5nolu Ibs Vana Pozisyoner - Sipart Ps2

Introduction 1
Safety information 2
Description 3
SIPART Installing/mounting 4
Connection 5
Electropneumatic positioners
SIPART PS2 with 4 to 20 mA/HART Operating 6
Commissioning 7
Operating Instructions Parameter assignment 8
Functional safety 9
Service and maintenance 10
Diagnostics and
troubleshooting 11
Technical data 12
Dimension drawings 13
Spare parts/accessories/
scope of delivery 14
Product documentation and
support A
External position detection B
Pressure gauge block C
Sealing plug / thread adapter D
Booster E
6DR50.. Positioner with remote
6DR51.. control electronics F
6DR52..
6DR53..
6DR59.. Abbreviations G
11/2019
A5E00074631-AE
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may 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:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG Document order number: A5E00074631 Copyright © Siemens AG 2019.

Digital Industries Ⓟ 01/2020 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Introduction.................................................................................................................................................13
1.1 Purpose of this documentation...............................................................................................13
1.2 Scope of documentation ........................................................................................................13
1.3 Document history ...................................................................................................................14
1.4 Designated use ......................................................................................................................15
1.5 Product compatibility ..............................................................................................................15
1.6 Checking the consignment.....................................................................................................16
1.7 Security information ...............................................................................................................16
1.8 Transportation and storage ....................................................................................................17
1.9 Notes on warranty ..................................................................................................................17
2 Safety information.......................................................................................................................................19
2.1 Precondition for use ...............................................................................................................19
2.2 Warning symbols on the device .............................................................................................19
2.3 Laws and directives................................................................................................................19
2.4 Conformity with European directives......................................................................................20
2.5 Product approval and UL compliance ....................................................................................20
2.6 Improper device modifications ...............................................................................................20
2.7 Improper modification on positioner 6DR5...6........................................................................21
2.8 Requirements for special applications ...................................................................................21
2.9 Use in hazardous areas .........................................................................................................22
3 Description..................................................................................................................................................23
3.1 Function .................................................................................................................................23
3.2 Structure.................................................................................................................................23
3.2.1 Overview of structure .............................................................................................................23
3.2.2 Nameplate layout ...................................................................................................................26
3.2.3 Explanation of Ex information ................................................................................................27
3.3 Device components................................................................................................................28
3.3.1 Overview of device components ............................................................................................28
3.3.2 Basic electronics ....................................................................................................................29
3.4 Mode of operation ..................................................................................................................30
3.4.1 Block circuit diagram for single-acting or double-acting actuators .........................................32
3.4.2 Mode of operation of the HART function................................................................................33
3.4.3 HART system configuration ...................................................................................................33
3.4.4 SIMATIC PDM........................................................................................................................34
SIPART PS2 with 4 to 20 mA/HART

Operating Instructions, 11/2019, A5E00074631-AE 3
Table of contents
4 Installing/mounting......................................................................................................................................37
4.1 Basic safety instructions.........................................................................................................37
4.1.1 Proper mounting.....................................................................................................................39
4.1.1.1 Loss of explosion protection...................................................................................................39
4.2 Mounting to linear actuator.....................................................................................................40
4.3 Mounting to part-turn actuator................................................................................................45
4.4 Setting and locking the transmission ratio..............................................................................48
4.5 Installing option modules........................................................................................................51
4.5.1 General information on installing option modules ..................................................................51
4.5.1.1 Opening the standard and intrinsically safe version...............................................................52
4.5.1.2 Closing the standard and and intrinsically safe version .........................................................53
4.5.1.3 Opening the device version with "flameproof enclosure" .......................................................55
4.5.1.4 Closing the device version with "flameproof enclosure".........................................................58
4.5.2 Digital I/O Module (DIO) 6DR4004-6A / -8A ..........................................................................59
4.5.3 Analog Output Module (AOM) 6DR4004-6J / -8J...................................................................60
4.5.4 Inductive Limit Switches (ILS) 6DR4004 6G / -8G .................................................................62
4.5.4.1 Inductive Limit Switches (ILS) - Mode of operation and equipment features .........................62
4.5.4.2 Installation procedure for Inductive Limit Switches (ILS) .......................................................63
4.5.4.3 Setting limits...........................................................................................................................64
4.5.5 Mechanic Limit Switches (MLS) 6DR4004-6K / -8K...............................................................65
4.5.5.1 Mechanic Limit Switches (MLS) - Mode of operation and equipment features ......................65
4.5.5.2 Installation procedure for Mechanic Limit Switches (MLS) ....................................................66
4.5.5.3 Setting limits...........................................................................................................................67
4.5.6 Internal NCS module (iNCS) 6DR4004-5L / -5LE ..................................................................68
4.5.7 Analog Input Module (AIM) 6DR4004-6F / -8F ......................................................................71
5 Connection .................................................................................................................................................75
5.1 Basic safety instructions.........................................................................................................75
5.2 Electrical wiring ......................................................................................................................79
5.2.1 Connection diagram for basic electronics ..............................................................................79
5.2.2 Connection diagram split range .............................................................................................82
5.2.3 Option modules ......................................................................................................................83
5.2.3.1 Digital I/O Module (DIO) 6DR4004-6A / -8A ..........................................................................83
5.2.3.2 Analog Output Module (AOM) 6DR4004-6J / -8J...................................................................84
5.2.3.3 Inductive Limit Switches (ILS) 6DR4004-6G / -8G.................................................................84
5.2.3.4 Mechanical Limit Switches (MLS) 6DR4004-6K / -8K............................................................85
5.2.3.5 Analog Input Module (AIM) 6DR4004-6F / -8F ......................................................................87
5.2.4 Optional version M12 device plug ..........................................................................................88
5.2.4.1 In the basic unit ......................................................................................................................88
5.2.4.2 In the basic unit with Analog Output Module (AOM) 6DR4004-6J/-8J (-Z D53).....................89
5.2.4.3 In the basic unit with Position Transmitter (-Z D54) ...............................................................89
5.2.4.4 In the basic unit with Digital I/O Module (DIO) 6DR4004-6A/-8A (-Z D55) ............................89
5.2.4.5 In the basic unit with Inductive Limit Switches (ILS) 6DR4004-6G/-8G (-Z D56)...................90
5.2.4.6 In the basic unit with Mechanic Limit Switches (MLS) 6DR4004-6K (-Z D57) .......................90
5.3 Pneumatic connection............................................................................................................90
5.3.1 Basic safety instructions for the pneumatic connection .........................................................90
5.3.2 Pneumatic connection in non-flameproof enclosure ..............................................................91
5.3.2.1 Structure of pneumatic connection.........................................................................................91

4 Operating Instructions, 11/2019, A5E00074631-AE
Table of contents
5.3.2.2 Integrated pneumatic connection ...........................................................................................91

5.3.3 Pneumatic connection in the flameproof enclosure ...............................................................92
5.3.4 Behavior in case of failure of the electrical auxiliary power and/or the supply pressure PZ ......93
5.4 Restrictors ..............................................................................................................................93
6 Operating....................................................................................................................................................95
6.1 Operating elements................................................................................................................95
6.1.1 Display ...................................................................................................................................95
6.1.2 Buttons ...................................................................................................................................96
6.1.3 Firmware version ...................................................................................................................97
6.2 Operating modes....................................................................................................................98
6.2.1 Overview of operating modes ................................................................................................98
6.2.2 Changing the operating mode................................................................................................98
6.2.3 Overview of configuration.......................................................................................................99
6.2.4 Description of operating modes .............................................................................................99
6.2.5 Optimization of controller data .............................................................................................101
7 Commissioning .........................................................................................................................................105
7.1 Basic safety instructions.......................................................................................................105
7.2 Overview ..............................................................................................................................107
7.3 Sequence of automatic initialization.....................................................................................109
7.4 RUN 1 sequence..................................................................................................................110
7.5 RUN 2 sequence with linear actuators.................................................................................111
7.6 RUN 2 sequence with part-turn actuators ............................................................................112
7.7 RUN 3 to 5 sequence...........................................................................................................113
7.8 Setting the friction clutch ......................................................................................................115
7.9 Purge air switching...............................................................................................................117
7.10 Commissioning linear actuators ...........................................................................................117
7.10.1 Preparing linear actuators for commissioning ......................................................................117
7.10.2 Automatic initialization of linear actuators ............................................................................119
7.10.3 Manual initialization of linear actuators ................................................................................121
7.11 Commissioning part-turn actuators ......................................................................................124
7.11.1 Preparing part-turn actuators for commissioning .................................................................124
7.11.2 Automatic initialization of part-turn actuators .......................................................................125
7.11.3 Manual initialization of part-turn actuators ...........................................................................126
7.12 Canceling initialization..........................................................................................................129
7.13 Device replacement .............................................................................................................129
8 Parameter assignment .............................................................................................................................133
8.1 Introduction to parameter assignment section .....................................................................133
8.2 Configuration schematic for parameter operating principle..................................................134
8.3 Tabular overview of the parameters.....................................................................................135
8.3.1 Overview of initialization parameters 1 to 5 .........................................................................135
8.3.2 Overview of application parameters 6 to 52.........................................................................136

Table of contents
8.3.3 Overview of advanced diagnostic parameters A to U ..........................................................139

8.4 Description of parameters ....................................................................................................143
8.4.1 Initialization parameters 1 to 5 .............................................................................................143
8.4.1.1 '1.YFCT' type of actuator......................................................................................................143
8.4.1.2 '2.YAGL' Rated angle of rotation of feedback ......................................................................145
8.4.1.3 '3.YWAY' Range of stroke....................................................................................................145
8.4.1.4 '4.INITA' Initialization (automatic).........................................................................................146
8.4.1.5 '5.INITM' Initialization (manual) ............................................................................................146
8.4.2 Application parameters 6 to 52 ............................................................................................147
8.4.2.1 '6.SCUR' Current range of setpoint......................................................................................147
8.4.2.2 '7.SDIR' Setpoint direction ...................................................................................................147
8.4.2.3 '8.SPRA' Setpoint split range start / '9.SPRE' Setpoint split range start end .......................147
8.4.2.4 '10.TSUP' Setpoint ramp UP / '11.TSDO' Setpoint ramp DOWN.........................................148
8.4.2.5 '12.SFCT' Setpoint function..................................................................................................149
8.4.2.6 '13.SL0' ... '33.SL20' Setpoint turning point..........................................................................149
8.4.2.7 '34.DEBA' Deadband of closed-loop controller ....................................................................150
8.4.2.8 '35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit.........151
8.4.2.9 '37.YNRM' Standardization of manipulated variable ............................................................151
8.4.2.10 '38.YDIR' Direction of manipulated variable for display and position feedback ...................153
8.4.2.11 '39.YCLS' Tight closing/fast closing with manipulated variable............................................153
8.4.2.12 '40.YCDO' Value for tight closing/fast closing Down............................................................154
8.4.2.13 '41.YCUP' Value for tight closing/fast closing Up.................................................................154
8.4.2.14 '42.BIN1' / '43.BIN2' digital input function.............................................................................155
8.4.2.15 '44.AFCT' Alarm function .....................................................................................................156
8.4.2.16 '45.A1' / '46.A2' Response threshold of alarm......................................................................158
8.4.2.17 '47.\\FCT' Function of the fault message output...................................................................158
8.4.2.18 '48.\\TIM' Monitoring period for setting of fault message 'Control deviation' ........................159
8.4.2.19 '49.\\LIM' Response threshold of fault message 'Control deviation' .....................................159
8.4.2.20 '50.PRST' Preset..................................................................................................................160
8.4.2.21 '51.PNEUM' Pneumatics type ..............................................................................................160
8.4.2.22 '52.XDIAG' Activating for extended diagnostics ...................................................................162
8.4.3 Advanced diagnostic parameters A to U..............................................................................163
8.4.3.1 Partial stroke test 'A.\\PST'...................................................................................................163
8.4.3.2 Monitoring of dynamic control valve behavior 'b.\\DEVI' ......................................................168
8.4.3.3 Monitoring/compensation of pneumatic leakage 'C.\\LEAK'.................................................170
8.4.3.4 Monitoring of stiction (slipstick) 'd.\\STIC'.............................................................................173
8.4.3.5 Monitoring of deadband 'E.\\DEBA'......................................................................................175
8.4.3.6 Monitoring of lower endstop 'F.\\ZERO' ...............................................................................176
8.4.3.7 Monitoring the upper endstop 'G.\\OPEN' ............................................................................177
8.4.3.8 Monitoring the lower limit temperature 'H.\\TMIN' ................................................................179
8.4.3.9 Monitoring the upper limit temperature 'J.\\TMAX' ...............................................................181
8.4.3.10 Monitoring of number of total strokes 'L.\\STRK'..................................................................182
8.4.3.11 Monitoring of number of changes in direction 'O.\\DCHG' ...................................................184
8.4.3.12 Monitoring the position average value 'P.\\PAVG'................................................................185
8.4.3.13 Pressure monitoring 'U.\\PRES' ...........................................................................................188
8.5 Overview of the assignment of the HART variables.............................................................189
9 Functional safety ......................................................................................................................................191
9.1 Range of applications for functional safety ..........................................................................191
9.2 Safety function .....................................................................................................................191

Table of contents
9.3 Safety Integrity Level (SIL)...................................................................................................193

9.4 Settings ................................................................................................................................194
9.5 Safety characteristics ...........................................................................................................195
9.6 Maintenance/check ..............................................................................................................195
10 Service and maintenance .........................................................................................................................197
10.1 Basic safety instructions.......................................................................................................197
10.1.1 Maintenance.........................................................................................................................197
10.2 Cleaning ...............................................................................................................................198
10.2.1 Positioners 6DR5..0, 6DR5..3 and 6DR5..5.........................................................................198
10.2.2 Positioners 6DR5..1, 6DR5..2 and 6DR5..6.........................................................................199
10.3 Maintenance and repair work...............................................................................................199
10.4 Replace basic electronics ....................................................................................................200
10.5 Replace pneumatic block .....................................................................................................202
10.6 Replace the pressure sensor module ..................................................................................203
10.7 Return procedure .................................................................................................................206
10.8 Disposal ...............................................................................................................................206
11 Diagnostics and troubleshooting ..............................................................................................................207
11.1 Output of system messages in the display...........................................................................207
11.1.1 System messages before initialization .................................................................................207
11.1.2 System messages during initialization .................................................................................207
11.1.3 System messages when exiting the Configuration mode ....................................................210
11.1.4 System messages during operation.....................................................................................210
11.2 Diagnostics...........................................................................................................................212
11.2.1 Display of diagnostics values ...............................................................................................212
11.2.2 Saving the diagnostics values..............................................................................................212
11.2.3 Overview of diagnostics values............................................................................................213
11.2.4 Meaning of the diagnostics values .......................................................................................215
11.2.4.1 Diagnostic value '1.STRKS - Number of total strokes' .........................................................215
11.2.4.2 Diagnostic value '2.CHDIR - Number of changes in direction' .............................................215
11.2.4.3 Diagnostic value '3.\\CNT - Number of fault messages'.......................................................215
11.2.4.4 Diagnostic value '4.A1CNT - Number of alarms 1' / '5.A2CNT - Number of alarms 2' .........215
11.2.4.5 Diagnostic value '6.HOURS - Number of operating hours' ..................................................216
11.2.4.6 Diagnostic value '7.HOURR - Resettable operating hours counter'.....................................216
11.2.4.7 Diagnostic value '8.WAY - Determined travel'......................................................................216
11.2.4.8 Diagnostic value '9.TUP - Travel time up' / '10.TDOWN - Travel time down' ......................216
11.2.4.9 Diagnostic value '11.LEAK - Leakage test' ..........................................................................217
11.2.4.10 Diagnostic value '12.PST - Monitoring of partial stroke test' ................................................218
11.2.4.11 Diagnostic value '13.PRPST' - Time since last partial stroke test' .......................................219
11.2.4.12 Diagnostic value '13.PRPST - Time since last partial stroke test' (version with pressure
sensor module) ....................................................................................................................219
11.2.4.13 Diagnostic value '14.NXPST - Time until next partial stroke test' ........................................219
11.2.4.14 Diagnostics value '15.DEVI - Dynamic control valve behavior' ............................................220
11.2.4.15 Diagnostic value '16.ONLK - Pneumatic leakage'................................................................220
11.2.4.16 Diagnostic value '17.STIC - Stiction (slipstick)' ....................................................................220

Table of contents
11.2.4.17 Diagnostic value '18.ZERO - Lower endstop'.......................................................................220

11.2.4.18 Diagnostic value '19.OPEN - Upper endstop' ......................................................................221
11.2.4.19 Diagnostic value '20.PAVG - Average value of position'......................................................221
11.2.4.20 Diagnostic value '21.P0 - Potentiometer value of lower endstop (0%)' / '22.P100 -
Potentiometer value of upper endstop (100%)' ....................................................................221
11.2.4.21 Diagnostic value '23.IMPUP - Pulse length up' / '24.IMPDN - Pulse length down' .............223
11.2.4.22 Diagnostic value '25.PAUTP - Pulse interval'.......................................................................223
11.2.4.23 Diagnostic value '26.DBUP - Deadband up' / '27.DBDN - Deadband down'........................223
11.2.4.24 Diagnostic value '28.SSUP - Slow step zone up' / '29.SSDN - Slow step zone down' ........224
11.2.4.25 Diagnostic value '30.TEMP - Current temperature'..............................................................224
11.2.4.26 Diagnostic value '31.TMIN - Minimum temperature' / '32.TMAX - Maximum temperature'....224
11.2.4.27 Diagnostic value '33.T1' ... '41.T9' - Number of operating hours in the temperature range
1 to 9 ....................................................................................................................................225
11.2.4.28 Diagnostic value '42.VENT1' / '43.VENT2' ..........................................................................225
11.2.4.29 Diagnostic value '44.VEN1R' / '45.VEN2R' ..........................................................................225
11.2.4.30 Diagnostic value '46.STORE - Save maintenance data' ......................................................226
11.2.4.31 Diagnostic value '47.PRUP - Prediction up' / '48.PRDN - Prediction down' .........................226
11.2.4.32 Diagnostic value '49.WT00' ... '56.WT95' - Number of operating hours in the travel range
WT00 to WT95 .....................................................................................................................227
11.2.4.33 Diagnostic value '57.LKPUL - Length of the leakage compensation pulse' .........................227
11.2.4.34 Diagnostic value '58.LKPER - Period of the leakage compensation pulse' .........................227
11.2.4.35 Diagnostic value '59.mA - Setpoint current' .........................................................................228
11.2.4.36 Diagnostic value '60.PZ Supply pressure (PZ)'....................................................................228
11.2.4.37 Diagnostic value '63.PZMAX Supply pressure (PZ) min/max pointer ..................................228
11.2.4.38 Diagnostic value '64.N_MIN Event counter' .........................................................................228
11.3 Online diagnostics................................................................................................................229
11.3.1 Overview of error codes .......................................................................................................229
11.3.2 Overview of online diagnostics.............................................................................................231
11.3.3 XDIAG parameter ................................................................................................................231
11.3.4 Meaning of error codes ........................................................................................................232
11.3.4.1 1 Remaining control deviation..............................................................................................232
11.3.4.2 2 Device not in "Automatic" mode ........................................................................................232
11.3.4.3 3 digital inputs BIN1 or BIN2 active......................................................................................232
11.3.4.4 4 Monitoring the number of total strokes..............................................................................232
11.3.4.5 5 Monitoring the number of changes in direction .................................................................232
11.3.4.6 6 Monitoring the lower endstop / 7 Monitoring the upper endstop .......................................232
11.3.4.7 8 Monitoring deadband ........................................................................................................233
11.3.4.8 9 Partial stroke test ..............................................................................................................233
11.3.4.9 10 Monitoring of dynamic control valve behavior .................................................................233
11.3.4.10 11 Monitoring/compensation of pneumatic leakage ............................................................234
11.3.4.11 12 Monitoring of stiction (slipstick) .......................................................................................234
11.3.4.12 13 Monitoring the lower limit temperature ............................................................................234
11.3.4.13 14 Monitoring the upper limit temperature ...........................................................................234
11.3.4.14 15 Monitoring the position average value ............................................................................234
11.3.4.15 16 Monitoring the plausibility of values for the partial stroke test.........................................234
11.3.4.16 17 Monitoring of pressure sensor module............................................................................234
11.3.4.17 18 Monitoring low limit of supply pressure (PZLIM) .............................................................234
11.3.4.18 19 Monitoring specific limits of supply pressure...................................................................234
11.4 Fault and remedy .................................................................................................................235

Table of contents
12 Technical data ..........................................................................................................................................239

12.1 HART operating conditions ..................................................................................................239
12.2 Pneumatic data ....................................................................................................................239
12.3 Construction .........................................................................................................................240
12.4 Controller..............................................................................................................................242
12.5 Certificates and approvals....................................................................................................243
12.5.1 Breakdown of the article numbers........................................................................................243
12.5.2 Basic unit and optional modules ..........................................................................................244
12.5.3 Maximal permissible ambient temperature ranges ..............................................................245
12.6 Electrical data.......................................................................................................................246
12.7 Electrical data for pressure sensor module..........................................................................248
12.8 Communication (HART) .......................................................................................................248
12.9 Technical data for natural gas as actuator medium .............................................................249
12.10 Option modules ....................................................................................................................250
12.10.1 Digital I/O Module (DIO) 6DR4004-6A / -8A ........................................................................250
12.10.2 Analog Output Module (AOM) 6DR4004-6J / -8J.................................................................251
12.10.3 Inductive Limit Switches (ILS) 6DR4004-6G / -8G...............................................................252
12.10.4 Mechanic Limit Switches (MLS) 6DR4004-6K / -8K.............................................................253
12.10.5 Analog Input Module (AIM) 6DR4004-6F / -8F ....................................................................254
12.10.6 Internal NCS module 6DR4004-5L / 6DR4004-5LE.............................................................254
12.10.7 Other technical specifications ..............................................................................................255
13 Dimension drawings .................................................................................................................................257
13.1 Positioner in non-flameproof enclosure................................................................................257
13.2 Terminal strip for enclosures 6DR5..0 and 6DR5..3 ............................................................258
13.3 Positioner in flameproof enclosure.......................................................................................259
14 Spare parts/accessories/scope of delivery ...............................................................................................261
14.1 Overview ..............................................................................................................................261
14.2 Spare parts...........................................................................................................................263
14.3 Scope of delivery Mechanic Limit Switches (MLS) ..............................................................266
14.4 Scope of delivery Analog Input Module (AIM)......................................................................267
14.5 Accessories..........................................................................................................................268
14.6 Order data ............................................................................................................................268
A Product documentation and support.........................................................................................................269
A.1 Product documentation ........................................................................................................269
A.2 Technical support.................................................................................................................270
B External position detection .......................................................................................................................271
B.1 Introduction ..........................................................................................................................271
B.2 Non-Contacting Sensor........................................................................................................272

Table of contents
B.2.1 Principle of operation of NCS...............................................................................................272

B.2.2 Mounting the NCS................................................................................................................273
B.2.2.1 Mounting on part-turn actuator ............................................................................................274
B.2.2.2 Mounting on linear actuator up to 14 mm (0.55 inch)...........................................................276
B.2.2.3 Mounting on linear actuator > 14 mm (0.55 inch).................................................................278
B.2.3 Connecting NCS to Analog Input Module (AIM)...................................................................281
B.2.4 Commissioning of NCS ........................................................................................................282
B.2.4.1 Prerequisites / default settings .............................................................................................282
B.2.4.2 Initialization of part-turn actuators ........................................................................................283
B.2.4.3 Initializing linear actuators with a stroke range up to 14 mm (0.55 inch) .............................283
B.2.4.4 Initializing linear actuators with a stroke range > 14 mm (0.55 inch) ...................................283
B.2.5 Technical specifications NCS...............................................................................................283
B.2.6 Dimensional drawing of non-contacting sensor ...................................................................285
B.2.7 NCS sensor scope of delivery..............................................................................................285
B.2.7.1 Scope of delivery of NCS for part-turn actuators .................................................................285
B.2.7.2 Scope of delivery of NCS for linear actuators up to 14 mm (0.55 inch) . .............................286
B.2.7.3 Scope of delivery of NCS for linear actuators > 14 mm (0.55 inch) . ...................................287
B.3 External position detection ...................................................................................................288
B.3.1 Mode of operation for external position detection ................................................................288
B.3.2 Installation of external position detection system.................................................................288
B.3.3 Connecting to Analog Input Module (AIM) ...........................................................................289
B.3.4 Technical specifications of the external position detection system ......................................289
B.3.4.1 Rated conditions for external position detection ..................................................................289
B.3.4.2 Electrical data for external position detection.......................................................................289
C Pressure gauge block...............................................................................................................................295
D Sealing plug / thread adapter ...................................................................................................................297
D.1 Intended use of accessory part ............................................................................................297
D.2 Safety instructions for accessory part ..................................................................................297
D.3 Technical specifications of accessory part...........................................................................298
D.4 Dimensional drawings for accessory part ............................................................................299
E Booster .....................................................................................................................................................301
E.1 Booster introduction .............................................................................................................301
E.2 Mounting a booster ..............................................................................................................301
E.3 Booster commissioning ........................................................................................................305
E.4 Booster dimension drawings ................................................................................................308
E.4.1 For positioners in non-flameproof enclosure........................................................................308
E.4.2 For positioners in flameproof enclosure ...............................................................................309
E.5 Technical specifications of booster ......................................................................................309
F Positioner with remote control electronics ................................................................................................311
F.1 Introduction to remote control electronics ............................................................................311
F.2 19" slide-in module...............................................................................................................311
F.2.1 Description of 19" slide-in module 4 to 20 mA .....................................................................311
F.2.2 Connecting the 19" slide-in module 4 to 20 mA ...................................................................312
F.2.2.1 Grounding concept of 19" slide-in module 4 to 20 mA .........................................................312

Table of contents
F.2.2.2 Electrical connection of 19" slide-in module 4 to 20 mA ......................................................314

F.2.3 Technical specifications of 19" slide-in module 4 to 20 mA .................................................316
F.2.4 Dimensional drawing of 19" slide-in module 4 to 20 mA ......................................................318
F.2.5 Scope of delivery of remote control electronics ...................................................................318
F.3 Positioner without basic electronics 6DR5910 .....................................................................318
G Abbreviations............................................................................................................................................321
G.1 Abbreviations for positioners................................................................................................321
G.2 Abbreviations for functional safety .......................................................................................322
Glossary ...................................................................................................................................................325
Index.........................................................................................................................................................333

Table of contents

Introduction 1
1.1 Purpose of this documentation
These instructions contain all information required to commission and use the device. Read the
instructions carefully prior to installation and commissioning. In order to use the device
correctly, first review its principle of operation.
The instructions are aimed at persons mechanically installing the device, connecting it
electronically, configuring the parameters and commissioning it, as well as service and
maintenance engineers.
1.2 Scope of documentation
Article no. Product

6DR50.. SIPART PS2, 2-wire (4 mA to 20 mA), without HART
6DR51.. SIPART PS2, 2-wire (4 mA to 20 mA), with HART
6DR52.. SIPART PS2, 2-wire, 3-wire, 4-wire (0/4 to 20 mA), with HART
6DR53.. SIPART PS2, 2-wire, 3-wire, 4-wire (0/4 mA to 20 mA), without HART
6DR5910-* SIPART PS2 without basic electronics with Position Transmitter and
pneumatics unit
A5E00151560 19" slide-in module with operating and control unit; 4 to 20 mA with 2-wire
connection
6DR4004-6A / -8A Digital I/O Module (DIO)
6DR4004-6F / -8F Analog Input Module (AIM)
6DR4004-6J / -8J Analog Output Module (AOM)
6DR4004-6G / -8G Inductive Limit Switches (ILS)
6DR4004-6K / -8K Mechanic Limit Switches (MLS)
6DR4004-5L / -5LE Internal NCS module
6DR4004-6N* / -8N* NCS sensor
6DR4004-1ES ... -4ES Position Transmitter
6DR4004-1R / -2R / -1RN / Pneumatic terminal strip
-2RN
6DR4004-8D and Installation for NAMUR part-turn actuators
TGX:16300-1556
6DR4004-8V / -8L / -8VK / Mounting kit for NAMUR linear actuator
-8VL
6DR4004-1RJ/K/P/Q and Booster
6DR4004-2RJ/K/P/Q

Introduction
1.3 Document history
1.3 Document history

The table shows the most important changes in the documentation compared to the previous
edition.
Edition Note
11/2019 ● New: Scope of documentation (Page 13)
● In the entire operating instructions: Option modules renamed
● In the entire operating instructions: Binary output renamed to digital output; bi‐
nary input renamed to digital input
● Section "Installing/mounting (Page 37)"
– Change in figure for option module "Analog Output Module (AOM)
6DR4004-6J / -8J (Page 60)"
– Text change for option module "Analog Input Module (AIM) 6DR4004-6F / -8F
(Page 71)"
● Section "Connection (Page 75)"
– Change in figure for option module "Analog Input Module (AIM)
6DR4004-6F / -8F (Page 87)"
– Terminology change:
"Plug M12" renamed to "Device plug M12";
"Outputs" and "Alarm outputs" renamed to "Digital outputs A1 and A2";
Pneumatic connection (Page 90): "Pneumatic auxiliary power" renamed to
"Supply pressure PZ"
– Terminological and textual revision of "Behavior in case of failure of the elec‐
trical auxiliary power and/or the supply pressure PZ (Page 93)"
● "Commissioning" section
– Change to the procedure in the flameproof enclosure Ex d for "Setting the
friction clutch (Page 115)":
– Commissioning of a tight closing valve with "Automatic initialization of linear
actuators (Page 119)" and "Automatic initialization of part-turn actuators
(Page 125)"
● The "Alarm, error and system messages" section is now called "Diagnostics and
troubleshooting (Page 207)"
– Format change in "Fault and remedy (Page 235)" section, tables were sum‐
marized into a single table.
● Section "Technical data (Page 239)"
– Section "Explosion protection" is now titled "Certificates and approvals
(Page 243)"; entire section has been revised terminologically; table header
for "Basic unit and optional modules (Page 244)" has been changed.
– Section "Electrical data for pressure sensor module (Page 248)" completely
revised
● Section "Spare parts/accessories/scope of delivery (Page 261)": Replacement
part "2-wire, Ex, with HART" added
● Section "External position detection (Page 271)": 6DR4004-1ES to -4ES added,
terminology adapted, C73451-A430-D78 no longer exists and was removed.
● Section "Booster (Page 301)": Texts revised, procedures for standard device and
Ex d device combined.

Introduction
1.5 Product compatibility
Edition Note
01/2019 ● Changes for FW 5.02.00, HART device revision 7
● Ex "nA" (non-sparking equipment) is replaced by Ex "ec" (increased safety)
● Option -Z P01 Extended diagnostics supported by pressure sensors
– Parameter assignment: U.\\PRES (Page 188)
– Diagnostics values: 60.PZ, 63.PZMAX und 64.N_Min (Page 228)
– Online diagnostics: Error codes 17 to 19 (Page 234)
Section "Installing/mounting (Page 37)"
– New markings on the lever with carrier pin (Page 40)
– Revised section "Setting and locking the transmission ratio (Page 48)"
● Section "Pneumatic connection (Page 90)"
– Revised section "Behavior in case of failure of the electrical auxiliary power
and/or the supply pressure PZ (Page 93)"
● Section "Commissioning (Page 105)"
– Revised section "Setting the friction clutch (Page 115)"
● Section "Service and maintenance (Page 197)"
– Section "Replacing the basic electronics" with the "Fail in Place" function has
been revised and is now called "Replace basic electronics (Page 200)"
– New section "Replace pneumatic block (Page 202)" and "Replace the pres‐
sure sensor module (Page 203)"
● Section "Technical data (Page 239)"
– Explosion protection (Page 243) restructured and contains a breakdown of
the article number
● Section "Spare parts/accessories/scope of delivery (Page 261)" extended
1.4 Designated use

Use the device in accordance with the information on the nameplate and in the Technical data
(Page 239).
1.5 Product compatibility

The following table describes the compatibility between document output, device revision,
engineering system and associated Electronic Device Description (EDD).
Manual Comments Device revision Compatible version of device integration package

edition
11/2019 New manual FW: 5.02.00 or higher SIMATIC PDM V9.0 EDD: 23.00.00 or higher
edition Device revision 7 or higher SIMATIC PDM V8.2 SP1 EDD: 23.00.00 or higher
AMS Device Manager V12.5 EDD: 23.00.00 or higher
SITRANS DTM V4.1 EDD: 23.00.00 or higher
Field communicator EDD: 23.00.00 or higher

Introduction
1.7 Security information
Manual Comments Device revision Compatible version of device integration package

edition
05/2019 New device FW: 5.02.00 or higher SIMATIC PDM V9.0 EDD: 23.00.00 or higher
features Device revision 7 or higher SIMATIC PDM V8.2 SP1 EDD: 23.00.00 or higher
AMS Device Manager V12.5 EDD: 23.00.00 or higher
SITRANS DTM V4.1 EDD: 23.00.00 or higher
Field communicator EDD: 23.00.00 or higher
1.6 Checking the consignment

1. Check the packaging and the delivered items for visible damages.
2. Report any claims for damages immediately to the shipping company.
3. Retain damaged parts for clarification.
4. Check the scope of delivery by comparing your order to the shipping documents for
correctness and completeness.
WARNING
Using a damaged or incomplete device
Risk of explosion in hazardous areas.
● Do not use damaged or incomplete devices.
1.7 Security information

Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be connected
to an enterprise network or the internet if and to the extent such a connection is necessary and
only when appropriate security measures (e.g. firewalls and/or network segmentation) are in
place.
For additional information on industrial security measures that may be implemented, please
visit
https://www.siemens.com/industrialsecurity.
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they are available
and that the latest product versions are used. Use of product versions that are no longer
supported, and failure to apply the latest updates may increase customer’s exposure to cyber
threats.

Introduction
1.9 Notes on warranty
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed under
https://www.siemens.com/industrialsecurity.
1.8 Transportation and storage

To guarantee sufficient protection during transport and storage, observe the following:
● Keep the original packaging for subsequent transportation.
● Devices/replacement parts should be returned in their original packaging.
● If the original packaging is no longer available, ensure that all shipments are properly
packaged to provide sufficient protection during transport. Siemens cannot assume liability
for any costs associated with transportation damages.
NOTICE
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
● Provide additional packaging as necessary.
Special conditions for storage and transportation of the device are listed in Technical data
(Page 239).

The contents of this manual shall not become part of or modify any prior or existing agreement,
commitment or legal relationship. The sales contract contains all obligations on the part of
Siemens as well as the complete and solely applicable warranty conditions. Any statements
regarding device versions described in the manual do not create new warranties or modify the
existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right
to make technical changes in the course of further development.

Introduction

Safety information 2
2.1 Precondition for use
This device left the factory in good working condition. In order to maintain this status and to
ensure safe operation of the device, observe these instructions and all the specifications
relevant to safety.
Observe the information and symbols on the device. Do not remove any information or symbols
from the device. Always keep the information and symbols in a completely legible state.
2.2 Warning symbols on the device
Symbol Explanation
Consult operating instructions
2.3 Laws and directives

Observe the safety rules, provisions and laws applicable in your country during connection,
assembly and operation. These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)
● Canadian Electrical Code (CEC) (Canada)
Further provisions for hazardous area applications are for example:
● IEC 60079-14 (international)
● EN 60079-14 (EU)
See also
Certificates (http://www.siemens.com/processinstrumentation/certificates)

Safety information
2.6 Improper device modifications
2.4 Conformity with European directives

The CE marking on the device shows conformity with the regulations of the following European
guidelines:
Electromagnetic com‐ Directive of the European Parliament and of the Council on the har‐
patibility EMC monization of the laws of the Member States relating to electromag‐
2014/30/EU netic compatibility.
Atmosphère explosi‐ Directive of the European Parliament and of the Council on the har‐
ble monization of the laws of the Member States relating to equipment and
ATEX protective systems intended for use in potentially explosive atmos‐
2014/34/EU pheres.
2011/65/EU RoHS Directive of the European Parliament and of the Council on the re‐
striction of the use of certain hazardous substances in electrical and
electronic equipment
The directives applied can be found in the EU declaration of conformity for the associated
device.
2.5 Product approval and UL compliance
Classification according to For fluid group 1 gases; fulfills requirements according to article 4, paragraph 3 (good
pressure equipment direc‐ engineering practice SEP)
tive (PED 2014/68/EU)
CE conformity The applicable directives and applied standards with their revision levels can be
found in the EU declaration of conformity on the Internet.
UL conformity You can find the appropriate "Standard(s) for Safety", including the relevant versions,
in the UL-CERTIFICATE OF COMPLIANCE on the Internet.
2.6 Improper device modifications
WARNING
Improper device modifications
Risk to personnel, system and environment can result from modifications to the device,
particularly in hazardous areas.
● Only carry out modifications that are described in the instructions for the device. Failure to
observe this requirement cancels the manufacturer's warranty and the product approvals.

Safety information
2.8 Requirements for special applications
2.7 Improper modification on positioner 6DR5...6
WARNING
Improper modification on positioner 6DR5...6
Danger of explosion. The pneumatic terminal plate on the SIPART PS2 positioner 6DR5..6 is
a safety-related component of the flameproof enclosure.
● Never loosen the screws ① of the pneumatic terminal plate.
Figure 2-1 Screws of the pneumatic terminal plate on the positioner 6DR5..6
2.8 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 considered in the instructions. If you need additional information not
covered by these instructions, contact your local Siemens office or company representative.
Note
Operation under special ambient conditions
We highly recommend that you contact your Siemens representative or our application
department before you operate the device under special ambient conditions as can be
encountered in nuclear power plants or when the device is used for research and development
purposes.

Safety information
2.9 Use in hazardous areas
2.9 Use in hazardous areas
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 or instructed in operating and maintaining devices and systems
according to the safety regulations for electrical circuits, high pressures, aggressive, and
hazardous media.
● They are authorized, trained, or instructed in carrying out work on electrical circuits for
hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the pertinent safety regulations.
WARNING
Use in hazardous area
Risk of explosion.
● Only use equipment that is approved for use in the intended hazardous area and labeled
accordingly.
● Do not use devices that have been operated outside the conditions specified for hazardous
areas. If you have used the device outside the conditions for hazardous areas, make all Ex
markings unrecognizable on the nameplate.
WARNING
Loss of safety of device with type of protection "Intrinsic safety Ex i"
If the device or its components have already been operated in non-intrinsically safe circuits or
the electrical specifications have not been observed, the safety of the device is no longer
ensured for use in hazardous areas. There is a risk of explosion.
● Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe
circuit.
● Observe the specifications for the electrical data on the certificate and/or in Technical data
(Page 239).

Description 3
3.1 Function
● The electropneumatic positioner and an actuator form a control loop. The current position
of the actuator is recorded by a servo potentiometer and the actual value x is fed back. The
setpoint and the actual value are also shown simultaneously on the display.
● The positioner works as a predictive five-point positioner, through whose output value ±Δy
the pneumatic block can be controlled by pulse length modulation.
● These control signals cause pressure changes in the actuator chamber(s) and thus an
adjustment of the actuator until the control deviation becomes zero.
● The three keys and the display are used to operate (manual mode) and configure
(structuring, initializing and parameter assignment) with the enclosure cover removed.
● By default, the basic unit has a digital input. This digital input is individually configured and
blocks the operating levels, for example.
● The positioner has a friction clutch and a selectable gearbox. It can therefore be used on a
large number of mechanical part-turn and linear actuators.
● In the case of positioners with the "Fail in Place" function, the current position of the actuator
is held if the electric and/or pneumatic auxiliary power fails. Does not function in conjunction
with SIL.
3.2 Structure
3.2.1 Overview of structure

The following sections describe the mechanical and electrical structure, components, and
principle functionality of the positioner.
The positioner is used to move and control pneumatic actuators. The positioner works
electropneumatically, using compressed air as auxiliary power. The positioner is used to
control valves, for example, with:
● Linear actuator
● Part-turn actuator VDI/VDE 3845
Various add-on extensions are available for linear actuators:
● IEC 60534-6-1 (NAMUR)
● Integrated mounting on ARCA, except with flameproof stainless steel enclosure (6DR5..6)
● Integrated mounting on SAMSON, not for Ex d

Description
3.2 Structure

① Pressure gauge block, single-acting

② Process valve
③ Yoke / actuator yoke
④ Single-acting positioner in non-flameproof aluminum enclosure
⑤ Actuator
Figure 3-1 Positioner attached to a single-acting linear actuator

① Part-turn actuator
② Pressure gauge block, double-acting
③ Double-acting positioner in polycarbonate enclosure
Figure 3-2 Positioner attached to double-acting part-turn actuator

Description
3.2 Structure

① Single-acting positioner in flameproof aluminum enclosure

② Pressure gauge block, single-acting
③ Yoke / actuator yoke
④ Actuator
Figure 3-3 Positioner in flameproof aluminum enclosure attached to linear actuator

① Part-turn actuator
② Double-acting positioner in flameproof aluminum enclosure
③ Pressure gauge block, double-acting
Figure 3-4 Positioner in flameproof aluminum enclosure attached to part-turn actuator

Description
3.2 Structure
3.2.2 Nameplate layout
Example of manufacturer nameplate

- DIO - ILS - MLS
- NCS X AIM - AOM

SIPART PS2 i/p Positioner -
IP66 / Type 4X

KCC-REM-S49
6DR5021 -0K*02 -0AA0 <SW: x.xx.xx(2)> - SIPART PS2
-Z S10;S11;S12;S13;S14;S15;S16 p = 1.4 … 7 bar
-
- -
8DX[ 9
- Iw=4…20mA <HW: x.xx.xx(2)>
- PROCESS CONTROL
Siemens AG, DE-76181 Karlsruhe EQUIPMENT
www.siemens.com/sipartps2 - Imax=100mA
- Umax=35VDC
MADE IN FRANCE - - S/N: N1A6101234567

① Manufacturer ⑧ Supply pressure PZ

② Degree of protection ⑨ Software version and hardware version
③ Observe the operating instructions ⑩ Country of origin
④ Conformity with country-specific directives ⑪ Supply voltage
⑤ Built-in option modules ⑫ Ordering supplement (Order code)
⑥ QR code to the mobile website with device-spe‐ ⑬ Article number
cific product information
⑦ Serial number ⑭ Product name
Example of explosion protection nameplate
S/N: ARR P3-123456 0518

BRA-18-GE-0006 X /
TÜV 17 ATEX 205947 X / IECEx TUN 17.0023 X
II 2 G Ex ia IIC T6/T4 Gb

II 3 G Ex ic IIC T6/T4 Gc
II 2 D Ex ia IIIC T130°C Db
II 2 D Ex tb IIIC T100°C Db
II 3 G Ex ec IIC T6/T4 Gc
-
Cl I Zn 1 AEx ib IIC Gb / Cl I Zn 1 Ex ib IIC Gb

Zn 21 AEx ib IIIC, T130°C Db / Zn 21 Ex ib IIIC, T130°C
IS Cl I, II, III Div 1 Gp A-G
FM17US0053X
FM17US0360X
-
Cl I Zn 2 AEx nA IIC Gc / Cl I Zn 2 Ex nA IIC Gc

For technical data and temperature classes, see certificate / Operating Instructions
S/N: N1A6101234567
NI Cl I Div 2 Gp A-D
TÜV 17 ATEX 205947 X / IECEx TUN 17.0023 X / BRA-18-GE-0006 X - Zn 21 AEx tb IIIC T100°C Db / Zn 21 Ex tb IIIC T100°C Db
II 2 G Ex ia IIC T6/T4 Gb II 3 G Ex ic IIC T6/T4 Gc DIP Cl II, III Div 1 Gp E-G
II 2 D Ex ia IIIC T130°C Db II 2 D Ex tb IIIC T100°C Db
-
II 3 G Ex ec IIC T6/T4 Gc - - GYJ18.1168X CSA18CA70166848X

Cl I Zn 1 AEx ib IIC Gb / Cl I Zn 1 Ex ib IIC Gb Zn 21 AEx ib IIIC, T130°C Db / Zn 21 Ex ib IIIC, T130°C Db -
IS Cl I, II, III Div 1 Gp A-G -
FM17US0053X
Cl I Zn 2 AEx nA IIC Gc / Cl I Zn 2 Ex nA IIC Gc NI Cl I Div 2 Gp A-D
Zn 21 AEx tb IIIC T100°C Db / Zn 21 Ex tb IIIC T100°C Db DIP Cl II, III Div 1 Gp E-G
GYJ18.1168X
For installations in U.S.A. and Canada: 13-KB4BO-0369X -
13-KB4BO-0369X
Install per control drawing A5E00065622D Rev.16 - -30°C ≤ Ta ≤ +60°C(T6)/80°C(T4)

0518
- 15-AV4BO-0297
CSA18CA70166848X
-30°C ≤ Ta ≤ +60°C(T6)/80°C(T4) - For technical data and temperature classes, see certificate
/ Operating Instructions
-
① Approvals ③ FM/CSA marking for hazardous area

② ATEX/IECEx marking for hazardous area ④ Permissible ambient temperature for operation in
hazardous areas

Description
3.2 Structure
3.2.3 Explanation of Ex information
Explanation of Ex information
Technical data and temperature classes see certificate / operating instructions
TÜV 12 ATEX 107540 X / IECEx TUN 12.0028 X / TÜV 11.0287 X
II 2 G Ex ia IIC T4 Gb II 3 G Ex ic IIC T4 Gc
II 2 D Ex ia IIIC 110°C Db II 2 D Ex tb IIIC T100°C Db
II 3 G Ex ec IIC T4 Gc

① Category for operating range

② Type of protection
③ Group (gas, dust)
④ Maximum surface temperature (temperature class)
⑤ Device protection level
Figure 3-5 Explanation of Ex information

Description
3.3 Device components
3.3.1 Overview of device components

: : r

r
P$
P$

%,1
r

r

Arrowhead means: Turn the device to see the corresponding view

① Wiring diagram on module cover ⑩ Restrictor Y1 for double-acting actuators
② Display ⑪ Exhaust air outlet with a sound absorber
③ Output: Actuating pressure Y1 ⑫ Transmission ratio selector2)
④ Input: Supply pressure PZ ⑬ Friction clutch adjustment wheel
⑤ Output: Actuating pressure Y21) ⑭ Basic electronics
⑥ Purging air selector ⑮ Connecting terminals of option modules
⑦ Buttons ⑯ Blanking plug
⑧ Restrictor Y2 for double-acting actuators1) ⑰ Cable gland
⑨ Restrictor Y1 for single-acting actuators
1)
for double-acting actuators
2)
visible when the positioner is open
Figure 3-6 View of positioner with cover open
See also
Structure of pneumatic connection (Page 91)

Description
$

$$
138
1
9
10
- +
238
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① Display ⑧ Output: Actuating pressure Y21)

② Restrictor Y1 ⑨ Restrictor Y21)
③ Output: Actuating pressure Y1 ⑩ Buttons
④ Input: Supply pressure PZ ⑪ Ground terminal
⑤ Safety catch ⑫ Connecting terminals of option modules
⑥ Transmission ratio selector 2)
⑬ Connecting terminals of basic electronics
⑦ Friction clutch adjustment wheel
1)
for double-acting actuators
2)
visible when the positioner is open
Figure 3-7 View of positioner in flameproof enclosure, cover opened
3.3.2 Basic electronics
Figure 3-8 Basic electronics, schematic representation
The basic electronics contains:

● CPU
● Memory
● Analog-to-digital converter
● Display

Description
3.4 Mode of operation
● Buttons
● Terminal strips to connect the option module to the basic electronics
Control loop
The electropneumatic positioner forms a control loop with the pneumatic actuator:
● The actual value x represents the position of the actuator spindle for linear actuators or the
position of the actuator shaft for part-turn actuators.
● The higher-level control loop provides the setpoint w.
The stroke or rotary movement of the actuator is transferred to a potentiometer using suitable
attachments, positioner shaft and a backlash-free, switchable gear drive, and then to the
analog input of the microcontroller.
The current position can also be forwarded to the positioner using an external sensor. A Non
Contacting Position Sensor (NCS) is used to record the stroke or rotary angle directly on the
actuator.
The microcontroller:
● Corrects the angle error of the shaft pick-up if necessary.
● Compares the potentiometer voltage as actual value x with setpoint w.
● Calculates the manipulated variable increments ±∆y.
Depending on the size and direction of the control deviation (x-w), pressurizing or
depressurizing occurs via the pneumatic block. The actuator volume integrates the controller
increment for the actuating pressure y which is proportional to the drive rod or the drive shaft.
This controller increment changes the actuating pressure until the control deviation becomes
zero.
Pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is ventilated and depressurized. The pressure developed
works against a spring. In a double-acting version, two pressure chambers work against each
other. Ventilating the volume of one chamber simultaneously depressurizes the volume of the
other.
Control algorithm
The control algorithm is an adaptive, predictive five-point controller.
In case of large control deviations, the valves are controlled using permanent contact. This
takes place in the so-called fast step zone.
For medium control deviations, the pneumatic block is controlled by pulses modulated by pulse
length. This takes place in the so-called slow step zone.

Description
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Figure 3-9 Functional principle of five-point controller
Small control deviations do not send control pulses in the zone. This takes place in the so-called
adaptive deadband. The deadband adaptation and the continuous adaptation of minimum
pulse lengths in "Automatic" mode ensure the best possible control accuracy with the smallest
number of operating cycles. The start parameters are determined during the initialization phase
and stored in the non-volatile memory. The most important start parameters are:
● The real actuator travel with end positions
● Travel times
● The deadband size
The number of fault messages, changes in direction, and the number of total strokes are
continuously determined during operation and saved every 15 minutes. Document and read
out these parameters via the communication software, e.g. SIMATIC PDM and AMS. By
comparing the old values with the current ones, you can draw conclusions about the wear and
tear of the valve. This is done using the diagnostics function.

Description
3.4.1 Block circuit diagram for single-acting or double-acting actuators

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6WURNH
6WURNH
① Basic electronics with microcontroller and input circuit
② Control pad with display and buttons
③ Single-acting or double-acting pneumatic block
④ Analog Output Module (AOM) for positioners
⑤ Digital I/O Module (DIO) for 3 digital outputs and 1 digital input
⑥ Inductive Limit Switches (ILS)
⑦ Mechanic Limit Switches (MLS)
⑧ Spring-loaded pneumatic actuator (single-acting)
⑨ Pneumatic actuator (double-acting)
⑩ Pressure sensor module
⑪ Pressure gauge block
Figure 3-10 Block circuit diagram for the electropneumatic positioner, functional diagram

Description
Note
Digital I/O Module (DIO), Inductive Limit Switches (ILS) and Mechanic Limit Switches (MLS)
Digital I/O Module (DIO)⑤, Inductive Limit Switches (ILS)⑥ and Mechanic Limit Switches
(MLS)⑦ can only be used alternatively.
3.4.2 Mode of operation of the HART function
Note
Priority of operation / failure of power supply
● Operation at the positioner has priority over specifications from the HART communicator.
● Failure of the auxiliary power to the positioner also interrupts communications.
Function
The positioner is also available with built-in HART functionality. The HART protocol allows you
to communicate with your device using a HART communicator, PC, or programming unit. You
can do the following with your device:
● Convenient configuration
● Store configurations
● Call up diagnostic data
● Show online measured values
Communication takes place as frequency modulation on the existing signal lines for the
setpoint of 4 to 20 mA.
The positioner is integrated into the following parameter assignment tools:
● HART communicator
● PDM (Process Device Manager)
● AMS (Asset Management System)
3.4.3 HART system configuration
Overview
The positioner can be used in a number of system configurations:
● Stand-alone, supplied with the required auxiliary power supply; communication with
supplementary units (handheld), for example
● As part of a complex system environment, e.g. SIMATIC S7

Description
System communication
Communication is via the HART protocol, using:
● HART Communicator (load 230 ... 1100 Ω)
● PC with HART modem, on which appropriate software is installed, e.g. SIMATIC PDM (load
230 ... 500 Ω)
● Control system which can communicate via the HART protocol, e.g. SIMATIC PCS7
SIMATIC PCS 7 Engineering Station

with SIMATIC PDM
Industrial Ethernet
S7-400
PROFIBUS DP
ET 200M
HART
Figure 3-11 Typical system configurations
3.4.4 SIMATIC PDM

SIMATIC PDM is a software package for configuring, parameter assignment, commissioning,
diagnostics and maintenance of this device and other process devices.
SIMATIC PDM offers simple monitoring of process values, alarms, and device status
information.
SIMATIC PDM allows the process device data to be:
● displayed
● set
● modified
● saved
● diagnosed
● checked for plausibility
● managed
● simulated
Additional information on SIMATIC PDM can be found at www.siemens.com/simatic-pdm
(www.siemens.com/simatic-pdm).

Description
See also
Overview of the assignment of the HART variables (Page 189)

Description

Installing/mounting 4
4.1 Basic safety instructions
WARNING
High operating force with pneumatic actuators
Risk of injury when working on control valves due to the high operating force of the pneumatic
actuator.
● Please observe the corresponding safety instructions for the pneumatic actuator in use.
WARNING
It is possible to damage the cover gasket
If the cover gasket is not positioned correctly in the groove of the base plate, it could be
damaged when the cover is mounted and screwed tight.
● Therefore make sure that the gasket is seated correctly.
WARNING
Exceeded maximum permissible operating pressure
Risk of injury or poisoning.
The maximum permissible operating pressure depends on the device version, pressure limit
and temperature rating. The device can be damaged if the operating pressure is exceeded.
Hot, toxic and corrosive process media could be released.
Ensure that maximum permissible operating pressure of the device is not exceeded. Refer to
the information on the nameplate and/or in Technical data (Page 239).
WARNING
Electrostatic charging of nameplates
The nameplates used on the device can reach a charging capacity of 5 pF.
● Keep the device and the cables at a distance from strong electromagnetic fields.

Installing/mounting
CAUTION
Unsuitable compressed air
Device damage. As a general rule, the positioner must only be operated with dry and clean
compressed air.
● Use the customary water separators and filters. An additional dryer is required in extreme
cases.
● Use dryers, especially if you operate the positioner at low ambient temperatures.
CAUTION
Adhere to the following instructions before working on the control valve and when attaching
the positioner
Danger of injury.
● Prior to working on the control valve, you must move the actuator and the process valve
into a completely pressureless state. Proceed as follows:
– Depressurize the actuator chambers.
– Switch off the supply pressure PZ.
– Secure the process valve.
● Make sure that the actuator has reached the pressureless state.
● If you interrupt the supply pressure PZ to the positioner, the pressureless position can only
be reached after a certain waiting time.
● When mounting, adhere strictly to the following order to avoid injuries or mechanical
damage to the positioner/mounting kit:
– Mount the positioner mechanically.
– Electric connection.
– Connect supply pressure PZ.
– Commission the positioner.
WARNING
Mechanical impact energy
In order to ensure the degree of protection of the housing (IP66), protect the housing versions
of the positioners listed here from mechanical impact energy:
● 6DR5..3; not greater than 2 Joule
● 6DR5..0; not greater than 1 Joule
● 6DR5..1 with inspection window; not greater than 1 Joule

Installing/mounting
NOTICE
Torque with NPT screwed gland
Device damage. The maximum torque of the cable gland must not be exceeded.
● To avoid damage to the device, the NPT adapter must be held in place while the NPT gland
is screwed into the NPT adapter. Refer to the section "Technical specifications
> Construction (Page 240)" for the torque value.
4.1.1 Proper mounting
NOTICE
Freezing of the exhaust air outlets
When devices of the type 6DR5..0/1/2/3 are used, the exhaust air outlets ② may freeze. The
function of the device is impaired.
● Do not install the positioner with the base plate ① pointing up.
① Base plate
② Exhaust air outlets
Figure 4-1 Exhaust air outlets, base plate
4.1.1.1 Loss of explosion protection
WARNING
Loss of explosion protection
Risk of explosion in hazardous areas if the device is open or not properly closed.
● Close the device as described in Installing/mounting (Page 37).

Installing/mounting
4.2 Mounting to linear actuator
NOTICE
Incorrect mounting
The device can be damaged, destroyed, or its functionality impaired through improper
mounting.
● Before installing ensure there is no visible damage to the device.
● Make sure that process connectors are clean, and suitable gaskets and glands are used.
● Mount the device using suitable tools. Refer to the information in Technical data
(Page 239).
Requirements
There are linear actuators for standard mounting in accordance with IEC 60534 and for
integrated mounting. Use the reduced mounting kit 6DR4004-8VK for actuators with integrated
mounting. Integrated mounting is not possible with flameproof stainless steel enclosure
(6DR5..6).
This section describes how to connect the positioner to the linear actuator according to
IEC 60534. Depending on the stroke height, you will need the following mounting kit:
● 3 to 35 mm mounting kit 6DR4004-8V
● 35 to 130 mm mounting kit 6DR4004-8V and additional 6DR4004-8L
See also
Construction (Page 240)
Procedure
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. no. *)
Quantity Name Note
① 1 NAMUR mounting bracket Standardized connection point for mount with fin, column or plane
IEC 60534 surface
② 1 Pick-up bracket Guides the pulley with the carrier pin and rotates the lever arm.
③ 2 Clamping piece Installs the pick-up bracket on the actuator spindle
④ 1 Carrier pin Installation with pulley ⑤ on lever ⑥
⑤ 1 Pulley Installation with carrier pin ④ on lever ⑥
⑥ 1 Lever For the range of stroke from 3 mm to 35 mm
The lever 6DR4004–8L is additionally required for ranges of stroke
> 35 mm to 130 mm (not included in the scope of delivery).
⑦ 2 U–bolts Only for actuators with columns

Installing/mounting
"Linear actuator IEC 60534 (3 to 35 mm)" mounting kit 6DR4004-8V and 6DR4004-8L
Sr. no. *) Quantity Name Note
⑧ 4 Hexagon bolt M8x20 DIN 933–A2
⑨ 2 Hexagon bolt M8x16 DIN 933–A2
⑩ 6 Spring lock washer A8 - DIN 127–A2
⑪ 6 Washer B8.4 - DIN 125–A2
⑫ 2 Washer B6.4 - DIN 125–A2
⑬ 1 Spring VD-115E 0.70 x 11.3 x 32.7 x 3.5
⑭ 1 Spring lock washer A6 - DIN 137A–A2
⑮ 1 Lock washer 3.2 - DIN 6799–A2
⑯ 3 Spring lock washer A6 - DIN 127–A2
⑰ 3 Socket cap screw M6x25 DIN 7984–A2
⑱ 1 Hexagon nut M6 - DIN 934–A4
⑲ 1 Square nut M6 - DIN 557–A4
⑳ 4 Hexagon nut M8 - DIN 934–A4
*)
The serial numbers refer to the images of the description of the installation steps below.
1. Install the clamping pieces ③ on the actuator spindle.
2. Slide the pick-up bracket ② into the milled recesses of the clamping pieces ③.

Figure 4-2 Pick-up bracket
3. Tighten the screws ⑰ so that you can still shift the pick-up bracket ②.

Installing/mounting
4. If you use a short lever, the carrier pin is already pre-mounted. If you use the long lever
6DR4004-8L, fasten the carrier pin ④ with the existing parts to the long lever.

Figure 4-3 Short lever

Figure 4-4 Long lever 6DR4004-8L with mounted carrier pin ④ and cylinder head screw ⑰
5. Set the stroke value. The stroke value is specified on the nameplate of the actuator. Position
the pin center of the carrier pin ④ on the corresponding value of the scale. If none of the
values on the lever scale matches the stroke value of the actuator, select the next higher
value on the scale.
For strokes ≥ 25 mm, select the scale (90). For strokes < 25 mm, select the scale (33).
6. Set the transmission ratio selector (Page 48) to the value of the selected scale.
7. If you need the value of actuator travel after initialization in mm: ensure that the configured
stroke value matches the value of the "3.YWAY" parameter.
8. Push the pre-installed lever ⑥ up to the endstop on the positioner shaft. Fasten the lever ⑥
with socket cap screw ⑰.

Installing/mounting
9. Install the mounting bracket ① at the rear side of the positioner. Use 2 hexagon bolts ⑨,
2 spring lock washers ⑩ and 2 flat washers ⑪ for this purpose.

Figure 4-5 Installation with mounting bracket

Figure 4-6 Installation with mounting bracket, flameproof enclosure
10.Select the row of holes. The selection of the row of holes depends on the yoke width of the
actuator. Select the row of holes in such a way that the carrier pin ④ meshes with the pick-
up bracket ② near the spindle.
11.Keep the positioner and the fastening bracket on the actuator. Ensure that the carrier pin ④
for the entire range of stroke of the actuator is guided inside the pick-up bracket ②. Ensure
that the carrier pin ④ does not touch the clamping pieces ③.

Installing/mounting
12.Tighten the pick-up bracket ②.

13.Fasten the positioner on the yoke. Use the installation parts suitable for the corresponding
actuator.
Actuator type Required installation compo‐

nents
Yoke with fin ● Hexagon bolt ⑧

● Washer ⑪

● Spring lock washer ⑩
Yoke with ● Four hexagon bolts ⑧

plane surface ● Washer ⑪
Yoke with col‐ ● Two U–bolts ⑦

umns ● Four hexagon nuts ⑳
● Washer ⑪


Installing/mounting
4.3 Mounting to part-turn actuator
Note
Height adjustment of the positioner
When you fasten the positioner on the yoke, the following applies to its height adjustment:
1. Set the height of the positioner in such a way that the horizontal lever position is near the
center of the stroke.
2. Orient yourself by the lever scale of the actuator.
3. If symmetrical mounting is not possible, you must always ensure that the horizontal lever
position is maintained within the range of stroke.
Requirements
You require an actuator-specific VDI/VDE 3845 mount to install the positioner on a part-turn
actuator. Because of the high weight of the version in the flameproof stainless steel enclosure
6DR5..6, you should select a particularly stable mount.
Procedure
"Part-turn actuator" mounting kit 6DR4004–8D

Sr. Quan Designation Note
no. *) tity
① 1 Coupling wheel Installation on positioner shaft
② 1 Carrier Installing on the actuator shaft
③ 1 Multiple plate Display of the position, consisting of scale ⑤ and pointer mark ⑥
④ 8 Scale Different divisions
⑤ 2 Pointer mark Reference point for scale
⑥ Mounting console Actuator-specific, VDI/VDE 3845
⑦ 4 Hexagon bolt M6x12 DIN 933, torque see the section "Technical specifications > Construction
(Page 240)"
⑧ 4 Lock washer S6
⑨ 1 Socket cap screw M6x16 DIN 84
⑩ 1 Washer 6.4 DIN 125
⑪ 1 Hex socket-head For coupling wheel
screw
1 Machinist's wrench For hexagon socket-head screw ⑪
*)
The serial numbers refer to the images in the description of the steps below.

Installing/mounting
1. Rest the actuator-specific VDI/VDE 3845 mount ⑥ on the rear side of the positioner.
Tighten the mount using the hexagon bolts ⑦ and lock washers ⑧.
2. Push the coupling wheel ① or the stainless steel coupling up to the endstop on the
positioner shaft. Then retract the coupling wheel or the stainless steel coupling by
approximately 1 mm. Tighten the hexagon socket-head screw ⑪ using the machinist's
wrench provided. Maximum tightening torque = 1 Nm. If you are using the stainless steel
coupling, omit the next step.
Note
Coupling wheel
Instead of the polycarbonate coupling wheel ①, it is possible to use a stainless steel
coupling (article number TGX:16300-1556).

Figure 4-7 Left: Coupling wheel, right: Coupling wheel, flameproof enclosure
3. Place the carrier ② on the actuator shaft. Tighten the carrier ② using the socket cap
screw ⑨ and the washer ⑩.

Figure 4-8 Carrier

Installing/mounting
4. Place the positioner and the mount on the actuator carefully. One of the two pins ⑫ of the
coupling wheel ① must fit in the carrier ② when you do this.

Figure 4-9 Left: Orientation of mount; right: Orientation of mount, flameproof enclosure
5. When using the stainless steel coupling (article number TGX:16300-1556): Place the
positioner and the mount on the actuator carefully. Place the stainless steel coupling on the
stump of the actuator's positioner shaft.
6. Align the positioner with mount at the center of the actuator.
7. Fasten the positioner with mount.
8. Initialize the positioner.
9. After commissioning, drive the positioner to the end position.
10.Stick the scale ④ with the direction of rotation or the swivel range on the coupling wheel ①.
The stickers with scale are self-adhesive.

Figure 4-10 Left: Adhesive label with scale; right: Adhesive label with scale, flameproof enclosure

Installing/mounting
4.4 Setting and locking the transmission ratio
Ø35
(1.38)

0

D
E
(0.26)
6.5
D
E F05-Lkr.-Ø50 (1.97)
H = height of shaft butt

① Fixing level of positioner on mount
② Part-turn actuator
Figure 4-11 Dimensions of mount in accordance with VDI/VDE 3845 (depends on actuator)
See also
Preparing part-turn actuators for commissioning (Page 124)
Introduction
The positioner has a friction clutch and a transmission ratio selector. The positioner can
therefore be used on a variety of mechanically different part-turn and linear actuators.
● The transmission ratio selector allows you to adapt the positioner to small or large strokes.
● You can then use the friction clutch to adjust the working area.
Strong acceleration forces act on control valves that are subjected to heavy mechanical loads,
e.g. breakaway valves, strongly shaking or vibrating valves, as well as in case of "vapor
shocks". These forces may be much higher than the specified data. This may move the
transmission ratio in extreme cases. In these cases it is possible to lock the transmission ratio
selector by means of the gear fixing.

Installing/mounting
When the positioner is mounted and fully operational, set the friction clutch as described in the
section Setting the friction clutch (Page 115).
NOTICE
Wrong registration of the rotary or part-turn movement
A different setting of the transmission ratio selector and the gear latch results in a hysteresis
in position detection. The hysteresis in position detection can result in unstable control
response of the higher level control loop.
● Make sure the transmission ratio selector ⑤ and the gear latch ① are set to the same
value, either to 33° or to 90°.
Note
Use of external NCS sensor / internal NCS module
If you use the accessory part "NCS sensor for non-contacting position detection" or a built-in
internal NCS module, the locking and fixing measures described in this section are not
necessary.
Requirement
● The positioner is mounted.
● You know whether the transmission ratio is to be set to 33° or 90°.
See also
Commissioning (Page 105)

Installing/mounting
Procedure
On the right in the graphic the positioner is shown in the flameproof enclosure Ex d with open
cover. The procedure is the same for both enclosure versions.
([G

r
r r
r
r

① Wheel for gear latch (yellow) ④ Locking transmission ratio to 90°
② Locking transmission ratio to 33° ⑤ Transmission ratio selector (yellow)
③ Neutral position
Figure 4-12 Locking the transmission ratio
1. Ensure that the wheel for the gear latch ① is in neutral position ③. The neutral position is
between 33° and 90°. The setting of the transmission ratio selector ⑤ can only be changed
effectively if the gear latch ① is in the neutral position ③.
2. Make sure the transmission ratio selector ⑤ is set to the same value as the gear latch ①,
either to 33° or to 90°.
3. Turn the wheel for the gear latch ① until the gear latch ① perceptibly locks. Use an approx.
4 mm wide standard screwdriver.
Turning right locks the transmission ratio to 33° ②. Turning left locks the transmission ratio
to 90° ④.
The transmission ratio ② is set and locked.

Installing/mounting
4.5 Installing option modules
See also
Opening the device version with "flameproof enclosure" (Page 55)
4.5.1 General information on installing option modules
WARNING
Use in hazardous area
Risk of explosion.
● Only use equipment that is approved for use in the intended hazardous area and labeled
accordingly.
● Do not use devices that have been operated outside the conditions specified for hazardous
areas. If you have used the device outside the conditions for hazardous areas, make all Ex
markings unrecognizable on the nameplate.

Installing/mounting
4.5.1.1 Opening the standard and intrinsically safe version
Overview screen

① Module cover ⑪ Adapter

② Fixing screws module cover ⑫ Transmission ratio selector
③ Fixing screws basic electronics ⑬ Pneumatic block
④ Ribbon cable/connector for fitted potentiom‐ ⑭ Warning label on the side opposite the
eter or fitted Analog Input Module (AIM) nameplate
⑤ Ribbon cable/connector for Digital I/O Mod‐ ⑮ Inductive Limit Switches (ILS) or Mechanic
ule (DIO), Inductive Limit Switches (ILS) or Limit Switches (MLS)
Mechanic Limit Switches (MLS)

Installing/mounting
⑥ Ribbon cable/connector for Analog Output ⑯ Insulating cover, yellow

Module (AOM)
⑦ Basic electronics ⑰ Special screw
⑧ Digital I/O Module (DIO) ⑱ Friction clutch adjustment wheel
⑨ Analog Output Module (AOM) ⑲ Wiring diagram on module cover
⑩ Nameplate
Figure 4-13 Installing the optional modules in the standard and intrinsically safe version
Procedure
1. Open the positioner.
2. Loosen the four fixing screws of the enclosure cover. Remove the enclosure cover.
3. Disconnect the power supply lines or de-energize the power supply lines.
4. Disconnect all other electrical connections of the device.
5. Loosen the two fixing screws ② of the module cover ①.
6. Remove the module cover ①.
If you are installing an option module, proceed as described for the respective option modules.
Remove the basic electronics for Inductive Limit Switches (ILS), Mechanic Limit Switches
(MLS), the internal NCS module and Analog Input Module (AIM).
If you are replacing the basic electronics, a pneumatic block or pressure sensor module,
proceed as described in the respective sections under "Service and maintenance (Page 197)".
4.5.1.2 Closing the standard and and intrinsically safe version
Procedure
The legend numbers refer to the figure in "Opening the standard and intrinsically safe version
(Page 52)"
1. Now start with the assembly. Place on the module cover ①. Make sure that the ribbon cable
is not trapped.
2. Turn the fixing screws ② counterclockwise until they noticeably engage in the thread pitch.
3. Carefully tighten both fixing screws ② in a clockwise direction.
The module cover protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using self-tapping screws, one screw for the base plate and
one screw for the pneumatic block.
● In order to avoid premature wear of the base plate and pneumatic block, proceed as
described here.
4. Connect the power supply lines or supply the power supply lines with voltage.

Installing/mounting
5. Put on the enclosure cover.

6. Tighten the fixing screws of the enclosure cover.

Installing/mounting
4.5.1.3 Opening the device version with "flameproof enclosure"
Overview screen
DANGER
Risk of explosion
Before supplying the positioner with auxiliary power in potentially hazardous areas, ensure the
following:
● The installed electronic unit has been approved.
● The enclosure of the positioner is closed.
● The duct openings for electronic connections must be closed. Only use the Ex d certified
cable entries or sealing plugs.
● If you use a "conduit piping system", install an ignition trap. The maximum distance
between the ignition trap and the positioner enclosure is 46 cm (18 inch).

Installing/mounting

① Module cover ⑬ Pneumatic block

② Fixing screws module cover ⑭ Warning label on the side opposite the nameplate
③ Fixing screws basic electronics ⑮ Screw cap
④ Ribbon cable/connector for fitted potentiometer or Position ⑯ Feedback lever bracket with pin
Transmitter
⑤ Ribbon cable/connector for Digital I/O Module (DIO), In‐ ⑰ Pin (feedback lever bracket)
ductive Limit Switches (ILS) or Mechanic Limit Switches
(MLS)
⑥ Ribbon cable/connector for Analog Output Module (AOM) ⑱ Adjustment wheel for external friction clutch
⑦ Basic electronics ⑲ Feedback shaft
⑧ Digital I/O Module (DIO) ⑳ Fixing screws adapter
⑨ Analog Output Module (AOM) Safety catch

Installing/mounting
⑩ Nameplate Clip
⑪ Adapter Enclosure
⑫ Transmission ratio selector
Figure 4-14 Installing the optional modules in the "flameproof enclosure" version
Procedure
1. Disconnect the power supply lines or de-energize the power supply lines.
2. Open the safety catch .
3. Unscrew the screw cap ⑮.
4. Completely dismount the positioner from the actuator.
5. Turn the feedback shaft ⑲ on the positioner until the pin (feedback lever bracket) ⑰ below
the adapter ⑪ shows in the direction of removal. If you look into the enclosure below the
adapter, you will see the position of the pin.
6. Screw out the four fixing screws ⑳ of the adapter ⑪.
7. Completely remove the adapter ⑪ carefully from the enclosure .
The positioner comes with a clip and a pin (feedback lever bracket) ⑰ which interlock
and ensure backlash-free position feedback. To ensure backlash-free position feedback
make sure you remove the adapter ⑪ carefully.
NOTICE
Displaced O-rings
There are several O-rings between adapter ⑪ and enclosure . These O-rings may
come off during removal.
● Carefully remove the adapter. Make sure the O-rings do not get lost during removal.
8. Loosen the two fixing screws ② of the module cover ①.

9. Remove the module cover ①.
If you are installing an option module, proceed as described for the respective option module.
Remove the basic electronics with an internal NCS module.
If you replace the basic electronics or a pneumatic block, proceed as described in the
respective sections under "Service and maintenance (Page 197)".
See also
Internal NCS module (iNCS) 6DR4004-5L / -5LE (Page 68)

Installing/mounting
4.5.1.4 Closing the device version with "flameproof enclosure"
Procedure
1. Now start with the assembly. Place on the module cover ①. Make sure that the ribbon cable
is not trapped.
2. Turn the fixing screws ② counterclockwise until they noticeably engage in the thread pitch.
Carefully tighten both fixing screws ② in a clockwise direction.
The module cover protects and locks the optional modules mechanically.
Note
Untimely wear
The module cover is fastened using a self-tapping screw for the pneumatic block.
● In order to avoid premature wear of the pneumatic block, proceed as described here.
3. Check whether the position of the O-rings is correct before inserting the adapter into the
enclosure.
– With an enclosure made from aluminum, O rings are inside the enclosure and on the rear
of the adapter.
– With an enclosure made from stainless steel, O-rings are on the rear of the adapter.
4. Make sure no loose items in the enclosure interfere with the assembly.
5. Push the adapter ⑪ fully into the enclosure .
The positioner comes with a clip and a pin (feedback lever bracket) ⑰ which interlock
and ensure backlash-free position feedback. To ensure backlash-free position feedback,
insert the adapter ⑪ carefully into the enclosure.
6. Screw in the four fixing screws ⑳ of the adapter ⑪. Tighten the screws.
Check carefully whether the feedback shaft ⑲ can be smoothly turned by 360°. If you feel
resistance, do not continue to turn but turn the feedback shaft ⑲ back again to the point of
removal.
7. Mount the positioner on the actuator.
8. Unscrew the screw cap ⑮.
9. Close the safety catch .
10.Connect the power supply lines or supply the power supply lines with voltage.

Installing/mounting
4.5.2 Digital I/O Module (DIO) 6DR4004-6A / -8A
Function
The Digital I/O Module (DIO) triggers fault messages and alarms via three digital outputs. The
message function is based on the change in the signal status:
● With the "HIGH" state, there is no alarm message and the digital outputs are conductive.
● With the "LOW" state, the module reports an alarm with high-resistance shutdown of the
digital outputs.
● Operational faults are signaled at a high-resistance digital output. Set the following
parameters to activate and configure the output of alarms and fault messages:
– "AFCT" - Alarm function
– "A1" - Response threshold, alarm 1
– "A2" - Response threshold, alarm 2
– "FCT" - Function for fault message output
– "TIM" - Monitoring time
– "LIM" - Response threshold
The Digital I/O Module (DIO) also has a digital input DI2 in addition to the digital outputs.
Depending on the selected parameters, this digital input is used, for example, to block the
actuator or to move it to its end position. Configure the suitable settings on parameter "BIN2".
Device features
Figure 4-15 Digital I/O Module (DIO), schematic representation

Installing/mounting
The Digital I/O Module (DIO) has the following features:

● Available in two versions
– Explosion-proof version for connecting to a switching amplifier in conformity with
EN 60947-5-6
– Non-explosion-proof version for connecting to power sources having a maximum of 35 V.
● 3 digital outputs. The digital outputs are galvanically isolated from the standard controller
and from each other.
● The digital input DI2 has 2 inputs. Both inputs are implemented as logical OR combination.
– Digital input DI1 on terminal 11/12: Is electrically isolated, and is triggered by an active
signal.
– Digital input DI2 on terminal 21/22: Is not electrically isolated, and is triggered by a
passive NO contact.
Procedure
1. Open the positioner as in the description depending on the device version:
– Opening the standard and intrinsically safe version (Page 52)
– Opening the device version with "flameproof enclosure" (Page 55)
2. Slide the Digital I/O Module (DIO) into the adapter below the basic electronics. Ensure that
you slide it up to the endstop.
3. Connect the Digital I/O Module (DIO) to the basic electronics. To do this, use the 8-pin flat
ribbon cable provided.
4. Close the positioner as in the description depending on the device version:
– Closing the standard and and intrinsically safe version (Page 53)
– Closing the device version with "flameproof enclosure" (Page 58)
4.5.3 Analog Output Module (AOM) 6DR4004-6J / -8J
Function
● The Analog Output Module (AOM) indicates the current position of the actuator as a two-
wire signal between 4 mA and 20 mA. The Analog Output Module (AOM) is galvanically
isolated from the basic unit.
● The current position is indicated as a passive mA signal only after successful initialization.
● Operational faults are signaled by a fault current of 3.6 mA.

Installing/mounting
Device features
Figure 4-16 Analog Output Module (AOM) 6DR4004-6J (Ex) and 6DR4004-8J (non-Ex), schematic
representation
The Analog Output Module (AOM) is:

● Single channel
● Galvanically isolated from the basic device
Requirement
A supply source corresponding to the technical specifications (Page 251) of the option module
must be available.
Procedure
2. Slide the Analog Output Module (AOM) into the lower bay of the adapter as far as it will go.
3. Connect the Analog Output Module (AOM) to the basic electronics. To do this, use the 6-pin
flat ribbon cable provided.

Installing/mounting
4.5.4 Inductive Limit Switches (ILS) 6DR4004 6G / -8G
4.5.4.1 Inductive Limit Switches (ILS) - Mode of operation and equipment features
Function
If the basic unit requires electrically independent limit messages, the Inductive Limit Switches
(ILS) with slotted initiators is used instead of the Digital I/O Module (DIO).
● A digital output is used to display a group fault message. Compare with the function of the
Digital I/O Module (DIO). The floating digital output is implemented as an automatic fault
indicating semiconductor output.
● The other two digital outputs are used to signal the two limits L1 and L2 which can be
adjusted mechanically using slotted initiators. These two digital outputs are electrically
independent from the remaining electronic unit.
Device features

① Actuating disk bearings ② Special screw

③ Pin ④ Upper actuating disk for limit L1, terminals 41/42
⑤ ⑥
Lower actuating disk for limit L2, termi‐ Digital outputs
nals 51/52
Figure 4-17 Inductive Limit Switches (ILS), schematic representation
The Inductive Limit Switches (ILS) have three digital outputs ⑥.

Installing/mounting
4.5.4.2 Installation procedure for Inductive Limit Switches (ILS)
Procedure
1. Open the positioner as described in Opening the standard and intrinsically safe version
(Page 52).
2. Remove the ribbon cable from the basic electronics.
3. Tighten the two fixing screws of the basic electronics. Remove the basic electronics.
4. Insert the Inductive Limit Switches (ILS) from the top to the upper printed circuit board guide
of the adapter.
5. Slide the Inductive Limit Switches (ILS) in the printed circuit board of the adapter approx.
3 mm to the right.
6. Screw the special screw ② through the Inductive Limit Switches (ILS) into the positioner
shaft. Tighten the special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align pin ③ with the groove of the special screw before inserting the head of the special
screw ② into the actuating disk bearing ①.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that the
pin ③ is inserted into the groove of the special screw ②.
7. An insulating cover (yellow) is required over the Inductive Limit Switches (ILS). This
insulating cover is supplied with the Inductive Limit Switches (ILS). Place the insulating
cover on one side under the basic electronics seat of the rack. The recesses of the insulating
cover must fit in the corresponding webs of the rack. To tighten the insulating cover, bend
the walls of the adapter slightly outwards.
Firmly press the other end until the insulating cover is underneath the contact surface of the
basic electronics. The recesses of the insulating cover must fit in the corresponding webs
of the rack.
8. Place the basic electronics onto the four holders of the adapter.
9. Tighten the two fixing screws of the basic electronics. Tighten the screws.
10.Reestablish all electrical connections between the basic electronics and the option modules.
11.Connect the basic electronics with the option modules and the potentiometer. Use the
corresponding ribbon cables.
12.Put on the supplied module cover. Make sure that the ribbon cable is not trapped.
Note
Module cover
Do not use the standard module cover. The provided module cover has a larger recess.
13.Select the labels that are already available on the standard version of the module cover from
the label set provided. Affix the selected labels onto the installed module cover as per the
standard version.

Installing/mounting
14.Close the positioner as described in Closing the standard and and intrinsically safe version
(Page 53).
15.Set the limits L1 and L2 as described in Setting limits (Page 64).
4.5.4.3 Setting limits
Procedure: Determining the switch status of the slotted initiators

You will require a suitable display device to determine the switch status. For example, use the
initiator tester type 2 / Ex from Pepperl + Fuchs.
1. Connect the display device to the following terminals of the Inductive Limit Switches (ILS):
– 41 and 42
– 51 and 52
2. Read the switch status of slotted initiators.
Procedure: Setting the limits L1 and L2

The consecutive numbers in the following text refer to the figure above in this section. Proceed
as follows to set the limits:
1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 41 and 42
changes. Set a high-low or a low-high switchover as follows:
– Rotate the actuating disc ④ beyond the switching point until you reach the next
switching point.
3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 51 and 52
– Rotate the actuating disc ⑤ beyond the switching point until you reach the next
switching point.
Note
Adjusting the actuating disk
The actuating disks ④ and ⑤ are relatively difficult to move. This design prevents their
unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing stiction temporarily.
● Move the actuator to and fro while simultaneously holding the actuating disks ④
and ⑤.

Installing/mounting
4.5.5 Mechanic Limit Switches (MLS) 6DR4004-6K / -8K
4.5.5.1 Mechanic Limit Switches (MLS) - Mode of operation and equipment features
Function
Mechanic Limit Switches (MLS) are used to report two limits. These limits are reported using
galvanic switching contacts.
Device features

① Actuating disk bearings ④ Upper actuating disk for limit L1, terminals
51/52
② Special screw ⑤ Lower actuating disk for limit L2, terminals
41/42
③ Pin
Figure 4-18 Mechanic Limit Switches (MLS), schematic representation
Mechanic Limit Switches (MLS) contain:

● One digital output to display a group fault message. Compare with the device features of the
Mechanic Limit Switches (MLS).
● Two switches to report two mechanically adjustable limits. Both these switches are
electrically independent from the remaining electronic unit.

Installing/mounting
4.5.5.2 Installation procedure for Mechanic Limit Switches (MLS)
Procedure
(Page 52).
3. Tighten the two fixing screws of the basic electronics. Remove the basic electronics.
4. Insert the Mechanic Limit Switches (MLS) from the top to the upper printed circuit board
guide of the adapter.
5. Slide the Mechanic Limit Switches (MLS) in the printed circuit board of the adapter approx.
3 mm to the right.
6. Screw the special screw ② through the Mechanic Limit Switches (MLS) into the positioner
shaft. Tighten the special screw ② with a torque of 2 Nm.
Note
Pin in the actuating disk bearing
A pin ③ is pressed in the actuating disk bearing①.
1. Align pin ③ with the groove of the special screw before inserting the head of the special
screw ② into the actuating disk bearing ①.
2. Rotate the actuating disk bearing ① and the special screw ② simultaneously so that the
pin ③ is inserted into the groove of the special screw ②.
7. An insulating cover (yellow) is required over the Mechanic Limit Switches (MLS). This
insulating cover is supplied with the Mechanic Limit Switches (MLS). Place the insulating
cover on one side under the basic electronics seat of the rack. The recesses of the insulating
cover must fit in the corresponding webs of the rack. To tighten the insulating cover, bend
the walls of the adapter slightly outwards.
Firmly press the other end until the insulating cover is underneath the contact surface of the
of the rack.
8. Place the basic electronics onto the four holders of the rack.
9. Tighten the two fixing screws of the basic electronics. Tighten the screws.
10.Reestablish all electrical connections between the basic electronics and the option modules.
11.Connect the basic electronics with the option modules and the potentiometer. Use the
corresponding ribbon cables.
12.Put on the supplied module cover. Make sure that the ribbon cable is not trapped.
Note
Module cover

Installing/mounting
(Page 53).
14.Set the limits L1 and L2 as described in Setting limits (Page 67).
4.5.5.3 Setting limits
Procedure: Setting the limits L1 and L2

1. Move the actuator to the first desired mechanical position.
2. Adjust the upper actuating disk ④ manually until the output signal at terminals 51 and 52
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
3. Move the actuator to the second desired mechanical position.
4. Adjust the lower actuating disk ⑤ manually until the output signal at terminals 41 and 42
– Rotate the actuating disc beyond the switching point until you reach the next switching
point.
Note
Adjusting the actuating disk
The actuating disks ④ and ⑤ are relatively difficult to move. This design prevents their
unintentional movement during operation. You can achieve an easier and finer
adjustment by reducing stiction temporarily.
● Move the actuator to and fro while simultaneously holding the actuating disks ④
and ⑤.

Installing/mounting
4.5.6 Internal NCS module (iNCS) 6DR4004-5L / -5LE
Function
Wear-free, non-contacting position detection
Device features

① Internal NCS module 6DR4004-5L. ④ Adjustment wheel for the magnet clamp
② Insulating cover, yellow ⑤ Adjustment wheel for the friction clutch (without
function)
③ Ribbon cable of the internal NCS mod‐
ule
Figure 4-19 Installing the internal NCS module, schematic diagram
Requirement
● The slot required for the internal NCS (iNCS) module in the rack is free. The following option
modules use the same slot in the rack:
– Digital I/O Module (DIO)
– Inductive Limit Switches (ILS)
– Mechanic Limit Switches (MLS)
– Internal NCS module
● The positioner is mounted, or is to be mounted, directly on the valve using the positioner
shaft.

Installing/mounting
Procedure
3. Tighten the two fixing screws of the basic electronics.
4. Remove the basic electronics.
5. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here
you fasten the ribbon cable to the container using a cable tie.

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6. Screw the special screw ⑥ into the shaft of the positioner.

7. Tighten the special screw with a torque of 2 Nm.

8. Press the adjustment wheel of the magnet clamp ④ firmly onto the special screw ⑥ of the
friction clutch until you clearly hear it click into place.


Installing/mounting
Installing the internal NCS module

1. Position the ribbon cable ③ ofthe internal NCS module ① on the top before you slide the
internal NCS module into the rack.
2. Slide the internal NCS module ① under the basic electronics into the rack until you hear it
click into place.
3. An insulating cover (yellow) is required over the module. This insulating cover is supplied
with the module. Place the insulating cover ② on one side under the basic electronics seat
of the rack. The recesses of the insulating cover must fit in the corresponding webs of the
rack.
4. To tighten the insulating cover, bend the walls of the adapter slightly outwards.
5. Firmly press the other end until the insulating cover is underneath the contact surface of the
of the rack.
Installing the basic electronics and closing the positioner

1. Place the basic electronics onto the four holders of the rack.
3. Tighten the screws.
4. Insert the ribbon cable connector of the internal NCS module ① onto the positioner basic
electronics.
Note for built-in Analog Output Module (AOM): Reestablish all electrical connections
between the basic electronics and the option module.
5. Put on the supplied module cover. Make sure that the ribbon cable is not trapped.
Note
Module cover

Result
The module is installed and connected to the basic electronics of the positioner. Now configure
the module with the parameter "1.YFCT (Page 143)".

Installing/mounting
4.5.7 Analog Input Module (AIM) 6DR4004-6F / -8F
Function
If you use a Position Transmitter on the positioner, you will need the Analog Input Module (AIM).
The Analog Input Module (AIM) forms the interface between Position Transmitter and the basic
electronics of the positioner.
Device features
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① Switch block 1
② Switch block 2
Figure 4-20 Analog Input Module (AIM), schematic representation
● Connection to basic electronics

● Connection terminals for:
– Position Transmitter (Potentiometer) with 3 kΩ, 5 kΩ or 10 to 20 kΩ
– Signals 0 to 20 mA
– Signals 0 to 10 V
Requirement
● You have at least one of the following modules:
– 6DR4004-8F Analog Input Module (AIM) - nEx
– 6DR4004-6F Analog Input Module (AIM) - Ex
● You have opened one of the following Position Transmitters:
– 6DR4004-6N*/-8N* NCS sensor
– 6DR4004-1ES Position Transmitter (Potentiometer)
– 6DR4004-2ES Position Transmitter (NCS)
– 6DR4004-3ES Position Transmitter (NCS, ILS)
– 6DR4004-4ES Position Transmitter (NCS, MLS)

Installing/mounting
Procedure

① Terminals of the Analog Input Module (AIM) ⑤ Basic electronics

② Yellow wheel for locking the position detection ⑥ Screw
③ Positioner ⑦ Analog Input Module (AIM)
6DR4004-6F/-8F
④ Ribbon cable connector of fitted potentiometer
or ribbon cable connector of Analog Input Mod‐
ule (AIM)
Figure 4-21 Installation of Analog Input Module (AIM)
(Page 52).
3. Loosen the two fixing screws of the basic electronics ⑤.
5. Loosen the screw ⑥ in the connection area of the positioner.
6. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here
you fasten the ribbon cable with the supplied cable tie at the container.

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7. Secure the Analog Input Module (AIM) using the screw ⑥.

8. Place the basic electronics ⑤ onto the four holders of the adapter.
9. Screw in the two fixing screws of the basic electronics ⑤.
10.Tighten the screws.

Installing/mounting
11.Insert the ribbon cable connector ④ of the Analog Input Module (AIM) onto the basic
electronics of the positioner.
12.Establish all electrical connections between the basic electronics and the option modules.
(Page 53).

Installing/mounting

Connection 5
WARNING
Lever for position detection
Danger of crushing and shearing with mounting kits which use a lever for position detection.
During commissioning and ongoing operation, severing or squeezing of limbs could occur as
a result of the lever. Risk of injury when working on control valves due to the high operating
force of the pneumatic actuator.
● Do not reach into the range of motion of the lever following mounting of the positioner and
mounting kit.
WARNING
With intrinsically device version (Ex i)
For intrinsically safe device versions only the certified circuits may be connected as auxiliary
power supply, control and signal circuits.
● Make sure that the power source of the used circuits is marked as intrinsically safe.
WARNING
Unsuitable cables, cable glands and/or plugs
● Use only cable glands/plugs that comply with the requirements for the relevant type of
protection.
● Tighten the cable glands in accordance with the torques specified in Technical data
(Page 239).
● Close unused cable inlets for the electrical connections.
● When replacing cable glands, only use cable glands of the same type.
● After installation, check that the cables are seated firmly.

Connection
NOTICE
Ambient temperature too high
Damage to cable sheath.
● At an ambient temperature ≥ 60 °C (140 °F), use heat-resistant cables suitable for an
ambient temperature at least 20 °C (36 °F) higher.
WARNING
Improper power supply
Risk of explosion in hazardous areas as result of incorrect power supply.
● Connect the device in accordance with the specified power supply and signal circuits. The
relevant specifications can be found in the certificates, in Technical data (Page 239) or on
the nameplate.
WARNING
Lack of equipotential bonding
Risk of explosion through compensating currents or ignition currents through lack of
equipotential bonding.
● Ensure that the device is potentially equalized.
Exception: It may be permissible to omit connection of the equipotential bonding for devices
with type of protection "Intrinsic safety Ex i".
WARNING
Unprotected cable ends
Risk of explosion through unprotected cable ends in hazardous areas.
● Protect unused cable ends in accordance with IEC/EN 60079-14.
WARNING
Improper laying of shielded cables
Risk of explosion through compensating currents between hazardous area and the
non‑hazardous area.
● Shielded cables that cross into hazardous areas should be grounded only at one end.
● If grounding is required at both ends, use an equipotential bonding conductor.

Connection
WARNING
Connecting device in energized state
● Connect devices in hazardous areas only in a de-energized state.
Exceptions:
● Devices having the type of protection "Intrinsic safety Ex i" may also be connected in
energized state in hazardous areas.
● Exceptions for type of protection "Increased safety ec" (Zone 2) are regulated in the
relevant certificate.
WARNING
Incorrect selection of type of protection
Risk of explosion in areas subject to explosion hazard.
This device is approved for several types of protection.
1. Decide in favor of one type of protection.
2. Connect the device in accordance with the selected type of protection.
3. In order to avoid incorrect use at a later point, make the types of protection that are not used
permanently unrecognizable on the nameplate.
NOTICE
Standard cable gland/torque
Device damage.
● Owing the reasons pertaining to tightness (IP enclosure rating) and the required tensile
strength, only use the cables having a diameter ≥ 8 mm for standard M20x1.5 cable gland,
or use a suitable seal insert in case of smaller diameters.
● In the NPT version, the positioner is delivered with a coupling. When inserting a counter
piece in the coupling, ensure that the maximum permissible torque of 10 Nm is not
exceeded.
CAUTION
Maximum AC/DC switching voltage with UL approval E344532
Mechanic Limit Switches (MLS) 6DR4004-6K/-8K are approved for use with positioners with
UL approval. The maximum switching voltage in this case is ≤ 30 V AC/DC.
If switching voltages greater than 30 V are connected, the UL approval for the positioner
becomes invalid.

Connection
NOTICE
Condensation in the device
Damage to device through formation of condensation if the temperature difference between
transportation or storage and the mounting location exceeds 20 °C (36 °F).
● Before taking the device into operation, let the device adapt for several hours in the new
environment.
Two-wire mode
NOTICE
Connection of voltage source to current input
Device damage if a voltage source is connected to the current input Iw (terminals 6 and 7).
● Never connect the current input Iw to a low-resistance voltage source, otherwise the
positioner may be destroyed.
● Always use a high-impedance power source.
● Observe the static destruction limit specified in the "Electrical data (Page 246)".
Note
Improvement of interference immunity
● Lay signal cables separate from cables with voltages > 60 V.
● Use cables with twisted wires.
● Keep device and cables at a distance from strong electromagnetic fields.
● Take account of the conditions for communication specified in the Electrical data
(Page 246).
● Use shielded cables to guarantee the full specification according to HART/PA/FF/Modbus/
EIA-485/Profibus DP.
Electromagnetic compatibility
The polycarbonate enclosure is metalized from inside to increase the electromagnetic
compatibility (EMC) with respect to high-frequency radiation. The shield is connected to the
threaded bush shown in the following picture such that it is electrically conductive.
Note that this protection is effective only if you connect at least one of these bushes to the
earthed control valves through electrically conductive (bare) attachments.

Connection
5.2 Electrical wiring
Shield
Figure 5-1 Base plate ①
5.2.1 Connection diagram for basic electronics

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① Non-hazardous area ④ Digital input DI1

② Hazardous area ⑤ Signal source
③ Basic electronics ⑥ HART communicator
nEx = Non-explosion-proof device version
Figure 5-2 Device version 2-wire

Connection
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② Hazardous area ⑤ Signal source
③ Basic electronics ⑥ HART communicator
Figure 5-3 Device version 2-/3-/4-wire, with wiring configuration 2-wire
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① Non-hazardous area ⑤ Power source

② Hazardous area ⑥ Signal source
③ Basic electronics ⑦ HART communicator
④ Digital input DI1 nEx = Non-explosion-proof device version
Figure 5-4 Device version 2-/3-/4-wire, with connection type 3-wire

Connection
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② Hazardous area ⑥ Signal source
③ Basic electronics ⑦ HART communicator
④ Digital input DI1 nEx = Non-explosion-proof device version
Figure 5-5 Device version 2-/3-/4-wire, with connection type 4-wire

Connection
5.2.2 Connection diagram split range

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② Hazardous area ④ Travel range ⑦ Travel range
⑨ Signal source ⑤ Digital input DI1 ⑧ Digital input DI1
⑩ Power source
⑪ HART communicator
Figure 5-6 Series connection of 2 positioners, e.g. split range

Connection
5.2.3 Option modules
5.2.3.1 Digital I/O Module (DIO) 6DR4004-6A / -8A
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② Hazardous area ⑥ Limit
③ Digital I/O Module (DIO) ⑦ Switching amplifier
④ Digital input DI2 ⑧ Switching output
Figure 5-7 Digital I/O Module (DIO)

Connection
5.2.3.2 Analog Output Module (AOM) 6DR4004-6J / -8J
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① Non-hazardous area ④ Feed splitter

② Hazardous area ⑤ Power source
③ Analog Output Module (AOM) nEx = Non-explosion-proof device version
Figure 5-8 Analog Output Module (AOM)
5.2.3.3 Inductive Limit Switches (ILS) 6DR4004-6G / -8G
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② Hazardous area ⑤ Limit
③ Inductive Limit Switches (ILS) ⑥ Switching amplifier
Figure 5-9 Inductive Limit Switches (ILS)

Connection
5.2.3.4 Mechanical Limit Switches (MLS) 6DR4004-6K / -8K
DANGER
Supply with hazardous voltage
If you connect the switching contacts of the 6DR4004-8K module to a hazardous voltage,
observe the following safety rules:
1. Isolate the device from power. Use a circuit breaker positioned near the device to do this.
2. Make sure that the device cannot be switched back on inadvertently.
3. Make sure the device is truly isolated from power.
CAUTION
Maximum AC/DC switching voltage with UL approval E344532
Mechanic Limit Switches (MLS) 6DR4004-6K/-8K are approved for use with positioners with
UL approval. The maximum switching voltage in this case is ≤ 30 V AC/DC.
If switching voltages greater than 30 V are connected, the UL approval for the positioner
becomes invalid.
Connection diagram Mechanic Limit Switches (MLS) 6DR4004-6K and -8K
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② Hazardous area ⑥ Switching amplifier
③ Mechanic Limit Switches (MLS) ⑦ Switching output
④ Fault message nEx = Non-explosion-proof device version
Figure 5-10 Mechanic Limit Switches (MLS)

Connection
Procedure
1. Loosen the screw ① on the transparent cover ②.
2. Pull the transparent cover ② up to the front end stop.
3. Tighten every cable in the corresponding terminal.
4. Slide the transparent cover ② up to the end stop of the basic electronics.
5. Tighten the screw ① of the transparent cover ②.
6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the
provided cable ties ③ for this purpose.

① Screw
② Cover
③ Cable tie
Figure 5-11 Connecting the cables

Connection
5.2.3.5 Analog Input Module (AIM) 6DR4004-6F / -8F
Procedure
1. Connect the external position detection as follows.
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① Connection of terminal Vcc is only needed for 6DR4004-2ES, -3ES and -4ES.
2. If potentiometers or external signal sources are used, configure the switch blocks in
accordance with the following table:
Measuring range Switch block 1 Switch block 2

S1-1 S1-2 S2-1 S2-2 S2-3 S2-4
6DR4004-.N/P/R (NCS) ON OFF ON OFF OFF OFF
6DR4004-1ES/-2ES/-3ES/-4E ON OFF ON OFF OFF OFF
S
10 ... 20 kΩ ON OFF ON OFF OFF OFF
5 kΩ OFF ON ON OFF OFF OFF
3 kΩ OFF OFF ON OFF OFF OFF
20 mA OFF OFF ON OFF ON OFF
10 V OFF OFF OFF ON OFF OFF

Connection
See also
'1.YFCT' type of actuator (Page 143)
5.2.4 Optional version M12 device plug
This section describes which terminal of the devices and option modules listed below is
connected with the respective pole of the M12 connector.
Note
Technical specifications
Observe the specifications for the electrical data in the certificate and/or in section "Technical
data (Page 239)".
View of the mating side pole pattern
Pole desig‐ Wire color of M12 ba‐

nation sic connector socket
1 Brown
4 Black
3 Blue
2 White
5.2.4.1 In the basic unit

You have a positioner 6DR50/1..-0.R.. or 6DR50/1..-0.S. In this version of the positioner, the
current input IW 4 to 20 mA of the basic electronics is connected via the M12 connector.
Table 5-1 Assignment diagram
Current input terminal Pole designation

6 (+) 1 - Brown
Shield support of enclosure 4 - Black
7 and 8 (-) 3 - Blue

Connection
5.2.4.2 In the basic unit with Analog Output Module (AOM) 6DR4004-6J/-8J (-Z D53)
You have a positioner with order suffix -Z order code D53. In this version of the positioner, the
current output of Analog Output Module (AOM) is electrically connected to the M12 connector.
Current output terminal Pole designation

61 (+) 1 - Brown
Shield support of enclosure 4 - Black
62 (-) 3 - Blue
5.2.4.3 In the basic unit with Position Transmitter (-Z D54)

installed Analog Input Module (AIM) 6DR4004-6F/-8F is electrically connected to the M12
connector. You connect the Position Transmitter 6DR4004-1ES/-2ES using the M12 connector.
Terminal Pole designation

REF 2 - White
POS 3 - Blue
GND 4 - Black
VCC 1 - Brown
5.2.4.4 In the basic unit with Digital I/O Module (DIO) 6DR4004-6A/-8A (-Z D55)
current output of Digital I/O Module (DIO) is electrically connected to the M12 connector.
Terminal of digital outputs A1 and A2 Pole designation

41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White

Connection
5.3 Pneumatic connection
5.2.4.5 In the basic unit with Inductive Limit Switches (ILS) 6DR4004-6G/-8G (-Z D56)
digital outputs A1 and A2 of the Inductive Limit Switches (ILS) are electrically connected to the
M12 device plug.

41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White
5.2.4.6 In the basic unit with Mechanic Limit Switches (MLS) 6DR4004-6K (-Z D57)
digital outputs A1 and A2 of the Mechanic Limit Switches (MLS) are electrically connected to
the M12 connector.

41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White
5.3.1 Basic safety instructions for the pneumatic connection
WARNING
Supply pressure PZ
For safety reasons, the supply pressure PZ can be fed after installation only if the positioner
is switched to "P-Manual mode" when an electrical signal is present. This operating mode is
preset in the delivery state.
Note
Specifications regarding air quality
Observe the specifications regarding the air quality in section "Technical specifications
> Pneumatic data (Page 239)".

Connection
Note
Leakage
Besides continuous air consumption, a leakage can cause the positioner to try to compensate
the position deviation. This will result in premature wear in the entire control device.
● Check offline for leakage using the "11.LEAK" diagnostic parameter.
● If there is leakage, check the pneumatic connections for leaks.
See also
Behavior in case of failure of the electrical auxiliary power and/or the supply pressure PZ
(Page 93)
Changing the operating mode (Page 98)
Diagnostic value '11.LEAK - Leakage test' (Page 217)
5.3.2 Pneumatic connection in non-flameproof enclosure
5.3.2.1 Structure of pneumatic connection

① Output: Actuating pressure Y2 *)

② Input: Supply pressure PZ
③ Output: Actuating pressure Y1
④ Exhaust air outlet with sound absorber, thread G¼
*) for double-acting actuators
Figure 5-12 Pneumatic connection, example
5.3.2.2 Integrated pneumatic connection

The following pneumatic connections are provided at the rear side of the basic device for the
integrated attachment for single-acting linear actuators:
● Actuating pressure Y1
● Exhaust air outlet

Connection
These connections are sealed with screws when the device is delivered.
The exhaust air outlet is corrosion-resistant for the blanketing of the pick-up room and the
spring chamber with dry instrument air.
① Actuating pressure Y1
② Exhaust air outlet
Figure 5-13 Integrated pneumatic connection
5.3.3 Pneumatic connection in the flameproof enclosure
Structure
The pneumatic connections are provided on the right side of the positioner.
① Restrictor Y2 *) ⑤ Output: Actuating pressure Y1

② Restrictor Y1 ⑦ Enclosure ventilation (2x)
③ Output: Actuating pressure Y2 *)
⑥ Exhaust air outlet
④ Input: Supply pressure PZ
*) for double-acting actuators
Figure 5-14 Pneumatic connection in the flameproof enclosure

Connection
5.4 Restrictors
5.3.4 Behavior in case of failure of the electrical auxiliary power and/or the supply
pressure PZ
Overview
CAUTION
Note the following before working on the control valve
Note that, before working on the control valve, you must first move it to the safety position.
Make sure that the process valve has reached the safety position. If you only interrupt the
supply pressure PZ to the positioner, the safety position may in some cases only be attained
after a certain delay period.
The difference between a failure of supply pressure PZ and a failure of electrical auxiliary
power:
● Failure of electrical auxiliary power means:
– Device version 2-wire: Failure of signal source 4 to 20 mA
– Device version 3/4-wire: Failure of power source 18 to 30 V
● Failure of the supply pressure PZ
With 3-wire/4-wire device version, the 0% position is approached if the 4 to 20 mA signal source
fails. The following table shows the pneumatic connection versions for different actuator types,
regulating action and safety position after failure.
Actuator type Behavior in case of failure: The actuator moves Fail in place, order suffix F01
into safety position
Failure of electrical Failure of supply pres‐ Failure of electrical Failure of supply pres‐
auxiliary power sure PZ auxiliary power sure PZ
Single-acting Y1 = depressurized Y1 = depressurized Y1 = closed Y1 = closed
Double-acting Y1 = pressurized Y1 = closed Y1 = closed Y1 = closed
Y2 = depressurized Y2 = closed Y2 = closed Y2 = closed
5.4 Restrictors
● Reduce the air output to achieve travel times of T > 1.5 s for small actuators. Use restrictors
Y1 ① and Y2 ② for this purpose.
● When turned clockwise, they reduce the air output and finally shut it off.

Connection
5.4 Restrictors
● In order to set the restrictors, we recommend closing them and then opening slowly.
● In case of double-acting valves, ensure that both restrictors have approximately the same
setting.

① Restrictor Y1
② Restrictor Y2, only in the version for double-acting actuators *)
③ Hexagon socket-head screw 2.5 mm
Figure 5-15 Restrictors
*) Restrictor Y2 ② is not active for single-acting Fail in Place F01
See also
Sequence of automatic initialization (Page 109)

Operating 6
6.1 Operating elements
6.1.1 Display
Introduction
Note
Repetition rate display
When operated in temperature ranges below -10°C, the liquid crystal display of the positioner
becomes sluggish and the repetition rate display reduces considerably.
The display has two lines. These two lines are segmented differently. Each element in the
upper line has 7 segments, whereas that in the lower line has 14 segments. Contents of the
display depend on the selected mode.
Display options as per the mode

An overview of mode-specific display options is given below.
Operating mode Representation in the display Pos. Legend

P manual mode ① Potentiometer setting [%]
② Blinking indicator for the non-initialized status.

Initialization mode ① Potentiometer setting [%]

② Display of the current status of initialization or a fault
message.
③ Indicator for ongoing initialization or a fault message.
Configuring ① Parameter value

② Parameter name

③ Parameter number

Operating
Operating mode Representation in the display Pos. Legend

Manual mode (MAN) ① Position [%]
② Setpoint [%]

③ Fault message
Automatic (AUT) ① Position [%]

② Setpoint [%]

③ Fault message
Diagnostics ① Diagnostics value

② Diagnostics name

③ Diagnostics number
See also
System messages before initialization (Page 207)
6.1.2 Buttons

① Display
② Operating mode button
③ Decrement button
④ Increment button
Figure 6-1 Display and buttons of the positioner

Operating
● You can use three buttons to operate the positioner.

● The function of the buttons depends on the mode selected.
● In a positioner with a flameproof enclosure, the buttons are protected by a cover. The button
cover can be opened after unlatching the locking screw.
Note
Button cover
In positioners with flameproof enclosures, the button cover prevents liquids from seeping
through. The IP66 / type 4X degree of protection is not ensured when the enclosure or the
button cover is open.
You have to remove the enclosure cover to operate the buttons of the basic device or the
"intrinsically safe" version.
Note
Degree of protection
The IP66 / type 4X degree of protection is not ensured as long as the positioner is open.
Function of buttons:
● The button is used to select the modes and to forward the parameters.
● The button is used to select parameter values in "Configuration" mode. You can use this
button to move the actuator in "Manual" mode.
● The button is also used to select parameter values in "Configuration" mode. You can use
this button to move the actuator in "Manual" mode.
Note
Order
Parameters are activated in the reverse order when the and buttons are pressed
simultaneously.
6.1.3 Firmware version

The current firmware version is displayed when you exit the operating mode "Configuration".
Figure 6-2 Firmware version, example

Operating
6.2 Operating modes
6.2 Operating modes
6.2.1 Overview of operating modes

You have five operating modes at your disposal to operate the positioner:
1. P-manual mode (as-delivered condition)
2. Configuration and initialization mode
3. Manual mode (MAN)
4. Automatic (AUT)
5. Diagnostics
6.2.2 Changing the operating mode

The following picture illustrates the available operating modes and switching between the
operating modes.
Operating mode Display (1)
P manual mode
Position of
potentiometer [%]
Change position using:
Not initialized
PRST
>5s
Configure Parameter value
Change parameter
name using:
or + Parameter number
Change value using: >5s
Parameter name
>5s >5s
Manual mode
Position[%]
Change position using:

Error code
Mode and
>2s
setpoint [%]
1x 1x
Automatic mode Position [%]
Error code
Mode and
setpoint [%]
+ +
Diagnostics >2s >2s
Diagnostics value
+ +
>2s
Diagnostics number
Diagnostics name
Figure 6-3 Switching between the operating modes

Operating
6.2 Operating modes
See also
Display (Page 95)
6.2.3 Overview of configuration

The following picture illustrates the handling of operating modes such as "Configuration" and
"Initialization mode":
VLPXOWDQHRXV VLPXOWDQHRXV
XQWLO
VLPXOWDQHRXV VLPXOWDQHRXV
Figure 6-4 Overview of the "Configuration" operating mode
6.2.4 Description of operating modes
P manual mode
Note
Delivery state
The "P manual mode" is preset for the positioner in the delivery state.
The display of the positioner shows the current potentiometer position in the upper line. "NOINI"
blinks in the second line of the display.
Move to the actuator with the or buttons.
Switch to "Configuration" mode to adapt the actuator to the positioner.
Alarms or position feedbacks can be triggered after initializing the positioner completely.

Operating
6.2 Operating modes
Configuration and initialization

To get to the "Configuration" mode, press the button for at least 5 seconds.
You can use the "Configuration" mode to adjust the positioner individually as per your actuator
and start commissioning or initialization.
The positioner reports the "Configuration" mode with a configurable fault message. A position
feedback or display of limits A1 and A2 is not possible.
Note
Failure of electrical auxiliary power
If electrical auxiliary power supply fails when configuring, the positioner responds as follows
when the power supply is reestablished:
● The positioner switches to the first parameter.
● Settings of the values already configured are retained.
In order to save the changed parameter values, exit the "Configuration" mode or switch to
another parameter. When "Configuration" mode is restarted, the output in the display switches
to the last activated parameter.
Manual mode (MAN)

In this mode, you move the actuator with or . The setting selected here is retained
irrespective of the setpoint current and leakages, if any.
Note
Accelerating the actuator movement
Proceed as follows if you wish to accelerate the actuator movement:
1. Keep one of the two direction buttons pressed.
2. Press the remaining direction button simultaneously.
Note
Failure of power supply
When the power supply is reestablished after a failure, the positioner switches to the
"Automatic" mode.
Automatic (AUT)
Automatic is the standard mode. In this mode, the positioner compares the setpoint position
with the actual position. The positioner moves the actuator until the control deviation reaches
the configurable deadband. An error message is displayed if the deadband cannot be reached.
Diagnostics
Proceed as follows to call the "Diagnostics" mode from the "Automatic" or "Manual" modes:

Operating
6.2 Operating modes
Press the three buttons of the positioner at the same time for at least 2 seconds.
Current operating data can be called and displayed in this mode, e.g.:
● Number of total strokes
● Number of changes in direction
● Number of fault messages
Note
Setting the mode
The "Automatic" and "Manual" modes remain set when switching to the "Diagnostics" mode.
The positioner responds as per the configured mode:
● The predefined setpoint is used as the control variable in "Automatic" mode.
● The last reached position is retained in "Manual" mode.
See also
Overview (Page 107)
Overview of advanced diagnostic parameters A to U (Page 139)
Overview of diagnostics values (Page 213)
6.2.5 Optimization of controller data
Note
Initializing
Initialize the positioner automatically before changing the parameter settings as per your
specific requirements.
The positioner determines the data for control quality automatically during the initialization
process.
The data determined is optimized for a short transient time in the case of minor overshoots.
The adjustment can be accelerated or the attenuation can be intensified by optimizing the data.
The following special cases are suitable for targeted data optimization:
● Small actuators with travel times < 1 s.
● Operation with boosters, described in section "Booster commissioning (Page 305)"
Procedure
1. Switch to "Diagnostics" mode.
2. Select the diagnostics parameters.

Operating
6.2 Operating modes
3. Press the three buttons of the positioner at the same time for at least 2 seconds.
4. Activate the setting function. Press the or button for at least 5 seconds.
The modified diagnostics values are effective immediately. The effects on the controller results
can then be tested.
In order to optimize the controller data, change the values of the diagnostics parameters listed
below.
Diagnostics parameters '23.IMPUP' Impulse length UP / '24.IMPDN' Impulse length DOWN

You can use these diagnostics parameters to determine the smallest impulse lengths for each
actuating direction. The actuator is then moved with these lengths. The optimum value
depends in particular on the volume of the actuator. Small values lead to small controller
increments and frequent activation of the actuator. Large values are advantageous for large
actuator volumes.
Note
Controller increments
● There is no movement if the values are too small.
● Large controller increments also lead to large movements with small actuators.
Diagnostics parameters '28.SSUP' Slow step zone UP / '29.SSDN' Slow step zone DOWN
The slow step zone is the area of mean control deviation. For more information on the slow step
zone, refer to the section "Mode of operation (Page 30)".
Select small values to achieve high speeds of shifting even with small control deviations. Select
large values to reduce overshoots particularly in case of large changes in the setpoint.
NOTICE
Overshoots or too low speeds of shifting
Too small values can result in overshoots.
● Enter a higher value.
Too large values result in too slow speeds of shifting near the adjusted status.
● Enter a smaller value.

Operating
6.2 Operating modes
Diagnostics parameters '47.PRUP' Prediction UP / '48.PRDN' Prediction DOWN

These diagnostics parameters act as attenuation factors and are used to set the control
dynamics. Changes in the diagnostics values have the following results:
● Small values result in quick adjustments with overshoots.
● Large values result in slow adjustments without overshoots.
Note
Reference variable
It is advantageous to use a fixed reference variable to optimize the control data. Therefore,
change the deadband of the controller in the '34.DEBA' parameter from "Auto" to a fixed
value.

Operating
6.2 Operating modes

Commissioning 7
WARNING
Lever for position detection
Danger of crushing and shearing with mounting kits which use a lever for position detection.
During commissioning and ongoing operation, severing or squeezing of limbs could occur as
a result of the lever. Risk of injury when working on control valves due to the high operating
force of the pneumatic actuator.
● Do not reach into the range of motion of the lever following mounting of the positioner and
mounting kit.
WARNING
Improper commissioning in hazardous areas
Device failure or risk of explosion in hazardous areas.
● Do not commission the device until it has been mounted completely and connected in
accordance with the information in Technical data (Page 239).
● Before commissioning take the effect on other devices in the system into account.
See also
Basic safety instructions (Page 105)
WARNING
Commissioning and operation with pending error
If an error message appears, correct operation in the process is no longer guaranteed.
● Check the gravity of the error.
● Correct the error.
● If the error still exists:
– Take the device out of operation.
– Prevent renewed commissioning.

Commissioning
WARNING
Loss of explosion protection
Risk of explosion in hazardous areas if the device is open or not properly closed.
● Close the device as described in Installing/mounting (Page 37).
WARNING
Opening device in energized state
Risk of explosion in hazardous areas
● Only open the device in a de-energized state.
● Check prior to commissioning that the cover, cover locks, and cable inlets are assembled
in accordance with the directives.
Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in
energized state in hazardous areas.
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 device
from the pneumatics during initial commissioning.
● Before commissioning, make sure that no water is present in the compressed air line.
If you cannot be sure that there is no water in the compressed air line:
● Set the purging air selector to "OUT". In this way, you prevent water from the compressed
air line from penetrating the device.
● Only set the purging air selector to "IN" again when all water has been discharged from the
compressed air line.
CAUTION
Increased sound pressure level
Changes to the sound absorber of the positioner or the mounting of pneumatic components
or pneumatic options on the positioner can cause a sound pressure with a level of 80 dBA to
be exceeded.
● Wear suitable hearing protection to protect yourself against hearing damage.

Commissioning
7.2 Overview
When operating the positioner with natural gas, you must follow and adhere to the following
safety notes:
WARNING
Operation with natural gas
1. Only positioners and option modules which are connected to power supplies with type of
protection "Intrinsic safety, protection level [ia]" may be operated with natural gas.
2. Do not operate the positioner with natural gas in closed spaces.
3. Natural gas is continuously blown off, depending on the model. Special care must therefore
be taken during maintenance activities near the positioner. Always ensure that the
immediate surroundings of the positioner are adequately ventilated.
The maximum values for ventilation are listed in section "Technical data (Page 239)".
4. If you operate the positioner with natural gas, it is not permitted to use Mechanic Limit
Switches (MLS).
5. Depressurize the devices operated with natural gas adequately during maintenance
activities. Open the cover in an explosion-free atmosphere and depressurize the device for
at least two minutes.
Note
Quality of natural gas
Only use natural gas which is clean, dry and free from additives.
7.2 Overview
Note
● During the initialization process, the operating pressure must be at least one bar more than
that required to close or open the valve. However, the operating pressure should not be
greater than the maximum permissible operating pressure for the actuator.
General information about commissioning

1. After installing the positioner on a pneumatic actuator, you must supply electric and
pneumatic auxiliary power to it.
2. The positioner is in the "P manual mode" before initialization. At the same time, "NOINI"
blinks in the lower line of the display.
3. Position feedback: You can adjust the range of position detection using the friction clutch if
necessary.
4. Adjust the positioner as per the respective actuator with the help of the initialization process
and by setting the parameters. If required, use the "PRST" parameter to cancel the
adjustment of the positioner on the actuator. The positioner is again in the "P manual mode"
after this process.

Commissioning
7.2 Overview
Types of initialization
You can initialize the positioner as follows:
● Automatic initialization:
during automatic initialization, the positioner determines the following one after the other:
– The direction of action
– The actuator travel and angle of rotation
– The travel time of the actuator
The positioner also adjusts the control parameters as per the dynamic response of the actuator.
● Manual initialization:
the actuator travel and the angle of rotation of the actuator are set manually. The remaining
parameters are automatically determined. This function is useful for valves which are lined,
for example, with PTFE.
● Copying the initialization data when replacing a positioner:
the initialization data of a positioner can be read and copied into another positioner. A
defective device can thus be replaced without interrupting an ongoing process through
initialization.
You have to define a few parameters for the positioner before initialization. Owing to the preset
values, you cannot adjust further parameters for initialization.
With a suitable parameter assignment of the parameter "BIN1" and enabled digital input "DI1",
you protect the configured settings against accidental adjustment.
See also
Overview of operating modes (Page 98)

Commissioning
7.3 Sequence of automatic initialization
7.3 Sequence of automatic initialization
Overview
The automatic initialization takes place in the following phases:
Automatic initialization phase Description

Start -
RUN 1 Establishing the direction of action.
RUN 2 Checking the actuator travel and trimming the lower and
upper endstops.
RUN 3 Establishing and displaying the travel time (leakage test)
RUN 4 Minimization of controller increments
RUN 5 Optimization of the transient response
End -
The following structured charts describe the sequence of initialization. The "Up/Down" names
indicate the direction of action of actuators.
Linear actuator Part-turn actuator
Open Closed Closed Open

Commissioning
7.4 RUN 1 sequence
7.4 RUN 1 sequence

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Commissioning
7.5 RUN 2 sequence with linear actuators
7.5 RUN 2 sequence with linear actuators

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contains information about the sequence for trimming the lower and upper endstops.

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Commissioning
7.6 RUN 2 sequence with part-turn actuators
7.6 RUN 2 sequence with part-turn actuators

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Commissioning
7.7 RUN 3 to 5 sequence

This structured chart describes:
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● Minimization of controller increments in RUN 4
● Optimization of the transient response in RUN 5

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Commissioning
7.8 Setting the friction clutch
Introduction
It has a friction clutch and a switchable gear (Page 48) so that the positioner can be used with
different mechanical part-turn and linear actuators. Use the friction clutch to adjust the position
detection area. For positioners in non-flameproof enclosures, you also have the option of
locking the friction clutch.
Requirement
● The positioner is mounted.

Commissioning
Procedure
In non-flameproof enclosure In flameproof enclosure Ex d

1. Adjust the working area to your application by turning the 1. Adjust the working range by slightly turning the adjust‐
adjustment wheel of the friction clutch ①. ment wheel of the friction clutch ① over the hole with a
2. Fasten the friction clutch. Insert a standard approx. 4 mm pin.
wide screwdriver in the friction clutch gear latch ②. CAUTION
3. Use the screwdriver to turn the friction clutch gear Follow the steps below to avoid damage to your device.
latch ② counterclockwise ③ until it engages. The friction ● The friction clutch ① is outside the flameproof enclosure
clutch ① is locked. at the bottom.
● Do not loosen the screws on the adjustment wheel of the
friction clutch ① .
● Frequent twisting of the friction clutch is not provided for
due to the design.
● It is not necessary to lock the friction clutch.

Commissioning
7.10 Commissioning linear actuators
7.9 Purge air switching

When the enclosure is open, the purge air switch above the pneumatic terminal strip on the
valve block can be accessed.
● In the IN position, the enclosure is flushed from inside with a small volume of clean and dry
instrument air.
● In the OUT position, the purge air is directly directed towards outside.

① Purging air selector

② Pneumatic connections Y1, PZ and Y2
Figure 7-1 Purge air switch on the valve block; view of the positioner on the pneumatic connection
side when the cover is open
The factory setting is the "IN" position.
7.10.1 Preparing linear actuators for commissioning
Condition
You have already installed the positioner using the suitable mounting kit.
Setting the transmission ratio selector
Note
Commissioning
The setting of the transmission ratio selector is extremely important to commission the
positioner.
Stroke [mm] Position of the transmission ratio selector

5 to 20 33°
25 to 35 90°
40 to 130 90°

Commissioning
Connecting the positioner

1. Connect a suitable power supply. The positioner is now in "P manual mode". The current
potentiometer voltage (P) in percent is shown in the upper line of the display, e.g.: 'P37.5',
and 'NOINI' flashes in the bottom line:
2. Connect the actuator and the positioner to the pneumatic lines.

3. Supplying the positioner with supply pressure PZ.
Setting the actuator

1. Check whether the mechanical unit can be moved freely in the entire travel range. Move the
actuator to the respective end position for this purpose using the or button.
Note
End position
By simultaneously pressing the and buttons, you reach the end position faster.
2. Now move the actuator to the horizontal position of the lever.

3. A value between 'P48.0' and 'P52.0' is shown on the display.
4. If a value beyond this value range is shown on the display, you must move the friction clutch.
Move the friction clutch until a value between 'P48.0' and 'P52.0' is reached. The closer this
value is to 'P50.0', the more accurately the positioner determines the stroke travel.
Note
For device versions with flameproof enclosure
The inner friction clutch is fixed. Therefore, only move the outer friction clutch. This also
applies when using an internal NCS module.
The following applies to device versions without flameproof enclosure with internal NCS
module 6DR4004-5L.:
The inner friction clutch has no function. This means you should only adjust the adjustment
wheel of the magnet clamp; see section "Internal NCS module (iNCS) 6DR4004-5L / -5LE
(Page 68)". Condition: The '1.YFCT' type of actuator (Page 143) parameter is set.
See also
Mounting to linear actuator (Page 40)
Opening the device version with "flameproof enclosure" (Page 55)

Commissioning
7.10.2 Automatic initialization of linear actuators
Requirements
The following conditions must be fulfilled before activating the automatic initialization:
1. The actuator spindle can be moved completely.
2. The actuator spindle is at a central position after travel.
Initializing the linear actuator automatically
Note
Interrupting initialization
An ongoing initialization can be interrupted at any time. To do this, press . The settings
configured until then are retained.
All parameters are reset to factory settings only if you have explicitly activated the preset
settings in the "PRST" parameter.
Note
Commissioning of a tight-closing valve
If the valve is tight-closing, set the "YCLS (Page 153)" parameter before commissioning. This
ensures that the end positions are approached for at least 15 seconds during initialization.
1. Switch to the "Configuration" mode. To do this, keep the button pressed for at least 5
seconds. The display shows the following:
2. Call the "2.YAGL" parameter. To do this, press . The following is shown on the display
depending on the setting:
3. Check whether the value displayed in the "2.YAGL" parameter matches the setting of the
transmission ratio selector. If required, change the setting of the transmission ratio selector
to 33° or 90°.

Commissioning
4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of parameter
3 is optional. The display shows the determined total stroke at the end of the initialization
phase.
– Press the button if you do not require any information about the total stroke in mm.
You then reach parameter 4.
– Call the "3.YWAY" parameter. To do this, press . The display shows the following:
Note
Set the "3.YWAY" parameter
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter with the buttons and to the read value.
5. Call the "4.INITA" parameter. To do this, briefly press the button. The display shows the
following:
6. Start the initialization process. To do this, keep the button pressed for at least 5 seconds
until the display shows the following:
The positioner runs through five initialization steps during the automatic initialization
process. The displays for the initialization steps from "RUN 1" to "RUN 5" are located in the
lower line of the display. The initialization process depends on the actuator used, and takes
up to 15 minutes.
7. The following display indicates that the automatic initialization is complete:
See also

Commissioning
7.10.3 Manual initialization of linear actuators

You can use this function to initialize the positioner without needing to move the actuator to the
lower and upper endstops. The lower and upper endstops of the actuator travel are set
manually. When the control parameters are optimized, the further initialization process runs
automatically.
Conditions
The following conditions must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on linear actuators.
2. The actuator spindle can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Initializing the linear actuator automatically

1. Switch to the "Configuration" mode. To do this, press the button for at least 5 seconds
2. Call the "2.YAGL" parameter. To do this, briefly press the button. The following is shown
on the display depending on the setting:
3. Check whether the value displayed of the "2.YAGL" parameter matches with the setting of
the transmission ratio selector. If required, change the setting of the transmission ratio
selector to 33° or 90°.

Commissioning
4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of the
"3.YWAY" parameter is optional. The display shows the determined total stroke only at the
end of the initialization phase.
– Briefly press the button if you do not require any information about the total stroke in
mm. You are then directed to parameter 4.
– Call the "3.YWAY" parameter. To do this, briefly press the button. The display shows
the following:
Note
Set the "3.YWAY" parameter
To set the "3.YWAY" parameter proceed as follows:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter to the read value with the or button.
5. Call the "5.INITM" parameter. To do this, press the button twice. The display shows the
following:
6. Start the initialization process. To do this, press the button for at least 5 seconds until the
display shows the following:
The current potentiometer position is output on the display after 5 seconds. Examples of the
displayed potentiometer positions are given below:
7. Determine the lower endstop of the actuator spindle.

8. Move the actuator to the desired position using the or button.

Commissioning
9. Press the button. The current position of the actuator is applied. The display shows the
following:
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
2. Press the button.
3. Move the actuator to another position using the or button.
4. Abort the manual initialization process by pressing the button.
5. Then return to "P manual mode".
6. Correct the actuator travel and the position detection.
10.Determine the upper endstop of the actuator spindle. Move the actuator to the desired
position using the or button.
11.Press the button. The current position of the actuator is applied.
Note
Fault message "Set Middl"
The lever arm is not in the horizontal position if the "Set Middl" message is output on the
display. To correct the fault, set the reference point of the sine correction. Proceed as
follows:
1. Move the lever arm to the horizontal position using the or button.
12.The initialization process is automatically resumed. Initialization steps "RUN 1" to "RUN 5"
are output in the bottom line of the display. The following is displayed when the initialization
has been completed successfully:
Note
Total stroke
If the "3.YWAY" parameter has been set, the display shows the total stroke in mm.

Commissioning
7.11 Commissioning part-turn actuators
7.11.1 Preparing part-turn actuators for commissioning
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°.
● Set the transmission ratio selector in the positioner to 90°.
Condition
The following conditions must be fulfilled before activating the initialization:
1. You have installed the positioner for the part-turn actuators using the suitable mounting kit.
2. You have connected the actuator and the positioner to the pneumatic lines.
3. Supplying the positioner with the supply pressure PZ.
4. The positioner has been connected to a suitable power supply.
Setting the actuator

1. The positioner is in the "P manual mode". The current potentiometer voltage P in percent is
shown on the upper line in the display. "NOINI" blinks in the lower line of the display.
Examples of corresponding displays are given below:
2. Check whether the mechanical unit can be moved freely in the entire travel range. Move the
drive to the respective end position for this purpose using the or button.
Note
End position
By simultaneously pressing the and buttons, you reach the end position faster.
3. After checking, move the actuator to a central position. This accelerates the initialization
process.

Commissioning
7.11.2 Automatic initialization of part-turn actuators
Requirement
The following conditions must be fulfilled before activating the automatic initialization:
1. The travel range of the actuator can be passed through completely.
2. The actuator shaft is at a central position.
Initializing the part-turn actuator automatically
Note
Interrupting initialization
An ongoing initialization can be interrupted at any time. To do this, press . The settings
configured until then are retained.
All parameters are reset to factory settings only if you have explicitly activated the preset
settings in the "PRST" parameter.
Note
Commissioning of a tight-closing valve
If the valve is tight-closing, set the "YCLS (Page 153)" parameter before commissioning. This
ensures that the end positions are approached for at least 15 seconds during initialization.
2. Use the button to change from linear actuator to part-turn actuator until the display shows
the following:
3. Call the "2.YAGL" parameter. To do this, briefly press the button. This parameter has
already been set to 90° automatically. The display shows the following:

Commissioning
4. Call the "4.INITA" parameter. To do this, briefly press the button. The display shows the
following:
5. Start the initialization process. To do this, press the button for at least 5 seconds until the
display shows the following:
The positioner runs through five initialization steps during the automatic initialization
process. The displays for the initialization steps from "RUN 1" to "RUN 5" are located in the
lower line of the display. The initialization process depends on the actuator used, and takes
up to 15 minutes.
6. The following display indicates that the automatic initialization is complete. The total angle
of rotation of the actuator is shown on the upper line on the display:
See also
7.11.3 Manual initialization of part-turn actuators

You can use this function to initialize the positioner without needing to move the actuator to the
lower and upper endstops. The lower and upper endstops of the actuator travel are set
manually. When the control parameters are optimized, the further initialization process runs
automatically.

Commissioning
Conditions
The following conditions must be fulfilled before activating manual initialization:
1. The positioner has been prepared for using on part-turn actuators.
2. The actuator can be moved completely.
3. The displayed potentiometer position is within the permissible range between "P5.0" and
"P95.0".
Note
Setting of the adjustment angle
The usual adjustment angle for part-turn actuators is 90°. Accordingly set the transmission
ratio selector in the positioner to 90°.
Initializing the positioner manually

2. Set the "YFCT" parameter to "turn". To do this, press . The display shows the following:
3. Call the second parameter "YAGL". To do this, press . The display shows the following:
4. Call the "INITM" parameter. To do this, press the button twice. The display shows the
following:
5. Start the initialization process. Press the button for at least 5 seconds until the display
shows the following:

Commissioning
6. The current potentiometer position is output on the display after 5 seconds:
7. Determine the lower endstop of the actuator.

8. Move the actuator to the desired position using the or button.
9. Press the button. The current position of the actuator is applied. The display shows the
following:
Note
Fault message "RANGE"
The selected end position is beyond the permissible measuring range if the "RANGE"
message is output on the display. Correct the settings as follows:
1. Move the friction clutch until the display shows "OK".
3. Move the actuator to another position using the or button.
4. Abort the manual initialization process by pressing the button.
5. Then return to "P manual mode".
6. Correct the actuator travel and the position detection.
10.Determine the upper endstop of the actuator. Move the actuator to the desired position
using the or button.
11.Press the button. The current position of the actuator is applied.
12.The initialization process is automatically resumed. Initialization steps "RUN 1" to "RUN 5"
are output in the bottom line of the display. The following display indicates that the
initialization has been completed successfully:

Commissioning
7.13 Device replacement
7.12 Canceling initialization

– Canceling automatic initialization: the display shows "INITA".
– Canceling manual initialization: the display shows "INITM".
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the button for at least 5 seconds.
The software version is displayed.
After releasing the button, the positioner is in "P manual mode". The positioner is not
initialized.
Introduction
Note
Initialization
The positioner can be replaced without having to interrupt the ongoing process. However,
copying and transferring of the initialization parameters only allows an approximate adjustment
of the positioner to your actuator. Following initialization, the positioner initially works with the
manually defined parameters.
● For this reason, an automatic or manual initialization should be carried out as soon as
possible.
Note
Deferred initialization
Initialize the new positioner as soon as possible. The following properties can be ensured only
after initializing:
● Optimum adjustment of the positioner as per the mechanical and dynamic properties of the
actuator
● Non-deviating position of endstops
● Correctness of the maintenance data
There are two ways of replacing a positioner when the equipment is in operation, without having
to interrupt the process. The two options depend on whether your positioner has
communication.
First possibility - with communication

1. Read the initialization parameters from the previous positioner. Use the parameter
assignment tools suitable for this purpose.
2. Transfer the initialization parameters read in the parameterization software under Point 1
into the new positioner.

Commissioning
3. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
4. Determine the actual position value. To do this, read the actual position value from the
display of the previous positioner. Note down the read value.
5. Dismount the previous positioner from the actuator.
6. Attach the lever arm of the previous positioner to the new positioner.
7. Mount the new positioner on the actuator.
8. Set the transmission ratio selector of the new positioner to the same position as that of the
previous positioner.
9. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
10.The new positioner is ready for operation when the displayed and noted values match.
11.Release the fixing of the actuator.
Second possibility - without communication

1. Fix the actuator at its current position mechanically or pneumatically. Use the locking
function of your mounting kit, if available.
2. Determine the actual position value. To do this, read the actual position value on the display
of the previous positioner. Note down the read value.
Note
Electronics defect
If the positioner's electronics are defective, measure the actual position value with a ruler or
protractor at the actuator or process valve. Convert the read value into %. Note down the
converted value.
3. Dismount the previous positioner from the actuator.

4. Attach the lever arm of the previous positioner to the new positioner.
5. To prevent interference with the ongoing process, initialize the new positioner on an
actuator with a similar stroke or swivel range. Attach the new positioner to this actuator.
Initialize the new positioner.
6. Then dismount the new, initialized positioner from this actuator.
7. Mount the new, initialized positioner on the fixed actuator.
8. If the displayed actual position value differs from the noted value, correct the deviation by
moving the friction clutch.
9. Use the buttons on the positioner to enter the parameters which deviate from the factory
setting, such as type of actuator or tight closing.
10.Change to the measured value view using the button, see section "Description of
operating modes (Page 99)".
11.Release the fixing of the actuator.

Commissioning
See also
Automatic initialization of linear actuators (Page 119)
Automatic initialization of part-turn actuators (Page 125)
Manual initialization of linear actuators (Page 121)
Manual initialization of part-turn actuators (Page 126)

Commissioning

Parameter assignment 8
8.1 Introduction to parameter assignment section
A positioner is responsible for controlling a valve and for monitoring the status of a valve. The
parameters described in this section are used to optimally adapt the positioner to the valve and
its application.
The parameters are divided into initialization parameters, application parameters, and the
extended diagnostics parameters.
● Initialization parameters 1 to 5 (Page 143): Describes die parameters which are relevant for
initial commissioning of the positioner on the valve. For example, you can start the
automatic initialization here.
● Application parameters 6 to 52 (Page 147): Describes die parameters with which the
positioner is adapted to the valve application, for example tight closing at the stops.
● Advanced diagnostic parameters A to U (Page 163): Describes the diagnostics functions
which are provided by the positioner. These include monitoring of leakages as well as the
partial stroke test. Following activation of these functions, the positioner continuously
monitors the status of the valve. If you enter thresholds in the parameters of the diagnostics
functions, the positioner actively signals high or low violation of these thresholds. The
current monitoring state for these thresholds is displayed as a diagnostic value. For
additional details on diagnostics and diagnostic values, refer to the section Diagnostics
(Page 212).
The following configuration schematic shows the principle of operation of the parameters. This
is followed by a tabular overview of the parameters. Finally, the individual parameters and their
functionality are described.
Furthermore, the positioners with HART, PA and FF communication interface in combination
with a host system, e.g. SIMATIC PDM or HART communicator etc., offer the following
advantages:
● Offline tests such as full stroke test, step response test, multi-step response test and valve
performance test.
● Diagnostics cockpit which provides an overview of the state of positioner and valve.
● Logbook with time stamp for documentation of all events such as the violation of thresholds.
● Wizards which provide prompting through the relevant parameters during commissioning,
the partial stroke test as well as the offline test.

Parameter assignment
8.2 Configuration schematic for parameter operating principle
8.2 Configuration schematic for parameter operating principle
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Figure 8-1 Configuration block schematic

8.3 Tabular overview of the parameters
8.3.1 Overview of initialization parameters 1 to 5
Introduction
Parameters 1 to 5 are the same for all versions of the positioner. These parameters are used
to adjust the positioner to the actuator. Normally, setting these parameters is sufficient to be
able to operate the positioner on an actuator.
If you want to get to know all details of the positioner, gradually try out the effects of the
remaining parameters by systematic testing.
Note
Factory-set parameter values are printed in bold in the following table.
Overview
Parameter Function Parameter values Unit

1.YFCT Type of actuator Normal Inverted
Part-turn actuator turn -turn
Linear actuator WAY -WAY
Linear actuator - carrier pin on actuator spindle FWAY -FWAY
Linear actuator - external linear potentiometer LWAY -LWAY
(e.g. with cylinder drives)
Part-turn actuator with NCS/iNCS ncSt -ncSt
Linear actuator with NCS ncSL -ncSL
Linear actuator with NCS/iNCS and lever ncSLL -ncLL
2.YAGL Rated angle of rotation of positioner shaft 1)
33° Degrees
90°
3.YWAY2) Range of stroke (optional setting) 3)
OFF mm
5 | 10 | 15 | 20
(Short lever 33°, range of stroke 5 mm to
20 mm)
25 | 30 | 35
(Short lever 90°, range of stroke 25 mm to
35 mm)
40 | 50 | 60 | 70 | 90 | 110 | 130
(Long lever 90°, range of stroke 40 mm to
130 mm)
4.INITA Initialization (automatic) NOINI | no / ###.# | Strt
5.INITM Initialization (manual) NOINI | no / ###.# | Strt

1)
Set the transmission ratio selector accordingly.
2)
Parameter only appears with "WAY", "-WAY", "ncSLL", and "-ncLL"
3)
If used, the value on the actuator must correspond to the set range of stroke on the lever arm.
Carrier must be set to the value of the actuator travel or, if this value is not scaled, to the next larger scale value.
8.3.2 Overview of application parameters 6 to 52
Introduction
These parameters are used to configure the following additional functions of the positioner:
● Setpoint preparation
● Actual value preparation
● Digital signals
● Tight closing function
● Limit detection
Note
Overview

6.SCUR Current range of setpoint
0 ... 20 mA 0 MA
4 ... 20 mA 4 MA
7.SDIR Setpoint direction
Rising riSE
Falling FALL
8.SPRA Setpoint split range start 0.0 ... 100.0 %
9.SPRE Setpoint split range end 0.0 ... 100.0 %
10.TSUP Setpoint ramp up Auto / 0 ... 400 s
11.TSDO Setpoint ramp down 0 ... 400 s


12.SFCT Setpoint function
Linear Lin
Equal percentage 1 : 25 1 - 25
1 : 33 1 - 33
1 : 50 1 - 50
Inverse equal percent‐ 25 : 1 n1 - 25
age 33 : 1 n1 - 33
50 : 1 n1 - 50
Freely adjustable FrEE
13.SL0 ... Setpoint turning point
33.SL20 1)
13.SL0 At 0% 0.0 ... 100.0 %
14.SL1 .... 5 % ...
32.SL19 95 %
33.SL20 100 %
34.DEBA Deadband of closed-loop controller Auto / 0.1 ... 10.0 %
35.YA Start of manipulated variable limit 0.0 ... 100.0 %
36.YE End of manipulated variable limit 0.0 ... 100.0 %
37.YNRM Standardization of manipulated variable
To mechanical travel MPOS
To flow FLoW
38.YDIR Direction of manipulated variable for display and position feedback
Rising riSE
Falling FALL
39.YCLS Tight closing/fast closing with manipulated variable
None no
Tight closing Up uP
Tight closing Down do
Tight closing Up and Down uP do
Fast closing Up Fu
Fast closing Down Fd
Fast closing Up and Down Fu Fd
Tight closing Up and fast clos‐ uP Fd
ing Down
Fast closing Up and tight clos‐ Fu do
ing Down
40.YCDO Value for fast closing/tight closing 0.0 ... 0.5 ... 100.0 %
Down
41.YCUP Value for fast closing/tight closing Up 0.0 ... 99.5 ... 100.0 %


42.BIN1 2) Digital input function DI1 NO contact NC contact
None OFF
Message only on -on
Block configuration bLoc1
Block configuring and manual bLoc2
operation
Move process valve to YE po‐ uP -uP
sition
Move process valve to YA po‐ doWn -doWn
sition
Block movement StoP -StoP
Partial Stroke Test PSt -PSt
43.BIN2 2)
Digital input function DI2 NO contact NC contact
None OFF
Message only on -on
Move process valve to YE po‐ uP -uP
sition
Move process valve to YA po‐ doWn -doWn
sition
Block movement StoP -StoP
Partial stroke test PSt -PSt
44.AFCT 3)
Alarm function Normal Inverted
None OFF
A1 = Min, A2 = Max
A1 = Min, A2 = Min
A1 = Max, A2 = Max
45.A1 Response threshold, alarm 1 0.0 ... 10.0 ... 100.0 %

46.A2 Response threshold, alarm 2 0.0 ... 90.0 ... 100.0 %
47. FCT 3)
Function for fault message output Normal Inverted
Fault
Fault + not automatic 4)
Fault + not automatic + DI 4)
48. TIM Monitoring period for setting of fault Auto / 0 ... 100 s
message 'Control deviation'
49. LIM Response threshold of fault message Auto / 0 ... 100 %
'Control deviation'


50.PRST Preset
Reset all parameters which ALL
can be reset by 'Init', 'PArA'
and 'diAg'.
Reset initialization parame‐ Init
ters '1.YFCT' to '5.INITM'.
Reset parameters '6.SCUR' to PArA
'49. LIM'.
Reset parameters A to U of diAg
the extended diagnostics func‐
tion as well as parameter
'52.XDIAG'.
51.PNEUM Pneumatics type
Standard pneumatic block Std
Fail in place pneumatic block FIP
Operation with boosters booSt
52.XDIAG Activation of extended diagnostics
Off OFF
Single stage message On1
Two stage message On2
Three stage message On3
1)
Setpoint turning points only appear when '12.SFCT = FrEE' is selected.
2)
'Normally closed' means: Operation when a switch is open or Low level
'Normally open' means: Action on switch closed or High level
3)
'Normal' means: High level, no fault message
'Inverted' means: Low level, no fault message
4)
'+' means: Logical OR combination
8.3.3 Overview of advanced diagnostic parameters A to U
Introduction
These parameters are used to set the extended diagnostics functions of the positioner.
Note
Factory setting

Note
Display
Parameters A to U and their sub-parameters are only displayed when the extended diagnostics
has been activated in parameter "52.XDIAG (Page 162)" with setting "On1", "On2" or "On3".
Overview parameter A

A. PST Partial stroke test with the following parameters:
A1.STPOS Start position 0.0 ... 100.0 %
A2.STTOL Start tolerance 0.1 ... 2.0 ... 10.0 %
A3.STRKH Stroke height 0.1 ... 10.0 ... 100.0 %
A4.STRKD Stroke direction uP / do / uP do
A5.RPMD Ramp mode OFF / On
A6.RPRT Ramp rate 0.1 ... 1.0 ... 100.0 %/s
A7.FLBH Response after failed partial stroke test Auto / HOLd / AirIn / AirOu
A8.INTRV Test interval OFF / 1 ... 365 Days
A9.PSTIN Reference stroke time for partial stroke test NOINI / (C)##.# / FdIni / rEAL s
AA.FACT1 Factor 1 0.1 ... 1.5 ... 100.0
Ab.FACT2 Factor 2 0.1 ... 3.0 ... 100.0
AC.FACT3 Factor 3 0.1 ... 5.0 ... 100.0
Overview parameter b

b. DEVI Monitoring of dynamic control valve behavior with the following parameters:
b1.TIM Time constant Auto / 1 ... 400 s
b2.LIMIT Limit 0.1 ... 1.0 ... 100.0 %
b3.FACT1 Factor 1 0.1 ... 5.0 ... 100.0
b4.FACT2 Factor 2 0.1 ... 10.0 ... 100.0
b5.FACT3 Factor 3 0.1 ... 15.0 ... 100.0
Overview parameter C

C. LEAK Monitoring/compensation of pneumatic leakage with the following parameters:
C1.LIMIT Limit 0.1 ... 30.0 ... 100.0 %
C2.FACT1 Factor 1 0.1 ... 1.0 ... 100.0
C3.FACT2 Factor 2 0.1 ... 1.5 ... 100.0
C4.FACT3 Factor 3 0.1 ... 2.0 ... 100.0

Overview parameter d

d. STIC Monitoring of stiction (slipstick) with the following parameters:
d1.LIMIT Limit 0.1 ... 1.0 ... 100.0 %
d2.FACT1 Factor 1 0.1 ... 2.0 ... 100.0
d3.FACT2 Factor 2 0.1 ... 5.0 ... 100.0
d4.FACT3 Factor 3 0.1 ... 10.0 ... 100.0
Overview parameter E

E. DEBA Monitoring of deadband with the following parameters:
E1.LEVL3 *) Threshold 0.1 ... 2.0 ... 10.0 %
*) The values are monitored in the range of '0.1' to '2.9'. Values between '3.0' and '10.0' are not
monitored.
Overview parameter F

F. ZERO Monitoring of lower endstop with the following parameters:
F1.LEVL1 Threshold 1 0.1 ... 1.0 ... 10.0 %
F2.LEVL2 Threshold 2 0.1 ... 2.0 ... 10.0
F3.LEVL3 Threshold 3 0.1 ... 4.0 ... 10.0
Overview parameter G

G. OPEN Monitoring of upper endstop with the following parameters:
G1.LEVL1 Threshold 1 0.1 ... 1.0 ... 10.0 %
G2.LEVL2 Threshold 2 0.1 ... 2.0 ... 10.0
G3.LEVL3 Threshold 3 0.1 ... 4.0 ... 10.0
Overview parameter H

H. TMIN Monitoring of lower limit temperature with the following parameters:
H1.TUNIT Temperature unit °C °F °C/°F
H2.LEVL1 Threshold 1 -40 ... -25 ... 90 -40 ... 194
H3.LEVL2 Threshold 2 -40 ... -30 ... 90 -40 ... 194
H4.LEVL3 Threshold 3 -40 ... 90 -40 ... 194

Overview parameter J

J. TMAX Monitoring of upper limit temperature with the following parameters:
J1.TUNIT Temperature unit °C °F °C/°F
J2.LEVL1 Threshold 1 -40 ... 75 ... 90 -40 ... 194
J3.LEVL2 Threshold 2 -40 ... 80 ... 90 -40 ... 194
J4.LEVL3 Threshold 3 -40 ... 90 -40 ... 194
Overview parameter L

L. STRK Monitoring of number of total strokes with the following parameters:
L1. LIMIT Limit 1 ... 1E6 ... 1E8
L2.FACT1 Factor 1 0.1 ... 1.0 ... 40.0
L3.FACT2 Factor 2 0.1 ... 2.0 ... 40.0
L4.FACT3 Factor 3 0.1 ... 5.0 ... 40.0
Overview parameter O

O. DCHG Monitoring of number of changes in direction with the following parameters:
O1.LIMIT Limit 1 ... 1E6 ... 1E8
O2.FACT1 Factor 1 0.1 ... 1.0 ... 40.0
O3.FACT2 Factor 2 0.1 ... 2.0 ... 40.0
O4.FACT3 Factor 3 0.1 ... 5.0 ... 40.0
Overview parameter P

P. PAVG Monitoring of position average value with the following parameters:
P1.TBASE Time basis of average value generation 0.5h / 8h / 5d / 60d / 2.5y
P2.STATE Status of monitoring of position average value IdLE / rEF / ###.# / Strt
P3.LEVL1 Threshold 1 0.1 ... 2.0 ... 100.0 %
P4.LEVL2 Threshold 2 0.1 ... 5.0 ... 100.0 %
P5.LEVL3 Threshold 3 0.1 ... 10.0 ... 100.0 %

8.4 Description of parameters
Overview parameter U

U. PRES Activate pressure monitoring
U1.PUNIT Pressure unit bar / psi / MPa
U2.PZLIM Low limit of the supply pressure (PZLIM) 1.4 ...7.0 bar
20.30 ... 101.52 psi
0.140 ... 0.700 MPa
U3.PZHYS Hysteresis of the low limit of the supply pres‐ 0.2 ... 1.0 bar
sure 2.90 ... 14.50 psi
0.020 ... 0.100 MPa
U4.PZ_FR Error response on undershoot of the supply cont / HOLd
pressure
8.4.1 Initialization parameters 1 to 5
8.4.1.1 '1.YFCT' type of actuator
Requirement: Type of actuator as well as mounting type and direction of action are
known.
Possible settings: Actuator with normal direction Actuator with inverted direction of
of action action
● turn ● -turn
● WAY ● -WAY
● FWAY ● -FWAY
● LWAY ● -LWAY
● ncSt ● -ncSt
● ncSL ● -ncSL
● ncSLL ● -ncLL
Purpose: Use this parameter to adjust the positioner to the respective actua‐
tor.
● turn/-turn: Use this setting for a part-turn actuator with a directly
mounted positioner.
● WAY/-WAY: Use this setting.
– For a linear actuator with a carrier pin mounted on the lever
– In conjunction with devices which use an internal potentiom‐
eter

● FWAY/-FWAY: Use this setting.

– For a linear actuator with a carrier pin mounted on the ac‐
tuator spindle
– In conjunction with devices which use an internal potentiom‐
eter
● LWAY/-LWAY: Use this setting for an external linear potenti‐
ometer on a linear actuator (e.g. with cylinder drives).
● ncSt/-ncSt: Use this setting for a part-turn actuator for:
– An NCS sensor 6DR4004-. N.10 and -.N.40
– A positioner 6DR5...-0..9.-....- L1A with internal NCS module
– A positioner 6DR59* with accessory NCS module
6DR4004-5L/-5LE
– Position Transmitter 6DR4004-2ES, -3ES and -4ES
● ncSL/-ncSL: Use this setting for an NCS sensor 6DR4004-.N.20
on a linear actuator for strokes < 14 mm (0.55 inch).
● ncSLL/-ncLL: Use this setting for a linear actuator for:
– An NCS sensor 6DR4004-.N.30 for strokes > 14 mm
(0.55 inch).
– A positioner 6DR5...-0..9.-....- L1A with internal NCS module
– A positioner 6DR59* with accessory NCS module
6DR4004-5L/-5LE
– Position Transmitter 6DR4004-2ES, -3ES and -4ES
In the case of actuators with inverted direction of action, use the
settings with the minus sign, e.g. -turn.
Description: Meaning of actuator with normal direction of action:
● Part-turn 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 moves down‐
wards and the positioner shaft or magnet of the NCS sensor
rotates in the anti-clockwise direction.
Meaning for actuator with inverted direction of action:
● Part-turn actuator closes when the drive shaft, positioner shaft
or magnet of the NCS sensor rotates in the anti-clockwise di‐
rection.
● Linear actuator closes when the actuator spindle moves up‐
wards and the positioner shaft or magnet of the NCS sensor
rotates clockwise.
Additional information:
● The '3.YWAY' Range of stroke (Page 145) parameter is dis‐
played only for 'WAY', '-WAY', 'ncSLL' or '-ncLL'.
● turn/-turn: The '2.YAGL' Rated angle of rotation of feedback
(Page 145) parameter is automatically set to 90° and cannot be
changed.

● WAY/-WAY: The positioner compensates the non-linearity. The

non-linearity is caused by the transformation of the linear move‐
ment of the linear actuator into the rotary movement of the po‐
sitioner shaft. For correct compensation, follow the instructions
in section "Preparing linear actuators for commissioning
(Page 117)".
Factory setting: WAY
8.4.1.2 '2.YAGL' Rated angle of rotation of feedback
Condition: Transmission ratio selector and the value set in the '2.YAGL' pa‐
rameter match. Only then does the value shown on the display
match the actual position.
Possible settings: ● 33°
● 90°
Purpose: Use this parameter for a linear actuator. For a linear actuator, set an
angle of 33° or 90° depending on the range of stroke. The current
setting of the actuator is then measured more accurately. The fol‐
lowing is applicable:
● 33°: Strokes ≤ 20 mm
● 90°: Strokes 25 mm to 35 mm
● 90°: Strokes > 40 mm to 130 mm
Use the mounting kit:
● 6DR4004-8V for strokes up to 35 mm
● 6DR4004-8L for strokes greater than 35 mm up to 130 mm
'2.YAGL' can only be adjusted if '1.YFCT' is set to 'WAY'/'-WAY' or
'FWAY'/'-FWAY'.
With all other settings of '1.YFCT', an angle of 90° is automatically
set for '2.YAGL'.
Factory setting: 33°
See also
8.4.1.3 '3.YWAY' Range of stroke
Condition: ● Positioner is mounted.

● Carrier pin is mounted on the lever in accordance with the ac‐
tuator's range of stroke as described in section Mounting to lin‐
ear actuator (Page 40).
Possible settings: ● OFF
● 5.0 | 10.0 | 15.0 | 20.0 | 25.0 |30.0 | 35.0 | 40.0 |
50.0 | 60.0 | 70.0 | 90.0 | 110.0 | 130.0

Purpose: Use this parameter to display the determined stroke value in mm

when initialization of a linear actuator has been completed.
If you select the 'OFF' setting, the real stroke is not displayed after
initialization.
From the possible settings shown above, select the value which
corresponds to the range of stroke of your actuator in mm.
If the range of stroke of the actuator does not correspond to a pos‐
sible setting, use the next higher value. Use the value specified on
the nameplate of the actuator for this purpose.
'3.YWAY' is only displayed if '1.YFCT' is set to 'WAY'/'-WAY' or
'ncSLL'/'-ncLL'.
Factory setting: OFF
See also
'1.YFCT' type of actuator (Page 143)
8.4.1.4 '4.INITA' Initialization (automatic)
Possible settings: ● NOINI

● no / ###.#
● Strt
Purpose: Use this parameter to start the automatic initialization process.
1. Select the "Strt" setting.
2. Then press the button for at least 5 seconds.
The sequence of the initialization process from "RUN 1" to "RUN 5"
is output in the bottom line of the display.
Factory setting: NOINI
8.4.1.5 '5.INITM' Initialization (manual)
Possible settings: ● NOINI

● no / ###.#
● Strt
Purpose: Use this parameter to start the manual initialization process.
1. Select the "Strt" setting.
2. Then press the button for at least 5 seconds.
Description: If the positioner has already been initialized and if the "4.INITA" and
"5.INITM" values are set, it is possible to reset the positioner to the
non-initialized status. To do this, press the button for at least 5
seconds.

8.4.2 Application parameters 6 to 52
8.4.2.1 '6.SCUR' Current range of setpoint
Requirement: ● You have a positioner in the 2-wire, 3-wire, 4-wire version.

● Positioner is connected in accordance with the connection
graphics for 2/3/4-wire systems shown in section "Electrical wir‐
ing (Page 79)".
Possible settings: ● 0 MA
● 4 MA
Purpose: This parameter is used to set the current range of the setpoint. The
selection of the current range depends on the type of connection.
The "0 MA" setting (0 to 20 mA) is only possible for three-wire and
four-wire connections.
Factory setting: 4 MA
8.4.2.2 '7.SDIR' Setpoint direction
Possible settings: ● riSE

● FALL
Purpose: This parameter is used to set the setpoint direction. The setpoint
direction is used to reverse the direction of action of the setpoint.
● Rising (riSE): A higher value at the setpoint input results in
opening of the valve.
● Falling (FALL): A higher value at the setpoint input results in
closing of the valve.
The setpoint direction is primarily used for the split-range mode and
for single-acting actuators with the safety setting 'uP'.
Factory setting: riSE
8.4.2.3 '8.SPRA' Setpoint split range start / '9.SPRE' Setpoint split range start end
Adjustment range: 0.0 ... 100.0

Purpose: With these two parameters in combination with parameter "'7.SDIR'
Setpoint direction (Page 147)", you can limit the effective setpoint.
Solve split-range tasks with the following characteristic curves:
● Rising/falling
● Falling/rising
● Falling/falling
● Rising/rising
Factory setting: With "SPRA": 0.0 With "SPRE": 100.0

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Figure 8-2 Example: Split-range operation with 2 positioners
8.4.2.4 '10.TSUP' Setpoint ramp UP / '11.TSDO' Setpoint ramp DOWN
Possible settings: With "TSUP" With "TSDO"

● Auto ● 0 ... 400
● 0 ... 400
Purpose: The setpoint ramp is effective in "Automatic" mode and limits the
speed of change of the effective setpoint. The parameter specifies
the duration in seconds that the positioner needs to move the stroke
from 0 to 100%. Example: If "TSUP" = 10 is set, the positioner
needs 10 s to move the stroke from 0 to 100% and 1 s to move the
stroke from 0 to 10%.
When switching over from "Manual" mode to "Automatic" mode, the
setpoint ramp is used to adjust the effective setpoint to the setpoint
of the positioner.
This smooth switching from "Manual" mode to "Automatic" mode
prevents pressure excess in long pipelines.
The "TSUP = Auto" parameter means that the slower of the two
actuating times determined during initialization is used for the set‐
point ramp. Parameter value "TSDO" then has no effect.
Factory setting: 0

8.4.2.5 '12.SFCT' Setpoint function
Possible settings: ● Lin

● 1 - 25
● 1 - 33
● 1 - 50
● n1 - 25
● n1 - 33
● n1 - 50
● FrEE
Purpose: This parameter is used to linearize nonlinear process valve char‐
acteristics. Optional flow characteristics as shown in the figure in
the '13.SL0' ... '33.SL20' Setpoint turning point (Page 149) param‐
eter description are simulated for linear process valve characteris‐
tics.
Factory setting: Lin
Seven process valve characteristics are stored in the positioner and are selected using the
'SFCT' parameter:
Process valve characteristic Set with parameter value

Linear Lin
Equal percentage 1:25 1-25
Inverse equal percentage 25:1 n1-25
Freely adjustable FrEE
8.4.2.6 '13.SL0' ... '33.SL20' Setpoint turning point
Setting range: 0.0 ... 100.0

Purpose: These parameters are used to assign a flow coefficient in units of
5% to each setpoint turning point. The setpoint breakpoints form a
polyline with 20 linear segments which models the process valve
characteristic; see figure below.
Factory setting: "0", "5" ... "95", "100"

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Setpoint characteristic curves, standardization of manipulated variables, and tight closing

function
Input of the setpoint turning points is only possible if the "'12.SFCT' Setpoint function
(Page 149)" parameter is set to "FrEE". You can only enter one monotone rising characteristic
curve and two consecutive interpolation points must differ by at least 0.2%.
8.4.2.7 '34.DEBA' Deadband of closed-loop controller
Possible settings: ● Auto

● 0.1 ... 10.0
Purpose: This parameter is used with the "Auto" setting to adjust the dead‐
band in automatic mode continually and adaptively to the require‐
ments of the control loop. If a regulator oscillation is detected, then
the deadband is incrementally enlarged. The reverse adaptation
takes place using a time criterion.
The deadband is set using the values 0.1 to 10.0. The value is given
in percent. Control oscillations can then be suppressed. The small‐
er the deadband, the better the control accuracy.
Factory setting: Auto

8.4.2.8 '35.YA' Start of manipulated variable limit / '36.YE' End of manipulated variable limit

Purpose: These parameters are used to limit the mechanical actuator travel
from stop to stop to the configured values. The value is given in
percent. This allows the mechanical travel range of the actuator to
be limited to the effective flow, preventing integral saturation of the
controlling closed-loop controller.
See the figure in the description of the '37.YNRM' Standardization
of manipulated variable (Page 151) parameter.
'Dead angle' function
The dead angle is the angle range in which the process valve allows
no flow. The dead angle range starts at the lower endstop of the
valve, for example, and ends at the angle at which the medium
begins to flow. Use this function if you want to use the entire signal
range for valve control (for example, 4 mA to 20 mA).
To now use the entire signal range for process valve control, set the
lower manipulated variable limit (YA) to the percentage value at
which the medium begins to flow.
To display the new initial value as 0%, set '37.YNRM' Standardiza‐
tion of manipulated variable (Page 151) to 'FloW'.
Factory setting: When 'YA': 0.0 When 'YE': 100.0
Note
'YE' must always be set larger than 'YA'.
8.4.2.9 '37.YNRM' Standardization of manipulated variable
Possible settings: ● MPOS

● FLoW
Purpose: Use the '35.YA' Start of manipulated variable limit / '36.YE' End of
manipulated variable limit (Page 151) parameters to limit the ma‐
nipulated variable. This limitation causes two different scaling types
'MPOS' and 'FLoW' for the display and for the position feedback
through the current output.
The MPOS scale shows the mechanical positions from 0% to 100%
between the upper and lower endstops of the initialization. The
position is not influenced by the '35.YA' Start of manipulated varia‐
ble limit / '36.YE' End of manipulated variable limit (Page 151) pa‐
rameters. The 'YA' and 'YE' parameters are shown in the MPOS
scale.

The FLoW scale is the standardization from 0% to 100% in the

range between the 'YA' and 'YE' parameters. Over this range, the
setpoint w is also always 0% to 100%. This results in a more or less
flow-proportional display and position feedback. The flow-propor‐
tional display and position feedback also results from the use of
process valve characteristics.
In order to calculate the control deviation, the setpoint in the display
is also shown in the corresponding scale.
Below, the example of an 80-mm linear actuator is used to illustrate
the dependence of the stroke on the scaling as well as on the 'YA'
and 'YE' scaling parameters; see the following figure.
Factory setting: MPOS

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See also
'39.YCLS' Tight closing/fast closing with manipulated variable (Page 153)
8.4.2.10 '38.YDIR' Direction of manipulated variable for display and position feedback
Possible settings: ● riSE

● FALL
Purpose: This parameter is used to set the direction of action of the display
and the position feedback. The direction is rising or falling.
Factory setting: riSE
8.4.2.11 '39.YCLS' Tight closing/fast closing with manipulated variable
Possible settings: no None

uP Tight closing Up
do Tight closing Down
uP do Tight closing Up and Down
Fu Fast closing Up
Fd Fast closing Down
Fu Fd Fast closing Up and Down
uP Fd Tight closing Up and fast closing Down
Fu do Fast closing Up and tight closing Down
Purpose: This parameter is used to drive the control valve to the endstops. If
the parameter is not activated, the control valve controls the two
endstops which were determined during the initialization.
With tight closing, the control valve requires longer to leave the
endstops. With fast closing, the endstops of the control valve are
left immediately.
The tight closing and fast closing functions are activated on one
side or for both endstops. Parameter 'YCLS' becomes effective if
the effective setpoint:
● Is at or below the value set in the ''40.YCDO' Value for tight
closing/fast closing Down (Page 154)' parameter.
● Is at or above the value set in the ''41.YCUP' Value for tight
closing/fast closing Up (Page 154)' parameter.
Factory setting: no

See the figure in the description of the '37.YNRM' Standardization of manipulated variable
(Page 151) parameter and the figure in the description of the '13.SL0' ... '33.SL20' Setpoint
turning point (Page 149) parameters.
Note
Activated tight closing/fast closing function
If the function is activated, then the monitoring of control deviation is turned off in the respective
overflow direction for the ''49.\\LIM' Response threshold of fault message 'Control deviation'
(Page 159)' parameter. The following applies: 'YCDO: < 0 %' and 'YCUP: > 100 %'. This
functionality is especially advantageous for valves with lining. For long-term monitoring of the
positions of the endstops, we recommend that you activate the 'F. ZERO' and 'G. OPEN'
parameters.
8.4.2.12 '40.YCDO' Value for tight closing/fast closing Down
Requirement: '39.YCLS' Tight closing/fast closing with manipulated variable

(Page 153) Parameter is set to 'do', 'uP do', 'Fd', 'Fu Fd', 'uP Fd' or
'Fu do'
Purpose: Use the 'YCDO' parameter to set the value as of which the "Tight
closing/fast closing Down" function is activated. If the effective set‐
point is at or below the value set here, the actuator moves in tight
closing Down or fast closing Down.
Factory setting: 0.5
Note
The value in the 'YCDO' parameter is always smaller than that in 'YCUP'. The tight closing/fast
closing function has a fixed hysteresis of 1%. The 'YCDO' parameter is relative to the
mechanical stops. The 'YCDO' is independent of the values set in the '7.SDIR' Setpoint
direction (Page 147) and '38.YDIR' Direction of manipulated variable for display and position
feedback (Page 153) parameters.
8.4.2.13 '41.YCUP' Value for tight closing/fast closing Up
Requirement: '39.YCLS' Tight closing/fast closing with manipulated variable

(Page 153) Parameter is set to 'do', 'uP do', 'Fd', 'Fu Fd', 'uP Fd' or
'Fu do'
Purpose: Use the 'YCUP' parameter to set the value as of which the tight
closing Up or fast closing Up is activated. If the effective setpoint is
at or above the value set here, the actuator moves in tight closing
Up or fast closing Up.

Note
The value in the 'YCDO' parameter is always smaller than that in 'YCUP'. The tight closing/fast
closing function has a fixed hysteresis of 1%. The 'YCUP' parameter is relative to the
mechanical stops. The 'YCUP' is independent of the values set in the '7.SDIR' Setpoint
direction (Page 147) and '38.YDIR' Direction of manipulated variable for display and position
feedback (Page 153) parameters.
8.4.2.14 '42.BIN1' / '43.BIN2' digital input function
Setting option ● Digital input DI1

NO contact NC contact
OFF OFF
on -on
bloc1 -uP
bloc2 -doWn
uP -StoP
doWn -PST
StoP
PST
● Digital input DI2
NO contact NC contact
OFF OFF
on -on
uP -uP
doWn -doWn
StoP -StoP
PST -PST
Purpose: These parameters determine the function of the digital inputs. The
possible functions are described below. The direction of action can
be adapted to a normally closed or normally open mode.
● BIN1 or BIN2 = On or -On
Digital messages from I/O devices, e.g. from pressure or tem‐
perature switches, are read out over the communication inter‐
face or result in a response from the fault message output
through an OR logic operation with other messages.
● BIN1 = bLoc1
Use this parameter value to interlock the "Configuration" mode
against adjustment. The lock is performed e.g. with a jumper
between terminals 9 and 10.
● BIN1 = bLoc2
If the DI1 digital input has been activated, 'Manual' mode is
blocked in addition to "Configuration" mode.

● BIN1 or BIN2 =
Contact uP or doWn closes or
Contact -uP or -doWn opens
If the digital input is activated, the actuator uses the value de‐
fined by the "'35.YA' Start of manipulated variable limit / '36.YE'
End of manipulated variable limit (Page 151)" parameter for
controlling in 'Automatic' mode.
● BIN1 or BIN2 =
Contact StoP closes or
Contact -StoP opens
When the digital input is activated, controlling the pneumatic
block is blocked in "Automatic" mode. The actuator remains at
the last position. Leakage measurements can be performed in
this way without using the initialization function.
● BIN1 or BIN2 = PSt or -PSt
Using the digital input DI1 or DI2, a partial stroke test can be
triggered by actuation of either a normally closed or normally
open contact.
● BIN1 or BIN2 = OFF
No function
Special function of digital input DI1: If digital input DI1 is activa‐
ted in 'P-manual mode' by means of a jumper between terminals
9 and 10, the firmware version will be displayed when the
button is pressed.
If one of the above functions is activated simultaneously with the
"BIN1" and "BIN2" parameters, then: "Blocking" has priority over
"uP". "uP" has priority over "doWn". "doWn" has priority over "PST".
8.4.2.15 '44.AFCT' Alarm function
Possible settings: See corresponding representation below

Purpose: This parameter can be used to determine the value at which going
above or below a given offset or angle will result in a message. The
triggering of alarms (limits) is relative to the MPOS scale. Alarms
are signaled through the Digital I/O Module (DIO). In addition,
alarms can also be read via the communication interface.
The direction of action of the digital outputs can be adjusted from
"High active" to "Low active" for the next systems.

Direction of action and hysteresis

Digital I/O Module
/LPLW
(DIO)
$ Examples A1 A2
A1 = 48
$ A2 = 52 AFCT = MIN / MAX
ZD\ Way =45 Active
Way =50
0,1 0$;
Way =55 Active
0,1 0,1
A1 = 48
A2 = 52 AFCT = -MIN / -MAX
0$; 0$; Way =45 Active
Way =50 Active Active
0,1 0$; Way =55 Active
0,1 0,1
A1 = 52
A2 = 48 AFCT = MIN / MAX
Way =45 Active
0$; 0$;
Way =50 Active Active
Way =55 Active
A1 = 52
A2 = 48 AFCT = -MIN / -MAX
Way =45 Active
Way =50
Way =55 Active
Note
If extended diagnostics is activated using parameter "'52.XDIAG' Activating for extended
diagnostics (Page 162)" with setting "On3", then the alarms are not output through the Digital
I/O Module (DIO). Alarm A1 is output with setting "On2". However, notification via the
communication interface is possible at any time.

8.4.2.16 '45.A1' / '46.A2' Response threshold of alarm

Purpose: These parameters are used to specify when an alarm should be
displayed. The response thresholds of the alarms (in percent) refer
to the MPOS scale in the '37.YNRM' Standardization of manipu‐
lated variable (Page 151) parameter. The MPOS scale corre‐
sponds to the mechanical travel.
Depending on the setting of the alarm function in the '44.AFCT'
Alarm function (Page 156) parameter, the alarm is triggered upon
an upward violation (Max) or downward violation (Min) of this re‐
sponse threshold.
Factory setting: With 'A1': 10.0 With 'A2': 90.0
8.4.2.17 '47.\\FCT' Function of the fault message output
Requirement: At least one of the following modules is fitted

● Digital I/O Module (DIO)
● Inductive Limit Switches (ILS)
● Mechanic Limit Switches (MLS)
Possible settings: Normal direction of action Inverted direction of action
● ● -
● nA ● - nA
● nAb ● - nAb
Purpose: The fault message in the form of monitoring of control deviation
over time is also triggered by the following events:
● Power failure
● Processor fault
● Actuator fault
● Process valve fault
● Failure of supply pressure PZ
● Threshold 3 message of extended diagnostics
See Parameter '52.XDIAG' Activating for extended diagnostics
(Page 162).
The fault message cannot be switched off, but it can be suppressed
(factory setting) when you exit 'Automatic' mode. Set the ' FCT'
parameter to ' nA' to also generate a fault message here.
You also have an option to "or" the fault message with the status of
the digital inputs. To do this, first set the '42.BIN1' / '43.BIN2' digital
input function (Page 155) parameter to 'on' or '-on'. Subsequently
set the ' FCT' parameter to ' nAb'.
Select the '- ' setting if you want the fault message to be output with
inverted direction of action.
Factory setting:

8.4.2.18 '48.\\TIM' Monitoring period for setting of fault message 'Control deviation'

● 0 ... 100
Purpose: The 'TIM' parameter is used to set the time in seconds within which
the positioner must have reached the regulated condition. The cor‐
responding response threshold is specified in the parameter.
When the configured time is exceeded, the fault message output is
set.
Note
If the function is activated, then for the ' LIM' parameter the monitoring of control deviation is
turned off in the appropriate overflow direction. The following applies: 'YCDO: < 0 %' and
'YCUP: > 100 %'. This functionality is especially advantageous for valves with lining. For long-
term monitoring of the end positions, we recommend that you activate the 'F. ZERO' and 'G.
OPEN' parameters.
8.4.2.19 '49.\\LIM' Response threshold of fault message 'Control deviation'

● 0 ... 100
Purpose: This ' LIM' parameter is used to set a value for the permissible size
of the control deviation to trigger a fault message. The value is given
in percent.
If the ' TIM' and ' LIM' parameters are set to 'Auto', then the fault
message is set if the slow step zone is not reached within a certain
period of time. Within 5 to 95% of the actuator travel, this time is
twice the initialization travel time, and ten times the initialization
travel time outside of 10 to 90%.
Note
If the function is activated, then for the ' LIM' parameter the monitoring of control deviation is
turned off in the appropriate overflow direction. The following applies: 'YCDO: < 0 %' and
'YCUP: > 100 %'. This functionality is especially advantageous for valves with lining. For long-
term monitoring of the end positions, we recommend that you activate the 'F. ZERO' and 'G.
OPEN' parameters.

8.4.2.20 '50.PRST' Preset
Possible settings: ● ALL

● Init
● PArA
● diAg
Purpose: Use this parameter to restore the factory settings for most parame‐
ters. The following parameter groups are available:
● ALL: Reset all parameters together which can be reset by 'Init',
'PArA' and 'diAg'.
● Init: Reset initialization parameters '1.YFCT' to '5.INITM'.
● PArA: Reset application parameters '6.SCUR' Current range of
setpoint (Page 147) to '49.\\LIM' Response threshold of fault
message 'Control deviation' (Page 159).
● diAg: Resetting the extended diagnostic parameters A to U
(Page 163) as well as parameter '52.XDIAG' Activating for ex‐
tended diagnostics (Page 162).
An overview of the parameters and factory settings can be found in
section Tabular overview of the parameters (Page 135).
In order to select one of the parameter groups listed above, repeat‐
edly press the button until the desired setting is output in the
display. Start the function by keeping the button pressed until
'oCAY' is output in the display. The values of the parameter group
are now the factory settings.
Description: If you wish to use a previously initialized positioner on a different
control valve, set the parameters to the factory settings prior to a
new initialization. To do this, use the 'ALL' or 'Init' setting.
Restore the factory settings if you have changed several parameters
at once without being able to predict their effect and the undesired
reactions which may occur as a result. To do this, use the 'ALL'
setting.
Factory setting: ALL
See also
Display of diagnostics values (Page 212)
8.4.2.21 '51.PNEUM' Pneumatics type
Requirements: FIP You have a positioner with the "Fail in place" function with
order suffix -Z, order code F01.
booSt You operate the positioner with a booster.
Possible settings: Std Standard pneumatic block
FIP Fail in place pneumatic block
booSt Operation with boosters

Purpose: Start the function by pressing the button for at least 5 seconds.
The display shows 'WAit' during these 5 seconds. Set the desired
function after 5 seconds.
Std Setting for a standard pneumatic block
FIP If you order a positioner for Fail in Place applications, it is
then equipped with a special pneumatic block. The
"PNEUM" parameter is preset to "FIP". The parameter
must be set to "FIP" again when the basic electronics are
replaced.
booSt Use this function if you operate the positioner with a
booster. This function then shows the actuator over‐
shoot. You can find a description of how to operate the
booster under Booster (Page 301).

8.4.2.22 '52.XDIAG' Activating for extended diagnostics

Use this parameter to activate the extended diagnostics functions and simultaneously the
online diagnostics. You also define which maintenance level is to be signaled. Maintenance
levels in the order of increasing importance are maintenance required, maintenance
demanded, maintenance alarm. At the factory, extended diagnostics are deactivated. 'XDIAG'
parameter is set to 'OFF'. To activate extended diagnostics, there are three modes available:
● On1: Extended diagnostics is activated. Threshold 3 messages will be output via the error
message output. Single stage message (maintenance alarm).
● On2: Extended diagnostics is activated. Threshold 2 messages will be activated via alarm
output 2. Threshold 3 messages will also be output via the error message output. Two-stage
message (maintenance demanded, maintenance alarm).
● On3: Extended diagnostics is activated. Threshold 1 messages will be activated via alarm
output 1. Threshold 2 messages will be activated via alarm output 2. Threshold 3 messages
will also be output via the error message output. Three-stage message (maintenance
required, maintenance demanded, maintenance alarm).
Note
Activation of extended diagnostics
Please note that the parameters of extended diagnostics from 'A.\\PST' to 'U.\\PRES' will
only be shown in the display following selection of one of the modes 'On1' to 'On3'.
In the factory settings, the parameters 'A.\\PST' to 'U.\\PRES' are deactivated by default.
'XDIAG' parameter is set to 'OFF'. The corresponding parameters are only displayed after
you have activated the appropriate menu item with 'On'.
Note
Cancellation of messages
If a threshold is exceeded or fallen below, the positioner outputs a message in the form of
an error code and a column in the display. The message is cancelled if, for example:
● The counter is reset.
● The threshold is set to a new value.
● The device is re-initialized at the upper and lower endstops.
● Monitoring is deactivated.
With extended diagnostics, the threshold of the message is displayed using columns ① in
addition to the error code ② (Overview of error codes (Page 229)). These columns ① and the
error code ② are shown on the display as follows:
Figure 8-6 Display of a threshold 1 error message with one column (maintenance required)

Figure 8-7 Display of a threshold 2 error message with two columns (maintenance demanded)
Figure 8-8 Display of a threshold 3 error message with three columns (maintenance alarm)
The factory setting is 'OFF'.
8.4.3 Advanced diagnostic parameters A to U
8.4.3.1 Partial stroke test 'A.\\PST'
A. PST - Partial Stroke Test
Requirement: The parameter "52.XDIAG (Page 162)" is set to "On1", "On2" or

"On3".
● On
Purpose: Use this parameter to activate and deactivate the partial stroke test.
To activate monitoring, assign the parameter value "On". Sub-pa‐
rameters are displayed.
Trigger the partial stroke test using:
● Buttons on the device
● A digital input
● Communication
● A cyclic test interval
The current status of the partial stroke test is displayed in the diag‐
nostic value "12.PST (Page 218)".
Diagnostic value "13.PRPST (Page 219)" and "14.NXPST
(Page 219)" provide additional information on the partial stroke test.

A1.STPOS - Start position

Purpose: Use this sub-parameter to define the start position of the partial
stroke test in percent. Set the start position in a range from "0.0" to
"100.0". The triggering of alarms (limits) is relative to the MPOS
scale.
The actuator moves during the partial stroke test from the start po‐
sition to the target position. The target position is determined from
the interaction between start position (A1.STPOS), stroke height
(A3.STRKH) and stroke direction (A4.STRKD).
A2.STTOL - Start tolerance

Purpose: Use this sub-parameter to assign the start tolerance of the Partial
Stroke Test in percent. Enter the start tolerance relative to the start
position in a range from "0.1" to "10.0".
Example: You have set "50.0" as start position and "2.0" as start tolerance. In
this case, a Partial Stroke Test is initiated during operation only
between a position of 48% and 52%.
A3.STRKH - Stroke height

Purpose: Use this sub-parameter to assign the stroke height of the Partial
Stroke Test in percent. Set the stroke height in a range from "0.1" to
"100.0".
A4.STRKD - Stroke direction
Possible settings: ● uP
● do
● uP do
Purpose: Use this sub-parameter to assign the stroke direction of the Partial
Stroke Test.
uP: Actuator only moves upward
● The actuator moves from its start position to the upper target
position.
● After reaching the upper target position, the actuator moves
back to the start position.

Formula (uP): Upper target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) + Stroke height (A3.STRKH)
do: Actuator only moves downward
● The actuator moves from its start position to the lower target
position.
● After reaching the lower target position, the actuator moves
Formula (do): Low target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) - Stroke height (A3.STRKH)
uP do: Actuator moves upwards and downwards
● The actuator first moves from its start position to the upper target
position.
● It then moves from the upper target position to the lower target
position.
● After reaching the lower target position, the actuator moves
Formula (uP do) Target position = Start position (A1.STPOS) ± Start tolerance
(A2.STTOL) ± Stroke height (A3.STRKH)
Factory setting: do
A5.RPMD - Ramp mode
Setting options: ● OFF

● On
Purpose: Enable or disable ramp mode.
● OFF: The partial stroke test is executed in an uncontrolled man‐
ner.
● On: The Partial Stroke Test is executed in a controlled manner.
The positioner controls according to the ramp rate set in param‐
eter "A6.RPRT".
Use ramp mode to shorten or extend the duration of the Partial
Stroke Test. Extend the Partial Stroke Test to give the higher-level
control loop a chance to react to the Partial Stroke Test.
A6.RPRT - Ramp rate

Purpose: Change the ramp rate to shorten or extend the duration of the partial
stroke test. The ramp rate refers to the total stroke of the control valve
and is set in % stroke per second (%/s). Smaller values extend the
duration, larger values shorten the duration of the Partial Stroke Test.
Example: Setting "10.0" means that the Partial Stroke Test is run with
10% stroke per second.

A7.FLBH - Response after failed partial stroke test
Setting options: ● Auto

● HOLd
● AirIn
● AirOu
Purpose: Assign how the positioner is to respond if a partial stroke test fails.
Note: A Partial Stroke Test fails if the limit threshold assigned in
"Factor 3 (AC.FACT3)" is exceeded.
● Auto: Switch to "Automatic" mode. "AUT" is displayed on the
device.
● HOLd: Hold current position.
● AirIn: Ventilate actuator with supply pressure PZ.
● AirOu: Depressurize actuator.
A8.INTRV - Test interval
Setting range: OFF, 1 ... 365

Purpose: Use this sub-parameter to enter the interval time for the cyclic Par‐
tial Stroke Test in days. Set the test interval in a range from 1 to 365.
A9.PSTIN - Reference stroke time for partial stroke test
Indication on the display: ● NOINI

● (C)##.#
● FdIni
● rEAL
Purpose: Status for reference stroke time in seconds
Description: Use this sub-parameter to measure the reference stroke time for
the Partial Stroke Test.
The reference stroke time corresponds to the controlled movement
from the start position to the target position.
If the positioner has already been initialized, the calculated average
travel time of the control valve is displayed as a reference value.
● NOINI: Positioner has not yet been initialized.
● (C)##.#: An average travel time of 1.2 seconds, for example, is
shown in the display as "C 1.2", whereby "C" stands for 'calcu‐
lated'. The average travel time can be used as a reference
stroke time. However, it merely represents a rough guideline
value.

● FdIni: If the starting position cannot be approached or the stroke

target cannot be achieved, "FdIni" is displayed. "FdIni" stands
for "failed PST initialization".
● rEAL: Set the sub-parameters "A1.STPOS" to "A5.RPMD" ac‐
cording to your requirements. Then start measuring the refer‐
ence stroke time by pressing the button for at least 5 seconds.
The display shows "rEAL" during these 5 seconds.
The device then moves to the configured start position automat‐
ically and executes the desired stroke. The current position in
percent is continuously shown on the display. "inPST" for "initi‐
alize partial stroke test" appears in the lower line of the display.
AA.FACT1 - Factor 1

Purpose: Use this sub-parameter to assign the factor to form threshold 1.
Set the factor in a range from "0.1" to "100.0". The threshold is the
product of the reference stroke time and "AA.FACT1". The process
to determine the reference stroke time is described under
"A9.PSTIN".
The threshold 1 message is displayed when threshold 1 is excee‐
ded. This message is only output if threshold 2 or 3 is not exceeded
at the same time. The process to activate and display this message
is described in the 'XDIAG' parameter.
Ab.FACT2 - Factor 2

product of the reference stroke time and "Ab.FACT2". The process
"A9.PSTIN".
ded. This message is only output if threshold 3 is not exceeded at
the same time. The process to activate and display this message is
described in the "XDIAG" parameter.

AC.FACT3 - Factor 3

product of the reference stroke time and "AC.FACT3". The process
"A9.PSTIN".
ded. The process to activate and display this message is described
in the "XDIAG" parameter.
The positioner responds in accordance with the option set in the
sub-parameter "A7.FLBH".
8.4.3.2 Monitoring of dynamic control valve behavior 'b.\\DEVI'
b. DEVI - Monitoring of dynamic control valve behavior
Requirement: The '52.XDIAG' Activating for extended diagnostics (Page 162) pa‐
rameter is set to 'On1', 'On2' or 'On3'.
● On
Purpose: This parameter allows you to monitor the dynamic control valve
behavior. The actual position course is compared with the expected
position course for this purpose. This comparison helps in drawing
a conclusion about the correct operational response of the control
valve. Monitoring is performed in three steps. To activate monitor‐
ing, set the parameter to 'On'. Sub-parameters are displayed. Ap‐
propriately set the sub-parameters.
The current value is displayed in Diagnostics value '15.DEVI - Dy‐
namic control valve behavior' (Page 220). The positioner triggers a
message if the current value exceeds one of the three thresholds.
b1.TIM - Time constant

● 1 ... 400
Purpose: Use this sub-parameter to define the attenuation effect of the low-
pass filter. The unit is seconds. The time constant 'b1.TIM' is cal‐
culated from the travel times 'uP' and 'doWn' determined during the
initialization. This time constant becomes effective when the
'b1.TIM' parameter is set to 'Auto'.

If the time constant is inadequate, the setting of 'b1.TIM' can be

changed manually. Set the time constant in a range from '1' to '400'.
In this case:
● Setting '1' indicates a very weak attenuation.
● Setting '400' indicates a strong attenuation.
The currently determined deviation is displayed in Diagnostics val‐
ue '15.DEVI - Dynamic control valve behavior' (Page 220). The
positioner triggers a message if the current value exceeds one of
the three parameterizable thresholds.
b2.LIMIT - Limit

Purpose: Use this sub-parameter to set a base limit in percent. The base limit
defines the magnitude of the permissible deviation from the expec‐
ted position course. The limit serves as a reference variable for the
fault message factors.
Set the base limit in a range from '0.1' to '100.0'.
b3.FACT1 - Factor 1

Purpose: Use this sub-parameter to set the factor for formation of threshold 1.
Set the factor in a range from '0.1' to '100.0'. The threshold is the
product of 'b2.LIMIT' and 'b3.FACT1'.
b4.FACT2 - Factor 2

described in the 'XDIAG' parameter.

b5.FACT3 - Factor 3

in the 'XDIAG' parameter.
8.4.3.3 Monitoring/compensation of pneumatic leakage 'C.\\LEAK'
C. LEAK - Monitoring/compensation of pneumatic leakage
Note
Accuracy of results
Note that this monitoring only delivers results in the case of single-acting, spring-loaded
actuators and a setpoint from 5% to 95%.
Note
Note that monitoring with an activated '39.YCLS' Tight closing/fast closing with manipulated
variable (Page 153) function only delivers results in the case of a setpoint with the following
values:
● Value for tight closing/fast closing Down (YCDO) +5% to
● value for tight closing/fast closing Up (YCUP) -5%
'40.YCDO' Value for tight closing/fast closing Down (Page 154)
and '41.YCUP' Value for tight closing/fast closing Up (Page 154)
Note
Update of the message
When the leakage has been rectified, the new status is displayed as message after some time.
● To determine the current leakage, start the online leakage test with Diagnostic value
'11.LEAK - Leakage test' (Page 217).

Condition: The '52.XDIAG' Activating for extended diagnostics (Page 162) pa‐
Operating mode 'Automatic' (AUT) is set for the leakage compen‐
sation.
● On
Purpose: This parameter is used to activate leak monitoring and leakage
compensation. Leakages mainly occur in the actuator or in the pipe
installation. To activate monitoring or compensation, set the pa‐
rameter to 'On'. Sub-parameters are displayed. Appropriately set
the sub-parameters.
The leakage compensation compensates the leakage in control
phases with constant setpoint. The control quality is increased by
reducing or preventing the typical, periodic oscillations of leaky
valves. The leakage compensation compensates leakages up to
2% of the positioner's air performance.
The two following diagnostics values indicate the length and period
of the current leakage compensation pulse:
Diagnostic value '57.LKPUL - Length of the leakage compensation
pulse' (Page 227), Diagnostic value '58.LKPER - Period of the leak‐
age compensation pulse' (Page 227)
The leak monitoring is carried out in three stages for all control
phases (dynamic and static setpoints).
The current value of the monitoring is displayed in Diagnostic value
'16.ONLK - Pneumatic leakage' (Page 220).
C1.LIMIT - Limit

Purpose: Use this sub-parameter to set the limit of the leakage indicator in
percent. Set the limit in a range from '0.1' to '100.0'. If no leakage
exists, monitoring of the pneumatic leakage is automatically cali‐
brated in such a way during the initialization (section Commission‐
ing (Page 105)) that the leakage indicator remains below the value
30. A value above 30 means that a leakage exists. '30.0' is therefore
an advisable setting for the parameter. After a certain time this limit
can be varied slightly depending on the application.

To optimize the sensitivity of the monitoring of the pneumatic leak‐

age to your specific application, follow these steps:
1. After initializing the positioner automatically, use a calibration
device to initiate a ramp movement.
2. Conditions for the ramp movement:
– The ramp covers the normal operating range of the valve.
– The steepness of the ramp matches the dynamic require‐
ments of the corresponding application.
– The characteristic of the ramp corresponds to the character‐
istic of the setpoint that actually occurs.
3. During the ramp movement, the Diagnostic value '16.ONLK -
Pneumatic leakage' (Page 220) provides information about the
actual values. Define the limit of the leakage indicator accord‐
ingly.
The positioner triggers a message if the current value exceeds one
of the three thresholds. How to set the three thresholds is described
below.
C2.FACT1 - Factor 1

product of 'C1.LIMIT' and 'C2.FACT1'.
A leakage was detected when threshold 1 is exceeded. The control
quality is not affected. The threshold 1 message is shown. This
message is only output if threshold 2 or 3 is not exceeded at the
same time.
The process to activate and display this message is described in the
'XDIAG' parameter.
C3.FACT2 - Factor 2

quality is affected. Maintenance is recommended. The threshold 2
message is shown. This message is only output if threshold 3 is not
exceeded at the same time.
'XDIAG' parameter.

C4.FACT3 - Factor 3

quality is strongly affected. Maintenance is necessary. The thresh‐
old 3 message is shown.
'XDIAG' parameter.
See also
11 Monitoring/compensation of pneumatic leakage (Page 234)
8.4.3.4 Monitoring of stiction (slipstick) 'd.\\STIC'
d. STIC - Monitoring of stiction (slipstick)
● On
Purpose: Use this parameter to continuously monitor the current stiction (slip‐
stick effect) of the control valve. If the parameter is activated, the
positioner detects the slipstick that can occur. Sudden changes in
the process valve position, so-called slip jumps, indicate excessive
stiction. Where slip jumps are detected, the filtered step height is
stored as a slipstick value. If slip jumps no longer exist, the stiction
(slipstick effect) is reduced slowly. Monitoring is performed in three
steps. To activate monitoring, set the parameter to 'On'. Sub-pa‐
rameters are displayed. Appropriately set the sub-parameters.
The current value is displayed in Diagnostic value '17.STIC - Stic‐
tion (slipstick)' (Page 220). The positioner triggers a message if the
current value exceeds one of the thresholds.
Note
Incorrect interpretation in case of travel times below one second
If the travel times are less than one second, the positioner does not accurately differentiate
between a normal movement of the actuator and a sudden change. Therefore, increase the
travel time if required.

d1.LIMIT - limit for slipstick detection

Purpose: Use this sub-parameter to set the base limit for slipstick detection in
percent. Set the base limit in a range from '0.1' to '100.0'.
d2.FACT1 - Factor 1

product of the values entered for 'd1.LIMIT' and 'd2.FACT1'.
d3.FACT2 - Factor 2

d4.FACT3 - Factor 3


8.4.3.5 Monitoring of deadband 'E.\\DEBA'
E. DEBA - Monitoring of deadband
rameter is set to 'On'.
The '34.DEBA' Deadband of closed-loop controller (Page 150) pa‐
rameter is set to 'Auto'.
● On
Purpose: Use this parameter to continuously monitor the automatic adapta‐
tion of the deadband. Monitoring is performed in one step. To acti‐
vate monitoring, set the parameter to 'On'. The sub-parameter is
displayed. Appropriately set the sub-parameter.
The current value is displayed in Diagnostic value '26.DBUP -
Deadband up' / '27.DBDN - Deadband down' (Page 223). The po‐
sitioner triggers a message if the current value exceeds the thresh‐
old.
E1.LEVL3 - Threshold

Purpose: Use this sub-parameter to set the threshold to the deadband in
percent. Set the threshold in a range from '0.1' to '10.0'. The values
are monitored in the range of '0.1' to '2.9'. Values between '3.0' and
'10.0' are not monitored.
The threshold 3 message is displayed when the current deadband
exceeds the threshold during the test. The process to activate and
display this message is described in the 'XDIAG' parameter.
Note
Fault message display
The three-stage fault message display has not been implemented for monitoring of the
deadband. The positioner triggers only threshold 3 messages depending on the setting.

8.4.3.6 Monitoring of lower endstop 'F.\\ZERO'
F. ZERO - Monitoring of lower endstop
Note
Fault detection
Monitoring of lower endstop not only responds to faults in the valve. If the limit thresholds of the
lower endstop are exceeded due to misalignment of the position feedback, the misalignment
also triggers a diagnostics message.
The '39.YCLS' Tight closing/fast closing with manipulated variable
(Page 153) parameter is set to one of the following values: 'do',
'uP do', 'Fd', 'Fu Fd', 'uP Fd', 'Fu do'.
● On
Purpose: Use this parameter to activate continuous monitoring of the lower
endstop. Monitoring is always carried out if the '39.YCLS' Tight
closing/fast closing with manipulated variable (Page 153) parame‐
ter is set to one of the following values: 'do', 'uP do', 'Fd', 'Fu Fd',
'uP Fd', 'Fu do'
It checks whether the lower endstop has changed compared to its
value during initialization. Monitoring is performed in three steps.
Set the following sub-parameters appropriately. To activate moni‐
toring, set the parameter to 'On'. Sub-parameters are displayed.
The current value is displayed in Diagnostic value '18.ZERO - Low‐
er endstop' (Page 220). The positioner triggers a message if the
current value undershoots one of the three thresholds.
F1.LEVL1 - threshold 1

Purpose: Use this sub-parameter to set threshold 1 for the lower endstop in
percent. Set the threshold in a range from '0.1' to '10.0'.
The positioner triggers a threshold 1 message if the difference be‐
tween the lower endstop and the initialization value undershoots
threshold 1. This message is only output if threshold 2 or 3 is not
unsershot at the same time. The process to activate and display this
message is described in the 'XDIAG' parameter.


threshold 2. This message is only output if threshold 3 is not un‐
dershot at the same time. The process to activate and display this
message is described in the 'XDIAG' parameter.

threshold 3. The process to activate and display this message is
8.4.3.7 Monitoring the upper endstop 'G.\\OPEN'
G. OPEN - Monitoring of upper endstop
Note
Fault detection
Monitoring of upper endstop not only responds to faults in the valve. If the limit thresholds of the
upper endstop are exceeded due to misalignment of the position feedback, the misalignment
also triggers a message.
The '39.YCLS' Tight closing/fast closing with manipulated variable
(Page 153) parameter is set to one of the following values: 'uP',
'uP do', 'Fu', 'Fu Fd', 'uP Fd', 'Fu do'
● On

Purpose: Use this parameter to activate continuous monitoring of the upper

endstop. Monitoring is always carried out if the '39.YCLS' Tight
closing/fast closing with manipulated variable (Page 153) parame‐
ter is set to one of the following values: 'uP', 'uP do', 'Fu', 'Fu Fd',
'uP Fd', 'Fu do'
It checks whether the upper endstop has changed compared to its
value during initialization. Monitoring is performed in three steps.
Set the following sub-parameters appropriately. To activate moni‐
toring, set the parameter to 'On'. Sub-parameters are displayed.
The value is displayed in Diagnostic value '19.OPEN - Upper end‐
stop' (Page 221). The positioner triggers a message if the current
value exceeds one of the three thresholds.
G1.LEVL1 - threshold 1

Purpose: Use this sub-parameter to set threshold 1 for the upper endstop in
tween the upper endstop and the initialization value exceeds thresh‐
old 1. This message is only output if threshold 2 or 3 is not exceeded

old 2. This message is only output if threshold 3 is not exceeded at


old 3. The process to activate and display this message is described
8.4.3.8 Monitoring the lower limit temperature 'H.\\TMIN'
H. TMIN - Monitoring the lower limit temperature
● On
Purpose: The current temperature inside the enclosure of the field device is
recorded by a sensor on the basic electronics. Use this parameter
to activate continuous monitoring of the lower limit temperature in‐
side the enclosure. Monitoring is performed in three steps. To acti‐
vate monitoring, set the parameter to 'On'. Sub-parameters are dis‐
played. Appropriately set the sub-parameters.
The value is displayed in Diagnostic value '31.TMIN - Minimum
temperature' / '32.TMAX - Maximum temperature' (Page 224). The
positioner triggers a message if the current value undershoots one
of the three thresholds.
H1.TUNIT - temperature unit
Possible settings: °C
°F
Purpose: Use this sub-parameter to set the temperature unit '°C' or '°F'. The
selected temperature unit is then also applicable for all other tem‐
perature-based parameters.
Factory setting: °C

H2.LEVL1 - threshold 1
Adjustment range: -40.0C ... 90.0C

-40.0F ... 194.0F
Purpose: Use this sub-parameter to set the temperature for threshold 1.
The positioner triggers a threshold 1 message if the current tem‐
perature inside the enclosure undershoots threshold 1. This mes‐
sage is only output if threshold 2 or 3 is not exceeded at the same
time. The process to activate and display this message is described
Factory setting: -25.0C

-40.0F ... 194.0F
perature inside the enclosure undershoots threshold 2. This mes‐
sage is only output if threshold 3 is not exceeded at the same time.
'XDIAG' parameter.

-40.0F ... 194.0F
perature inside the enclosure undershoots threshold 3. The proc‐
ess to activate and display this message is described in the 'XDIAG'
parameter.
See also
'39.YCLS' Tight closing/fast closing with manipulated variable (Page 153)

8.4.3.9 Monitoring the upper limit temperature 'J.\\TMAX'
J. TMAX - Monitoring the upper limit temperature
● On
Purpose: The current temperature inside the enclosure of the field device is
recorded by a sensor on the basic electronics. Use this parameter
to activate continuous monitoring of the upper limit temperature
inside the enclosure. Monitoring is performed in three steps. To
activate monitoring, set the parameter to 'On'. Sub-parameters are
displayed. Appropriately set the sub-parameters.
The value is displayed in Diagnostic value '31.TMIN - Minimum
temperature' / '32.TMAX - Maximum temperature' (Page 224). The
positioner triggers a message if the current value exceeds one of
the three thresholds.
J1.TUNIT - temperature unit
Possible settings: °C
°F
Purpose: Use this sub-parameter to set the temperature unit '°C' or '°F'. The
selected temperature unit is then also applicable for all other tem‐
perature-based parameters.
Factory setting: °C
J2.LEVL1 - threshold 1

-40.0F ... 194.0F
perature inside the enclosure exceeds threshold 1. This message is
only output if threshold 2 or 3 is not exceeded at the same time. The
process to activate and display this message is described in the
'XDIAG' parameter.
Factory setting: 75.0C


-40.0F ... 194.0F
perature inside the enclosure exceeds threshold 2. This message is
only output if threshold 3 is not exceeded at the same time. The
process to activate and display this message is described in the
'XDIAG' parameter.

-40.0F ... 194.0F
perature inside the enclosure exceeds threshold 3. The process to
activate and display this message is described in the 'XDIAG' pa‐
rameter.
8.4.3.10 Monitoring of number of total strokes 'L.\\STRK'
L. STRK - Monitoring of number of total strokes
● On
Purpose: Use this parameter to continuously monitor the total strokes cov‐
ered by the actuator. A total stroke corresponds to the path from the
lower endstop of the actuator to the upper endstop and back again,
in other words twice the travel. During operation, partial strokes of
the actuator are added together into total strokes. Monitoring is
performed in three steps. To activate monitoring, set the parameter
to 'On'. Sub-parameters are displayed. Appropriately set the sub-
parameters.
The current value is displayed in Diagnostic value '1.STRKS - Num‐
ber of total strokes' (Page 215). The positioner triggers a message
if the current value exceeds one of the three thresholds. This mes‐
sage is only output if threshold 2 or 3 is not exceeded at the same
time.

L1.LIMIT - Limit
Adjustment range: 1 ... 1.00E8

Purpose: Use this sub-parameter to set the base limit for the number of total
strokes. Set the base limit in a range from '1' to '1.00E8'.
Factory setting: 1.00E6
L2.FACT1 - Factor 1

product of 'L1.LIMIT' and 'L2.FACT1'.
L3.FACT2 - Factor 2

L4.FACT3 - Factor 3

See also

8.4.3.11 Monitoring of number of changes in direction 'O.\\DCHG'
O. DCHG - Monitoring of number of changes in direction
● On
Purpose: Use this parameter to continuously monitor the number of changes
in direction of the actuator beyond the deadband. Monitoring is per‐
formed in three steps. Set the following sub-parameters appropri‐
ately. To activate monitoring, set the parameter to 'On'. Sub-pa‐
rameters are displayed.
The current value is displayed in Diagnostic value '2.CHDIR - Num‐
ber of changes in direction' (Page 215). The positioner triggers a
message if the current value exceeds one of the three thresholds.
O1.LIMIT - Limit
Adjustment range: 1 ... 1.00E8

Purpose: Use this sub-parameter to set the base limit for the changes of
direction of the actuator. Set the base limit in a range from '1' to
'1.00E8'.
Factory setting: 1.00E6
O2.FACT1 - Factor 1

product of 'O1.LIMIT' and 'O2.FACT1'.

O3.FACT2 - Factor 2

O4.FACT3 - Factor 3

See also
8.4.3.12 Monitoring the position average value 'P.\\PAVG'
P. PAVG - Monitoring the position average value
● On
Purpose: Use this parameter to activate the test to calculate and monitor the
average value of position. During the test, the average values of
position and reference are always compared at the end of a time
interval.
The current value is displayed in Diagnostic value '20.PAVG - Aver‐
age value of position' (Page 221). The positioner triggers a mes‐
sage if the current average value of position undershoots one of the
three thresholds.

P1.TBASE - Time basis of average value generation
Possible settings: 0.5h / 8h / 5d / 60d / 2.5y

Purpose: Use this sub-parameter to set the time interval to calculate the
average value of position. The following values are available to
define the time intervals:
● 30 minutes
● 8 hours
● 5 days
● 60 days
● 2.5 years
After starting the calculation for average value of reference and
expiry of the time interval, a position average over the interval pe‐
riod is determined and compared with the average value of refer‐
ence. The test is then restarted.
Factory setting: 0.5h
P2.STATE - Status of monitoring position average value
Possible settings: IdLE / rEF / ###.# / Strt

Purpose: Use this sub-parameter to start the calculation for average value of
position. If an average value of reference has never been deter‐
mined, the parameter value is 'IdLE'.
Then start the calculation by pressing the button for 5 seconds.
The value in the display changes from 'IdLE' to 'rEF'. The average
value of reference is calculated.
When the time interval expires, the calculated average value of
reference is shown on the display.
Factory setting: IdLE
Note
Current average value of position
The respective current average value of position is displayed in the Diagnostic value '20.PAVG
- Average value of position' (Page 221). If no average value of position has been calculated,
'COMP' is displayed as the diagnostic value.

P3.LEVL1 - threshold 1
Possible settings: 0.1 ... 100.0

Purpose: Use this sub-parameter to set threshold 1 for the maximum devia‐
tion of the current average value of position from the average value
of reference. The value is given in percent. Set the threshold in a
range from '0.1' to '100.0'.
The positioner triggers the threshold 1 message if the difference
between the average value of position and the average value of
reference exceeds threshold 1. This message is only output if
threshold 2 or 3 is not exceeded at the same time. The process to
activate and display this message is described in the 'XDIAG' pa‐
rameter.

range from '0.1' to '100.0'.
reference exceeds threshold 2. This message is only output if
threshold 3 is not exceeded at the same time. The process to acti‐
vate and display this message is described in the 'XDIAG' param‐
eter.

range from '0.1' to '100.0'.
reference exceeds threshold 3. The process to activate and display
this message is described in the 'XDIAG' parameter.

8.4.3.13 Pressure monitoring 'U.\\PRES'
U. PRES - Activate pressure monitoring
Requirement: The parameter "XDIAG (Page 162)" is set to "On1", "On2" or "On3".
● On
Purpose: Activates or deactivates all pressure-based diagnostics.
Factory setting: On
U1.PUNIT - Pressure unit
Possible settings: bar / psi / MPa

Purpose: Defines the pressure unit for all pressure-based diagnostic param‐
eters.
Factory setting: bar
U2.PZLIM - Low limit of the supply pressure (PZLIM)
Possible settings: 1.4 to 7.0 (bar)

20.30 … 101.52 psi
0.140 ... 0.700 MPa
Purpose: Defines the minimum required supply pressure.
When the value is undershot, the message "18 (Page 234)" ap‐
pears on the display in "Automatic" and "Manual" modes.
U3.PZHYS - Hysteresis of the low limit of the supply pressure
Possible settings: 0.2 to 1.0 (bar)

2.90 … 14.50 psi
0.020 ... 0.100 MPa
Purpose: Defines the hysteresis of the low limit of the supply pressure
(U2.PZLIM).
The error message 18 (Page 234) in the "Automatic" and "Manual"
modes is deleted when the value of the supply pressure PZ is
"PZHYS" larger than the value assigned in "U2.PZLIM". The control
becomes active again if the configured fault reaction was "HOLd".

8.5 Overview of the assignment of the HART variables
U4.PZ_FR - Error response on undershoot of the supply pressure
Possible settings: cont / HOLd

Purpose: Defines the behavior of the device when the limit value of the supply
pressure (U2.PZLIM) is undershot.
Cont = Chamber pressure is controlled via supply pressure PZ.
HOLd = Chamber pressure is maintained, corresponds to the re‐
sponse for Fail in Place.
Factory setting: cont
Dynamic variables for device revision 6, as of firmware 5.01.xx HART 7

For positioners with HART communication, the variables PV, SV, TV and QV are assigned as
follows:
Variable Meaning Physical variable

HART Primary Variable (PV) Primary variable W (setpoint) in %
HART Secondary Variable (SV) 1st secondary variable X (actual value) in %
HART Tertiary Variable (TV) 2nd secondary variable Xd (control deviation) in %
HART Quaternary Variable (QV) 3rd secondary variable t (temperature) in °C


Functional safety 9
9.1 Range of applications for functional safety
The positioner is suitable for use on valves that satisfy the special requirements in terms of
functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511. The 6DR5.1.-0....-....-
Z C20 versions are available for this.
These are single-acting positioners for mounting on pneumatic actuators with spring return.
The positioner automatically depressurizes the actuator on demand or in case of faults. The
actuator brings the process valve to the specified safety position in this way.
This positioner meets the following requirement:
● Functional safety up to SIL 2 in accordance with IEC 61508 or IEC 61511 for safe venting
See also
Functional safety in process instrumentation (http://www.siemens.com/SIL)
9.2 Safety function

Depressurizing of the connected actuator is the safety function for the SIPART PS2 positioner.
The built-in spring brings the process valve to the required safety position. Depending on the
direction of action of this spring, the process valve is completely opened or closed.
The positioner starts the depressurizing process of the connected pneumatic actuator at the
latest 100 ms after the request. The progress of the depressurizing process depends on the
connections and properties of the pneumatic actuator.
This safety function can be triggered by:
● With 2-wire connection: a signal source with 0 mA.
● With 3/4-wire connection: a power supply source with 0 V.
The safety function is not affected by other device functions, particularly the microcontroller,
software and communication interface. With respect to this safety function, the positioner must
therefore be considered as a type A subsystem in accordance with IEC 61508-2.

Functional safety
9.2 Safety function
Situations in which it is not possible to depressurize the actuator on demand or in the case of
a fault represent hazardous failure.
WARNING
Disregarding conditions for fulfilling the safety function
Disregarding conditions can result in a malfunction of the process system or application, for
example, process pressure too high, maximum level exceeded.
The mandatory settings and conditions are listed in sections "Settings (Page 194)" and
"Safety characteristics (Page 195)".
● These conditions must be met in order to fulfill the safety function.
The pneumatic block of the positioner pressurizes and depressurizes the actuator. The
characteristic service life of the pneumatic block depends on the load. On average, it is approx.
200 million switching cycles. The number of control procedures for the switching cycles is called
in the local display or via HART communication. For more details, see Diagnostic value
'42.VENT1' / '43.VENT2' (Page 225).
NOTICE
Freezing of the exhaust air outlets
When devices of the type 6DR5..0/1/2/3 are used, the exhaust air outlets ② may freeze. The
function of the device is impaired.
● Do not install the positioner with the base plate ① pointing up.
① Base plate
② Exhaust air outlets
Figure 9-1 Exhaust air outlets, base plate

Functional safety
9.3 Safety Integrity Level (SIL)
Safety-instrumented system in single-channel operation (SIL 2)
Transmitter Automation system

Final controlling element
0HDVXUHG 6KXWGRZQVLJQDO
YDOXH
Figure 9-2 Safety-instrumented system in single-channel operation
The combination of transmitter, automation system and final controlling element forms a safety-
instrumented system that performs a safety function.
The transmitter generates a process-related measured value that is transferred to the
automation system. The automation system monitors this measured value. If the measured
value violates the high or low limit, the automation system generates a shutdown signal for the
connected final controlling element, which switches the corresponding process valve to the
specified safety position.
9.3 Safety Integrity Level (SIL)

The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from
SIL 1 to SIL 4. Each level corresponds to a range of probability for failure of a safety function.
Description
The following table shows the dependency of the SIL on the "average probability of dangerous
failure of a safety function of the entire safety-instrumented system" (PFDAVG). "Low demand
mode" is examined. The safety function is required a maximum of once per year on average.
Table 9-1 Safety Integrity Level
SIL Interval
4 10-5 ≤ PFDAVG < 10-4
3 10-4 ≤ PFDAVG < 10-3
2 10-3 ≤ PFDAVG < 10-2
1 10-2 ≤ PFDAVG < 10-1
The "average probability of dangerous failure of the entire safety-related system" (PFDAVG) is
normally split between the following three components:
7UDQVPLWWHU $XWRPDWLRQ )LQDOFRQWUROOLQJ

V\VWHP HOHPHQW
3)'$9*3DUW

Functional safety
9.4 Settings
Figure 9-3 PFD distribution
The following table shows the achievable Safety Integrity Level (SIL) for the entire safety-
related system for type A devices depending on the safe failure fraction (SFF) and the hardware
fault tolerance (HFT).
● Type A devices include analog transmitters and solenoid valves without complex
components, e.g. microprocessors (see also IEC 61508, Section 2).
● The specific values for your device are listed in the manufacturer's declaration of the device
(SIL Declaration of Conformity, Functional Safety according to IEC 61508 and IEC 61511):
Certificates (http://www.siemens.com/processinstrumentation/certificates).
SFF HFT for type A devices

0 1 2
< 60% SIL 1 SIL 2 SIL 3
60 to 90% SIL 2 SIL 3 SIL 4
90 to 99% SIL 3 SIL 4 SIL 4
> 99% SIL 3 SIL 4 SIL 4
9.4 Settings
No special parameter settings are required for the safety function.
Protection against configuration changes

You should attach the housing cover so that the device is protected against unwanted and
unauthorized changes/operation.
Checking the safety function
Prerequisite for checking the safety function

● Positioner is in operation.
● The actuator belonging to the positioner is not in the safety position.
Procedure
1. On the positioner, switch the signal source to 0 mA or the power supply source to 0 V.
2. Reduce the inlet pressure (PZ) to a third of the maximum supply pressure.
3. Always carry out the validation of the safety function with positioner, actuator and process
valve under operating conditions.
Result
The actuator brings the process valve to the specified safety position.

Functional safety
9.6 Maintenance/check
See also
Safety function (Page 191)
9.5 Safety characteristics

The safety characteristics necessary for use of the system are listed in the SIL declaration of
conformity. These values apply under the following conditions:
● The positioner is only used in applications with low demand rate for the "Low demand mode".
● The positioner is blocked against unwanted and unauthorized changes/operation.
● The signal source with 0 mA or the power supply source with 0 V for the SIPART PS2
positioner is generated by a safe system that fulfills SIL 2 for single-channel operation.
● The connected actuator must be single-acting and return the process valve to the safe end
position by spring force in the following scenarios:
– With a chamber pressure (Y1 connection) up to a third of the maximum available supply
pressure (PZ connection)
● The air outlet does not contain any additional cross-sectional contractions leading to an
increased dynamic pressure. In particular, a silencer is only allowed if icing or other
contamination is ruled out.
● The restrictor in the Y1 circuit may not be completely closed during operation.
● According to ISO 8573-1, the air quality is Class 3 maximum and free of oil, water and dirt.
● The average temperature viewed over a long period is 40 °C.
● Fault rates are calculated on the basis of a mean time to repair (MTTR) of 8 hours.
● In case of a fault, the pneumatic outlet of the positioner is depressurized. A spring in the
pneumatic actuator must move the process valve to the pre-defined, safe end position.
● A dangerous failure of the positioner is one in which the pressure outlet is not depressurized
or the safety position is not reached when the signal source is 0 mA or the power supply
source is 0 V.
See also
Settings (Page 194)
Interval
We recommend that the functioning of the positioner is checked at regular intervals of one
year.

Functional safety
Checking the safety function

Check the safety function as detailed in chapter "Settings (Page 194)"
Checking safety
Verify the safety function of the entire safety circuit on a regular basis in accordance with
IEC 61508/61511. The test intervals are determined in the course of calculations for each
safety circuit of a system (PFDAVG).

Service and maintenance 10
10.1.1 Maintenance
The device is maintenance-free. However, a periodic inspection according to pertinent
directives and regulations must be carried out.
An inspection can include, for example, check of:
● Ambient conditions
● Seal integrity of the process connections, cable entries, and cover
● Reliability of power supply, lightning protection, and grounds
WARNING
Dust layers above 5 mm
Device may overheat due to dust build up.
● Remove dust layers in excess of 5 mm.
CAUTION
Releasing button lock
Improper modification of parameters could influence process safety.
● Make sure that only authorized personnel may cancel the button locking of devices for
safety-related applications.
NOTICE
Penetration of moisture into the device
Device damage.
● Make sure when carrying out cleaning and maintenance work that no moisture penetrates
the inside of the device.

Service and maintenance
10.2 Cleaning
10.2 Cleaning
The positioner is maintenance-free to a large extent. Screens are installed in the pneumatic
connections of the positioners to protect them from rough dirt particles. If there are dirt particles
in the supply air (PZ), they damage the screens and hamper the function of the positioner.
Clean the screens as described in the following two chapters.
10.2.1 Positioners 6DR5..0, 6DR5..3 and 6DR5..5
Procedure for removal and cleaning of the screens

1. Switch off the supply pressure PZ.
2. Remove the pneumatic pipelines.
3. Unscrew the cover of the 6DR5..0 or 6DR5..3 enclosure.
4. Remove the three screws on the pneumatic terminal strip.
5. Remove the screens and O-rings behind the terminal strip.
6. Clean the screens, e.g. using compressed air.
Procedure for installation of the screens
CAUTION
Damage to the polycarbonate enclosure 6DR5..0
● The enclosure is damaged due to screwing in the self-tapping screws improperly.
● Ensure that the available thread pitches are used.
● Turn the screws anticlockwise until they engage noticeably in the thread pitch.
● Tighten the self-tapping screws only after they have engaged.
1. Insert the screens into the recesses of the enclosure.

2. Place the O-rings on the screens.
3. Insert the pneumatic terminal strip.
4. Tighten the three screws. Note: With the polycarbonate enclosure, the screws are self-
tapping.
5. Place the cover and tighten it.
6. Connect the pneumatic pipelines again.

10.3 Maintenance and repair work
10.2.2 Positioners 6DR5..1, 6DR5..2 and 6DR5..6
Removal, cleaning and installation of the screens

1. Switch off the supply pressure PZ.
2. Remove the pneumatic connecting cables.
3. Remove the metal screen from the bores carefully.
4. Clean the metal screens, e.g. using compressed air.
5. Insert the screens.
6. Connect the pneumatic pipelines again.
Cleaning the enclosure

● Clean the outside of the enclosure with the inscriptions and the display window using a cloth
moistened with water or a mild detergent.
● Do not use any aggressive cleansing agents or solvents, e.g. acetone. Plastic parts or the
painted surface could be damaged. The inscriptions could become unreadable.
WARNING
Electrostatic charge
Risk of explosion in hazardous areas if electrostatic charges develop, for example, when
cleaning plastic surfaces with a dry cloth.
● Prevent electrostatic charging in hazardous areas.
10.3 Maintenance and repair work

Send defective devices to the repairs department, together with information on the malfunction
and the cause of the malfunction. When ordering replacement devices, please provide the
serial number of the original device. You can find the serial number on the nameplate.
WARNING
Impermissible repair of the device
● Repair must be carried out by Siemens authorized personnel only.

10.4 Replace basic electronics
WARNING
Maintenance during continued operation in a hazardous area
There is a risk of explosion when carrying out repairs and maintenance on the device in a
hazardous area.
● Isolate the device from power.
- or -
● Ensure that the atmosphere is explosion-free (hot work permit).
WARNING
Impermissible accessories and spare parts
● Only use original accessories or original spare parts.
● Observe all relevant installation and safety instructions described in the instructions for the
device or enclosed with the accessory or spare part.
WARNING
Improper connection after maintenance
● Connect the device correctly after maintenance.
● Close the device after maintenance work.
Refer to Electrical data (Page 246).
Condition
● You are familiar with the general procedure described in the section "General information on
installing option modules (Page 51)".
Procedure
Note
Possible movement of the actuator
While replacing the basic electronics, the actuator can unintentionally vent itself.
● Observe the procedure described below.

Removing
1. Switch off the supply pressure PZ and depressurize the actuator.
6. Place the new basic electronics onto the four holders of the rack.
Installation
2. Tighten the screws.
4. For a positioner with order option -Z F01 "Fail in Place", adjust the parameter "51.PNEUM
(Page 160)" from "Std" to "FIP".
5. Switch on the supply pressure PZ.
6. Initialize the positioner as described in section "Commissioning (Page 105)".

10.5 Replace pneumatic block
10.5 Replace pneumatic block
Requirement
● You are familiar with the general procedure described in the section "General information on
installing option modules (Page 51)".
Procedure

① Cord seal ③ Mounting screws

② Pneumatic block ④ Centering elements
Figure 10-1 Pneumatic block
Removing
6. Remove the fixing screws ③ of the pneumatic block ②.
Four screws for the single-acting pneumatic block. Five screws for the double-acting
pneumatic block.
7. Remove the pneumatic block ② and the cord seal ①.
8. Blow the existing dirt from the surface on which the pneumatic block was placed.
Installation
1. Insert the new cord seal ① into the new pneumatic block ②.
2. Press the cord seal ① into the groove on the pneumatic block ② on all sides.

10.6 Replace the pressure sensor module
3. Place the new pneumatic block on the base plate.

Make sure that the pneumatic block engages with the centering elements ④ on the
baseplate.
4. Screw the supplied fixing screws ③ into the pneumatic block.
5. Tighten the fixing screws with a torque of 1.1 Nm.
6. Place the new basic electronics onto the four holders of the adapter.
8. Tighten the fixing screws.
10.For a positioner with order option -Z F01 "Fail in Place", adjust the parameter '51.PNEUM'
Pneumatics type (Page 160) from "Std" to "FIP".
11.Switch on the supply pressure PZ.
12.Initialize the positioner as described in section "Commissioning (Page 105)".
Condition
● You have a positioner with a built-in pressure sensor module, order suffix -Z P01.
● You are familiar with the procedure described in the section "Replace pneumatic block
(Page 202)".

Overview screen

① Pneumatic block ⑥ Fixing screws basic electronics

② Mounting screws ⑦ Ribbon cable, covered with plastic cap ⑨
③ Pressure sensor module ⑧ Adapter
④ Cord seal ⑨ Plastic cap
⑤ Basic electronics
Figure 10-2 Pressure sensor, schematic diagram
Procedure
Removing
2. Open the positioner as described in section "Opening the standard and intrinsically safe
version (Page 52)".
3. Remove the plastic cap ⑨.
4. Remove the ribbon cable ⑦ and all other ribbon cables from the basic electronics ⑤.

5. Loosen the two fixing screws ⑥ of the basic electronics.

6. Remove the basic electronics ⑤.
7. Remove the fixing screws ② of the pneumatic block ①.
Four screws for the single-acting pneumatic block. Five screws for the double-acting
pneumatic block.
8. Remove the pneumatic block ①.
Make sure that the cord seal ④ of the pneumatic block is in the pneumatic block.
9. Blow the existing dirt from the surface on which the pneumatic block was placed.
10.Remove the pressure sensor module ③ and the cord seal ④ of the pressure sensor
module.
Installation
1. Insert the new cord seal ④ into the new pressure sensor module ③.
2. Press the cord seal ④ into the groove on the pressure sensor module ③ on all sides.
3. Place the pressure sensor module ③ on the baseplate.
4. Place the pneumatic block ① on the pressure sensor module ③.
– Make sure that the cord seal ④ of the pneumatic block is in the pneumatic block.
– Make sure that the pneumatic block engages with the centering elements ④ (Page 202)
on the baseplate.
5. Screw the fixing screws ② into the pneumatic block ①.
6. Tighten the fixing screws ② with a torque of 1.1 Nm.
7. Place the basic electronics ⑤ onto the four holders of the adapter ⑧.
8. Screw in the two fixing screws ⑥ of the basic electronics.
9. Tighten the fixing screws ⑥.
10.Insert the ribbon cable ⑦ and all other ribbon cables onto the basic electronics ⑤.
11.Place the plastic cap ⑨.
12.Close the positioner as described in section "Closing the standard and and intrinsically safe
version (Page 53)".
13.For a positioner with order option -Z F01 "Fail in Place", adjust the parameter '51.PNEUM'
Pneumatics type (Page 160) from "Std" to "FIP".
14.Switch on the supply pressure PZ.
15.Initialize the positioner as described in section "Commissioning (Page 105)".
Result
The pressure sensor module is ready to use again.

10.8 Disposal
See also
Closing the device version with "flameproof enclosure" (Page 58)
Parameter assignment (Page 133)
General information on installing option modules (Page 51)
10.7 Return procedure

Enclose the bill of lading, return document and decontamination certificate in a clear plastic
pouch and attach it firmly to the outside of the packaging.
Required forms
● Delivery note
● Return document (http://www.siemens.com/processinstrumentation/returngoodsnote)
with the following information:
– Product (item description)
– Number of returned devices/replacement parts
– Reason for returning the item(s)
● Decontamination declaration (http://www.siemens.com/sc/declarationofdecontamination)
With this declaration you warrant "that the device/replacement part has been carefully
cleaned and is free of residues. The device/replacement part does not pose a hazard for
humans and the environment."
If the returned device/replacement part has come into contact with poisonous, corrosive,
flammable or water-contaminating substances, you must thoroughly clean and
decontaminate the device/replacement part before returning it in order to ensure that all
hollow areas are free from hazardous substances. Check the item after it has been cleaned.
Any devices/replacement parts returned without a decontamination declaration will be
cleaned at your expense before further processing.
10.8 Disposal
Devices described in this manual should be recycled. They may not be

disposed of in the municipal waste disposal services according to the Di‐
rective 2012/19/EC on waste electronic and electrical equipment (WEEE).
Devices can be returned to the supplier within the EC, or to a locally ap‐
proved disposal service for eco-friendly recycling. Observe the specific
regulations valid in your country.
Further information about devices containing batteries can be found at:
Information on battery/product return (WEEE) (https://
support.industry.siemens.com/cs/document/109479891/)

Diagnostics and troubleshooting 11
11.1 Output of system messages in the display
11.1.1 System messages before initialization

Remarks about the tables:
nn Stands for variable numeric values

Error symbol
/ (slash): the texts on the left and right of the slash flash alternately
Messages before initialization (first commissioning)
Message Line Meaning / cause Measure

Up Down
CPU X Message after application of electrical auxili‐ ● Maintenance
Start X ary power
Pnnn.n X Potentiometer voltage of a non-initialized po‐ ● Check whether the complete travel can be
sitioner (P-manual mode) (actual position val‐ covered using the and buttons and
ue in % of the measuring range). that "P---" is never displayed.
● Execute the initialization process.
P--- X Measuring range was exceeded, the potenti‐ ● Switch the transmission ratio selector to
ometer is in the inactive zone, the transmis‐ 90°, especially in the case of part-turn ac‐
sion ratio selector or the effective lever arm tuators.
are not adjusted as per the actuator travel.
● Adjust the effective lever length of linear
actuators as per the measuring range.
NOINI X Positioner is not initialized. ● Start initialization.
See also
Display (Page 95)
11.1.2 System messages during initialization


Error symbol

Diagnostics and troubleshooting
Messages during initialization
Message Line Meaning/cause Measure

Up Down
P--- X Measuring range was exceeded, the potenti‐ ● Switch the transmission ratio selector to
ometer is in the inactive zone, the transmis‐ 90°, especially in the case of part-turn ac‐
sion ratio selectors or the effective lever arm tuators.
are not adjusted as per the actuator travel
● Adjust the effective lever length of linear
actuators as per the measuring range.
RUN 1 X Initialization was started, part 1 is active (the ● Wait.
direction of action is determined)
RUN 2 X Initialization part 2 is active (actuator travel ● Wait.
check and determination of stops)
RUN 3 X Initialization part 3 is active (determination ● Wait.
and display of travel times)
RUN 4 X Initialization part 4 is active (determination of ● Wait.
the minimum controller increment length)
RUN 5 X Initialization part 5 is active (optimization of ● Wait until "FINSH" is displayed. Initializa‐
the transient response) tion was completed successfully.
YEND1 X The first position of the stop can be approach‐ 1. Approach first position of the stop with the
ed only in case of a manual initialization button or .
2. Acknowledge using button.
YEND2 X The second position of the stop can be ap‐ 1. Approach second position of the stop with
proached only in case of a manual initialization the button or .
2. Acknowledge using button.
RANGE X The position of the stop or the measuring ● Approach a different position of the stop
span is beyond the permissible measuring using or button and acknowledge
range only in case of a manual initialization using button.
● Move the friction clutch until "ok" is dis‐
played, and then acknowledge with the
button.
● Terminate the initialization process using
the button, switch to the P-manual
mode, and correct the actuator travel and
the position displacement sensor.
ok x The permissible measuring range of end po‐ ● Use the button to acknowledge; the re‐
sitions is achieved only in case of a manual maining steps ("RUN 1" to "FINSH") run
initialization automatically.
RUN 1 / X Error in "RUN 1", no movement e.g. due to the Possible causes:
ERROR lack of compressed air ● Insufficient supply of compressed air.
● Restrictor(s) blocked.
● Actuator does not move freely.
Measures:
1. Eliminate possible causes.
2. Restart initialization.


Up Down
d___U X Bar graph display of the zero point is outside 1. Set between "P 4.0" and "P 9.9" ( >0< )
the tolerance range using friction clutch.
2. Continue using or button.
SEt X Friction clutch was moved; "P 50.0" not dis‐ 1. In the case of linear actuators, use the
MIDDL X played when the lever is horizontal or button to bring the lever perpendic‐
ular to the spindle.
2. Briefly acknowledge using button (ini‐
tialization is continued).
UP > X "UP" tolerance range was exceeded or the in‐ 1. Increase the effective lever length of the
active zone of the potentiometer was covered. linear actuators or switch the transmission
ratio selector to 90°.
2. Briefly acknowledge using button.
90_95 X Possible only in case of part-turn actuators: 1. Use the or button to move it in the
actuator travel is not in the range between 90 range between 90 and 95%.
and 95%
U-d> X "Up-Down" measuring span was undershot 1. Decrease the effective lever length of the
linear actuators or switch the transmission
ratio selector to 33°.
U nn.n X Display of the "Up" travel time ● Wait until initialization continues in RUN 4.
D->U X ● To change the travel time, interrupt the in‐
itialization process using the button.
● Activate the leakage test using the but‐
ton.
D nn.n X Display of the "Down" travel time ● Wait until initialization continues in RUN 4.
U->d X ● To change the travel time, interrupt the in‐
itialization process using the button.
● Activate the leakage test using the but‐
ton.
NOZZL X Actuator stops (the initialization process was 1. The travel time can be changed by adjust‐
interrupted using the "-" button when the ac‐ ing the restrictor(s).
tuation speed display was active)
2. Redetermine the positioning speed using
the button.
3. Continue using button.
TESt X Leakage test active (the "+" button was press‐ ● Wait for one minute.
LEAKG X ed when the actuation speed display was ac‐
tive)
nn.n X Value and unit of the result after the leakage ● Rectify the leakage if the value is too large.
%/MIN X test ● Continue using button.


Up Down
nn.n X Initialization completed successfully with the 1. Briefly acknowledge using button.
FINISH X display of actuator travel or the actuator angle 2. Leave configuration level with a long
press on the button.
See also
System messages before initialization (Page 207)
11.1.3 System messages when exiting the Configuration mode


Error symbol
Messages when exiting the configuration mode:
Message Line Operating mode Meaning / cause Measure

Up Bot‐ Automatic Manual mode P manual mode
tom
n.nn.nn- X Software version ● Maintenance
nn X
Error X Monotony interruption ● Correct the value
SLnn X of the free character‐
istic on the setpoint
turning point n
11.1.4 System messages during operation


Error symbol
/ (slash): The texts on the left and right of the slash flash alternately

Messages during operation
Message Line Operating mode Meaning / cause Measure

Top Bot‐ Automat‐ Manual P man‐
tom ic mode ual mode
CPU X Message after application of elec‐ ● Wait
START X trical auxiliary power.
HW / X Fault in the hardware. ● Replace electronics.
ERROR
NOINI X X Positioner is not initialized. ● Start initialization.
nnn.n X X X Actual position [in %] for initial‐
ized positioner. Flashing decimal
point shows communication with
a class 2 master.
AUTnn X X Automatic mode (nn = setpoint)
MANnn X X Manual mode ● Switch to automatic
(nn = setpoint) mode with .
oFL / X X X Display range exceeded. ● Offset friction clutch
127.9 Possible causes: so that, when the ac‐
● Friction clutch or tuator moves, the ac‐
tual value display
● Transmission ratio selector
stays between 0.0 and
was moved or
100.0, or
● Positioner was installed on a
● Adjust the transmis‐
different actuator without be‐
sion ratio selector or
ing re-initialized.
● Perform factory set‐
tings (Preset) and initi‐
alization.
EXSTP X X Actuator was stopped by the dig‐
ital input.
EX UP X X Actuator is moved to the upper
endstop by the digital input.
EXDWN X X Actuator is moved to the lower
endstop by the digital input.
EXPSt The partial stroke test was activa‐
ted, e.g. by the digital input.
InPSt Cyclic partial stroke test.
FST X X Full stroke test running.
SRT X X Step response test running.
MSRT X X Multi-step response test running.
VPT X X Valve performance test running.
LEAKR X X A leakage test started by commu‐
nication is running.

11.2 Diagnostics
11.2 Diagnostics
11.2.1 Display of diagnostics values
Structure of the diagnostics display

The display in "Diagnostics" mode has a structure similar to that in "Configuration" mode:
● The upper line shows the value of the diagnostics variable.
● The lower line shows the number and the abbreviation of the displayed variable.
Some diagnostics value can be greater than 99999. In such a case, the display switches over
to the exponential view. Example: The value "1234567" is shown as "1.23E6".
General procedure
1. Press all three buttons at the same time for at least 2 seconds. You are now in the
diagnostics display.
2. Use the button to select the next diagnostics value.
3. Press the button for at least 2 seconds in order to exit the diagnostics display.
How to show the diagnostics values in reverse order

Press the and buttons simultaneously.
How to set values to zero

Specific values can be set to zero by pressing the button for at least 5 seconds. The
diagnostics values which can be reset are listed in the table in section "Overview of diagnostics
values (Page 213)".
11.2.2 Saving the diagnostics values

The diagnostic values are written into a non-volatile memory every 15 minutes so that, in the
event of a power failure, only the diagnostic values of the previous 15 minutes are lost. The
values in the resettable parameters can be set to zero.
To do this, press the button for at least 5 seconds.
The diagnostic values which can be reset can be found in the table in section Overview of
diagnostics values (Page 213).

11.2 Diagnostics
11.2.3 Overview of diagnostics values
Explanatory notes on the following table

● The "Representable diagnostics values" column shows the factory settings for the
diagnostics parameters in bold type.
● The "Properties" column shows the properties of the diagnostics parameters:
– ① Diagnostics value can be read and reset
– ② Diagnostics value can be read but not reset
– ③ Diagnostics value can be read but not reset. A function can be executed.
– ④ Diagnostics value can be read, manually reset, and manually changed
Overview of diagnostics values
No. Short desig‐ Meaning Representable di‐ Unit Properties

nation agnostics values
1 STRKS Number of total strokes 0 ... 4.29E9 - ①
2 CHDIR Number of changes in direction 0 ... 4.29E9 - ①
3 CNT Number of fault messages 0 ... 4.29E9 - ①
4 A1CNT Number of alarms 1 0 ... 4.29E9 - ①
5 A2CNT Number of alarms 2 0 ... 4.29E9 - ①
6 HOURS Number of operating hours 0 ... 4.29E9 Hours ②
7 HOURR Resettable operating hours counter 0 ... 4.29E9 ①
8 WAY Determined travel 0 ... 130 mm or ° ②
9 TUP Travel time up 0.0 / 0 ... 1000 s ②
10 TDOWN Travel time down 0.0 / 0 ... 1000 s ②
11 LEAK Leakage test - / 0.0 ... 100.0 %/minute ③
12 PST Monitoring of partial stroke test OFF / ###.#, FdI‐ s for ###.# ③
ni, notSt, SdtSt,
fdtSt, notoL, Strt,
StoP
13 PRPST Time since last partial stroke test ###, notSt, Sdtst, Days ②
fdtSt
14 NXPST Time until next partial stroke test OFF / ### Days ②
15 DEVI Dynamic control valve behavior 0.0 ... 100.0 % ②
16 ONLK Pneumatic leakage 0.0 ... 100.0 - ②
17 STIC Stiction (slipstick) 0.0 ... 100.0 % ②
18 ZERO Lower endstop 0.0 ... 100.0 % ②
19 OPEN Upper endstop 0.0 ... 100.0 % ②
20 PAVG Average value of position OFF, IdLE, rEF, % ②
COMP
0.0 ... 100.0
21 P0 Potentiometer value of lower endstop (0%) 0.0 ... 100.0 % ③
22 P100 Potentiometer value of upper endstop (100%) 0.0 ... 100.0 % ③

11.2 Diagnostics
No. Short desig‐ Meaning Representable di‐ Unit Properties

nation agnostics values
23 IMPUP Pulse length up 6 ... 160 ms ④
24 IMPDN Pulse length down 6 ... 160 ms ④
25 PAUTP Pulse pause 2 ... 28 ... 320 ms ④
26 DBUP Deadband up 0.1 ... 10.0 % ②
27 DBDN Deadband down 0.1 ... 10.0 % ②
28 SSUP Slow step zone up 0.1 ... 10.0 ... % ④
100.0
29 SSDN Slow step zone down 0.1 ... 10.0 ... % ④
100.0
30 TEMP Current temperature -50 ... 100 °C ②
-58 ... 212 °F
31 TMIN Minimum temperature (min/max pointer) -50 ... 100 °C ②
-58 ... 212 °F
32 TMAX Maximum temperature (min/max pointer) -50 ... 100 °C ②
-58 ... 212 °F
33 T1 Number of operating hours in temperature range 1 0 ... 4.29E9 Hours ②
42 VENT1 Number of switching cycles pneumatic block, Valve 1 0 ... 4.29E9 - ②
43 VENT2 Number of switching cycles pneumatic block, Valve 2 0 ... 4.29E9 - ②
44 VEN1R Number of switching cycles pneumatic block, Valve 1, 0 ... 4.29E9 - ①
resettable
45 VEN2R Number of switching cycles pneumatic block, Valve 2, 0 ... 4.29E9 - ①
resettable
46 STORE Save the current values as 'last maintenance' - - ③
(press button for 5 seconds)
47 PRUP Prediction up 1 ... 40 - ④
48 PRDN Prediction down 1 ... 40 - ④
49 WT00 Number of operating hours in the travel range WT00 0 ... 4.29E9 Hours ①
57 LKPUL Length of the leakage compensation pulse -256 ... 0 ... 254 ms ②
58 LKPER Period of the leakage compensation pulse 0.00 ... 600.00 s ②

11.2 Diagnostics
59 mA Setpoint current 0.0 ... 20.0 mA ②
60 PZ Supply pressure (PZ) 99.999 (bar) - ③

63 PZMAX Supply pressure (PZ) min/max pointer 999.99 (psi) - ①
9.9999 (MPa)
64 N_MIN Event counter 0 ... 99999 - ①
11.2.4 Meaning of the diagnostics values
11.2.4.1 Diagnostic value '1.STRKS - Number of total strokes'
Display range: 0 ... 4.29E9

Purpose: In operation, the movements of the actuator are summed up and
displayed in this diagnostics parameter as the number of strokes.
Unit: 100% strokes, i.e. the path between 0% and 100% and back.
11.2.4.2 Diagnostic value '2.CHDIR - Number of changes in direction'

Purpose: Every change in direction of the actuator is noted in the controller
and added to the number of changes in direction.
11.2.4.3 Diagnostic value '3.\\CNT - Number of fault messages'

Purpose: Every fault is noted in the closed-loop controller with '3. CNT' and
added to the number of fault messages.
11.2.4.4 Diagnostic value '4.A1CNT - Number of alarms 1' / '5.A2CNT - Number of alarms 2'
Requirement: '44.AFCT' Alarm function (Page 156) parameter is activated.

Purpose: This value indicates how often the alarm has been triggered.

11.2 Diagnostics
11.2.4.5 Diagnostic value '6.HOURS - Number of operating hours'

Purpose: The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner.
11.2.4.6 Diagnostic value '7.HOURR - Resettable operating hours counter'

Purpose: The runtime meter is incremented every hour as soon as electric
auxiliary power is supplied to the positioner. In contrast to Diagnos‐
tic value '6.HOURS - Number of operating hours' (Page 216), this
value can be reset.
Description: In order to minimize the control valve wear resulting from a poor
control quality, it makes sense to optimize the positioner's param‐
eters. You can recognize optimum parameter settings when the
values of the Diagnostic value '44.VEN1R' / '45.VEN2R' (Page 225)
are low. Low values mean that the switching frequency of the posi‐
tioner pneumatics is also low. In order to carry out a comparison
with various parameter settings, determine the number of switching
cycles per hour. To do this, use the values of the Diagnostic value
'44.VEN1R' / '45.VEN2R' (Page 225) and '7.HOURR'. These three
parameters can be reset to enable simpler determination of the
values.
11.2.4.7 Diagnostic value '8.WAY - Determined travel'
Condition for The travel is set in the '3.YWAY' Range of stroke (Page 145) pa‐
linear actuator: rameter.
Display range: 0 ... 130
Purpose: This value in mm or ° specifies the travel determined during the
initialization.
11.2.4.8 Diagnostic value '9.TUP - Travel time up' / '10.TDOWN - Travel time down'

Purpose: This value indicates the current UP or DOWN travel time in seconds
determined during the initialization.

11.2 Diagnostics
11.2.4.9 Diagnostic value '11.LEAK - Leakage test'
Condition The positioner is initialized and in manual mode (MAN).

Display range: ● -
● 0.0 ... 100.0
Purpose: You can use this diagnostics parameter to read the last test result or
start an offline leakage test with which you can detect leakages in
the actuator or in the pipe installation. Display is percent stroke per
minute referred to the total stroke. A test result originates from one
of the following options:
● Function '11.LEAK' has already been carried out.
● Leakage test was already carried out during initialization, see
procedure of RUN 3 in section Sequence of automatic initializa‐
tion (Page 109).
● 'Offline leakage test' function was already executed by a HOST
system.
"-" in the display can have the following causes:
● A leakage test has not yet been carried out.
● Resetting to the factory settings was carried out using
the '50.PRST' Preset (Page 160) > ALL parameter.
● Positioner is not initialized.
How to start the test
1. Move the actuator to the position at which you wish to start the
test.
2. In 'Diagnostics' mode, go to the '11.LEAK' diagnostic value as
described in section Display of diagnostics values (Page 212).
3. Start the function by pressing the button for at least 5 sec‐
onds.
Description: 'Strt' is output in the display. The function is started after 5 seconds.
'tESt' and the current position of the actuator (actual value) are then
displayed alternately for one minute.
After one minute, the display shows the difference in the actuator
position before and after the test. This means: the actuator position
has changed by the displayed value in one minute.

11.2 Diagnostics
11.2.4.10 Diagnostic value '12.PST - Monitoring of partial stroke test'
Indication on the display: ● OFF

● C-ERR
● FdIni
● notSt
● ###.#
● SdtSt
● FdtSt
Purpose: This diagnostics parameter indicates the stroke time measured
during the last partial stroke test.
A partial stroke test can be initiated manually or a current partial
stroke test can be interrupted by pressing the button.
Description of indications ● OFF: The partial stroke test function is deactivated.
on the display: ● C-ERR: Configuration error. Partial stroke test cannot be star‐
ted. Settings in the 'A1.STPOS start position', 'A3.STRKH stroke
height' and 'A4.STRKD stroke direction' are not plausible.
● FdIni - Failed PST Initialization: The reference stroke time meas‐
urement of the partial stroke test has failed.
● notSt - No Test: A partial stroke test has not yet been executed.
● ###.#: Corresponds to the measured stroke time in seconds.
The last partial stroke test was successfully executed.
● SdtSt - Stopped Test: The last partial stroke test was interrupted.
● FdtSt - Failed Test: The last partial stroke test has failed.
Status messages: The following status messages appear when you hold the button
pressed:
● notoL - No Tolerance: The control valve is beyond the tolerance
range to start the partial stroke test. A manual partial stroke test
is not started.
● Strt - Start: A manual partial stroke test is started five seconds
after pressing the button.
● StoP - Stop: The current partial stroke test is interrupted. 'WAIT'
is output in the display.

11.2 Diagnostics
11.2.4.11 Diagnostic value '13.PRPST' - Time since last partial stroke test'
Indication on the display: ● ###

● notSt
● Sdtst
● FdtSt
Purpose: This diagnostics parameter shows the elapsed time in days since
the last partial stroke test.
Status messages: ● notSt - No Test: A manual partial stroke test has not yet been
executed.
11.2.4.12 Diagnostic value '13.PRPST - Time since last partial stroke test' (version with pressure
sensor module)
Indication on the display: ● ###

● notSt
● noREF
● Sdtst
● FdtSt
Purpose: This diagnostics parameter shows the elapsed time in days since
the last partial stroke test.
Status messages: ● notSt - No Test: A manual partial stroke test has not yet been
executed.
● noREF: A reference partial stroke test has not yet been execu‐
ted.
11.2.4.13 Diagnostic value '14.NXPST - Time until next partial stroke test'
Requirement: ● The partial stroke test is activated in 'Configuration' mode.

● The test interval is set in the 'A8.INTRV' parameter.
● ###
Purpose: This diagnostics parameter shows the time in days until the next
partial stroke test. If one of the above-mentioned conditions is not
met, 'OFF' is shown on the display.

11.2 Diagnostics
11.2.4.14 Diagnostics value '15.DEVI - Dynamic control valve behavior'
Requirement: Monitoring of dynamic control valve behavior 'b.\\DEVI' (Page 168)

parameter is activated.
Display range: 0.0 ... 100.0
Purpose: This value in percent provides information about the current dynam‐
ically determined deviation from the model response.
11.2.4.15 Diagnostic value '16.ONLK - Pneumatic leakage'
Requirement: Monitoring/compensation of pneumatic leakage 'C.\\LEAK'

(Page 170) parameter is activated.
Purpose: This diagnostics parameter shows the current leakage indicator.
11.2.4.16 Diagnostic value '17.STIC - Stiction (slipstick)'
Requirement: Monitoring of stiction (slipstick) 'd.\\STIC' (Page 173) parameter is

activated.
Purpose: This diagnostics parameter shows the filtered value of the slip
jumps in percent resulting from the stiction.
11.2.4.17 Diagnostic value '18.ZERO - Lower endstop'
Requirement: Monitoring of lower endstop 'F.\\ZERO' (Page 176) parameter is

activated.
'39.YCLS' Tight closing/fast closing with manipulated variable
(Page 153) Parameter is set to one of the following values: 'do', 'uP
do', 'Fd', 'Fu Fd', 'uP Fd', 'Fu do'
Purpose: Indication of how many percent the lower endstop has changed
compared to its value during initialization.

11.2 Diagnostics
11.2.4.18 Diagnostic value '19.OPEN - Upper endstop'
Requirement: Monitoring the upper endstop 'G.\\OPEN' (Page 177) parameter is

activated.
'39.YCLS' Tight closing/fast closing with manipulated variable
(Page 153) parameter is set to one of the following values: 'uP',
'uP do', 'Fu', 'Fu Fd', 'uP Fd', 'Fu do'
Purpose: An indication of the current shift of the upper endstop compared to
its initialization value.
11.2.4.19 Diagnostic value '20.PAVG - Average value of position'

● IdLE
● rEF
● COMP
Purpose: This value shows the last calculated comparison average. Meaning
of the displays:
● OFF: The underlying function is deactivated in the configuration
menu.
● IdLE : Inactive. The function has not been started yet.
● rEF: The reference average is calculated. The function was
started, and the reference interval is in progress at the moment.
● COMP: The comparison average is calculated. The function
was started, and the comparison interval is in progress at the
moment.
11.2.4.20 Diagnostic value '21.P0 - Potentiometer value of lower endstop (0%)' / '22.P100 -
Potentiometer value of upper endstop (100%)'
Display range: ● NO
● 0.0 ... 100.0
'NO': Changing the low or upper endstop is not possible in the cur‐
rent state of the control valve. Initialize the positioner again.
Condition 1 - The positioner is initialized.
read values
Purpose 1 Read values
You can use the P0 and P100 parameters to read the values for the
lower endstop (0%) and the upper endstop (100%) of the position
measurement as determined during the automatic initialization. The
values of manually approached end positions are applicable for
manual initialization.

11.2 Diagnostics
Condition 2 - ● The positioner is initialized and in manual mode (MAN) or auto‐

change values matic mode (AUT).
● The current position of the actuator is within the range -10% to
+10% of the lower endstop (P0).
● The current position of the actuator is within the range 90% to
110% of the upper endstop (P100).
Purpose 2: Change values
You can use these two parameters to change the lower endstop (P0)
and the upper endstop (P100).
Since initialization is not usually carried out under process condi‐
tions, the values for the lower endstop (P0) and the upper endstop
(P100) can change when the process is started. These changes can
result from temperature changes with the associated thermal ex‐
pansion of the material. If the Monitoring of lower endstop 'F.\\ZERO'
(Page 176) and Monitoring the upper endstop 'G.\\OPEN'
(Page 177) parameters are active, the thresholds set in these two
parameters can be exceeded as a result of thermal expansion. An
error message is output in the display.
The process-dependent thermal expansion might represent the nor‐
mal state in your application. You do not wish to receive an error
message as a result of this thermal expansion. Therefore reset the
'P0' and/or 'P100' parameters after the process-dependent thermal
expansion has had its complete effect on the control valve. The
procedure is described in the following.
Description: Procedure for manual mode (MAN)
1. Move the actuator to the desired position of the lower endstop
(upper endstop) using the and buttons.
2. Switch to diagnostics mode.
3. Go to diagnostic value 21.P0 (22.P100).
4. Apply the setting by pressing the button for at least 5 seconds.
After 5 seconds, '0.0' (with 22.P100: '100.0') is displayed. Result:
The lower endstop (upper endstop) now corresponds to the cur‐
rent position of the actuator.
5. Switch to manual mode (MAN). Result: Values for the upper
endstop (lower endstop) have changed.
Procedure for automatic mode (AUT)
1. Check in the display whether the current position of the actuator
is at the desired position of the lower endstop (upper endstop).
2. Switch to diagnostics mode.
3. Go to diagnostic value 21.P0 (22.P100).
4. Apply the setting by pressing the button for at least 5 seconds.
After 5 seconds, '0.0' (with 22.P100: '100.0') is displayed. Result:
The lower endstop (upper endstop) now corresponds to the cur‐
rent position of the actuator.
5. Switch to automatic mode (AUT).

11.2 Diagnostics
See also
11.2.4.21 Diagnostic value '23.IMPUP - Pulse length up' / '24.IMPDN - Pulse length down'

Purpose: The smallest impulse lengths that can be used to move the actuator
are determined during the initialization process. They are separate‐
ly determined for the 'Up' and 'Down' directions and displayed here.
Display in ms.
In the case of special applications you can additionally set the
smallest impulse lengths in these two parameters.
Factory setting: 6
See also
Mode of operation (Page 30)
Optimization of controller data (Page 101)
11.2.4.22 Diagnostic value '25.PAUTP - Pulse interval'

Purpose: This value is not changed during an initialization process. Display in
ms.
For applications with high stiction (slipstick), adjusting this param‐
eter improves the control quality.
This parameter can be set for special applications.
Factory setting: 28
See also
11.2.4.23 Diagnostic value '26.DBUP - Deadband up' / '27.DBDN - Deadband down'

Purpose: In this parameter, you can read the deadbands of the controller in
the 'Up' and 'Down' directions. Display in percent. The values cor‐
respond either to the manually configured value of the '34.DEBA'
Deadband of closed-loop controller (Page 150) parameter or to the
value automatically adapted by the device if 'DEBA' was set to 'Auto'.

11.2 Diagnostics
11.2.4.24 Diagnostic value '28.SSUP - Slow step zone up' / '29.SSDN - Slow step zone down'

Purpose: The slow step zone is the zone of the closed-loop controller in which
control signals are issued in a pulsed manner. Display is in percent.
The impulse length is thus proportional to the control deviation. If
the control deviation is beyond the slow step zone, the valves are
controlled using permanent contact.
This parameter can be set for special applications.
See also
Optimization of controller data (Page 101)
11.2.4.25 Diagnostic value '30.TEMP - Current temperature'
Display range: °C: -50 ... 100

°F: -58 ... 212
Purpose: Current temperature in the positioner enclosure. The sensor is
present on the basic electronics. In order to switch over the temper‐
ature display between °C and °F, press the button.
11.2.4.26 Diagnostic value '31.TMIN - Minimum temperature' / '32.TMAX - Maximum temperature'
Display range: °C: -50 ... 100

°F: -58 ... 212
Purpose: The minimum and maximum temperatures within the enclosure are
constantly determined and saved as with a min/max pointer. This
value can only be reset in the factory.
In order to switch over the temperature display between °C and °F,
press the button.

11.2 Diagnostics
11.2.4.27 Diagnostic value '33.T1' ... '41.T9' - Number of operating hours in the temperature range
1 to 9

Purpose: Statistics about the duration of operation in different temperature
ranges is maintained in the device. An average of the measured
temperature is taken every hour and the counter assigned to the
corresponding temperature range is incremented. This helps in
drawing conclusions about the past operating conditions of the de‐
vice and the entire control valve.
The temperature ranges are classified as follows:
T1 T2 T3 T4 T5 T6 T7 T8 T9
Temperature range [°C] - ≥ -30 ≥ -15 ≥0 ≥ 15 ≥ 30 ≥ 45 ≥ 60 ≥ 75
≤ -30 < -15 <0 < 15 < 30 < 45 < 60 < 75 -
Operating hours in temperature ranges T1 to T2
11.2.4.28 Diagnostic value '42.VENT1' / '43.VENT2'
'42.VENT1' number of switching cycles pneumatic block, Valve 1

'43.VENT2' number of switching cycles pneumatic block, Valve 2
Purpose: Control operations of the pneumatic block are summarized and dis‐
played in this parameter.
Description: The pneumatic block of the positioner pressurizes and depressurizes
the actuator. The characteristic service life of the pneumatic block de‐
pends on the load. The average service life is approx. 200 million
switching cycles. The number of control procedures for the switching
cycles serves to assess the switching frequency of the pneumatic block.
Counting procedure for single-acting actuators:
● Pressurize => 42.VENT1
● Depressurize => 43.VENT2
Counting procedure for double-acting actuators:
● Pressurize (Y2) / Depressurize (Y1) => 42.VENT1
● Depressurize (Y1) / Pressurize (Y2) => 43.VENT2
The value is written hourly into a nonvolatile memory.
11.2.4.29 Diagnostic value '44.VEN1R' / '45.VEN2R'
'44.VEN1R' number of switching cycles pneumatic block, Valve 1, resettable

'45.VEN2R' number of switching cycles pneumatic block, Valve 2, resettable

11.2 Diagnostics
Purpose: Control procedures of the pneumatic block are counted since the last
time this parameter was reset, and displayed here.
Description: Corresponds to the description for Diagnostic value '42.VENT1' /
'43.VENT2' (Page 225) referred to the diagnostics parameters
'VEN1R' and 'VEN2R' described here.
11.2.4.30 Diagnostic value '46.STORE - Save maintenance data'
Purpose: The minimum and maximum temperatures within the enclosure are
constantly determined and saved as with a min/max pointer. This
value can only be reset in the factory. In order to switch over the
temperature display between °C and °F, press the button for at
least 5 seconds in order to initiate a save function. The values of the
diagnostics parameters Diagnostic value '8.WAY - Determined
travel' (Page 216) to Diagnostic value '11.LEAK - Leakage test'
(Page 217) and Diagnostic value '21.P0 - Potentiometer value of
lower endstop (0%)' / '22.P100 - Potentiometer value of upper end‐
stop (100%)' (Page 221) to Diagnostic value '28.SSUP - Slow step
zone up' / '29.SSDN - Slow step zone down' (Page 224) are saved
in the non-volatile memory as 'data of last maintenance'. This diag‐
nostics data contains selected values whose changes can give in‐
formation about mechanical wear and tear of the valve.
This function is normally operated through the PDM, menu com‐
mand 'Diagnostics-> Save maintenance information'. The data of
the last maintenance operation can be compared with the current
data using SIMATIC PDM.
11.2.4.31 Diagnostic value '47.PRUP - Prediction up' / '48.PRDN - Prediction down'

Purpose: This value specifies the prediction of the controller for the up
(PRUP) and down (PRDN) movements.
For more information, refer also to the section Optimization of con‐
troller data (Page 101).
Factory setting: 1

11.2 Diagnostics
11.2.4.32 Diagnostic value '49.WT00' ... '56.WT95' - Number of operating hours in the travel range
WT00 to WT95

Purpose: When the positioner is in "Automatic" mode, statistics are continu‐
ously maintained regarding the duration for which a process valve
is operated in a particular section of the travel range. The entire
travel range is divided into 8 sections from 0 to 100 %. The posi‐
tioner records the current position continuously and increments the
runtime meter assigned to the corresponding travel range every
hour. This helps in drawing conclusions about the past operating
conditions and especially in assessing the control properties of the
control loop and the entire control valve.
Travel range WT00 WT05 WT10 WT30 WT50 WT70 WT90 WT95
Travel range section [%] - ≥5 ≥ 10 ≥ 30 ≥ 50 ≥ 70 ≥ 90 ≥ 95
<5 < 10 < 30 < 50 < 70 < 90 < 95 -
Division of travel ranges
You can simultaneously set the eight operating hours counters to

zero.
TIP: Since the travel ranges are provided at the end of the diag‐
nostics parameters, press the button several times along with
the button. This will help you to access the desired diagnostics
parameters faster.
11.2.4.33 Diagnostic value '57.LKPUL - Length of the leakage compensation pulse'
Display range: -256 ... 0 ... 254

Purpose: This value in milliseconds indicates the length of a compensation
pulse when Monitoring/compensation of pneumatic leakage 'C.\
\LEAK' (Page 170) is active. The sign indicates the control direction
of the pulse.
Factory setting: 0
11.2.4.34 Diagnostic value '58.LKPER - Period of the leakage compensation pulse'

Purpose: This value in seconds indicates the period of the leakage compen‐
sation pulses when Monitoring/compensation of pneumatic leak‐
age 'C.\\LEAK' (Page 170) is active.

11.2 Diagnostics
11.2.4.35 Diagnostic value '59.mA - Setpoint current'

Here you can display the current setpoint in mA.
11.2.4.36 Diagnostic value '60.PZ Supply pressure (PZ)'
Indication on the display: ##.### (bar)

###.## (psi)
#.#### (MPa)
Purpose: Shows the current supply pressure PZ. The value refers to the
pressure unit assigned in "U1.PUNIT (Page 188)".
If the supply pressure PZ is switched off, the pressure value shown
in the display is 0. Depending on the height at which you use the
positioner, the displayed pressure value is ≠0. Press the button
for at least 5 seconds to set the value to 0. "reset" is shown in the
display for as long as you press the button. This calibration is
only possible if the displayed pressure value is in the range -0.5 to
+0.5 bar.
11.2.4.37 Diagnostic value '63.PZMAX Supply pressure (PZ) min/max pointer
Indication on the display: ##.### (bar)

###.## (psi)
#.#### (MPa)
Purpose: The supply pressure (PZ) is continuously monitored and the maxi‐
mum value (min/max pointer) is displayed.
The min/max pointer can be reset via HART communication.
11.2.4.38 Diagnostic value '64.N_MIN Event counter'

Purpose: Each new measured value of the pressure monitoring is compared
with the value set in "U.PZLIM (Page 188)". The counter increases
when the supply pressure is lower than the configured limit value.
The counter can be reset via HART communication.

11.3 Online diagnostics
11.3.1 Overview of error codes
Overview of error codes that activate the fault message output

You can find where the error codes are output in the display under "52.XDIAG (Page 162)".
Error Three- Event Parameter setting Error message disappears Possible causes
code stage when
1 No Control deviation: Always active ... the actual value response Supply pressure PZ missing,
Actual value re‐ falls below the value for LIM actuator fault, process valve
sponse has excee‐ fault (e.g. blockage).
ded values for TIM
and LIM
2 No Device not in "Au‐ **. FCT1) ... the device is changed to The device has been config‐
tomatic" mode = nA or = nAB "Automatic" mode. ured or is in the manual mode
3 No Digital input BIN1 **. FCT1) ... the digital input is no longer The contact connected to the
or BIN2 active = nAB and digital activated. digital input was active (e.g.
function BIN1 or packing gland monitoring,
BIN2 to "On" overpressure, temperature
switch).
4 Yes Limit for number of L. STRK≠OFF ... the stroke counter is reset The total path covered by the
total strokes ex‐ or the thresholds are in‐ actuator exceeds one of the
ceeded creased configured thresholds.
5 Yes Limit for number of O. DCHG≠OFF ... the counter for changes of The number of changes of di‐
changes in direc‐ direction is reset or the thresh‐ rection exceeds one of the
tion exceeded olds are increased. configured thresholds.
6 Yes Lower endstop lim‐ F. ZERO≠OFF ... the deviation of the endstop Wear and tear of the process
it exceeded **.YCLS = do or up disappears or the device is re- valve, deposits or foreign bod‐
do initialized. ies in the process valve, me‐
chanical misalignment, fric‐
tion clutch moved.
7 Yes Upper endstop lim‐ G. OPEN≠OFF ... the deviation of the endstop Wear and tear of the process
it exceeded **.YCLS1) = do or disappears or the device is re- valve, deposits or foreign bod‐
up do initialized. ies in the process valve, me‐
chanical misalignment, fric‐
tion clutch moved.
8 No Deadband limit ex‐ E. DEBA≠OFF ... the limit is undershot again Increased packing gland fric‐
ceeded **.DEBA1) = Auto tion, mechanical gap in the po‐
sition feedback.

Error Three- Event Parameter setting Error message disappears Possible causes
code stage when
9 Yes Case 1: Reference A. PST≠OFF Case 1: ... a partial stroke test Case 1: Process valve is stuck
stroke time for par‐ is successfully executed with‐ or rusted. Increased stiction.
tial stroke test is ex‐ in the reference stroke time or
ceeded. the function is deactivated.
Case 2: Start posi‐ Case 2: Move the actuator into Case 2: Valve is present in the
tion outside the the range of the PST start tol‐ safety position.
start tolerance erance. Or increase the PST
start tolerance until the actua‐
tor (PST start position) is with‐
in the PST start tolerance.
Start the partial stroke test
again.
10 Yes Deviation from ex‐ b. DEVI≠OFF ... the position is again in a Actuator fault, process valve
pected dynamic narrow corridor between the fault, process valve jams, in‐
control valve be‐ setpoint and the model, or the creased stiction, decreased
havior function is deactivated. supply pressure PZ
11 Yes Valve leakage C. LEAK≠OFF ... the valve leakage has been Pneumatic leakage
remedied or the function is de‐
activated.
12 Yes Stiction limit (slip‐ d. STIC≠OFF ... Slipjumps can no longer be Increased stiction, process
stick) exceeded detected, or the function is de‐ valve no longer moves
activated. smoothly but in jerky motion.
13 Yes Temperature un‐ H. TMIN≠OFF ... the low temperature thresh‐ Ambient temperature too low
dershot olds are no longer undershot.
14 Yes Temperature over‐ J. TMAX≠OFF ... the high thresholds are no Ambient temperature too high
shot longer overshot.
15 Yes Position average P. PAVG≠OFF ... the average position value In the last comparison inter‐
deviates from the calculated after a comparison val, the process valve charac‐
reference value interval is again within the teristic was changed so signif‐
thresholds for the reference icantly that a deviating aver‐
value, or the function is deac‐ age value of position was cal‐
tivated. culated.
16 No Partial stroke test A. PST≠OFF the parameter values entered Parameters for partial stroke
is to be carried out in A1.STPOS, A3.STRKH and test are non-plausible
with non-plausible A4.STRKD are plausible.
parameter values
17 No Pressure sensor U. PRES≠OFF ... the device is restarted with
module defective the functioning pressure sen‐
sor module or the pressure
sensor module is deactivated.
18 No Value below sup‐ U. PRES≠OFF ... the supply pressure PZ is Supply pressure PZ is too low
ply pressure PZ higher than the limit value in
low limit U2.PZLIM including the hyste‐
resis in U3.PZHYS
19 No Supply pressure U. PRES≠OFF ... the supply pressure PZ is Supply pressure PZ too high
PZ outside of spec‐ within the positioner specifica‐ or too low
ification tion of 1.4 bar to 7.0 bar in‐
cluding the hysteresis in
U3.PZHYS.

1)
Refer to the corresponding parameter descriptions for additional information about parameters
11.3.2 Overview of online diagnostics

Online diagnostics means diagnostics during ongoing operation. During operation of the
positioner, a few important values and parameters are continually monitored. In configuration
mode, you can configure that monitoring so that the fault message output will be activated if, for
instance, a limit is exceeded.
Information about what events can activate the fault message output can be found in the table
in section "Overview of error codes (Page 229)".
This section contains particular information about the following situations:
● Possible causes of the fault message.
● Events which activate the fault message output or alarm outputs.
● Settings of parameters needed for event monitoring.
● Cancelling an error message
When the fault message output is triggered in "Automatic" or "Manual" mode, the display shows
which fault triggered the message. The two digits on the lower left show the corresponding error
code. If multiple triggers occur at the same time, they are displayed one after the other
cyclically. The device status, including all fault messages, can be called up using command
"#48" over HART.
See also
'52.XDIAG' Activating for extended diagnostics (Page 162)
Advanced diagnostic parameters A to U (Page 163)
11.3.3 XDIAG parameter

You can use the extended diagnostics parameters to display error messages in one, two or
three stages. In addition to the fault message output, the digital outputs A1 and A2 are then
used. For this purpose, set the "XDIAG" parameter as described in the following table:
XDIAG settings Message due to

OFF Extended diagnostics not activated
On1 Fault message output for threshold 3 error message (maintenance alarm, single-stage)
On2 Fault message output for threshold 3 error messages and digital output A2 for threshold 2
error messages (maintenance demanded, two-stage)
On3 Fault message output for threshold 3 error messages, digital output A2 for threshold 2 error
messages and digital output A1 for threshold 1 error messages (maintenance required,
three-stage)
Possible parameter setting 'XDIAG'

11.3.4 Meaning of error codes
11.3.4.1 1 Remaining control deviation

The deviation between the setpoint and the actual value is continuously monitored in
"Automatic" mode. The fault message for a remaining control deviation is activated depending
on the setting of the application parameters " TIM" - monitoring time for setting the fault
messages - and " LIM" - response threshold for the fault message. The fault message is
cancelled as soon as the control deviation drops below the response threshold. This monitoring
function is always active.
11.3.4.2 2 Device not in "Automatic" mode

When the device is not in automatic mode, an error message is generated if the ' FCT'
parameter (function of fault message output) is set correctly. A warning is then sent to the
control system if the device was switched to manual or configuration mode on-site.
11.3.4.3 3 digital inputs BIN1 or BIN2 active

If the digital input is activated, a fault message is generated when the ' FCT' and 'BIN1'
parameters are set accordingly. A fault message can be generated, for example, by a switch to
monitor the packing glands, a temperature switch or a limit switch (e.g. for pressure).
Configure the digital input BIN2 on the Digital I/O Module (DIO) in the same way.
11.3.4.4 4 Monitoring the number of total strokes

The diagnostics value "1 STRKS" is constantly compared with the thresholds that are
determined from the "L1.LIMIT" to "L4.FACT3" parameters. If the thresholds are exceeded, the
fault message output or the digital outputs A1 and A2 respond, depending on the operating
mode of the extended diagnostics . These two functions can be deactivated using the
parameter setting "OFF" for "L. STRK".
11.3.4.5 5 Monitoring the number of changes in direction

The diagnostics value "2 CHDIR" is constantly compared with the thresholds that are
determined from the "O1.LIMIT" to "O4.FACT3" parameters. If the thresholds are exceeded,
the fault message output or the digital outputs A1 and A2 respond, depending on the operating
mode of the extended diagnostics . These two functions can be deactivated using the
parameter setting "OFF" for "O. DCHG".
11.3.4.6 6 Monitoring the lower endstop / 7 Monitoring the upper endstop

If the parameter "F. ZERO" is set to "ON", monitoring of the lower endstop is activated. This
function can be used to detect the errors in the process valve. An overshot limit indicates the
possibility of deposits or foreign bodies in the process valve. If the value falls below the limit, this
indicates wear of the process valve or restrictor body. A mechanical misalignment of the
position feedback also triggers this fault message.

Monitoring is always carried out whenever the process valve is in the "tight closing/fast closing
Down" position. The current position is compared with the position that was determined as the
lower endstop at the time of initialization. Requirement: '39.YCLS' Tight closing/fast closing
with manipulated variable (Page 153) parameter is set to one of the following values: 'do',
'uP do', 'Fd', 'Fu Fd'.
Example: A value of 3% is set. The position is normally adopted for "tight closing/fast closing
Down". A fault is reported if a value > 3% or < -3% is determined instead.
The fault message remains activated until either subsequent monitoring remains within the
tolerance or a re-initialization process is executed. Even the deactivation of monitoring ("F.
ZERO"=OFF) may trigger an error message.
This monitoring function does not deliver any utilizable results if the endstops were not
determined automatically at the time of initialization, but the limits were set manually (manual
initialization, "5.INITM").
Similar diagnostics is carried out for the upper endstop. The "G. OPEN" parameter is used to
set the limit for this. Requirement: '39.YCLS' Tight closing/fast closing with manipulated
variable (Page 153) parameter is set to one of the following values: 'uP', 'uP do', 'Fu', 'Fu Fd',
'uP Fd', 'Fu do'.
11.3.4.7 8 Monitoring deadband

If the deadband increases disproportionately when adjusting it automatically ("DEBA"=Auto
parameter), it indicates an error in the system (e.g. severely increased packing gland friction,
play in the position displacement sensor, leakage). A limit can therefore be entered for this
value ("E1.LEVL3", threshold for deadband monitoring). An error message output is activated
when this value is exceeded.
11.3.4.8 9 Partial stroke test

On the one hand, this fault message appears when a manual or cyclic partial stroke test is
initiated and the test cannot be started since the process valve is not within the starting
tolerance. On the other hand, the fault message appears when one of the three thresholds of
the partial stroke test that are determined from the 'A9.PSTIN' reference stroke time multiplied
by factors 'AA.FACT1', 'Ab.FACT2' and 'AC.FACT3' is violated. The severity of the fault
message is shown by the number of bars on the display. The severity of the fault message is
simultaneously displayed using the fault message output or digital outputs A1 and A2
depending on the mode of extended diagnostics.
11.3.4.9 10 Monitoring of dynamic control valve behavior

The monitoring of the operational behavior responds when the actual process valve position
shifts from a narrow corridor between the setpoint and the expected position course. In this
case, the deviation between the expected and actual position course is output filtered. The
deviation is compared with the configured thresholds that are determined from the "b2.LIMIT"
limit multiplied by the factors "b3.FACT1" to "b5.FACT3".

11.3.4.10 11 Monitoring/compensation of pneumatic leakage

This fault message appears if a leakage is present. For additional information, see Monitoring/
compensation of pneumatic leakage 'C.\\LEAK' (Page 170).
11.3.4.11 12 Monitoring of stiction (slipstick)

If the stiction of the control valve increases during operation or if an increasing number of
Slipjumps is detected, "d1.LIMIT" could be exceeded and result in this fault message.
11.3.4.12 13 Monitoring the lower limit temperature

This fault message appears when the lower limit temperature thresholds are undershot.
11.3.4.13 14 Monitoring the upper limit temperature

This fault message appears when the upper limit temperature thresholds are overshot.
11.3.4.14 15 Monitoring the position average value

This fault message appears when a position value calculated after the expiry of a comparison
interval deviates from the reference value by more than the configured thresholds.
11.3.4.15 16 Monitoring the plausibility of values for the partial stroke test
This error message is triggered if, when starting a partial stroke test, the plausibility check of the
"A1.STPOS", "A3.STRKH" and "A4.STRKD" parameters was not successful.
11.3.4.16 17 Monitoring of pressure sensor module

If the pressure sensor module is activated and defective, this fault message is displayed.
11.3.4.17 18 Monitoring low limit of supply pressure (PZLIM)

If the supply pressure is below the configured low limit (PZLIM), this alarm message is
displayed.
11.3.4.18 19 Monitoring specific limits of supply pressure

If the supply pressure lies outside the positioner specification from 1.4 bar to 7.0 bar, this alarm
message is displayed.

11.4 Fault and remedy
Fault profile (symptoms) Possible cause(s) Remedy

Positioner remains in "RUN 1". ● Initialization started from the end po‐ ● A waiting time of up to 1 minute is
sition required
● The response time of a maximum of ● Do not start initialization from the
1 minute was not observed end position.
● Supply pressure PZ not connected ● Ensure supply pressure PZ.
or supply pressure PZ too low. ● Free up blocked lines
● Compressed air line blocked, e.g.
solenoid valve
Positioner remains in "RUN 2". ● Transmission ratio selector and pa‐ ● Check settings: Parameters 2 and 3
rameter 2 ● Check the stroke setting on the lever
● "YAGL" and the real stroke do not
match.
● Incorrectly set stroke on the lever
● The pneumatic block does not
switch.
Positioner remains in "RUN 3". ● Actuator travel time is too high ● Open the restrictor completely
and/or set supply pressure PZ to the
highest permissible value.
● Use a booster if required.
Positioner remains in "RUN 5", does not ● "Gap" (play) in the positioner - ac‐ ● Part-turn actuator: Check for firm
go to "FINISH" (waiting time > 5 min.). tuator - control valve system seating of set screw on coupling
wheel
● Linear actuator: Check for firm seat‐
ing of lever on positioner shaft.
● Correct any other play between the
actuator and the control valve.
● Diagnostic value "9.TUP" or ● Set the traversing velocity to > 1.5 s
"10.TDOWN" < 1.5 s using the internal restrictor.
"CPU test" flashes on the local display ● Water in the pneumatic block (due to ● At an early stage, this fault can be
approximately every 2 seconds. wet compressed air) rectified with subsequent operation
The pneumatic block does not switch. using dry air, in a temperature cabi‐
In the manual and automatic modes, the ● Moisture in the pneumatic block net at 50 to 70 °C if required.
actuator cannot be moved or can be ● Otherwise: Repair
moved only in one direction.


The pneumatic block does not switch. A ● The screw between the cover and ● Tighten the screw firmly; if required,
gentle click sound is also not audible the pneumatic block has not been rectify the deadlock.
when the or buttons are pressed tightened firmly or the cover is jam‐
in manual mode. med.
● Dirt (swarf, particles) in the pneumat‐ ● Repair or a new device; built-in fine
ic block screen, can also be replaced and
cleaned.
● Deposits on the contacts between ● Clean all contact surfaces with spirit;
the electronic printed circuit board bend the pneumatic block contact
and the pneumatic block can devel‐ springs slightly if required.
op due to abrasion owing to continu‐
ous loads resulting from strong vi‐
brations.
Actuator does not move. ● Compressed air < 1.4 bar ● Set supply pressure PZ to > 1.4 bar.
Pneumatic block does not switch (how‐ ● Restrictor valve turned off (screw at ● Open the restrictor screw by turning
ever, a gentle clicking sound can be the right endstop) it to the left.
heard when the or button is press‐
● Dirt in the pneumatic block ● Repair or a new device; built-in fine
ed in "Manual" mode.)
screen, can also be replaced and
cleaned.
A pneumatic block continually switches ● Pneumatic leakage in the positioner ● Rectify leakage in the actuator
in stationary automatic mode (constant - actuator system; start the leakage and/or feed line.
setpoint) and in "Manual" mode. test in "RUN 3" (initialization). ● In case of an intact actuator and tight
feed line: Repair or new device
● Dirt in the pneumatic block ● Repair or a new device; built-in fine
screen, can also be replaced and
cleaned.
In stationary automatic mode (constant ● Stiction of the packing gland from ● Reduce stiction or increase dead‐
setpoint) and in "Manual" mode, the the control valve or actuator too large band of positioner (parameter "dE‐
pneumatic block continually switches bA") until the oscillation stops.
and the actuator oscillates around a
mean value. ● Looseness (play) in the positioner/ ● Part-turn actuator: Check for firm
actuator/control valve system seating of set screw on coupling
wheel.
● Linear actuator: Check for firm seat‐
ing of lever on positioner shaft.
● Correct any other play between the
actuator and the control valve.
● Actuator too fast ● Increase travel times using restrictor
screws.
● If a quick travel time is needed, in‐
crease the deadband (parameter
"dEbA") until the oscillation stops.
Positioner does not move control valve ● Supply pressure too low. Load on ● Increase supply pressure, insert bal‐
to the endstop (at 20 mA). the feeding controller or system out‐ last converter
put is too low. ● Select 3/4-wire mode.


Zero point displaces sporadically (> 3%). Impact or shock loads result in acceler‐ ● Rectify the causes for shock loads.
ations so high that the friction clutch ● Re-initialize the positioner.
moves, e.g. due to "vapor shocks" in va‐
por lines.
The device function has completely Electrical auxiliary power is not ade‐ ● Check the electrical auxiliary power.
failed: No representation on the display quate.
either. In case of very high continuous loads ● Tighten the screws firmly and secure
due to vibrations (oscillations): using sealing wax.
● Screws of the electrical connecting ● Repair
terminals may be loosened.
● For prevention: Install the positioner
● Electrical connecting terminals on damping pads.
and/or electronic components may
be knocked out.
Pressure sensor module
With diagnostic value "60.PZ ● Pressure sensor module defective ● Replace the pressure sensor mod‐
(Page 228)", display shows "99999". ule (Page 203)
Display shows fault message "17
(Page 234)".
Display shows fault message "18 ● Supply pressure undershoots the ● Increase the supply pressure until
(Page 234)". lower limit (U2.PZLIM (Page 188)). the limit (U2.PZLIM) incl. hysteresis
Display shows "HOLd". ● Device is set to "Hold position", (U3.PZHYS) is exceeded.
when (U4.PZ_FR) "HOLd" is as‐
signed as error response.
Display shows fault message "19 ● Supply pressure outside the specifi‐ ● Increase the supply pressure until
(Page 234)". cation the limit (U2.PZLIM) incl. hysteresis
(U3.PZHYS) is exceeded.
● Lower the supply pressure until the
limit (U2.PZLIM) incl. hysteresis
(U3.PZHYS) is undershot.


Technical data 12
12.1 HART operating conditions
Rated conditions
Ambient conditions For use indoors and outdoors.
Ambient temperature In hazardous areas, observe the maximum permissible am‐
bient temperature corresponding to the temperature class.
● Permissible ambient temperature for operation 2)3) -30 ... +80 °C (-22 ... +176 °F)
● Height 2000 m above sea level. At altitudes greater than 2000 m
above sea level, use a suitable power supply.
● Relative humidity 0 ... 100%
Degree of pollution 2
Overvoltage category II
Degree of protection 1)
IP66 / Type 4X to UL 50E
Mounting position Any; pneumatic connections and exhaust air outlet not fac‐
ing up in wet environment, Proper mounting (Page 39)
Vibration resistance
● Harmonic oscillations (sine) according 3.5 mm (0.14"), 2 ... 27 Hz, 3 cycles/axis
to EN 60068-2-6/10.2008 98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axis
● Bumping (half-sine) according to EN 60068-2-27/02.2010 150 m/s² (492 ft/s²), 6 ms, 1000 shocks/axis
● Noise (digitally controlled) according to EN 10 ... 200 Hz; 1 (m/s²)²/Hz (3.28 (ft/s²)²/Hz)
60068-2-64/04.2009 200 ... 500 Hz; 0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz)
4 hours/axis
● Recommended range of continuous operation of the entire ≤ 30 m/s² (98.4 ft/s²) without resonance peak
control valve
Climate class According to IEC/EN 60721-3
● Storage 1K5, but -40 ... +80°C (1K5, but -40 ... +176°F)
● Transport 2K4, but -40 ... +80°C (2K4, but -40 ... +176°F)
1)
Max. impact energy 1 Joule for enclosure with inspection window 6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3
2)
At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited.
3)
The following applies to order suffix (order code) -Z M40: -40 ... +80 °C (-40 ... +176°F)
12.2 Pneumatic data
Pneumatic data
Auxiliary power (air supply) Compressed air, carbon dioxide (CO2), nitrogen (N), noble
gases or cleaned natural gas
● Pressure 1) 1.4 ... 7 bar (20.3 ... 101.5 psi)

Technical data
12.3 Construction
Pneumatic data
Air quality to ISO 8573-1
● Solid particulate size and density Class 3
● Pressure dew point Class 3 (min. 20 K (36 °F) below ambient temperature)
● Oil content Class 3
Unrestricted flow (DIN 1945)
● Pressurize actuator 2)
2 bar; 0.1 KV (29 psi; 0.116 CV) 4.1 Nm³/h (18.1 USgpm)
● Depressurize actuator for all versions except fail in place 2)
● Depressurize actuator for fail in place version
Valve leakage < 6⋅10-4 Nm³/h (0.0026 USgpm)
Throttle ratio Adjustable up to ∞: 1
Auxiliary power consumption in the controlled state < 3.6⋅10-2 Nm³/h (0.158 USgpm)
Sound pressure level LA eq < 75 dB
LA max < 80 dB
Sound pressure with installed booster 3) LAeq < 95.2 dB
LA max < 98.5 dB
1)
The following applies to fail in place double acting: 3 ... 7 bar (43.5 ... 101.5 psi)
2)
When using device versions Ex d (6DR5..5-... and 6DR5..6-...), values are reduced by approximately 20%.
3)
Read the warning notice "Increased sound pressure level (Page 105)".
See also
Basic safety instructions (Page 105)
12.3 Construction
Construction
How does it work?
● Range of stroke (linear actuator) 3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the posi‐
tioner shaft 16 ... 90°)
● Angle of rotation (part-turn actuator) 30 to 100°
Mounting method

Technical data
12.3 Construction
Construction
● On the linear actuator Using mounting kit 6DR4004-8V and, where necessary, an
additional lever arm 6DR4004-8L on actuators according to
IEC 60534-6-1 (NAMUR) with a fin, columns, or a plane
surface.
● On the part-turn actuator Using mounting kit 6DR4004-8D or TGX:16300-1556 on
actuators with mounting plane according to VDI/VDE 3845
and IEC 60534-6-2: The required mount must be provided
on the actuator-side.
Weight, positioner without option modules or accessories
● 6DR5..0 Glass-fiber reinforced polycarbonate enclosure Approx. 0.9 kg (1.98 lb)
● 6DR5.11 aluminum enclosure, only single-acting Approx. 1.3 kg (2.86 lb)
● 6DR5..2 stainless steel enclosure Approx. 3.9 kg (8.6 lb)
● 6DR5..3 aluminum enclosure Approx. 1.6 kg (3.53 lb)
● 6DR5..5 aluminum enclosure, flameproof, rugged Approx. 5.2 kg (11.46 lb)
● 6DR5..6 stainless steel enclosure, flameproof, rugged Approx. 8.4 kg (18.5 lb)
Material
● Enclosure
6DR5..0 polycarbonate Glass-fiber reinforced polycarbonate (PC)
6DR5.11 aluminum, only single-acting GD AISi12
6DR5..2 stainless steel Austenitic stainless steel 316Cb, mat. No. 1.4581
6DR5..3 aluminum GD AlSi12
6DR5..5 aluminum, flameproof, rugged GK AISi12
6DR5..6 stainless steel enclosure, flameproof, rugged Austenitic stainless steel 316L, mat. No. 1.4409
● Pressure gauge block Aluminum AIMgSi, anodized or stainless steel 316
Versions
● In the polycarbonate enclosure 6DR5..0 Single-acting and double-acting
● In aluminum enclosure 6DR5.11 Single-acting
● In aluminum enclosures 6DR5..3 and 6DR5..5 Single-acting and double-acting
● In stainless steel enclosures 6DR5..2 and 6DR5..6 Single-acting and double-acting
Torques
● Part-turn actuator fixing screws DIN 933 M6x12-A2 5 Nm (3.7 ft lb)
● Linear actuator fixing screws DIN 933 M8x16-A2 12 Nm (8.9 ft lb)
● Gland pneumatic G¼ 15 Nm (11.1 ft lb)
● Pneumatic gland 1/4-18 NPT
Without sealant 12 Nm (8.9 ft lb)
With sealant 6 Nm (4.4 ft lb)
● Cable glands
Screw-in torque for plastic gland in all enclosures 4 Nm (3 ft lb)
Screw-in torque for cable gland made of metal/stainless 6 Nm (4.4 ft lb)
steel in polycarbonate enclosure
Screw-in torque for metal/stainless steel glands in alumi‐ 6 Nm (4.4 ft lb)
num/stainless steel enclosure

Technical data
12.4 Controller
Construction
Screw-in torque for NPT adapter made of metal/stainless 8 Nm (5.9 ft lb)
steel in polycarbonate enclosure
Screw-in torque for NPT adapter made of metal/stainless 15 Nm (11.1 ft lb)
steel in aluminum/stainless steel enclosure
Screw-in torque for NPT gland in the NPT adapter 68 Nm (50 ft lb)
NOTE: To avoid damage to the device, the NPT adapter
must be held in place while the NPT gland is screwed into
the NPT adapter.
Tightening torque for union nut made of plastic 2.5 Nm (1.8 ft lb)
Tightening torque for union nut made of metal/stainless 4 Nm (3 ft lb)
steel
● Pressure gauge block fixing screws 6 Nm (4.4 ft lb)
Manometer
● Degree of protection
Manometer made of plastic IP31
Manometer, steel IP44
Manometer made of stainless steel 316 IP54
● Vibration resistance In accordance with DIN EN 837-1
Connections, electrical
● Screw terminals 2.5 mm2 AWG30-14
● Cable gland
Without Ex protection as well as with Ex i M20 x 1.5 or 1/2-14 NPT
With explosion protection Ex d Ex d-certified M20 x 1.5; 1/2-14 NPT or M25 x 1.5
Connections, pneumatic Female thread G¼ or ¼-18 NPT
12.4 Controller
Controller
Control unit
● Five-point controller Adaptive
● Dead zone
dEbA = auto Adaptive
dEbA = 0.1 ... 10 % Can be set as fixed value
Analog-to-digital converter
● Scanning time 10 ms
● Resolution ≤ 0,05 %
● Transmission error ≤ 0,2 %
● Temperature influence ≤ 0.1 %/10 K (≤ 0.1 %/18 °F)

Technical data
12.5 Certificates and approvals
12.5.1 Breakdown of the article numbers

Each device has a nameplate. This nameplate shows a specific article number for the device.
Lower-case letters are used and explained in the tables below for the variable digits in the
article number. Each variable that is used stands for a different order version. You will find the
order data in the FI 01 catalog on the Internet.
Table 12-1 Article number

' 5 D E F G H I J K = M M M
Table 12-2 Enclosure in explosion-proof version and the relevant variables
Enclosure polycarbonate Enclosure aluminum single-act‐ Enclosure stainless steel Enclosure aluminum single/
6DR5 (b = 0) ing 6DR5 (b = 1) 6DR5 (b = 2) double-acting 6DR5 (b = 3)
Enclosure aluminum flameproof 6DR5 (b = 5) Enclosure stainless steel flameproof 6DR5 (b = 6)
6DR5a*b-0cdef-g**h-Zjjj If enclosure If type of protection If order code

b= c= Z=
Electronics: a =
● 0, 2, 5, 6 0, 1, 2, 3 D, E, G, F, K -
● 0, 1, 2, 3, 5, 6 5, 6 E -
● 0, 2, 5, 6 5, 6 E K50
● 0, 2, 5, 6 5, 6 G, F, K -
● 1 3 D, E, G, F, K P01…P02

Technical data
6DR5a*b-0cdef-g**h-Zjjj If enclosure If type of protection If order code

b= c= Z=
Enclosure version b =
0, 1, 2, 3, 5, 6
Type of protection c =
D, E, F, G, K
Connection thread d =
● G, N, M, P, R, S 0, 1, 2, 3
● G, N, M, P, Q 5, 6
Limit monitor e =
0, 1, 2, 3, 9
Option modules f =
0, 1, 2, 3
Customer-specific design g =
0, 3, 7
Pneumatic accessories h =
0, 1, 2, 3, 4, 9R**
Order code Z = jjj
A**, C**, D53…D57, F**, K50, L1A,
M40, P01…P02, R**, S**, Y**
12.5.2 Basic unit and optional modules
Type of protection 6DR5ayb-*cdef-g*Ah-Zjjj Ex marking Ex marking

ATEX 205947X FM 17US0053X
IECEx TUN 17.0023X CSA 18CA70166848X
For c = D, II 2 D Ex tb IIIC T100°C Db Zn 21 AEx tb IIIC T100°C Db
● a = 0, 2, 5, 6 and b = 1, 2, 3 II 3 G Ex ec IIC T6/T4 Gc Zn 21 Ex tb IIIC T100°C Db
DIP Cl II, III Div 1 Gp E-G
● a = 1 and b = 3
Cl I Zn 2 AEx nA IIC Gc
Cl I Zn 2 Ex nA IIC Gc
For c = E, II 2 G Ex ia IIC T6/T4 Gb Cl I Zn 1 AEx ib IIC Gb
● a = 0, 2, 5, 6 and b = 0 II 3 G Ex ic IIC T6/T4 Gc Cl I Zn 1 Ex ib IIC Gb
IS Cl I Div 1 Gp A-D
For c = E, II 2 G Ex ia IIC T6/T4 Gb Cl I Zn 1 AEx ib IIC Gb
● a = 0, 2, 5, 6 and b = 1, 2, 3 II 3 G Ex ic IIC T6/T4 Gc Cl I Zn 1 Ex ib IIC Gb
Zn 21 AEx ib IIIC, T130°C Db
● a = 1 and b = 3 II 2 D Ex ia IIIC T130°C Db
Zn 21 Ex ib IIIC, T130°C Db
IS Cl I, II, III Div 1 Gp A-G

Technical data
Type of protection 6DR5ayb-*cdef-g*Ah-Zjjj Ex marking Ex marking

ATEX 205947X FM 17US0053X
IECEx TUN 17.0023X CSA 18CA70166848X
For c = E, Il 2 G Ex db llC T6/T4 Gb FM
● a = 0, 1, 2, 3, 5, 6 and b = 5, 6 II 2 D Ex tb IIIC T100°C Db Cl I Zn 1 AEx db IIC Gb
XP Cl I Div 1 Gp A-D
CSA
Cl I Zn 1 Ex db IIC Gb
XP Cl I Div 1 Gp C-D
FM + CSA
Zn 21 AEx tb IIIC T100°C Db
Zn 21 Ex tb IIIC T100°C Db
For c = F, II 2 G Ex ia IIC T6/T4 Gb Cl I Zn 1 AEx ib IIC Gb
● a = 0, 2, 5, 6 and b = 1, 2, 3, 5, 6 II 3 G Ex ic IIC T6/T4 Gc Cl I Zn 1 Ex ib IIC Gb
Zn 21 AEx ib IIIC T130°C Db
Zn 21 Ex ib IIIC T130°C Db
Non Contacting Sensor (NCS) II 3 G Ex ec IIC T6/T4 Gc IS Cl I, II, III Div 1 Gp A-G
● 6DR4004-6N Cl I Zn 2 AEx nA IIC Gc
For c = G, II 3 G Ex ec IIC T6/T4 Gc Cl I Zn 2 AEx nA IIC Gc
● a = 0, 2, 5, 6 and b = 1, 2, 3, 5, 6 Cl I Zn 2 Ex nA IIC Gc
● a = 1 and b = 3
For c = K and b = 1, 2, 3, 5, 6 II 2 G Ex ia IIC T6/T4 Gb Cl I Zn 1 AEx ib IIC Gb
● a = 0, 2, 5, 6 and b = 1, 2, 3, 5, 6 II 3 G Ex ic IIC T6/T4 Gc Cl I Zn 1 Ex ib IIC Gb
Zn 21 AEx ib IIIC, T130°C Db
Zn 21 Ex ib IIIC, T130°C Db
Position Transmitter: II 2 D Ex tb IIIC T100°C Db IS Cl I, II, III Div 1 Gp A-G
● 6DR4004-1ES II 3 G Ex ec IIC T6/T4 Gc Cl I Zn 2 AEx nA IIC Gc
● 6DR4004-2ES
● 6DR4004-3ES
Zn 21 AEx tb IIIC T100°C Db
● 6DR4004-4ES Zn 21 Ex tb IIIC T100°C Db
12.5.3 Maximal permissible ambient temperature ranges
Positioner and option modules Temperature class T4 Temperature class T6

Positioner
● 6DR5ayb-0cdef-g*Ah-Z jjj -30 °C ≤Ta ≤ +80 °C -30 °C ≤Ta ≤ +50 °C
● 6DR5ayb-0cdef-g*Ah-Z M40 -40 °C ≤Ta ≤ +80 °C -40 °C ≤Ta ≤ +50 °C
● 6DR5ayb-0cdef-g*Ah-Z jjj -30 °C ≤Ta ≤ +80 °C -30 °C ≤Ta ≤ +60 °C
for a = 0, 1, 2 and f = 0, 2
● 6DR5ayb-0cdef-g*Ah-Z M40 -40 °C ≤Ta ≤ +80 °C -40 °C ≤Ta ≤ +60 °C
for a = 0, 1, 2 and f = 0, 2

Technical data
12.6 Electrical data
Positioner and option modules Temperature class T4 Temperature class T6

Option modules
● Non-Contacting Sensor (NCS) -40 °C ≤Ta ≤ +90 °C -40 °C ≤Ta ≤ +70 °C
6DR4004-6N
● Position Transmitter (Potentiometer) -40 °C ≤Ta ≤ +90 °C -40 °C ≤Ta ≤ +60 °C
6DR4004-1ES
● Position Transmitter (NCS) -40 °C ≤Ta ≤ +90 °C -40 °C ≤Ta ≤ +50 °C
6DR4004-2ES
● Position Transmitter (NCS, ILS)
6DR4004-3ES
● Position Transmitter (NCS, MLS)
6DR4004-4ES
Basic electronics Basic electronics Basic electronics Basic electronics

without explosion with explosion pro‐ with explosion pro‐ with explosion pro‐
protection tection Ex "db" tection Ex "ia", "db ia" tection Ex "ic", "ec",
"tb"
Current input IW
● Rated signal range 4 ... 20 mA
● Test voltage 840 V DC, 1 s
● Digital input DI1 (terminals Suitable only for floating contact; max. contact load
9/10; galvanically connec‐ < 5 μA with 3 V
ted to basic device)
2-wire connection
6DR50.. and 6DR53.. 4 ... 20 mA
6DR51.. and 6DR52.. HART
Current to maintain the auxiliary ≥ 3.6 mA
power
Required load voltage UB (cor‐
responds to Ω at 20 mA)
● 4 to 20 mA 6DR50..
Typical 6.36 V (= 318 Ω) 6.36 V (= 318 Ω) 7.8 V (= 390 Ω) 7.8 V (= 390 Ω)
Max. 6.48 V (= 324 Ω) 6.48 V (= 324 Ω) 8.3 V (= 415 Ω) 8.3 V (= 415 Ω)
● 4 to 20 mA 6DR53..
Typical 7.9 V (= 395 Ω) - - -
Max. 8.4 V (= 420 Ω) - - -
● HART 6DR51..
Typical 6.6 V (= 330 Ω) 6.6 V (= 330 Ω) - -
Max. 6.72 V (= 336 Ω) 6.72 V (= 336 Ω) - -
HART 6DR52..

Technical data

protection tection Ex "db" tection Ex "ia", "db ia" tection Ex "ic", "ec",
"tb"
Typical - 8.4 V (= 420 Ω) 8.4 V (= 420 Ω) 8.4 V (= 420 Ω)
Max. - 8.8 V (= 440 Ω) 8.8 V (= 440 Ω) 8.8 V (= 440 Ω)
● Static destruction limit ± 40 mA ± 40 mA - -
Effective inner capacitance Ci - -
● 4 to 20 mA - - 11 nF "ic": 11 nF
● HART - - 11 nF "ic": 11 nF
Effective inner inductance Li - -
● 4 to 20 mA - - 209 µH "ic": 209 µH
● HART - - 312 µH "ic": 312 µH
For connecting to circuits with - - Ui ≤ 30 V "ic":
the following peak values Ii ≤ 100 mA Ui ≤ 30 V
Pi ≤ 1 W Ii ≤ 100 mA
"ec"/"tb":
Un ≤ 30 V
In ≤ 100 mA
3-/4-wire connection
6DR52.. HART, explosion proof
6DR53.. 4 ... 20 mA, non-explosion-proof
Load voltage at 20 mA ≤ 0.2 V (= 10 Ω) ≤ 0.2 V (= 10 Ω) ≤ 1 V (= 50 Ω) ≤ 1 V (= 50 Ω)
Auxiliary power UAux 18 ... 35 V DC 18 ... 35 V DC 18 ... 30 V DC 18 ... 30 V DC
● Current consumption IAux (UAux - 7.5 V) / 2.4 kΩ [mA]
Pi ≤ 1 W Ii ≤ 100 mA
"ec"/"tb":
Un ≤ 30 V
In ≤ 100 mA
Effective inner capacitance Ci - - 22 nF 22 nF
Effective inner inductance Li - - 0.12 mH 0.12 mH
Galvanic isolation Between UAux and IW Between UAux and IW Between UAux and IW Between UAux and IW
(2 intrinsically safe
circuits)

Technical data
12.8 Communication (HART)
12.7 Electrical data for pressure sensor module

protection tection Ex "db" tection Ex "ia", tection Ex "ic", "ec",
Ex "db ia" "tb"
Basic electronics for the pressure sensor module
6DR51.. -Z P01 und -Z P02 HART, non-Ex
6DR51.. -Z P01 und -Z P02 HART, Ex
Current input IW
● Rated signal range 4 ... 20 mA
● Test voltage 840 V DC, 1 s
● Digital input DI1 (terminals Suitable only for floating contact; max. contact load
9/10; galvanically connec‐ < 5 μA with 3 V
ted to basic device)
Current to maintain the auxiliary ≥ 3.6 mA
power
Required load voltage UB (cor‐ 9.4 V (= 470 Ω) 9.4 V (= 470 Ω) 9 V (= 450 Ω) 9 V (= 450 Ω)
responds to Ω at 20 mA)
Static destruction limit ± 30 V ± 30 V - -
Effective inner capacitance Ci - - 12.2 nF "ic": 12.2 nF
Effective inner inductance Li - - 105 µH "ic": 105 µH
Pi ≤ 1 W Ii ≤ 100 mA
"ec"/"t":
Un ≤ 30 V
In ≤ 100 mA
12.8 Communication (HART)
HART communication
HART version 7
PC parameter assignment soft‐ SIMATIC PDM; supports all device objects. The software is not included in the scope of
ware delivery.

Technical data
12.9 Technical data for natural gas as actuator medium
12.9 Technical data for natural gas as actuator medium
Introduction
Note when using an actuator with natural gas that this can escape at the exhaust air outlets.

① Base plate ③ Exhaust air outlet sound absorber

② Exhaust air outlet enclosure ventilation ④ Exhaust air outlet near the pneumatic connections
Note
The following applies for exhaust air outlet with sound absorber ③:
The positioner is supplied as standard with a sound absorber. To provide an outlet for the
exhaust air, replace the sound absorber by a G¼ pipe coupling.
The following applies for enclosure ventilation ② and control air outlet ④:
1. With the "flameproof enclosure" device version in an aluminum enclosure with order suffix
-Z K50 "Operation with natural gas", you can completely collect and discharge the escaping
natural gas.
2. In all other device versions, the escaping natural gas is released into the environment.
Maximum values for escaping natural gas

● The quantity of escaping natural gas is negligible during regulated operation.
● If a control error occurs, a maximum of 30 Nl/min of natural gas will escape at the enclosure
vent ② and a maximum of 89 Nl/min at the control air outlet ④.
See also
Proper mounting (Page 39)

Technical data
12.10 Option modules
12.10.1 Digital I/O Module (DIO) 6DR4004-6A / -8A
Without explosion protec‐ With explosion protection With explosion protection

tion or suitable for use in Ex "ia" Ex "ic", "ec", "tb"
Ex "db" version
6DR4004-8A 6DR4004-6A 6DR4004-6A
3 digital output current circuits
● Digital output DO1: Terminals 41 and 42
● Digital output DO2: Terminals 51 and 52
● Fault message output: Terminals 31 and 32
● Auxiliary power supply UAux ≤ 35 V and the current con‐ - -
sumption is to be limited to
< 25 mA
● Signal status
High (not addressed) Conductive, R = 1 kΩ, ≥ 2.1 mA ≥ 2.1 mA
+3/-1 % *)
Low *) (addressed) Deactivated, IR < 60 µA ≤ 1.2 mA ≤ 1.2 mA
*) The status is also Low if the *) When using in the flame‐ Switching threshold for Switching threshold for
basic device is faulty or without proof enclosure, the cur‐ supply according to supply according to
a auxiliary power. rent consumption must be EN 60947-5-6: EN 60947-5-6:
restricted to 10 mA per out‐ UAux = 8.2 V, Ri = 1 kΩ UAux = 8.2 V, Ri = 1 kΩ
put.
● For connecting to circuits with the - Ui = 15 V DC "ic":
following peak values Ii = 25 mA Ui = 15 V DC
Pi = 64 mW I i = 25 mA
"ec"/"tb":
Un ≤ 15 V DC
Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF
Effective internal inductance - Li = negligibly small Li = negligibly small
1 digital input current circuit

● Digital input DI2: Terminals 11 and 12, terminals 21 and 22 (jumper)
● Galvanically connected with the
basic device
Signal status 0 Floating contact, open
Signal status 1 Floating contact, closed
Contact load 3 V, 5 μA
● Electrically isolated from the basic
device
Signal status 0 ≤ 4.5 V or open
Signal status 1 ≥ 13 V
Internal resistance ≥ 25 kΩ

Technical data

Ex "db" version
6DR4004-8A 6DR4004-6A 6DR4004-6A
● Static destruction limit ± 35 V - -
● Connecting to circuits with the fol‐ - Ui = DC 25.2 V "ic":
lowing peak values Ui = DC 25.2 V
"ec"/"tb":
Un ≤ DC 25.2 V
Effective internal capacitance - Ci = negligibly small Ci = negligibly small
Galvanic isolation The three outputs, the BI2 input and the basic device are galvanically isolated from
each other.
Test voltage DC 840 V, 1 s
12.10.2 Analog Output Module (AOM) 6DR4004-6J / -8J

Ex d version
6DR4004-8J 6DR4004-6J 6DR4004-6J
Direct current output for position feed‐
back
1 current output, terminals 61 and 62 2-wire connection
● Rated signal range 4 ... 20 mA, short-circuit proof
● Dynamic range 3.6 ... 20.5 mA
● Auxiliary power supply UAux +12 ... +35 V +12 ... +30 V +12 ... +30 V
● External load RB [kΩ] ≤ (UAux [V] - 12 V)/I [mA]
● Transmission error ≤ 0.3%
● Temperature influence ≤ 0.1%/10 K (≤ 0.1%/18 °F)
● Resolution ≤ 0.1%
● Residual ripple ≤1%
● For connecting to circuits with the - Ui = DC 30 V "ic":
following peak values Ii = 100 mA Ui = DC 30 V
Pi = 1 W Ii = 100 mA
"ec"/"tb":
Un ≤ DC 30 V
In ≤ 100 mA
Pn ≤ 1 W
Effective internal capacitance - Ci = 2 nF Ci = 2 nF
Effective internal inductance - Li = 3 μH Li = 3 μH
Galvanic isolation Electrically isolated from the alarm option and safely isolated from the basic device

Technical data
12.10.3 Inductive Limit Switches (ILS) 6DR4004-6G / -8G

tion Ex "ia", "db ia" Ex "ic", "ec", "tb"
6DR4004-8G 6DR4004-6G 6DR4004-6G
Limit encoder with slotted initiators
and fault message output
2 slotted initiators
● Digital output (limit monitor) A1: Terminals 41 and 42
● Digital output (limit monitor) A2: Terminals 51 and 52
● Connection 2-wire technology in accordance with EN 60947-5-6 (NAMUR), for switching ampli‐
fiers connected on load side
● Signal state High > 2.1 mA
(not triggered)
● Signal state Low (triggered) < 1.2 mA
● 2 slotted initiators Type SJ2-SN
● Function NC contact (NC, normally closed)
● Connecting to circuits with the fol‐ Rated voltage 8 V, power Ui ≤ DC 15 V "ic":
lowing peak values consumption: Ii ≤ 25 mA Ui ≤ DC 15 V
≥ 3 mA (limit not activa‐ Pi ≤ 64 mW Ii ≤ 25 mA
ted), "ec"/"tb":
≤ 1 mA (limit activated) Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance - Ci ≤ 161 nF Ci ≤ 161 nF
Effective internal inductance - Li ≤ 120 μH Li ≤ 120 μH
1 fault message output

● Digital output: Terminals 31 and 32
● Connection At switching amplifier in accordance with EN 60947-5-6: (NAMUR), UAux = 8.2 V, Ri =
1 kΩ).
● Signal state High R = 1.1 kΩ > 2.1 mA > 2.1 mA
(not triggered)
● Signal state Low (triggered) R = 10 kΩ < 1.2 mA < 1.2 mA
● Auxiliary power UAux UAux ≤ DC 35 V - -
I ≤ 20 mA
● Connecting to circuits with the fol‐ - Ui ≤ DC 15 V "ic":
lowing peak values Ii ≤ 25 mA Ui ≤ DC 15 V
Pi ≤ 64 mW Ii ≤ 25 mA
"ec"/"tb":
Un ≤ DC 15 V
Pn ≤ 64 mW
Effective internal capacitance - Ci ≤ 5.2 nF Ci ≤ 5.2 nF
Galvanic isolation The 3 outputs are galvanically isolated from the basic device.

Technical data
12.10.4 Mechanic Limit Switches (MLS) 6DR4004-6K / -8K

tion Ex "ia", "db ia" Ex "ic", "tb"
6DR4004-8K 6DR4004-6K 6DR4004-6K
Limit encoder with mechanical switch‐
ing contacts
2 limit contacts
● Digital output DO1: Terminals 41
and 42
● Digital output DO2: Terminals 51
and 52
● Max. switching current AC/DC 4A - -
● For connecting to circuits with the - Ui ≤= 30 V "ic":
following peak values Ii ≤ 100 mA Ui ≤ 30 V
Pi ≤ 750 mW Ii ≤ 100 mA
"tb":
Un ≤ 30 V
In ≤ 100 mA
Effective internal capacitance - Ci = negligibly small Ci = negligibly small
● Max. switching voltage AC/DC 250 V/24 V DC 30 V DC 30 V
● Connection On switching amplifier according to EN 60947-5-6: (NAMUR), UAux = 8.2 V, Ri = 1 kΩ).
(not triggered)
● Auxiliary power UAux ≤ DC 35 V - -
I ≤ 20 mA
● Connecting to circuits with the fol‐ - Ui ≤ 15 V "ic" :
lowing peak values Ii ≤ 25 mA Ui ≤ 15 V
Pi ≤ 64 mW Ii ≤ 25 mA
"tb":
Un ≤ 15 V
In ≤ 25 mA
Effective internal capacitance - Ci ≤ 5.2 nF Ci ≤ 5.2 nF
Galvanic isolation The 3 outputs are galvanically isolated from the basic device
Test voltage 3150 V DC, 2 s
Rated condition height Max. 2 000 m above sea - -
level. Use a suitable power
supply at an altitude of
more than 2 000 m above
sea level.

Technical data
12.10.5 Analog Input Module (AIM) 6DR4004-6F / -8F
Without explosion With explosion protection With explosion protection

protection Ex "ia", "db ia", "ic" Ex "ec", "tb"
6DR4004-8F 6DR4004-6F 6DR4004-6F
The Analog Input Module (AIM) 6DR4004-6F and -8F is required to connect a Non-Contacting Sensor (NCS) or Position
Transmitter 6DR4004-1ES to -4ES.
For devices without explosion protection, other types of potentiometers with resistance values between 3 and 20 KΩ can be
connected.
R-potentiometer
● Peak values when supplied by other Umax = 5 V Uo ≤ 5 V Umax = 5 V
basic devices (6DR50/1/2/3/9) Io ≤ 100 mA
Po ≤ 33 mW
Co ≤ 1 μF
Lo ≤ 1 mH
● Maximum values when powered by the Umax = 5 V Uo ≤ 5 V Umax = 5 V
base unit with PA (6DR55) or FF com‐ Io ≤ 75 mA static
munication (6DR56) Io ≤ 160 mA transient
Po ≤ 120 mW
Co ≤ 1 μF
Lo ≤ 1 mH
Signal 20 mA
● Rated signal range 0 ... 20 mA -
● Internal load RB 200 Ω -
● Static destruction limit 40 mA -
Signal 10 V
● Rated signal range 0 ... 10 V -
● Internal resistance Ri 25 kΩ -
● Static destruction limit 20 V -
Supply and signal power circuits Galvanically connected with the basic device
12.10.6 Internal NCS module 6DR4004-5L / 6DR4004-5LE
Additional modules Without explosion protec‐ With explosion protection With explosion protection
tion Ex "ia", "db ia" Ex "ic", "ec", "tb"
6DR4004-5L 6DR4004-5LE 6DR4004-5LE
Linearity (after corrections made by ±1%
positioner)
Hysteresis ± 0.2 %
For connecting to circuits with the fol‐ - Ui ≤ 5 V Ui ≤ 5 V
lowing peak values Ii ≤ 160 mA
Pi ≤ 120 mW
Effective internal capacitance - Ci = 110 nF + 110 nF per meter of connecting cable
Effective internal inductance - Li = 270 µH + 6.53 µH per meter of connecting cable

Technical data
12.10.7 Other technical specifications

Technical specifications for additional option modules and accessories is available at:
● Technical specifications NCS (Page 283)
● Technical specifications of the external position detection system (Page 289)
● Sealing plug / thread adapter (Page 297)
● Positioner with remote control electronics (Page 311)

Technical data

Dimension drawings 13
13.1 Positioner in non-flameproof enclosure
A
0
GHHS

B

C

<

D
0
GHHS [
0 E
GHHS [
F

J

O
N
< 3= <
[

H M
0

G K L

① M20 x 1.5 or NPT adapter

Figure 13-1 Dimension drawing, dimensions in mm (inch)
6DR5..0 6DR5..1 6DR5..2 6DR5..3

G¼ 1/4-18 NPT G¼ 1/4-18 NPT
A 184.5 [7.26] 186.5 [7.34] 185 [7.28] 186.5 [7.34] 186.5 [7.34] 188.5 [7.42]
B - - - - 15 [0.59]
C 95 [3.74] 84 [3.31] 99 [3.90] 98.6 [3.88]
D 47.5 [1.87] 49.5 [1.95] 49.5 [1.95] 49.3 [1.94]
E 88.5 [3.48] 88.8 [3.50] 88.5 [3.48] 88.8 [3.50]
F*)
29.5 [1.16] - 29.5 [1.16] 29.5 [1.16]
G 39 [1.54] 44 [1.73] 39 [1.54] 39 [1.54]
H 14.5 [0.57] 16 [0.63] 16 [0.63] 14.5 [0.57]
J 96.6 [3.80] 96.6 [3.80] 98.5 [3.88] 103 [4.06]
K 18.5 [0.73] 22 [0.87] 18.5 [0.73] 18.5 [0.73]
L 18.5 [0.73] 7 [0.23] 18.5 [0.73] 18.5 [0.73]

Dimension drawings
13.2 Terminal strip for enclosures 6DR5..0 and 6DR5..3
6DR5..0 6DR5..1 6DR5..2 6DR5..3

G¼ 1/4-18 NPT G¼ 1/4-18 NPT
M - 26.5 [1.04] 41.5 [1.53] 40 [1.57]
N - 7.5 7.5 7.5
O 14.5 [0.57] 14.5 [0.57] 14.5 [0.57] 15.5 [0.61]
P > 150 (5.91)
Adhere to this minimum clearance P for service and maintenance above the cover.
Dimensions in mm [inch]
*) Dimensions only apply to double-acting actuators.
6DR5..0 Polycarbonate enclosure; dimensions with pneumatic connection G¼ or 1/4-18 NPT

6DR5..1 Aluminum enclosure, single-acting
6DR5..2 Stainless steel enclosure, without inspection window
6DR5..3 Aluminum enclosure, single/double-acting; dimensions with pneumatic connection
G¼ or 1/4-18 NPT
13.2 Terminal strip for enclosures 6DR5..0 and 6DR5..3

[
*RU
ಯ137

[0

137

*
0

① Thread depth
Figure 13-2 Terminal strip, dimensions in mm (inch)

Dimension drawings
13.3 Positioner in flameproof enclosure

0
GHHS [

A

E

0
B
GHHS [

0

GHHS [

C
00RU
ಯ137 [

F
ෘ

ෘ K

G
① All air connections G¼ or ¼-18 NPT

② Air connection Y2, only with double-acting version
Figure 13-3 Dimensions of positioner in flameproof enclosure
6DR5..5 6DR5..6
A 5 [0.2] -
B 60 (2.36) -
C 25.7 (1.01) 21.7 (0.85)
D 33.5 (1.32) 25 [0.99]
E 33.5 (1.32) -
F 158.5 [6.24] 160 [6.3]
G 235.3 [9.26] 227.6 [8.96]
Dimensions in mm [inch]
6DR5..5 Aluminum enclosure, flameproof; dimensions with pneumatic connection G¼ or

1/4-18 NPT
6DR5..6 Stainless steel enclosure, flameproof

Dimension drawings

Spare parts/accessories/scope of delivery 14
14.1 Overview
WARNING
Assembling the components
When assembling components, ensure that only those positioners and option modules are
combined with each other that are approved for the corresponding operating range.
These conditions particularly apply to safe operation of the positioner in hazardous areas.
Observe the applicable certificates and approvals or the "Technical data (Page 239)".
Basic version
The positioner can be delivered for:
● Double-acting actuators
● Single-acting actuators
The positioner and its option modules are delivered as separate units and with different
versions for the operation in:
● Hazardous environments and atmospheres
● Non-hazardous environments and atmospheres
Enclosure
The electronic unit with display, the position feedback, and the pneumatic block are integrated
in the enclosure.
The enclosure is available in the following versions:
● Polycarbonate enclosure for single-acting and double-acting actuators
● Aluminum enclosure for single-acting or double-acting actuators
● Stainless steel enclosure for single and double-acting actuators
● Flameproof enclosure for single and double-acting actuators
Options
The following option modules are available for the positioner:
● Analog Output Module (AOM) 6DR4004-6J / -8J: 2-wire current output 4 to 20 mA for
position feedback
● Digital I/O Module (DIO) 6DR4004-6A / -8A: 3 digital outputs and 1 digital input

Spare parts/accessories/scope of delivery
14.1 Overview
● Inductive Limit Switches (ILS) 6DR4004-6G / -8G: 1 digital output for fault signals, 2 digital
outputs for limit monitors
● Mechanic Limit Switches (MLS) 6DR4004-6K / -8K: 1 digital output for fault signals, 2 digital
outputs for limit monitors
● Internal NCS module 6DR4004-5L/-5LE
The Inductive Limit Switches (ILS) and Mechanic Limit Switches (MLS) cannot be used in
device versions with flameproof enclosure. Additional restrictions in section "Technical data
(Page 239)".
Accessories
● Pressure gauge block: 2 or 3 pressure gauges for single and double-acting positioners
● Mounting kits for linear and part-turn actuators
For separate mounting of positioner and position sensor
● Position Transmitter
● NCS sensor for non-contacting position detection
Note
The version is identified using a special nameplate.

14.2 Spare parts
14.2 Spare parts
Description Article no. For version

Basic electronics
2-wire, not Ex, without HART A5E00082459 6DR50..-.N
2-wire, Ex, without HART A5E00082457 6DR50..-.D/E/F/G/K
2- wire, Ex, with HART A5E45152746 6DR51..-.D/E/F/G/K
2-wire, not Ex, with HART A5E00082458 6DR51..-.N
2- wire, non-Ex, with HART, with interface for pressure A5E45152693 6DR51..-.N* -Z P01
sensor module
2/3/4-wire, Ex, with HART A5E00082456 6DR52..-.D/E/F/G/K
2/3/4-wire, not Ex, without HART A5E00102018 6DR53..-.N
PROFIBUS PA, not Ex A5E00141523 6DR55..-.N
PROFIBUS PA, Ex A5E00141550 6DR55..-.D/E/F/G/K
FOUNDATION Fieldbus, not Ex A5E00215467 6DR56..-.N
FOUNDATION Fieldbus, Ex A5E00215466 6DR56..-.D/E/F/G/K
Interface module for positioner without basic electronics A5E00151572 6DR5910-*
Interface module for 19-inch slide-in module 4 ... 20 mA A5E00151571 A5E00151560

14.2 Spare parts

Pneumatic block
Single-acting, with seal and screws C73451-A430-D80 6DR5.1.*
Double-acting, with seal and screws C73451-A430-D81 6DR5.2.*
Fail in place, with seal and screws A5E34409029 6DR5* -Z F01
Single-acting for temperature range extension -40 °C … A5E35377156 6DR5.1.* -Z M40

80 °C, with seal and screws
Double-acting for temperature range extension A5E35377157 6DR5.2.* -Z M40

-40 °C … 80 °C, with seal and screws
Optimized for small actuators with seal and screws A5E43291389 6DR5.1.* -Z K10
Enclosure cover without Ex d

Made from polycarbonate, with inspection window, sin‐ C73451-A430-D82 6DR5..0-.N/E
gle and double-acting, with cover seal and screws
Made from aluminum, with inspection window, single- C73451-A430-D83 6DR5.11-.N/E/F/G

acting, with cover seal and screws
Made from aluminum, without inspection window, sin‐ A5E00065819 6DR5.11-.D/K*

gle-acting, with cover seal and screws
Made from aluminum, with inspection window, single A5E39637097 6DR5..3-*

and double-acting, with cover seal and screws

14.2 Spare parts

Made from aluminum, without inspection window, single A5E39636806 6DR5..3-*- -Z M40
and double-acting, with cover seal and screws 6DR4004-1/2/3/4ES
Magnet clamp, pressure gauge, sound absorber

Magnet clamp for linear actuators A5E00078031 6DR4004-...2*
Magnet clamp made from anodized aluminum for part- A5E00524070 6DR4004-...1/4*
turn actuators
Pressure gauge steel, process connection G1/8 (3 units) A5E32527731 6DR5…-…..-…9 -R1A/-
R2A
6DR4004-1P/-2P
Pressure gauge stainless steel, process connection A5E32527735 6DR5…-…..-…9 -R1C/-

G1/8 (3 units) R2C
6DR4004-1QP/-2Q
Stainless steel sound absorber (3 units) A5E32527711 6DR5..0/1/2/3/6-*
Spare parts for flameproof enclosure Ex d

Pneumatic connection board 1/4-18 NPT with seals and A5E37056680 6DR5..6-..N/M/S*
screws
Pneumatic connection board G1/4 with seals and A5E37056681 6DR5..6-..G/P/R/Q*
screws
Sealing plugs M25 and thread adapter M25 on M20 with A5E37056682 6DR5..5/6-..G/M/Q*
seals
Sealing plugs M25 and thread adapter M25 on A5E37056685 6DR5..5/6-..N/P/Q*
1/2-14 NPT with seals
Enclosure cover with seal A5E37056687 6DR5..6*
Sealing set with seals for cover, button cover, pneumat‐ A5E37056923 6DR5..6*
ic termination board, duckbill valve for enclosure venti‐
lation and shaft sealing ring

14.3 Scope of delivery Mechanic Limit Switches (MLS)

Small part set
With cover seal, pneumatic terminal A5E33519995 6DR5..0/3
strips with G thread, air filter, O rings
for pneumatic connections, screws,
sound absorber, metal cable gland
With cover seal, pneumatic terminal A5E33519994 6DR5..0/3

strips with NPT thread, air filter, O-
rings for pneumatic connections,
screws, sound absorber, metal ca‐
ble gland and metal NPT adapter
Pressure sensor module

With seal, for monitoring of supply A5E45153857 6DR5*-Z P01
pressure PZ
With seal, for premium diagnostics, A5E45153928 6DR511*-Z P02
single-acting
With seal, for premium diagnostics, A5E45154086 6DR512*-Z P02
double-acting
Note
See Catalog FI 01 "Field Instruments for Process Automation" for more add-ons and possible
modules.
14.3 Scope of delivery Mechanic Limit Switches (MLS)

If the Mechanic Limit Switches (MLS) were ordered for later installation, then the following
components are included in the scope of delivery:
● Mechanic Limit Switches (MLS) with accessories
● One housing cover with enlarged aperture
● One insulating cover

14.4 Scope of delivery Analog Input Module (AIM)
● Two cable ties

● One set of signs; how these are to be attached depends on the version.
14.4 Scope of delivery Analog Input Module (AIM)
Cable glands and adapters

The Analog Input Module (AIM) is supplied with various cable glands and adapters.
1 2 3
6 5 4
Connections ① to ③ for power supply Connections ④ to ⑥ for optional modules

① Adapter M20 to ½-14 NPT for ④ Cable gland for connection thread M20x1.5
6DR5..0/1/2/3-0.N/P with seal insert for 6DR55/6..0-0.G/M/R/S
② M12 connector for device version with ⑤ Blanking plug for device version without op‐
PROFIBUS communication or Fieldbus tional modules 6DR5...-0..00
FOUNDATION for 6DR55/6..-0.R/S
③ Cable gland for connection thread M20x1.5 ⑥ Adapter M20 to ½-14 NPT for
for 6DR5..0/1/2/3-0.G/M 6DR5..0/1/2/3-0.N/P
Figure 14-1 Positioner with the different cable glands and adapter
Scope of delivery Analog Input Module (AIM)
Description
Analog Input Module (AIM) C73451-A430-L8
Sealing ring for ⑥
Cable tie
⑥ Adapter M20 to ½-14 NPT

④ Cable gland for connection thread, gray
④ Cable gland for connection thread, blue
Sealing set for ④
Sealing set plug for ④

14.6 Order data
Description
Screw for plastic
Oval head screw M3x6
14.5 Accessories
For accessories, refer to Catalog FI 01 "Field devices for process automation", for example:
● Option modules
● NCS sensor for non-contacting position detection
● Mounting kits
● Operating software
14.6 Order data

In order to ensure that the ordering data you are using is not outdated, the latest ordering data
is always available on the Internet:
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)

Product documentation and support A
A.1 Product documentation
Process instrumentation product documentation is available in the following formats:
● Certificates (http://www.siemens.com/processinstrumentation/certificates)
● Downloads (firmware, EDDs, software) (http://www.siemens.com/processinstrumentation/
downloads)
● Catalog and catalog sheets (http://www.siemens.com/processinstrumentation/catalogs)
● Manuals (http://www.siemens.com/processinstrumentation/documentation)
You have the option to show, open, save, or configure the manual.
– "Display": Open the manual in HTML5 format
– "Configure": Register and configure the documentation specific to your plant
– "Download": Open or save the manual in PDF format
– "Download as html5, only PC": Open or save the manual in the HTML5 view on your PC
You can also find manuals with the Mobile app at Industry Online Support (https://
support.industry.siemens.com/cs/ww/de/sc/2067). Download the app to your mobile device
and scan the device QR code.
Product documentation by serial number

Using the PIA Life Cycle Portal, you can access the serial number-specific product information
including technical specifications, spare parts, calibration data, or factory certificates.
Entering a serial number

1. Open the PIA Life Cycle Portal (ttps://www.pia-portal.automation.siemens.com).
2. Select the desired language.
3. Enter the serial number of your device. The product documentation relevant for your device
is displayed and can be downloaded.
To display factory certificates, if available, log in to the PIA Life Cycle Portal using your login or
register.
Scanning a QR code
1. Scan the QR code on your device with a mobile device.
2. Click "PIA Portal".
To display factory certificates, if available, log in to the PIA Life Cycle Portal using your login or
register.

Product documentation and support
A.2 Technical support
A.2 Technical support
Technical support
If this documentation does not completely answer your technical questions, you can enter a
Support Request (http://www.siemens.com/automation/support-request).
Additional information on our technical support can be found at Technical Support (http://
www.siemens.com/automation/csi/service).
Service & support on the Internet

In addition to our technical support, Siemens offers comprehensive online services at Service
& Support (http://www.siemens.com/automation/serviceandsupport).
Contact
If you have further questions about the device, contact your local Siemens representative at
Personal Contact (http://www.automation.siemens.com/partner).
To find the contact for your product, go to "all products and branches" and select "Products &
Services > Industrial automation > Process instrumentation".
Contact address for business unit:
Siemens AG
Digital Industries
Process Automation
Östliche Rheinbrückenstr. 50
76187 Karlsruhe, Germany

External position detection B
B.1 Introduction
WARNING
Position Transmitter
Device versions with flameproof enclosures may only be operated with a Position Transmitter
with the same type of protection.
In some cases it makes sense to mount the position detection and the controller unit separately.
A separate mounting the case, for example, with continuous and strong vibrations, high or too
low ambient temperatures and nuclear radiation. A universal component is available for this
purpose. It is suitable for part-turn and linear actuators. You will require the following:
One of the following Position Transmitters

● Position Transmitter with article no. 6DR4004-2ES, 3ES or 4ES consisting of:
– Positioner enclosure
– Internal NCS module
– Various blanking plugs and seals
– Position Transmitter (NCS, ILS) 6DR4004-3ES or Position Transmitter (NCS, MLS)
6DR4004-4ES
● NCS sensor for non-contacting position detection 6DR4004-6N/-8N
● Potentiometers with 3 kΩ, 5 kΩ or 10 kΩ
● Position sensor with a signal range from 0 to 20 mA
● Position sensor with a signal range from 0 to 10 V
And a positioner
● Positioner in combination with Analog Input Module (AIM) 6DR5..0/1/2/3-0...2/3 or
retrofitted as accessory 6DR4004-6F/-8F
– An Analog Input Module (AIM) as an accessory is provided in a set along with cable
clamps and M20 cable glands.

External position detection
B.2 Non-Contacting Sensor
B.2.1 Principle of operation of NCS

The NCS contains a magnetic field sensor. This sensor changes its electrical resistance in
response to the immediate presence of a permanent magnet. The sensor has a high signal-to-
noise ratio to external magnetic fields due to the measurement method used.
The following figure shows the mode of operation with a rotating magnet.
① Magnet ③ Resistance change

② Sensor ④ Angle
Figure B-1 Relative resistance change depending on the angle of the magnet
The figure shows that a circular movement of the magnet generates a sinusoidal change of the
resistance. The mechanical stops of the fitting ensure that only one part (quadrant) of the
sinusoidal curve is used at any one time. The principle-related non-linearity of the curve is
corrected by means of software based on a curve that is stored in the positioner.
A linear movement of the magnet in the sensor range also generates a resistance change that
is used to identify the position. The following figure highlights the principle:

① Magnet ③ Resistance change

② Sensor ④ Angle
Figure B-2 Resistance change depending on the position of the magnet
Non-linearity is corrected automatically in the positioner by software.

The great advantage of this principle is the absence of wear. Moreover, vibration, dampness
and temperature only have a minor impact on the measurement result.

B.2.2 Mounting the NCS
Function
The positioner facilitates the separate installation of the position detection system. The stroke
or rotary angle is measured directly at the actuator by means of a non-contacting sensor. It is
therefore possible to install the controller unit at some distance away, e.g. on a mounting pipe
or similar. The positioner is connected to the position detection system by means of an
electrical cable.
Such a separate installation is useful whenever the ambient conditions at the valve exceed the
specified positioner values.
The NCS consists of a molded sensor for fixed installation and a magnet. The magnet is
mounted to the spindle on linear actuators, or to the stub shaft on part-turn actuators. The
sensor housing is mounted onto the console on part-turn actuators and to the bracket on linear
actuators. The bracket can be a NAMUR type, or any other mounting bracket.
Auxiliary power is supplied to the NCS via the Analog Input Module (AIM) 6DR4004-6F and
EMC compatibility is ensured at the same time.
You have the following options:
● To order the Analog Input Module (AIM) already installed in the positioner, Catalog FI 01
● To retrofit the Analog Input Module (AIM) in the positioner; article number 6DR4004-6F. For
information on retrofitting the Analog Input Module (AIM), refer to the Installing/mounting
(Page 37) section of the positioner operating instructions.

① Pneumatic line
② Pneumatic line for double-action actuators
③ Position detection system (10 kΩ potentiometer or NCS)
④ Electrical cable
⑤ Retrofittable Analog Input Module (AIM) (in the positioner)
⑥ Positioner
Figure B-3 Separate installation of the NCS and positioner

B.2.2.1 Mounting on part-turn actuator
Requirement
1. An Analog Input Module (AIM) built into the positioner
2. A non-contacting sensor for part-turn actuators 6DR4004-.N.10 or 6DR4004-.N.40
3. A part-turn actuator with interface acc. to VDI/VDE 3845 and mounting console acc. to VDI/
VDE 3845, or
A part-turn actuator with manufacturer-specific interface
NOTICE
Incorrect mounting
A clearance of 3 mm must be maintained between the magnet and the mounting console in
order to ensure correct measurement of the actuator position. The values transferred may be
incorrect if this clearance is not given.
● Maintain a clearance of 3 mm between the top edge of the magnet ④ and the top edge of
the mounting console ⑩.
Description

s
s
① Tensioning ring ⑧ Washer

② Hex socket head screw size M3x12 ⑨ Clamping table
③ Spring element ⑩ Mounting console
④ Magnet ⑪ Hexagon nut
⑤ Hooks ⑫ Hex socket head screw size M6x25
⑥ Plastic washer ⑬ Non Contacting Sensor (NCS)
⑦ Hex socket head screw size M6x12
Figure B-4 Mounting on part-turn actuator with magnet holder made of glass fiber reinforced polyester (left figure) or
anodized aluminum (right figure)

Procedure for the part-turn actuator to VDI/VDE 3845

1. Slide the clamping table ⑨ onto the stub shaft of the part-turn actuator.
2. Mount the clamping table ⑨ to the stub shaft using a hex socket head screw ⑦ and
washer ⑧.
3. Depending on the material of the magnet holder, proceed as follows:
Magnet holder made of glass fiber reinforced Magnet holder made of anodized aluminum
polyester
1. Insert the plastic washer ⑥ into the mag‐ 1. Place the magnet ④ onto the clamping ta‐
net ④. ble ⑨.
2. Fix the magnet ④ onto the clamping 2. Secure the magnet ④ to the clamping ta‐
table ⑨. The magnet ④ can now be rotated ble⑨ by connecting the two parts of the ten‐
easily on the clamping table ⑨. sioning ring ① to the two hex socket head
3. Slide the tensioning ring ① over the mag‐ screws ②. The magnet ④ can now be ro‐
net ④. Make sure that the spring tated easily on the clamping table ⑨.
elements ③ and the hook ⑤ on the mag‐ 3. Then tighten the two hex socket head
net ④ are lined up above one another and screws ②. The magnet ④ can then no lon‐
that they engage. You will now have more ger be rotated on the clamping table ⑨.
resistance when turning the tensioning
ring ① and magnet ④.
4. Screw the NCS ⑬ onto the mounting console ⑩ using the hexagon socket-head screw ⑫,
hex nut ⑪ and the washer ⑧.
5. Once the NCS ⑬ is mounted, the clearance of 3 mm between the top edge of the
magnet ④ and the top edge of the mounting console ⑩ is set automatically.
Procedure for part-turn actuators with manufacturer-specific interface

1. Steps 1 to 4 as above
2. Set a clearance of 3 mm between the top edge of the magnet ④ and the top edge of the
mounting console ⑩. Extend the stub shaft accordingly, or insert washers underneath the
NCS housing ⑬.
Reference
For information on the scope of delivery, refer to section "Scope of delivery of NCS for part-turn
actuators (Page 285)".

B.2.2.2 Mounting on linear actuator up to 14 mm (0.55 inch)
Requirement
1. An Analog Input Module (AIM) built into the positioner.
2. An NCS for linear actuators up to 14 mm (0.55 inch) 6DR4004-.N.20.
3. A linear actuator with interface to NAMUR. This installation must be carried out individually.
Only a NAMUR mounting bracket can be used as mounting base. The following figure
shows the assembly with NAMUR mounting bracket. Or:
A linear actuator without interface to NAMUR and individual mounting solution.

Description
The dimensions of magnet and NCS can be found under Dimensional drawing of non-
contacting sensor (Page 285).

s

s

% &

Dimensions in mm
A Mounting on a yoke with fin ③ Non Contacting Sensor (NCS)
B Mounting on a yoke with plane surface ④ Hex socket head screw M6x25
C Mounting on a yoke with columns ⑤ Magnet
① NAMUR mounting bracket IEC 60534 - ⑥ Hex socket head screw M6x12
not included in the scope of delivery
② Assembly panel for Non Contacting ⑦ Mounting bracket for the magnet - individual
Sensor (NCS) - individual solution; not solution; not included in the scope of delivery
included in the scope of delivery
Figure B-5 Example of the assembly on a linear actuator with a stroke up to 14 mm (0.55 inch)
Procedure
1. Produce the mounting panel ② and mounting bracket ⑦ individually.
2. Align the sensor to the center of the stroke. Observe the dimensions specified in the figure.

Reference
For information on the scope of delivery, refer to section "Scope of delivery of NCS for linear
actuators up to 14 mm (0.55 inch) . (Page 286)".
B.2.2.3 Mounting on linear actuator > 14 mm (0.55 inch)
Requirement
1. An Analog Input Module (AIM) built into the positioner.
2. An NCS for linear actuators > 14 mm (0.55 inch) 6DR4004-.N.30.
3. Linear actuator with interface to NAMUR
Item no. based on the respective stroke range: 6DR4004-8V or 6DR4004-8V +
6DR4004-8L.
or
linear actuator without interface to NAMUR and individual mounting solution. Item No.
6DR4004-8VK or 6DR4004-8VL can be used as individual assembly solution, depending on
the stroke range.
Description
You can find the dimensions in the dimension drawing in the section "Scope of delivery of NCS
for linear actuators > 14 mm (0.55 inch) . (Page 287)".

r

r


$ % &

A Mounting on a yoke with fin ⑨ Spring washer A8

B Mounting on a yoke with plane surface ⑩ Washer B 8.4
C Mounting on a yoke with columns ⑪ Washer B 6.4
① NAMUR mounting bracket IEC 60534 ⑫ Spring lock washer
② Pick-up bracket ⑬ Spring washer A6
③ Clamping piece ⑭ Hexagonal screw size M6x25
④ Carrier pin ⑮ Hexagonal nut M6
⑤ Lever ⑯ Square-head nut M6
⑥ U bracket ⑰ Hexagonal nut M8
⑦ Hexagonal screw size M8x20 ⑱ Shaft
⑧ Hexagonal screw size M8x16 ⑲ Hex socket head screw size M6x25
Figure B-6 Mounting instructions for linear actuators with a stroke > 14 mm (0.55 inch)
Procedure
1. Mount the clamping pieces ③ to the actuator spindle using the hexagonal screw ⑭ and
spring washers ⑬.
2. Slide the pick-up bracket ② into the milled recesses of the clamping pieces.
3. Set the necessary length.
4. Tighten the screws so that you can still shift the pick-up bracket ②.
5. Set the center of the pin ④ to the stroke range value specified on the actuator, or to the next
higher scaling value of the lever ⑤. The actuating distance in mm will be displayed on
successful initialization if you set the same value at parameter "3.YWAY" when
commissioning the system.
6. Slide the lever ⑤ onto the shaft ⑱ up to the endstop.
7. Secure the lever ⑤ using the hex socket head screw ⑲.

8. Mount the bracket ① to the NCS mounting kit using:

– Two hexagonal screws ⑧
– Spring washer ⑨
– Washer ⑩
– Hexagonal nut ⑰
The selection of the row of holes depends on the yoke width of the actuator. Make sure that
the dog pin ④ engages in the pick-up bracket ② as close as possible to the spindle over
the complete stroke range. The dog pin must not touch the clamping pieces.
9. Place the NCS assembly kit with the mounting bracket ① onto the actuator. Ensure that the
dog pin ④ is guided inside the pick-up bracket ②.
10.Tighten the pick-up bracket ② .
11.Prepare the assembly parts for the relevant actuator type for installation:
– For mounting on yoke with fin: hexagonal screw ⑦, washer ⑩ and spring washer ⑨.
– For mounting on a yoke with plane surface: Four hexagonal screw ⑦ with washer ⑩
and spring washer ⑨.
– For actuator with columns: Two U brackets ⑥, four hexagonal screw ⑰ with washer ⑩
and spring washer ⑨.
12.Mount the NCS assembly kit to the yoke using the assembly parts that you prepared.
Note
Observe the height
Adjust the height of the NCS assembly kit so that the lever position is in line horizontally with
the stroke center. Use the lever scale on the actuator for orientation. If a symmetrical
assembly is not possible, you must always ensure that the lever is in horizontal position
within the range of the stroke.

B.2.3 Connecting NCS to Analog Input Module (AIM)
Requirement
You need the Analog Input Module (AIM), article number 6DR4004-6F or -8F, for the electrical
connection of the accessory part "NCS sensor for non-contacting position measurement" to the
positioner. The positioner supplies auxiliary power to the NCS sensor via the option module.
Wiring diagram
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Positioner (open state) ⑦ Cable clamp

② Terminal Ref: Green ⑧ Screw F3x8
③ Terminal Pos: Black ⑨ Cable gland
④ Terminal GND: Brown ⑩ Four-pole NCS cable
⑤ Terminal Vcc: Yellow ⑪ Non Contacting Sensor (NCS)
⑥ Analog Input Module (AIM) ⑫
Cable shielding lug
Figure B-7 Example of connecting the NCS to the Analog Input Module (AIM)

Procedure
The NCS sensor is equipped with a shielded 4-pin cable. Connect this 4-pin cable to the
positioner as follows:
1. Feed the 4-pin NCS cable ⑩ through the union nut and the cable gland. Note: The type of
cable gland depends on the positioner version.
2. Tighten the cable gland ⑨.
3. Connect the 4-pin NCS cable ⑩ to the Analog Input Module (AIM) of the positioner in
accordance with the wiring diagram.
4. Place the cable clamp ⑦ onto the outer insulation of the 4-pin NCS cable ⑩.
5. Use the screw ⑧ to bond the cable shielding lug ⑫ and the cable clamp ⑦ to the ground
terminal of the positioner.
6. Grounding:
The rear steel panel of the NCS sensor is inevitably bonded to the ground potential of the
system when mounting on the console. This ground connection is only functional if there is
a low-impedance connection to ground potential of the system. Ensure this connection by
measuring the resistance. If necessary, ensure proper grounding by means of an additional
cable from the NCS sensor to ground potential.
B.2.4 Commissioning of NCS
B.2.4.1 Prerequisites / default settings

1. Supply electrical and pneumatic auxiliary power to the positioner. The top row of the display
shows the current sensor voltage (0 to 100%), while the "NOINI" info flashes in the bottom
row. The pneumatic actuator does not move.
2. If the positioner has already been initialized, perform a reset. Carry out the reset of
parameter group "Init" in the '50.PRST' Preset (Page 160) parameter.
3. Preset for part-turn actuators:
While the process valve is closed, align the magnet so that the north pole is in the direction
of the cable; "N" in position ⑦ in "Figure B-4 Mounting on part-turn actuator with magnet
holder made of glass fiber reinforced polyester (left figure) or anodized aluminum (right
figure) (Page 274)".
4. Monitor the display of the positioner while adjusting the actuator to its mechanical stops by
means of and at the positioner. Verify that the displayed values never exceed the
range from P2.0 to P98.0.
Note
This condition cannot be met with slipping flaps or linear actuators that exceed the
mechanical actuation limits.

B.2.4.2 Initialization of part-turn actuators
Procedure
1. For part-turn actuators operating in standard control direction, set parameter "1.YFCT" to
"ncSt", or to "-ncSt" in case of inverse control direction.
2. Launch initialization as usual with "INITA".
B.2.4.3 Initializing linear actuators with a stroke range up to 14 mm (0.55 inch)
Requirements
1. Set the "1.YFCT" parameter of the positioner to "ncSL" or - with inverse control direction -
to "-ncSL".
B.2.4.4 Initializing linear actuators with a stroke range > 14 mm (0.55 inch)
Note
Parameter values "ncSLL" and "-ncLL" are only available for devices of the 6DR5... series and
only with the firmware version > C4. Set the value to 90° on devices of the 6DR5... series with
firmware version < C5 (YAGL). This setting is also necessary for devices of the 6DR4... series.
Resultant non-linearity can be corrected by means of the programmable characteristic by
setting the parameter value from "SFCT" to "FrEE" and adapting the interpolation points.
Requirements
1. Set the "1.YFCT" parameter of the positioner to "ncSLL" or - with inverse control direction
- to "-ncLL".
B.2.5 Technical specifications NCS
Additional modules Without Ex protection With Ex protection With explosion protection

Ex "ia" Ex "ic", "ec"
Travel range
● Linear actuator 6DR4004-6/8N.20 3 to 14 mm (0.12 to 0.55")
● Linear actuator 6DR4004-6/8N.30 10 to 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
● Part-turn actuator 30 to 100°

Additional modules Without Ex protection With Ex protection With explosion protection

Ex "ia" Ex "ic", "ec"
positioner)
Hysteresis ± 0.2 %
Temperature influence (range: rota‐ ≤ 0.1 %/10 K (≤ 0.1 %/18 °F) for -20 to +90 °C (-4 to +194 °F)
tion angle 120° or stroke 14 mm) ≤ 0.2%/10 K (≤ 0.2%/18 °F) for -40 to -20 °C (-40 to -4 °F)
● Storage 1K5, but -40 to +90 °C (-40 to +194 °F)
● Transport 2K4, but -40 to +90 °C (-40 to +194 °F)
● Harmonic oscillations 3.5 mm (0.14"), 2 to 27 Hz, 3 cycles/axis
(sine) according to IEC 60068-2-6 98.1 m/s² (321.84 ft/s²), 27 to 300 Hz, 3 cycles/axis
● Bumping according to IEC 300 m/s2(984 ft/s2), 6 ms, 4000 shocks/axis
60068-2-29
Torque for cable gland nut made of Plastic Metal Stainless steel
2.5 Nm (1.8 ft lb) 4.2 Nm (3.1 ft lb) 4.2 Nm (3.1 ft lb)
Torque of hexagon socket-head 4 Nm (3 ft lb)
screw M6x12 (shaft end or mounting
bracket)
Torque of hexagon socket head screw 4 Nm (3 ft lb)
M6x25 (mounting console or mount‐
ing plate)
Torque of hexagon socket head screw 1 Nm (0.7 ft lb)
M3x12 (clamping ring)
Degree of protection IP68 / type 4X
For connecting to circuits with the fol‐ - Ui = 5 V Ui = 5 V
lowing peak values Ii = 160 mA
Pi = 120 mW
Effective internal capacitance - Ci = 1) Ci = 1)
Effective internal inductance - Li = 2) Li = 2)
1)
Ci = 110 nF + 110 nF per meter of connecting cable
2)
Li = 270 µH + 6.53 µH per meter of connecting cable

B.2.6 Dimensional drawing of non-contacting sensor
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A NCS B Magnet
Figure B-8 Dimensional drawing of the NCS and magnet
B.2.7 NCS sensor scope of delivery
B.2.7.1 Scope of delivery of NCS for part-turn actuators
6DR4004-.N.10 6DR4004-.N.40
Quantity Quantity Name Note
1 1 Magnet clamp
5 5 Washer 6
2 2 Hex socket head screw M6x12
1 - Plastic washer
1 1 Magnet

6DR4004-.N.10 6DR4004-.N.40
1 2 Tensioning ring
4 4 Hexagon nut M6
2 2 Hex socket head screw M6x25
- 2 Hex socket head screw M3x12
1 1 Non-contacting sensor Cable lengths as ordered
1 1 Self-tapping screw for polycar‐ F3x8
bonate enclosure
1 1 Sealing For cable bushings
1 1 Plugs For closing the sealing insert
1 1 Cable clamp
1 1 DVD with documentation
See also
Mounting the NCS (Page 273)
B.2.7.2 Scope of delivery of NCS for linear actuators up to 14 mm (0.55 inch) .
Linear actuator with a stroke range up to 14 mm (0.55 inch) 6DR4004-.N.20

Quantity Designation Notes
1 Magnet
5 Washer 6
2 Hex socket head screw M6x12
4 Hexagon nut M6
2 Hex socket head screw M6x25
1 Non-contacting sensor Cable lengths as ordered
1 Screw F3x8
1 Sealing For cable bushings
1 Plugs For closing the sealing insert
1 Cable clamp
1 DVD with documentation
See also
Mounting the NCS (Page 273)

B.2.7.3 Scope of delivery of NCS for linear actuators > 14 mm (0.55 inch) .
Linear actuator > 14 mm (0.55 inch) 6DR4004-.N.30

Quantity Designation Notes
1 NCS assembly kit, completely Mounting by means of assembly kit for NAMUR linear
assembled actuators
Mounting kit available on separate order, see 'Accessor‐
ies' in Catalog FI 01.
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Figure B-9 Dimension drawing NCS module > 14 mm (0.55 inch)

B.3 External position detection
B.3.1 Mode of operation for external position detection

The Position Transmitter essentially consists of an enclosure and an internal position detection
system. The position is recorded by a potentiometer or an internal NCS module, section
"Principle of operation of NCS (Page 272)". The controller unit is separated from the positioner.
Such a separate installation is useful whenever the ambient conditions at the valve exceed the
specified positioner values.
The Position Transmitter is secured to a console with part-turn actuators and to a mounting
bracket with linear actuators, section "Mounting to linear actuator (Page 40)".
Auxiliary power is supplied to the Position Transmitter via the Analog Input Module (AIM) and
EMC compatibility is ensured at the same time.

① Pneumatic line
② Pneumatic line for double-action actuators
③ Position Transmitter
④ Electrical cable
⑤ Analog Input Module (AIM) (fitted in the positioner or retrofittable)
⑥ Positioner
Figure B-10 Position Transmitter and positioner
B.3.2 Installation of external position detection system

Mounting of the Position Transmitter corresponds to the mounting of the positioner in a non-
flameproof enclosure. Proceed as described in Section "Installing and mounting (Page 37)".
The connection of the Analog Input Module (AIM) is described in the section "Analog Input
Module (AIM) 6DR4004-6F / -8F (Page 87)".

B.3.3 Connecting to Analog Input Module (AIM)
Wiring diagram
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① Connection of terminal Vcc is only needed for 6DR4004-2ES, -3ES and -4ES.
B.3.4 Technical specifications of the external position detection system
B.3.4.1 Rated conditions for external position detection
Rated conditions
Ambient temperature In hazardous areas, observe the maximum permissible ambient
temperature corresponding to the temperature class.
● Permissible ambient temperature for operation -40 ... +90 °C (-40 ... +194 °F)
Degree of protection 1)
IP66 / Type 4X to UL 50E
● Storage 1K5, but -40 ... +90 °C (1K5, but -40 ... +194 °F)
● Transport 2K4, but -40 ... +90 °C (2K4, but -40 ... +194 °F)
● Operation 4K3, but -40 ... +90 °C (4K3, but -40 ... +194 °F)
1
) Impact energy max. 1 joule.
B.3.4.2 Electrical data for external position detection
External NCS sensors 6DR4004-6N / -8N

tion Ex "ia", "db ia", "ic" Ex "ec"
6DR4004-8N 6DR4004-6N 6DR4004-6N
Travel range
● Linear actuator 3 to 14 mm (0.12 to 0.55")
6DR4004-6/-8N.20
● Linear actuator 10 to 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
6DR4004-6/-8N.30


tion Ex "ia", "db ia", "ic" Ex "ec"
6DR4004-8N 6DR4004-6N 6DR4004-6N
positioner)
Hysteresis ± 0.2 %
60068-2-29
Torque for cable gland nut made of Plastic Metal
2.5 Nm (1.8 ft lb) 4.2 Nm (3.1 ft lb)
bracket)
ing plate)
Degree of protection IP68 according to IEC/EN 60529; Type 4X according to UL 50E
Pi ≤ 120 mW
Position Transmitter (Potentiometer) 6DR4004-1ES
Additional modules With explosion protection With explosion protection

Ex "ia", "db ia", "ic" Ex "ec", "tb"
Degree of protection IP66 according to IEC/EN 60529; Type 4X according to
UL 50E
For connecting to circuits with the following peak values Ui ≤ 5 V Ui ≤ 5 V
Effective internal capacitance Ci ≤ 10 nF -
Effective internal inductance Li ≤ 240 μH -

Position Transmitter (NCS) 6DR4004-2ES

tion Ex "ia", "db ia", "ic" Ex "ec", "tb"
Travel range
● Linear actuator 3 to 14 mm (0.12 to 0.55")
10 to 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
positioner)
Hysteresis ± 0.2 %
60068-2-29
Torque for cable gland nut made of Plastic Metal
2.5 Nm (1.8 ft lb) 4.2 Nm (3.1 ft lb)
bracket)
ing plate)
Degree of protection provided by en‐ IP66 according to IEC/EN 60529; Type 4X according to UL 50E
closure
Pi ≤ 120 mW
Position Transmitter (NCS, ILS) 6DR4004-3ES

Degree of protection provided by en‐ IP66 according to IEC/EN 60529; type 4X according to UL 50E
closure
NCS module (NCS) 6DR4004-5L 6DR4004-5LE 6DR4004-5LE


● For connecting to circuits with the - Ui ≤ 5 V Ui ≤ 5 V
following peak values Ii ≤ 160 mA Ii ≤ 160 mA
Pi ≤ 120 mW
● Effective internal capacitance - Ci = 110 nF + 690 pF/m -
Connecting cable
● Effective internal inductance - Li = 270 μH + 6,53 μH/m -
Connecting cable
Inductive Limit Switches (ILS) 6DR4004-8G 6DR4004-6G 6DR4004-6G
2 slotted initiators
● Digital output (slot-type initiators) A1: Terminals 41 and 42
● Digital output (slot-type initiators) A2: Terminals 51 and 52
● Connection 2-wire system according to EN 60947-5-6 (NAMUR), for switching amplifier connec‐
ted on load side
● Signal state High > 2.1 mA
(not triggered)
● Signal state Low (triggered) < 1.2 mA
● 2 slotted initiators Type SJ2-SN
● Function NC (normally closed)
● Connecting to circuits with the fol‐ Rated voltage 8 V, power Ui ≤ DC 15 V Un ≤ DC 15 V
lowing peak values consumption: Ii ≤ 25 mA In ≤ 25 mA
≥ 3 mA (limit not activa‐ Pi ≤ 64 mW
ted), ≤ 1 mA (limit activa‐
ted)
Effective internal capacitance - Ci ≤ 161 nF -
Effective internal inductance - Li ≤ 120 μH -
● Connection At switching amplifier in accordance with EN 60947-5-6: (NAMUR), UAux = 8.2 V, Ri =
1 kΩ)
(not triggered)
● Auxiliary power UAux UAux ≤ DC 35 V - -
I ≤ 20 mA
● Connecting to circuits with the fol‐ - Ui ≤ DC 15 V Ui ≤ 15 V
lowing peak values Ii ≤ 25 mA Ii ≤ 25 mA
Pi ≤ 64 mW
Effective internal capacitance - Ci = 5.2 nF -
Galvanic isolation The 3 digital outputs are galvanically isolated from the basic unit.

Position Transmitter (NCS, MLS) 6DR4004-4ES

Degree of protection provided by en‐ IP66 according to IEC/EN 60529; type 4X according to UL 50E
closure
NCS module (NCS) 6DR4004-5L 6DR4004-5LE 6DR4004-5LE
● For connecting to circuits with the Ui ≤ 5 V Ui ≤ 5 V
following peak values Ii ≤ 160 mA Ii ≤ 160 mA
Pi ≤ 120 mW
● Effective internal capacitance Ci = 110 nF + 690 pF/m -
Connecting cable
● Effective internal inductance Li = 270 μH + 6,53 μH/m -
Connecting cable
Mechanic Limit Switches (MLS) 6DR4004-8K 6DR4004-6K 6DR4004-6K
2 limit contacts
● Digital output (switching contact) A1: Terminals 41 and 42
● Digital output (switching contact) A2: Terminals 51 and 52
● Max. switching current AC/DC 4A - -
● For connecting to circuits with the - Ui ≤ 30 V Un ≤ 30 V
following peak values Ii ≤ 100 mA In ≤ 100 mA
Pi ≤ 750 mW
Effective internal capacitance - Ci = negligibly small -
Effective internal inductance - Li = negligibly small -
● Max. switching voltage AC/DC 250 V/24 V DC 30 V DC 30 V
● Connection On switching amplifier according to EN 60947-5-6: (NAMUR), UAux = 8.2 V, Ri = 1 kΩ)
(not triggered)
● Auxiliary power UAux ≤ DC 35 V - -
I ≤ 20 mA
● Connecting to circuits with the fol‐ - Ui ≤ 15 V Un ≤ 15 V
lowing peak values Ii ≤ 25 mA In ≤ 25 mA
Pi ≤ 64 mW
Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF
Effective internal inductance - Li = negligibly small
Galvanic isolation The 3 digital outputs are galvanically isolated from the basic unit
Test voltage 3150 V DC, 2 s
Rated condition height Max. 2 000 m above sea - -
level. Use a suitable power
supply at an altitude of
more than 2 000 m above
sea level.



Pressure gauge block C
Pressure gauge block
Pressure gauge blocks that are available as accessories are illustrated below. The gauges
display measured values for the actuating pressure and supply pressure. The figure to the left
shows the pressure gauge block for single-acting actuators. The image to the right shows the
pressure gauge block for double-acting actuators.
Y1 Actuating pressure
PZ Supply pressure
Y2 Actuating pressure
Fixing the pressure gauge block

The pressure gauge block is fixed onto the lateral pneumatic connection of the positioner using
the screws provided. Use the provided O-rings as sealing elements.

Pressure gauge block

Sealing plug / thread adapter D
D.1 Intended use of accessory part
The sealing plug and the thread adapter (components) can be used for installation in electrical
equipment of flameproof" "Ex d" type of protection of groups IIA, IIB, IIC as well as dust
protection by enclosure "Ex t" type of protection.
D.2 Safety instructions for accessory part
WARNING
Incorrect assembly
● The component can be damaged or destroyed or its functionality impaired through
incorrect assembly.
– Mount the component using a suitable tool. Refer to the information in Chapter
"Technical specifications of accessory part (Page 298)", for example, torques for
installation.
● For "Explosion-proof Ex d" type of protection: To ensure an engagement depth of 8 mm,
the enclosure must have a wall thickness of at least 10 mm.
Improper modifications
Danger to personnel, system and environment can result from modifications and repairs of the
component, particularly in hazardous areas.
● Any modification which deviates from the delivery state is not permitted.
Loss of enclosure type of protection
IP protection is not guaranteed without sealant.
● Use a suitable thread sealant.
● If you are using the component in type of protection dust protection by enclosure "Ex t", use
the supplied sealing ring (①, figure in Chapter "Dimensional drawings for accessory part
(Page 299)").
Unsuitable fluids in the environment
Danger of injury or damage to device.
Aggressive media in the environment can damage the sealing ring. Type of protection and
device protection may no longer be guaranteed.
● Make sure that the sealing material is suitable for the area of use.

Sealing plug / thread adapter
D.3 Technical specifications of accessory part
Note
Loss of type of protection
Changes in the ambient conditions can loosen the component.
● As part of the recommended maintenance intervals: Check the compression fitting for tight
fit and tighten, if necessary.
D.3 Technical specifications of accessory part
Technical specifications sealing plug and thread adapter

Sealing plug suitable for types of protection Explosion-proof enclosure "d" of groups IIA, IIB, IIC
Dust protection by enclosure "t"
Standard compliance The components meet Directive 94/9. They meet the requirements of
standards IEC/EN 60079-0; IEC/EN 60079-1; IEC/EN 60079-31.
Explosion protection
● Gas explosion protection II2G Ex d IIC
● Dust explosion protection II1D Ex t IIIC
Certificates IECEx TUN 13.0022 U
TÜV 13 ATEX 121710 U
Material for sealing plug / thread adapter Stainless steel
Material for seal Vulcanized fiber or Victor Reinz AFM 30
Ambient temperature range -40 ... +100 °C (-40 ... +212 °F)
For "Ex d" type of protection:
Required wall thickness for tappings 10 mm
Torque
● For thread size M20 x 1.5 65 Nm
● For thread size M25 x 1.5 95 Nm
● For thread size ½-14 NPT 65 Nm
Width A/F for thread size M20 x 1.5 27
Width A/F for thread size M25 x 1.5 30
Key size for thread size ½-14 NPT 10

D.4 Dimensional drawings for accessory part
Sealing plug Ex d, M20 x 1.5, dimensions in mm Sealing plug Ex d, M25 x 1.5, dimensions in mm

① Sealing ring: Use for dust protection "Ex t" type

of protection.
Thread adapter Ex d, M25 x 1.5 on M20 x 1.5 and

M25 x 1.5 on ½-14 NPT, dimensions in mm
Sealing plug Ex d ½ -14 NPT

Booster E
CAUTION
Increased sound pressure level
Changes to the sound absorber of the positioner or the mounting of pneumatic components
or pneumatic options on the positioner can cause a sound pressure with a level of 80 dBA to
be exceeded.
● Wear suitable hearing protection to protect yourself against hearing damage.
E.1 Booster introduction

In order to shorten the travel times, use a booster between the positioner and actuator.
Note
Positioner with booster, double-acting
If the supply pressure PZ fails, the booster changes the failure behavior of the positioner. The
position of the valve is random.
The booster has no effect in the event of an electrical power failure.
E.2 Mounting a booster
Requirement
1. You are familiar with the safety instructions in section "Installing and mounting (Page 37)".
2. You have one of the following boosters:
– With single-acting positioners, booster with the article numbers 6DR4004-1RJ, -1RK,
-1RP or -1RQ
– With double-acting positioners, booster with the article numbers 6DR4004-2RJ, -2RK,
-2RP or -2RQ

Booster
A. Mount extension shaft and booster

Using the example of a single-acting positioner. The figure on the right shows the devices in a
flameproof enclosure.
1. Plug the extension shaft ① onto the shaft of the positioner.
2. Tighten the locking screw ② at the flat end of the positioner shaft.

3. Check that the extension shaft ① sits properly.

4. Turn the short threaded end of the threaded bolts ③ into the positioner up to the endstop.

5. Tighten the threaded bolts ③ lightly using an open-ended wrench.

Booster
6. Insert the booster ⑭ via the threaded bolts ③.

7. Fasten the booster ⑭ with the lock washers ④ and nuts ⑤. When tightening, make sure
that the shaft ① can be turned easily.


Booster
B. Mounting the pressure gauge and connection block

1. Check whether the O-rings are in the pressure gauge block. There are two O-rings in the
single-acting version. There are three O rings in the double-acting version.
2. Fasten the pressure gauge block ⑥ with the screws ⑦ and lock washers ⑧. Position the
screws, do not tighten them.

3. Fasten the connection block ⑨ with the screws ⑩, ⑫ and lock washers ⑪, ⑬. Position
the screws, do not tighten them.


Booster
E.3 Booster commissioning
C. Tightening screws
Tighten the screws in the following order.

1. Screws ⑦ which are used to fasten the pressure gauge block ⑥ to the positioner
2. Screws ⑫ which are used to fasten the connection block ⑨ to the booster
3. Screws ⑩ which are used to fasten the connection block ⑨ to the pressure gauge block ⑥
4. Mount the positioner on the actuator as described in:
– Mounting to linear actuator (Page 40)
– Mounting to part-turn actuator (Page 45)
5. Use the existing interfaces on the booster.
Requirement
1. You operate the positioner with a booster.
2. '51.PNEUM' Pneumatics type (Page 160) parameter is set to 'booSt'.

Booster
Procedure for commissioning the booster

1. Check whether the restrictor(s) on the positioner are completely open. With a new
positioner, the restrictors are factory-set to open. The position of the restrictors is shown in
the figure in section Device components (Page 28).
2. Set '34.DEBA' Deadband of closed-loop controller (Page 150) to the largest value
permissible for your process. The largest value is usually 0.5.
3. Start the automatic initialization process as described under Commissioning (Page 105).
4. With RUN 3, the initialization is stopped for five seconds. During these five seconds, start
the function for setting the booster using the button.
A cycle is started which continuously determines the overshoots. The values 'oSuP' and
'oSdo' are shown alternately in the display. 'oSuP' and 'oSdo' represent the values of the
overshoot in % of the total stroke.
5. During the automatic initialization, adjust the booster bypass using the adjustment screw on
the booster. For single-acting actuators, there is one adjustment screw; there are two
adjustment screws for double-acting actuators.

① Booster bypass on single-acting positioner ① Booster bypass on single-acting positioner in

flameproof enclosure
If 'oCAY' is shown on the display, the overshoot is less than 3%.
6. Press the or button. The positioner again runs through the initialization step RUN 3,
starting with determination of the travel times. The following figure schematically shows the
RUN 3 sequence for the booster.
7. 'FINISH' is shown on the display when the initialization has been completed.
If the process value on the display does not remain stable or if a constant manipulated variable
cannot be achieved for a constant setpoint, further optimization of the controller data is
necessary. This is described in section Optimization of controller data (Page 101).
See also

Booster
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Figure E-1 RUN 3 and 4 (booster)
See also

Booster
E.4 Booster dimension drawings
E.4 Booster dimension drawings
E.4.1 For positioners in non-flameproof enclosure

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Figure E-2 Dimension drawings booster mounted on positioner, dimensions in mm (inch)

Booster
E.5 Technical specifications of booster
E.4.2 For positioners in flameproof enclosure

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Figure E-3 Dimension drawings booster mounted on positioner in a flameproof enclosure, dimensions
in mm (inch)
Booster
Weight booster, single-acting
● BOOSTER KIT for 6DR5.10 and 6DR5.13 2.9 kg (6.5 lb)
● BOOSTER KIT for 6DR5.15 3.3 kg (7.3 lb)
Weight booster, double-acting

Booster
Booster
● BOOSTER KIT for 6DR5.20 and 6DR5.23 4.3 kg (9.4 lb)
● BOOSTER KIT for 6DR5.25 4.7 kg (10.4 lb)
Connections, pneumatic 1/2-14 NPT or G½
Air consumption 1.2 x 10-2 Nm3/h
Pressure gauge Made of steel IP44. Scaling MPa, bar, psi
Flow capacity Cv 2.0

Positioner with remote control electronics F
F.1 Introduction to remote control electronics
In some cases it is advisable to use the positioner separately from the control electronics. The
option of separating the control electronics of the positioner is available for this purpose. The
positioner is in a different location than the control electronics. This remote control electronics
of the positioner allows the valves to be controlled in radiation contaminated environment, as
all highly integrated electronic components are located in the area that is protected from
radiation. Highly integrated electronic components are, for example, memory blocks and
microprocessor blocks.
For the above described deployment you required the two following components:
● Component 1 consisting of the control electronics in the form of a 19" slide-in module. The
19" slide-in module is installed in the control cabinet. Available in the following variants:
– Slide-in module as 4 to 20 mA with 2-wire connection, article number A5E00151560
● Component 2 consisting of the positioner without control electronics. The positioner with
control electronics is mounted on the valve.
– Positioner without control electronics with Position Transmitter and pneumatic unit,
mounted on the valve, article number 6DR5910-0NG00-0AA0.
Positioner without basic electronics 6DR5910 (Page 318)
Components 1 and 2 are connected electrically to each other. The components are described
below.
F.2 19" slide-in module
F.2.1 Description of 19" slide-in module 4 to 20 mA
Description
This component is a control electronics in the 19" slide-in module in 4 to 20 mA version.
Commissioning is only possible in conjunction with a positioner component 6DR5910. The 19"
slide-in module has three channels and controls up to three valves.
The control electronics supplies the current position of the valve in the form of a current of 4 to
20 mA, which corresponds to the position feedback.

Positioner with remote control electronics

① 19" slide-in module 4 to 20 mA ④ Channel 3

② Sub-D 15-pin socket connector for cable to ⑤ Channel 2
the valve
③ Sub-D male connector 9-pin for cable to the ⑥ Channel 1
control system
Figure F-1 Device view of 19" slide-in module 4 to 20 mA, rear view

① 19" slide-in module 4 to 20 mA ④ Channel 2

③ Channel 1 ⑤ Channel 3
② Display ⑥ Input keys
Figure F-2 Device view of 19" slide-in module 4 to 20 mA, front view
F.2.2 Connecting the 19" slide-in module 4 to 20 mA
F.2.2.1 Grounding concept of 19" slide-in module 4 to 20 mA
NOTICE
Interference
To dissipate interference pulses the positioner components must be connected to an
equipotential bonding cable (ground potential) using a low resistance.
● Connect the positioner 6DR5910 according to the grounding concept described below.

Note
Properties of the cable
To avoid interference, the cable between 19" slide-in module, positioners 6DR59.. and field
distributors should have the following signal pairs (twisted pair):
● Discharge - / Discharge +
● Supply - / Supply +
● GND / POS
● V_REF GND

*URXQG

*URXQG *URXQG

*URXQG
*URXQG
① Control system ⑤ Shield

② 3 x 1 cable to the control system ⑥ Positioner 6DR5910
③ Field distributor ⑦ 19" slide-in module
④ Connection point
Ground

Figure F-3 Grounding concept of 19" slide-in module 4 to 20 mA version
Notes on the individual connection points:
The cable shield is not connected to the positioner 6DR5910.
The positioner 6DR5910 is connected via the mechanical assembly to Ground 2 ,

see Installing/mounting (Page 37). Section Basic safety instructions (Page 75) de‐
scribes how to ground the enclosure.
Each field distributor is grounded. The cable shields in the field distributor are not
grounded. The cable shields are interconnected.
The cable shields on the 19" slide-in module are connected to the field distributor.
The 19" slide-in module is connected to Ground 1.
The cable shields on the control system are not connected to ground.
F.2.2.2 Electrical connection of 19" slide-in module 4 to 20 mA
Requirement
You have read sections Connection (Page 75) and Grounding concept of 19" slide-in module
4 to 20 mA (Page 312).

Connecting

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① D-SUB male connector 15-pin ⑧ Cable to control system

② Cable to the positioner 6DR5910 ⑨ Signal source
③ Positioner 6DR59.. ⑩ Control system
④ Connecting terminals, positioner ⑪ Auxiliary power supply UAux
⑤ Signal cables for potentiometer ⑫ Earth potential
⑥ Signal cables for pneumatic block ⑬ Control electronics in the 19" slide-in module
4 to 20 mA
⑦ D-SUB female connector 9-pin ⑭ Channel 1 of 3
Figure F-4 Connecting basic electronics to power supply
Procedure
Observe the safety instructions for connection in section Basic safety instructions (Page 75).
1. Strip 5 mm of the cable shield on the cable ②.
2. Open the positioner 6DR5910. Unscrew the four fixing screws of the enclosure cover.
3. Insert the prepared cable ② through the cable entry of the positioner.
4. Tighten the cable entry.

5. Connect the wires of the cable ② to the connecting terminals ④ and to the SUB-D male
connector ① according to the following table:
Connecting Assignment Assignment, Connecting Assignment Assignment,

terminals male terminals male
④/⑤ connector ① ④/⑥ connector ①
2 GND 7 6 Not assigned -
3 Vref 6 7 Discharge + 2
4 Vcc - 8 Discharge - 1
5 Vpos 4 9 Supply + 15
10 Supply - 14
6. Connect the positioner 6DR5910 ③ with the 19" slide-in module ⑬ using the SUB-D male
connector ①.
7. Connect the wires of the cable ⑧ to the signal source ⑨ and the power source ⑪ as well
as the SUB-D female connector ⑦ according to the following table:
Assignment of female connector ⑦ for ⑨ Assignment of female connector ⑦ for ⑪

1 Signal source + 6 -
2 Signal source - 7 -
3 - 8 UAux+
4 - 9 UAux-
5 -
8. Connect the 19" slide-in module ⑬ with the control system ⑩ using the SUB-D female
connector ⑦.
F.2.3 Technical specifications of 19" slide-in module 4 to 20 mA

You can find the valid technical specifications for the positioner Technical data (Page 239). The
technical specifications valid for the 19" slide-in module 4 to 20 mA are set out below.
Rated conditions
● Front IP40 acc. to DIN EN 60529
● Back page IP20 acc. to DIN EN 60529
Mounting position Any
● Harmonic oscillations (sine wave) according to 3.5 mm (0.14"), 5 ... 8.4 Hz, 4 cycles/axle
DIN EN 60082-2-6/05.96 10 m/s² (33 ft/s²), 8.4 ... 500 Hz, 4 cycles/axle
● Oscillations (sinusoidal) according to KWU DD 7080.9/93
DIN EN 60068-2-6/04.96 KTA 3503 from 11.86
● Shock (half-sine) according to DIN EN 60068-2-27/02.2010 150 m/s² (492 ft/s²), 11 ms, 6 shocks/axle

Construction
Weight Approx. 1.8 kg
Material body 19" slide-in module, 2HM, aluminum
Number of channels, basic electronics: 3
● Storage -25°C to 80°C, 75% at 25°C, without condensation
● Transport -25°C to 80°C, 75% at 25°C, without condensation
● Operation 0°C to 50°C, 75% at 25°C, without condensation
Electrical data
Electrical connection 9-pin Sub-D plug
15-pin Sub-D female connector
Current input IW
● Rated signal range 4 to 20 mA
● Current to maintain the auxiliary power ≥ 3.6 mA
2-wire connection
● Current to maintain the auxiliary power ≥ 3.6 mA
● Required load voltage UB (corresponds to Ω at 20 mA) 6.4 V (= 320 Ω)
● Static destruction limit ± 40 mA
Technical specifications for the controller unit is available at Controller (Page 242).
Technical specifications of the Analog Output Module (AOM) are available at Analog Output
Module (AOM) 6DR4004-6J / -8J (Page 251).
Cable data (minimum requirements)

Cable length ≤ 130 m
Capacity wire / wire ≤ 150 nF/km
Capacity wire / shield ≤ 200 nF/km
Inductance ≤ 1 mH/km
Copper resistance ≤ 100 Ω/km
Insulation conductance ≥ 0.5 x 107 S/km
Ambient temperature -30 ... +80 °C
Number of poles
● Cable to the control system (min/max) 4 or 9
● Cable to the positioner 6DR5910 8 or 15
Connection
● Cable to the control system (min/max) 9-pin Sub-D female connector
● Cable to the positioner 6DR5910 15-pin Sub-D male connector

F.3 Positioner without basic electronics 6DR5910
F.2.4 Dimensional drawing of 19" slide-in module 4 to 20 mA
① Rear view ② Side view

Figure F-5 19" slide-in module 4 to 20 mA, dimensions in mm
The dimensions of the positioner without basic electronics 6DR5910 correspond to the
dimensions 6DR5..0. You can find these dimensions in the Positioner in non-flameproof
enclosure (Page 257) section.
F.2.5 Scope of delivery of remote control electronics
Description Article number

19" slide-in module as 4 to 20 mA version, aluminum, 3 channels, non-Ex A5E00151560
SIPART PS2 without basic electronics, single-acting, polycarbonate enclosure, 6DR5910-...
non-Ex
See also
Spare parts (Page 263)

This component is a positioner without basic electronics (6DR5910). Commissioning is only
possible in conjunction with a basic electronics component in the form of a 19" slide-in module.
The positioner without basic electronics is available in the device version in polycarbonate
enclosure, single-acting.
The following section describes how you mount, connect and commission the positioner
without basic electronics.

Installing/mounting
Mounting of this positioner without basic electronics corresponds to the mounting of the
positioner in non-flameproof enclosure. Proceed as described in Section "Installing/mounting
(Page 37)".
Connecting
Connect the positioner as described in Section "Positioner without basic electronics 6DR5910
(Page 318)". Please also observe Basic safety instructions (Page 75) for connection.
Commissioning
Commission the positioner as described in Section "Commissioning (Page 105)".
Device view of positioner 6DR5910

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① Output: Actuating pressure Y1 ⑦ Friction clutch adjustment wheel

② Input: Supply pressure PZ ⑧ Connecting terminals, positioner
③ Output: Actuating pressure Y2 (not for ⑨ Blanking plug
6DR59..)
④ Restrictor Y1 ⑩ Cable gland
⑤ Exhaust air outlet with a sound absorber ⑪ Wiring diagram on module cover
⑥ Transmission ratio selector ⑫ Purging air selector


Abbreviations G
G.1 Abbreviations for positioners
Abbreviation Long form Meaning

A/D Analog-to-digital converter -
AC Alternating current Alternating current
AI Analog Input -
AMS Asset Management Solutions Communication software from Emerson Process comparable
with SIMATIC PDM
AO Analog Output -
AUT Automatic Operating mode
ATEX Atmosphère explosible Product and operation directive of European Commission for
explosion protection.
CENELEC Comité Européen de Normalisation Standards organization, responsible for European standardi‐
Electrotechnique zation in the field of electrical engineering.
CPU Central Processing Unit Master processor
CSA Canadian Standard Association Canadian standards organization
DC Direct current Direct current
DI Digital Input -
DIN Deutsche Industrie Norm -
DO Digital Output -
DTM Device Type Manager -
EDD Electronic Device Description -
Ex Explosion protection -
EMC Electromagnetic compatibility -
FDT Field Device Tool -
FF FOUNDATION Fieldbus Fieldbus of the Fieldbus Foundation
FM Factory Mutual American testing agency/insurance company
FW Firmware Device-specific software
GSD Device master data -
HART® Highway Addressable Remote Trans‐ Communication system for the development of industrial field
ducer busses.
IEC International Electrotechnical Com‐ International standards organization for standards in electrical
mission engineering and electronics.
IP International Protection International degrees of protection (long form as per DIN)
Ingress Protection Seepage protection (long form as used in US)
ISO International Organization for Stand‐
ardization
LC Liquid Crystal Liquid crystal
MAN Manual Operating mode

Abbreviations
G.2 Abbreviations for functional safety
Abbreviation Long form Meaning

NAMUR Standards working group for meas‐ Association of users in process conductor technology
urement and control technology in the
chemicals industry
µC Microcontroller One-Chip computer system
NCS Non-Contacting Sensor Sensor for non-contacting position detection
NEMA National Electrical Manufacturers As‐ US standards institution
sociation National Electrical Manufacturers Association
NPT National Pipe Thread Taper Pipe threading for self-sealing threads as per ANSI B.1.20.1
OPOS interface® Open Positioner Interface Standard interface for the connection between a positioner and
a pneumatic linear or part-turn actuator
PA Process Automation Process automation
PDM Process Device Manager Siemens communication software / Engineering tool
PROFIBUS Process Field Bus Fieldbus
RSS feed Rich Site Summary Feed Shows changes in regular intervals to web sites you are sub‐
scribed to.
VDE Verband der Elektrotechnik, Elektro‐ Industrial and professional association
nik und Informationstechnik e. V.
VDI Verein Deutscher Ingenieure e. V. Technical/scientific association
Abbreviation Full term in English Meaning

FIT Failure in Time Frequency of failure
Number of faults within 109 hours
HFT Hardware Fault Tolerance Hardware fault tolerance:
Capability of a function unit to continue executing a required
function in the presence of faults or deviations.
MooN "M out of N" voting Classification and description of the safety-instrumented system
in terms of redundancy and the selection procedures used.
A safety-instrumented system or part that consists of "N" inde‐
pendent channels. The channels are connected to each other in
such a way that "M" channels are in each case sufficient for the
device to perform the safety instrumented function.
Example:
Pressure measurement: 1oo2 architecture. A safety-instrumen‐
ted system decides that a specified pressure limit has been ex‐
ceeded if one out of two pressure sensors reaches this limit. In a
1oo1 architecture, there is only one pressure sensor.
MTBF Mean Time Between Failures Average period between two failures
MTTR Mean Time To Restoration Average period between the occurrence of a fault in a device or
system and restoration of functionality
PFD Probability of Dangerous Failure on Probability of dangerous failures of a safety function on demand
Demand
PFDAVG Average Probability of Dangerous Fail‐ Average probability of dangerous failures of a safety function on
ure on Demand demand

Abbreviations
Abbreviation Full term in English Meaning

SFF Safe Failure Fraction Proportion of safe failures:
Proportion of failures without the potential to bring the safety-in‐
strumented system into a dangerous or non-permissible func‐
tional status.
SIL Safety Integrity Level The international standard IEC 61508 defines four discrete Safe‐
ty Integrity Levels (SIL 1 to SIL 4). Each level corresponds to a
range of probability for failure of a safety function. The higher the
Safety Integrity Level of the safety-instrumented system, the low‐
er the probability that it will not execute the required safety func‐
tions.
SIS Safety Instrumented System A safety-instrumented system (SIS) executes the safety func‐
tions that are required to achieve or maintain a safe status in a
system. It consists of sensors, logic unit/control system and final
controlling elements.

Abbreviations

Glossary
Actuator
Converter that converts electric signals into mechanical or other non-electric variables.
Actuator chamber
For pneumatic actuators which consist of two pressure chambers in double-acting versions and
of a pressure chamber and a spring chamber in single-acting versions.
Analog
A signal type which represents data using continuously varying, measurable and physical
quantities, e.g. current or voltage. Opposite to digital. The range between 4 and 20 mA is often
used to transfer analog signals.
Analog-to-digital converter
An analog-to-digital converter is an interface between the analog environment and the digitally
working computers. Only then can the computers be used for measurement and control tasks.
Analog-to-digital converters convert analog input signals to digital signals. Analog
measurement data is thus converted into digital information. On the other hand, a digital-to-
analog converter coverts digital information into analog signals.
Asset Management Solution (AMS)

Software package by Emerson Process. The AMS Device Manager, which is somewhat similar
to the PDM, is the most significant part of the package.
ATEX
ATEX is the abbreviation of the French term "Atmosphère explosible". ATEX stands for the two
directives of the European Community in the field of explosion protection: the ATEX product
directive 2014/34/EU and the ATEX operation directive 1999/92/EC.
Auxiliary voltage
Auxiliary voltage is an electric supply or reference voltage that is required by some electric
circuits in addition to the standard supply. The auxiliary voltage can, for example, be specially
stabilized, have a particular level or polarity and/or other properties which are important for the
correct functioning of switch components. Auxiliary voltage is used, for example, with four-wire
systems.

Glossary
Chamber
A largely or completely enclosed cavity in a machine or apparatus.
Conduit piping system

A piping system for the American market, wherein the electric and pneumatic lines are
protected by a casing.
Configuring
See parameter assignment.
Control fitting
A valve consisting of an actuator + control valve + positioner.
Decrement
From the Latin word decrementare, decrease. Decrement is the defined amount of change
when decreasing a variable gradually. IT term that refers to a step-by-step decrease in a
numeric value.→Increment.
The degree of protection of a device indicates the extent of protection. The extent of protection
includes the safety of persons against coming in contact with live or rotating parts, and the
protection of electric resources against the penetration of water, foreign bodies and dust. The
degrees of protection of electric machines are indicated by an abbreviation comprising two
letters and two numbers (e.g. IP55). The degree of protection is coded using the IP code. The
degrees of protection are standardized in DIN EN 60529.
Device category 1
Category 1 devices must be procured such that they ensure an extremely high degree of safety.
Devices in this category must ensure an extremely high degree of safety even for faults that
occur rarely. Even if two faults occur in the device, it should not lead to ignition. Devices in this
category are suitable for use in zone 0 or 20.
Device category 2
Category 2 devices must be procured such that they ensure a high degree of safety. Devices
in this category must ensure the required degree of safety in case of frequent faults or ones that
can be normally expected, e.g. defects in the device, and avoid ignition sources. Devices in this

Glossary
Device category 3
Category 3 devices must be procured such that they ensure a normal degree of safety. Devices
in this category must ensure the required degree of safety in case of frequent faults or ones that
can be normally expected, e.g. defects in the device, and avoid ignition sources. Devices in this
Digital
Representation of a variable in the form of characters or numbers. The functional course of an
originally changeable analog variable is simulated in predefined stages. Predefined values are
assigned to these stages. Opposite to "analog".
EEPROM
EEPROM (Electrically Erasable Programmable Read-Only Memory; literally: elektrisch
löschbarer, programmierbarer Nur-Lese-Speicher in German) is a non-volatile electronic
memory. EEPROMs are often used when individual data bytes change over long time periods
and need to be saved in a manner protected against power failure, e.g. configuration data or
operating hours counters.
Electromagnetic compatibility
Definition as per the EMC law: EMC is the capability of a device to operate satisfactorily in an
electromagnetic environment without itself emitting electromagnetic signals which interfere
with other devices in that environment.
Ex d
"Flameproof enclosure" type of protection. When the potentially explosive mixtures enter the
enclosure of a resource and an ignition source exists in the enclosure. The transfer of the
explosion inside the enclosure to the surrounding space must be ruled out.
● d: flameproof enclosure
Ex ia / Ex ib / Ex ic
If potentially explosive mixtures enter the enclosure of a resource, it should not lead to ignition.
Demarcation of energy and increased temperatures.
Ex n
Equipment containing energy-limiting, non-sparking contacts as well as circuits whose
contacts are supplied with limited energy.
Ex t
Dust ignition protection with "t" enclosure. Dust ignition protection where the electric equipment
has an enclosure providing protection against dust ingress and a measure for limiting the
surface temperature.

Glossary
Factory Mutual
Industrial property insurer and certification agency in the USA. FM Global is one of the largest
industrial insurers in the world who are specialized in the field of technically-supported property
insurance. It offers services like product research, testing and certification.
Firmware
Firmware (FW) is software that is embedded on a chip in electronic devices – in contrast to
software which is saved on hard disks, CD-ROMs or other media. These days, firmware is
mostly stored in a flash memory or an EEPROM. Firmware is software in the hardware, and is
thus an intermediate between software and hardware. Firmware is normally model-specific.
This means that it does not function on other device models and is delivered by the
manufacturing company. The corresponding devices cannot function without the firmware. The
firmware mostly contains elementary functions to control the device, as well as input and output
routines.
Frequency shift keying

ENGLISH: Frequency shift keying (FSK)
Frequency shift keying is a simple modulation format in which digital values 0 and 1 are
represented by two different frequencies.
GSD file
The file that describes the properties of a PROFIBUS DP slave or a PROFINET IO device.
The GSD file is a database file for PROFIBUS devices. The device manufacturer provides the
corresponding GSD file containing the description of device properties. The information in the
file can be read using Engineering Tools.
HART
HART (Highway Addressable Remote Transducer) is a standardized and widely used
communication system for configuring industrial fieldbuses. This communication system
enables digital communication of multiple participants (field devices) using a common data bus.
HART implements the widely used 4/20 mA standard to transfer analog sensor signals.
Existing cables of the old system can be used directly and both systems can be operated
simultaneously. HART specifies several protocol levels in the OSI model. HART enables
transfer of process and diagnostics information and control signals between field devices and
the higher-level control system. Standardized parameter sets can be used for manufacturer-
independent operation of all HART devices.
HART communication
HART devices use the 4 to 20 mA lines for data exchange, and communicate with each other
using the HART protocol. The process enables bidirectional data exchange even in hazardous
environments. With HART communication, digital data from an FSK modem is modulated to the
analog 4 to 20 mA signals. As a result, additional information such as measuring and/or device
data can be transmitted without influencing the analog signals. The FSK modem required for

Glossary
this is installed in the field device or HART communicator. In the case of an operator station, the
connection is made externally via the serial interface. A point-to-point connection is used
between the field and HMI device. In this case, a HART HMI device is connected to exactly one
HART field device. However, further devices can be integrated using a multiplexer.
HART communicator
For parameter assignment with the HART Communicator, the connection is made directly to
the 2-wire cable. For parameter assignment with a laptop or a PC, a HART modem is connected
in between.
Increment
From the Latin word incrementare, increase. Increment is the defined amount of change when
increasing a variable gradually. IT term that refers to a step-by-step increase in a numeric
value.→Decrement.
Initialization
Setting the most important basic parameters. Requirement for commissioning the positioner.
IP code
The abbreviation IP stands for International Protection as per DIN. In English-speaking
countries, IP stands for Ingress Protection.
Microcontroller
Microcontrollers (also µController, µC, MCU) are single-chip computer systems in which almost
all components such as master processor, program memory, working memory and input/output
interfaces are included in a single chip.
NAMUR
Standardization association for measurement and control in chemical industries. NAMUR is an
association of users of process control technology. The members are mainly companies from
German-speaking countries. The association was formed in Leverkusen in 1949.
NEMA
National Electrical Manufacturers Association. NEMA is a standardization institute in the USA.
NEMA was formed in 1926 with the merge of Associated Manufacturers of Electrical Supplies
and the Electric Power Club.

Glossary
Individual parameter settings are specifically changed to adjust the positioner as per the
actuator or other requirements. Parameter assignment is carried out after the complete
commissioning of the positioner.
Piezoelectric effect
Name of a physical phenomenon. Due to mechanical compression loads on a crystal, an
electric potential develops on specific crystal surfaces. In a reverse case, applying an electric
field to specific crystal surfaces leads to crystal deformation.
Potentially explosive atmosphere

Mixture of air, combustible gases, fluff, fibers or dusts.
Pressure chamber
The pneumatic actuators are available in single and double-acting versions. In a single-acting
version, only one pressure chamber is pressurized and depressurized. The pressure
developed works against a spring. In a double-acting version, two pressure chambers work
against each other. Pressurizing the volume of one chamber simultaneously depressurizes the
volume of the other.
Process Device Manager

PDM is a Siemens software package for configuration, parameter assignment, commissioning
and maintenance of network configurations and field devices. Part of SIMATIC STEP 7. Used
for configuration and diagnostics.
Protection level
● ia: Protection level. Electric equipment operating fault-free, and with existence of two
countable errors.
● ib: Protection level. Electric equipment operating fault-free, and with existence of one
countable error.
● ic: Protection level. Electrical equipment is not able to cause an ignition when operating fault-
free.
Protocols
Protocols contain information about data formats, time sequences and error handling when
exchanging data between computers.
A protocol is a convention about establishing, monitoring and terminating a connection.
Different protocols are required for a data connection. Protocols can be assigned to every layer
of the reference model. Transport protocols are used for the lower four layers of the reference
model and higher protocols are used for control, data provision and application.

Glossary
Sensor
Converter that converts mechanical or other non-electric variables into electric signals.
SIMATIC software
Programs for process automation (e.g. PCS 7, WinCC, WinAC, PDM, STEP 7).
Type 4X
according to UL 50E. This standard contains additional requirements relating to the design and
performance of enclosures which are to be used indoors and outdoors.
Zone 0
Area in which potentially explosive atmospheres build up often, regularly or over long durations
during the normal operation of a device.
Zone 1
Area in which potentially explosive atmospheres build up occasionally during the normal
operation of a device.
Zone 2
Area in which a potentially explosive atmosphere normally never builds up or builds up only for
a short while during the normal operation of a device.
Zone 20
Zone 20 is an area in which a potentially explosive atmosphere in the form of a cloud of
combustible dust in air is present continuously, over a long period, or frequently.
Zone 21
Zone 21 is an area in which a potentially explosive atmosphere in the form of a cloud of
combustible dust in air can be occasionally produced during normal operation.
Zone 22
Zone 22 is an area in which a potentially explosive gaseous atmosphere in the form of a cloud
of combustible dust in air never develops or develops only for a short while during normal
operation.

Glossary

Index
Commissioning
Automatically, 119, 125
A Cancel, 129
Interrupting, 119
Accessories, 262
Manual, 121, 127
Actuating pressure
Compensation
Figure, 91
Pneumatic leakage, 140
Position, 28, 92
Compressed air, 38
Adapter, 267
Connecting
Alarm module
Inductive Limit Switches (ILS), 84
see Digital I/O Module (DIO), 83
NCS sensor, 281
Amplifier, (See booster)
Connecting terminals
Analog Input Module (AIM)
Option modules, 28
Figure of ribbon cable, 52
Connection
Installation, 72
Pneumatic, 91, 117
Retrofitting, 273
Construction
Scope of delivery, 267
Technical specifications, 240, 241, 242
Analog Output Module
Control system, 193
Installation, 60
Customer Support, (Refer to Technical support)
Analog Output Module (AOM), 84
Position, 53, 56
Article number
on the nameplate, 26
D
Dead angle function, 151
Diagnostics, 212
B During ongoing operation, 231
Extended, 139, 162
Basic electronics
Digital I/O Module (DIO), 83, 89
Graphic, 29
Installation, 59
Position, 28, 53, 56
Blanking plug
Display
Position, 28
Position, 28
Block circuit diagram, 32
Disposal, 206
Booster, 301
Documentation
Buttons
Edition, 14
Position, 28
Downloads, 269
Dynamic variables, 189
C
Cable gland, 267 E
Position, 28
EMC filter module
Technical specifications, 241
See Analog Input Module (AIM), 72, 89
Carrier, 45, 136
Enclosure, 261
Carrier pin, 120, 122
Exhaust air outlet
Catalog
Position, 28
catalog sheets, 269
Extended diagnostics, 162
Certificates, 19, 269
Parameter, 139
characteristics
External position detection system
Safety, 195
See Position Transmitter, 89
Cleaning, 199

Index
Insulating cover, 53, 68

Internal NCS module
F Commissioning, 118
Installation, 49, 68
Factory setting
Iy module, (See Analog Output Module (AOM))
Reset to ~, 119, 125
Fast closing, 153
Final controlling element, 193
Five-point controller, 23, 31
L
Freezing Laws and directives
Exhaust air outlet, 39, 192 Disassembly, 19
Friction clutch, 23 Personell, 19
Position, 28, 53 Leakage
Set, 116 Pneumatic, 140
Leakage test
Offline, 217
G Linear actuator
Add-on extensions, 23
Gear
Automatic commissioning, 119
switchable, 23
Automatic commissioning (flowchart), 109
Gear latch, 50
Manual commissioning, 121
Pneumatic connection, integrated, 91
Single-acting, 24
H
HART
Modem, 34 M
HART module, 33
Maintenance, 197
HART variables, 189
Manometer
Hazardous area
Mounting, 295
Laws and directives, 19
Qualified personnel, 22
Manuals, 269
History, 14
Material
Hotline, (Refer to Support request)
Mechanic Limit Switches (MLS), 107
Installation, 65, 66
I Position, 52, 56
I/Os Mechanical limit switch module
Technical specifications, 242 See Mechanic Limit Switches (MLS), 65, 107
iNCS See Mechanical Limit Switches (MLS), 66
Installation, 68 Mode of operation, 30, 32
Inductive Limit Switches (ILS) Modifications
Connecting, 84 correct usage, 20
Installation, 63 improper, 20
Position, 52, 56 Module cover
Initialization Position, 52, 56
Automatically, 109 Motherboard, (See basic electronics)
Cancel, 129 Mounting console
Interrupting, 125 Dimensions, 48
Installation Mounting kit
Analog Output Module, 60 Linear actuator, 40
Digital I/O Module (DIO), 59
Mechanic Limit Switches (MLS), 65, 66

Index
Pressure gauge block, 24

Torque, 242
N Printed circuit board, (See basic electronics)
Product name, 26
Nameplate
Purging air selector, 117
Position, 53, 57
Position, 28
Natural gas, 249
Operation, 107
NCS
Installation, 49
Q
NCS module Qualified personnel, 22
Internal, 49
NCS sensor
Connecting to Analog Input Module (AIM), 281 R
Reading initialization parameters, 129
Restrictor
O Position, 28
Offline leakage test, 217 Return procedure, 206
Online diagnostics, 231 Ribbon cable
Operation Figure, 52, 56
Natural gas, 107
Option modules, 261
Installation, 53 S
Order code, 26
Safety position, 93
Ordering supplement, 26
Scope of delivery, 16
Analog Input Module (AIM), 267
Screen
P Cleaning of~, 198
Parameters 1 to 5 Sealing plug
Overview, 135 Technical specifications, 298
Parameters 6 to 51 Service, 270
Overview, 136 Service and support
Parameters A to P Internet, 270
Overview, 140 Settings, 194
Part-turn actuator SIA module
Automatic commissioning, 125 See Inductive Limit Switches (ILS), 62, 84
Automatic commissioning (flowchart), 109 SIL 2, 193
Double-acting, 24 Single-channel operation, 193
Manual commissioning, 127 Slot initiator, (See Inductive Limit Switches (ILS))
Mounting, 45 Sound absorber
Pneumatic actuator, 30 Position, 28
Pneumatic block Special screw
Position, 52, 56 Position, 53
Pneumatic connections, 117 Supply air PZ, 195
Position feedback module Supply pressure
see Analog Output Module (AOM), 56, 84 Position, 28
See Analog Output Module (AOM), 53 Support, 270
Positioner Support request, 270
Replacing, 129 System pressure, (See Supply air)
Potentiometer
Position, 52, 56

Index
T
Technical support, 270
partner, 270
personal contact, 270
Terminal strip, 117
Test certificates, 19
Threaded adapter
Tight closing, 153
Tightening torque
Technical specifications, (Torque)
Torque, 241, 298
Transmission ratio selector, 50
Transmitter, 193
V
Valve block, (See Valve block)
Purging air selector, 117
Version
W
Warning label
Position, 52, 56
Warranty, 17
Weight
Wiring diagram
Position, 28
Wiring diagram on module cover, 53
Y
Y1, 195


5nolu Ibs Vana Pozisyoner - Sipart Ps2

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Introduction 1

Siemens AG Document order number: A5E00074631 Copyright © Siemens AG 2019.

SIPART PS2 with 4 to 20 mA/HART

SIPART PS2 with 4 to 20 mA/HART

5.3.2.2 Integrated pneumatic connection ...........................................................................................91

SIPART PS2 with 4 to 20 mA/HART

8.3.3 Overview of advanced diagnostic parameters A to U ..........................................................139

SIPART PS2 with 4 to 20 mA/HART

9.3 Safety Integrity Level (SIL)...................................................................................................193

SIPART PS2 with 4 to 20 mA/HART

11.2.4.17 Diagnostic value '18.ZERO - Lower endstop'.......................................................................220

SIPART PS2 with 4 to 20 mA/HART

12 Technical data ..........................................................................................................................................239

SIPART PS2 with 4 to 20 mA/HART

B.2.1 Principle of operation of NCS...............................................................................................272

SIPART PS2 with 4 to 20 mA/HART

F.2.2.2 Electrical connection of 19" slide-in module 4 to 20 mA ......................................................314

SIPART PS2 with 4 to 20 mA/HART

SIPART PS2 with 4 to 20 mA/HART

1.2 Scope of documentation

Article no. Product

SIPART PS2 with 4 to 20 mA/HART

1.3 Document history

SIPART PS2 with 4 to 20 mA/HART

1.4 Designated use

1.5 Product compatibility

Manual Comments Device revision Compatible version of device integration package

SIPART PS2 with 4 to 20 mA/HART

Manual Comments Device revision Compatible version of device integration package

1.6 Checking the consignment

1.7 Security information

SIPART PS2 with 4 to 20 mA/HART

1.8 Transportation and storage

1.9 Notes on warranty

SIPART PS2 with 4 to 20 mA/HART

SIPART PS2 with 4 to 20 mA/HART

2.2 Warning symbols on the device

2.3 Laws and directives

SIPART PS2 with 4 to 20 mA/HART

2.4 Conformity with European directives

2.5 Product approval and UL compliance

2.6 Improper device modifications

SIPART PS2 with 4 to 20 mA/HART

2.7 Improper modification on positioner 6DR5...6

2.8 Requirements for special applications

SIPART PS2 with 4 to 20 mA/HART

2.9 Use in hazardous areas

Qualified personnel for hazardous area applications

SIPART PS2 with 4 to 20 mA/HART

3.2.1 Overview of structure

SIPART PS2 with 4 to 20 mA/HART

① Pressure gauge block, single-acting

SIPART PS2 with 4 to 20 mA/HART

① Single-acting positioner in flameproof aluminum enclosure

SIPART PS2 with 4 to 20 mA/HART

3.2.2 Nameplate layout

Example of manufacturer nameplate

 - DIO - ILS - MLS

- NCS X AIM - AOM

- DIO - ILS - MLS

Cl I Zn 1 AEx ib IIC Gb / Cl I Zn 1 Ex ib IIC Gb

: : r

Yoke with ● Four hexagon bolts ⑧

Yoke with col‐ ● Two U–bolts ⑦