limit value...
  • Page 134 Care and Maintenance Possible combinations of useful data and position in the address space. For communication of cyclic useful data between the master and the positioner you can select a combination of values during configuration: Setpoint Output (master view) Initial address SP -- Floating-point number SP -- status...
  • Page 135 Care and Maintenance Output (master view) Initial address SP -- Floating-point number SP -- status Checkback, SP Checkback, setpoint Input (master view) Initial address CHECKBACK Output (master view) Initial address SP -- Floating-point number SP -- status READBACK, Readback, position discrete, checkback, setpoint CHECKBACK, POS_D, SP Input (master view)
  • Page 136 Care and Maintenance RCAS_OUT, Remote cascade output, checkback, remote cascade input CHECKBACK, RCAS_IN Input (master view) Initial address RCAS_OUT -- Floating-point number RCAS_OUT – status CHECKBACK Output (master view) Initial address RCAS_IN -- Floating-point number RCAS_IN -- status READBACK, Readback, remote cascade output, position discrete, checkback, RCAS_OUT, setpoint, remote cascade input POS_D, CHECK-...

  • Page 137: Status

    Care and Maintenance Ouptut (master view) Initial address SP -- Floating--point number SP -- status RCAS_IN -- Floating--point number RCAS_IN – status 5.3.2.1 Status Status gives information regarding: 1. Whether the measured values can be used in the application program 2.

  • Page 138: Diagnostics

    Care and Maintenance Accompanying PDM display Cause Action status code READBACK, POS_D bad, Function block has been disa- For normal operation reinstate out of service, bled by command. Device will target mode ”AUTO” value con- move to safety position stant READBACK, POS_D uncertain, Connection is disconnected or...

  • Page 139: Diagnostics Acc. To Profibus Dp (Ddlm_Slave_Diag)

    Care and Maintenance To communicate diagnostic information standard mechanisms within the PROFIBUS--DP can be called upon and an active report made to the class 1 master. PROFIBUS--DP provides a protocol for this to con- vey information that is of higher precedence than operating data to the class 1 master.
  • Page 140 Care and Maintenance Byte Meaning for “1” Cause Action Memory error During operation the memory is Exchange the electronics. continually checked for check sum errors and read / write errors. If an error occurs, this report is generated. Device not initialized The initialization run required for Perform initialization.

  • Page 141: Service And Maintenance

    Technical Data Service and Maintenance The positioner is largely maintenance-free. The positioners are fitted with filters in the pneumatic connections as protection against coarse particles of dirt. This dirt will be deposited under pressure on to the filter and the filters may clog and impair the function of the positioner. In this case the filters can be cleaned as follows.
  • Page 142 Technical Data Important: Make sure that the same thread is used. To do this turn the screws counterclockwise until they snap into the thread audibly. Only then should you tighten the screws. 8. Replace the cover and screw it tight. 9.

  • Page 143: Technical Data

    Scope of deliver Technical Data (see following pages) SIPART PS2 PA Manual A5E00127926-03...
  • Page 144 Scope of delivery ■ (continued) Technical data Technical data Material of: SIPART PS2 SIPART PS2 EEx d • Casing SIPART PS2 PA - 6DR5 0-... (plastic) Glass-fiber-reinforced Macrolon SIPART PS2 EEx d PA - 6DR5 1-... (metal) GK-AISi12 - 6DR5 5-...
  • Page 145 Scope of deliver ■ Technical data SIPART PS2 PA Basic device Basic device Basic device Basic device without Ex protection with Ex protection with Ex protection with Ex protection EEx d (flameproof cas- EEx ia/ib EEx n ing) Explosion protection to Without EEx d EEx ia/ib...
  • Page 146 Scope of delivery ■ Technical data (continued) SIPART PS2 PA Basic device Basic device Basic device Basic device without Ex protection with Ex protection with Ex protection with Ex protection EEx d (flameproof cas- EEx ia/ib EEx n ing) Electrical data (continued) Current consumption 10.5 mA ±...
  • Page 147 Scope of deliver ■ Technical data Option modules Without Ex protection With Ex protection Electrical data Ex protection to EN 50 014, EN 50 020 and 50 021 – II 2G EEx ia/ib II C T4/T5/T6 ) II 3G EEx nA L [L] II C T6 Mounting location –...
  • Page 148 Scope of delivery ■ Technical data (continued) Option modules Without Ex protection With Ex protection Electrical data Ex protection to EN 50 014, EN 50 020 and 50 021 – II 2G EEx ia/ib II C T4/T5/T6 ) II 3G EEx nA L [L] II C T6 Mounting location –...

  • Page 149: Scope Of Delivery

    Scope of deliver Scope of Delivery The positioner and its options modules are delivered as separate units and in different versions. positioners and options modules for operation in hazardous areas and non-hazardous areas are available. These ver- sions are identified respectively by a special rating plate. WARNING In the combination of components it must be ensured that only positio- ners and options modules are combined which are approved for the...

  • Page 150: Ordering Data

    Scope of delivery Ordering Data ■ ■ Ordering data Order No. Ordering data Order No. SIPART PS2 (PA) electropneu- 6DR5 7 7 7 7 7 7 7 7 SIPART PS2 (PA) electropneu- 6DR5 7 7 7 7 7 7 7 7 matic positioner matic positioner see left...

  • Page 151: Scope Of Delivery Of Options

    Scope of deliver Scope of delivery of options Option Order number SIA module non Ex 6DR4004-8G 1) 2) SIA module Ex (CENELEC / FM) 6DR4004-6G Alarm module non Ex 6DR4004-8A Alarm module Ex (PTB) 6DR4004-6A Alarm module Ex (FM) 6DR4004-7A -module non Ex 6DR4004-8J -module Ex (PTB)
  • Page 152 Scope of delivery SIPART PS2 PA Manual A5E00127926-03...

  • Page 153: Index

    Einführung Index Diagnostic display, Changing the operating mode, 88 Accessories, 37 Diagnostic values, Meaning of the ~, 104 Alarm function, 98 Digital input, electrical connection, 60, 62, 63 Alarm module, 36, 63 Digital output, electrical connection, 60, 62, Ex, 62 non Ex, 60 Dimensional drawings, 39 Application...
  • Page 154 Einführung Installation positions, favorable and PROFIBUS unfavorable, 43, 45 Bus topology, 17 Instrument identification, 39 Transmission method, 17 PROFIBUS PA, functions and operation, 119 Purge air switching, 28 Jy module, 36 Ex, 61 Qualified Personnel, 9 Jy module non Ex, 60 Jy--Modul, Ex, 63 Regulations, 12 Reset, 101...

  • Page 155: Appendix

    The file is available in the Internet: www.ad.siemens.de/csi_e/gsd Please find above the printed version of the GSD: ;********************************************************************* GSD Datei für SIPART PS 2 PA”, SIEMENS AG MLFB: 6DR410x-xx and 6DR55xx Stand: 09.08.01 SIS18079.GSE ;********************************************************************* ; ********************************************************* ;...
  • Page 156 Scope of delivery OrderNumber = ”6DR410* / 6DR55**” Info_Text = ”Electropneumatic positioner, PROFIBUS PA Profile 3.0” Freeze_Mode_supp ; 0 = no Freeze Mode supported Sync_Mode_supp ; 0 = no Sync Mode supported Auto_Baud_supp Set_Slave_Add_supp ; 1 = Set Slave AddrFunction supported Min_Slave_Intervall = 200 ;...
  • Page 157 Scope of delivery Info_Text = ”Setpoint” EndModule ;Extended identifier formats Module = ”READBACK + POS_D, SP” 0xC6,0x84,0x86,0x08,0x05,\ 0x08,0x05,0x05,0x05 1 ; Module-Reference Info_Text = ”Readback, discrete Position, Setpoint” EndModule Module = ”CHECKBACK, SP” 0xC3,0x84,0x82,0x08,0x05,\ 0x0A 2 ; Module-Reference Info_Text = ”Checkback and Setpoint” EndModule Module = ”READBACK+POS_D+CHECKBACK, SP”...

  • Page 158: Literature And Catalogs

    Issued by Order number PNO guide PNO-- 2.091 PROFIBUS PA Technologiefabrik Haid-und-Neu-Str. 7 D--76131 Karlsruhe SIMATIC field technology package Siemens AG Internet address: http://www.ad.siemens.de:80 80/virlib/html_00/ doc/index.htm on: Profibus descriptions (free) / system description / PA system description, German ST PI catalog...

  • Page 159: Certificates

    Scope of delivery 10.3 Certificates 10.3.1 EC Declaration of Conformity (EEx d) SIPART PS2 PA Manual A5E00127926-03...

  • Page 160: Ec Declaration Of Conformity

    Scope of delivery 10.3.2 EC Declaration of Conformity SIPART PS2 PA Manual A5E00127926-03...

  • Page 161: Ec Type-Examination Certificate Ptb 99 Atex 1101 (Eex D)

    Scope of delivery 10.3.3 EC Type-Examination Certificate PTB 99 ATEX 1101 (EEx d) (type of protection “flameproof enclosure”) SIPART PS2 PA Manual A5E00127926-03...
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  • Page 164: Ec Type-Examination Certificate Tüv 00 Atex 1654

    Scope of delivery 10.3.4 EC Type-Examination Certificate TÜV 00 ATEX 1654 SIPART PS2 PA Manual A5E00127926-03...
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  • Page 172: Statement Of Conformity Tüv 01 Atex 1786

    Scope of delivery 10.3.5 Statement of conformity TÜV 01 ATEX 1786 X SIPART PS2 PA Manual A5E00127926-03...
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  • Page 175: Fm Approval Report (Eex D)

    Scope of delivery 10.3.6 FM Approval Report (EEx d) SIPART PS2 PA Manual A5E00127926-03...
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  • Page 177: Fm Approval Report

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  • Page 179: Csa Certificate Of Compliance

    Scope of delivery 10.3.8 CSA Certificate of Compliance SIPART PS2 PA Manual A5E00127926-03...
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  • Page 181: Control Drawing A5E00065622D

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  • Page 191: Control Drawing A5E00065622Aa

    Scope of delivery 10.3.10 Control Drawing A5E00065622AA SIPART PS2 PA Manual A5E00127926-03...
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