The

High
R

Company
Performance
POSITIONERS
SERIES 6A MANUAL
Series 6A

6DR50xx
6DR51xx
6DR52xx
6DR53xx

Edition 03/2006

Manual

Electropneumatic Positioner for

Linear and Part-Turn Actuators

Series 6A Manual
A5E00756809--01 1
License by Siemens AG 2006 All rights reserved Disclaimer of Liability

The reproduction, transmission or use of this docu- We have checked the contents of this manual for
ment or its contents is not permitted without ex- agreement with the hardware and software descri-
press written authority. Offenders will be liable for bed. Since deviations cannot be precluded entirely,
damages. All rights, including rights created by pa- we cannot guarantee full agreement. However, the
tent grant or registration of a utility model or design, data in this manual are reviewed regularly and any
are reserved. necessary corrections included in subsequent edi-
tions. Suggestions for improvement are welcomed.
BRAY Controls
A Devision of BRAY INTERNATIONAL, Inc. e Siemens AG 2006
Houston, Texas 77041 Technical data subject to change.

Series 6A Manual
2 A5E00756809--01
Contents

0 Information for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

0.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
0.2 Classification of Safety Related Notices . . . . . . . . . . . . . . . . . . . . . . . . . 6
0.3 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.4 Use as intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0.5 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0.6 Delivery Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
0.7 Standards and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 General information about the positioner . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Design and Method of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Design Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Instrument Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.4 Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.5 Purge air switching (not in the explosion proof version) . . . . . . . . . . . . 22
2.3.6 Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Method of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 HART-function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 State as supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Options modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.1 Installation of options modules in normal and intrinsically safe versions 27
2.7.2 Installation of options modules in explosion proof version . . . . . . . . . . 29
2.7.3 Iy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7.4 Alarm module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7.5 SIA module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7.6 Mechanical limit switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.7.7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Instrument identification (type key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3.1 Instructions for using positioners in a wet environment . . . . . . . . . . . . . 42
3.3.2 Instructions for using positioners which are exposed to strong accelerations
or vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.3 Mounting kit ”linear actuator” 6DR4004-8V and 6DR4004-8L . . . . . . . 47
3.3.4 Assembly procedure (see figure 3-7, page 49) . . . . . . . . . . . . . . . . . . . . 48
3.3.5 Mounting kit ”part-turn actuator” 6DR4004-8D . . . . . . . . . . . . . . . . . . . . 50
3.3.6 Assembly procedure (see figure 3-8 and figure 3-9) . . . . . . . . . . . . . . . 51
3.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Series 6A Manual
A5E00756809--01 3
 3.4.1 Connection in non-intrinsically safe and explosion proof version . . . . . 57
3.4.2 Connection in intrinsically safe version . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4.3 Connection in type of protection “n” version . . . . . . . . . . . . . . . . . . . . . . 66
3.5 Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.1 Preparations for linear actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.2 Automatic initialization of linear actuator . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.6.3 Manual initialization of linear actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.6.4 Preparations for part-turn actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.6.5 Automatic initialization of part-turn actuator . . . . . . . . . . . . . . . . . . . . . . 77
3.6.6 Manual initialization of part-turn actuators . . . . . . . . . . . . . . . . . . . . . . . . 79
3.6.7 Automatic initialization (structograms) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.7 Copying initialization data (positioner exchange) . . . . . . . . . . . . . . . . . . 85
4 Operation .............................................................. 87
4.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2 Input keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.5 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.5.1 Diagnostic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.5.2 Meaning of the diagnostic values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.5.3 Online-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.5.4 Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.6 Meanings of other display texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.7 Optimization of the control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7 Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.1 Ordering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.2 Scope of delivery of standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3 Scope of delivery of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.4 Scope of delivery of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.5 List of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Series 6A Manual
4 A5E00756809--01
 Information for the Operator

Information for the Operator

0
Dear customer,
Please read this manual before starting work!
It contains important information and data which, when observed,
ensure full availability of the equipment and save service costs. This
simplifies handling of this control instrument considerably and provides
accurate measuring results.

You have purchased an instrument which can be installed in various

configurations:
S Series 6A without Ex-protection in a metal-- or plastic housing.
S Series 6A with EEx ia/ib-protection in a metal-- or plastic housing.
This manual takes each of these possibilities into consideration. Any
differences between the devices are indicated specially.
Scope of delivery, see chapter 7, page 133.

0.1 General information

The product described in this manual left the factory in a perfectly safe
and tested condition. To maintain this condition and to achieve perfect
and reliable operation of this product, it must only be used in the way
described by the manufacturer. Successful and safe operation of this
equipment is dependent on proper handling, installation, operation and
maintenance.
This manual contains the information required for use as intended of
the product it describes. It is addressed to technically qualified
personnel specially trained or having relevant knowledge of instrumen-
tation and control technology, hereafter called automation technology.
Familiarity with and proper technical observance of the safety notes
and warnings contained in this manual are essential for safe installation
and commissioning and for safety in operation and maintenance of the
product described. Only qualified personnel as defined in Chapter 0.3
has the necessary specialist knowledge to interpret the general safety
notes and warnings given in this document in specific cases and to
take the necessary action.

Series 6A Manual
A5E00756809--01 5
Information for the Operator

This manual is not a permanent part of the scope of supply. For

reasons of clarity, it does not contain every detail about every version
of the product described and cannot take every eventuality in installa-
tion, operation, maintenance and use in systems into account. If you
require further information or if problems occur that have not been dealt
with in sufficient detail in this document, please request the required
information from your local Siemens office or the office responsible for
you.
Functionality, commissioning and operation are described in this
manual.
Please pay special attention to the Warning and Note texts. These are
separated from the remaining text by horizontal lines and specially
marked with symbols (see Chapter 0.2).

0.2 Classification of Safety Related Notices

This manual contains notices which you should observe to ensure your
own personal safety, as well as to protect the product and connected
equipment. These notices are highlighted in the manual by a warning
triangle and are marked as follows according to the level of danger:

DANGER
! indicates an immenently hazardous situation which, if not avoided, will
result in death or serious inury.

WARNING
! indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

CAUTION
! used with the safety alert symbol indicates a potentially hazardous si-
tuation which, if not avoided, may result in minor or moderate injury.

CAUTION
used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.

Series 6A Manual
6 A5E00756809--01
 Information for the Operator

NOTICE
indicates a potential situation which, if not avoided, may result in an
undesirable result or state.

. NOTE
highlights important information on the product, using the product, or
part of the documentation that is of particular importance and that will
be of benefit to the user.

0.3 Qualified Personnel

The result of unqualified intervention in the instrument or

nonobservance of the warnings given in this manual or on product
labels can be severe personal injury and/or serious material damage.
Therefore only properly qualified personnel must make changes and
settings in the instrument.
For the purpose of the safety information in this manual and on the
product labels, qualified personnel are those who
S in the case of ex-proof equipment, are trained, instructed or
authorized to perform work on electrical circuits of equipment
subject to explosion hazard.
S if they are configuration personnel, are familiar with the safety
concepts of automation technology
S if they are operating personnel, have been instructed in the handling
of automation equipment and know the content of this manual
relating to operation
S if they are commissioning and/or service personnel, are trained to
repair such automation equipment and authorized to energize,
de-energize, clear ground and tag circuits and equipment according
to safety engineering standards.
S and instructed additionally in first aid

Series 6A Manual
A5E00756809--01 7
Information for the Operator

WARNING
! The instrument must only be installed and commissioned by qualified
personnel.
The device may be used solely for the purposes described in this
manual.
The instrument is designed for connection to functional and safety
extra low voltage.
Electrical safety depends only on the power supply equipment.
Pneumatic actuators exert considerable positioning forces. The safety
precautions of the actuator used must therefore be scrupulously
observed during installation and commissioning in order to prevent
injuries.
We explicitly draw your attention to the necessity of observing safety
regulations regarding operation in zones subject to explosion hazard, if
applicable.
The specifications of the examination certificate valid in your country
must be observed. Laws and regulations valid in your country must be
observed for the electrical installation in explosions hazardous areas.
In Germany these are for example:
-- Working reliability regulations
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079--14 (in the past VDE 0165, T1).
It should be checked whether the available power supply, insofar as
this is required, is compliant with the power supply specified on the
rating plate and specified in the examination certificate valid in your
country.
Take care to avoid electrostatic discharges within the hazardous area,
such as can arise if a dry cloth is used to clean the positioner in the
plastic housing.
Devices with the protection type ”flameproof enclosure” may only be
opened when the power is off.

WARNING
! Devices with the protection type ”intrinsically safe” lose their certifica-
tion as soon as they are operated with circuits that do not conform to
the specifications laid down in the examination certificate valid in your
country.
The successful and safe operation of this equipment is dependent
upon its proper handling, installation, operation and maintenance.

WARNING
! The device may not be operated as long as the quick start guides are
inside the housing.

Series 6A Manual
8 A5E00756809--01
 Information for the Operator

0.4 Use as intended

Use as intended for the purpose of this manual means that this product
must only be used for the applications described in the technical
description (see also Chapter 3 of this manual).
The product described in this manual has been developed, manufac-
tured, tested and documented observing the relevant safety standards.
If the handling rules and safety information for configuration, installa-
tion, use as intended and maintenance are observed, there is normally
no danger with regard to material damage or for the health of
personnel. Extra low voltages that are connected must be fed in by
safe isolation.

0.5 Warranty Information

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

Series 6A Manual
A5E00756809--01 9
Information for the Operator

0.6 Delivery Notes

The scope of delivery is listed on the dispatch papers accompanying

the delivery in accordance with the valid contract of sale.
When you open the packaging please observe the information on the
packaging. Check that the delivery is complete and undamaged. If
possible, compare the order number on the rating plates with the
ordering data.
For the scope of delivery please see Chapter 7, page 133.

0.7 Standards and Regulations

As far as possible, the harmonized European standards were used to

specify and manufacture this equipment. If harmonized European
standards have not been applied, the standards and regulations of the
Federal Republic of Germany apply (see also the Technical Data in
Chapter 6, page 127).
If this product is used outside the area of applicability of these
standards and regulations, please observe the standards and
regulations in force in the country where the product is operated.

Series 6A Manual
10 A5E00756809--01
 Introduction

Introduction
1

1.1 General information about the positioner

The positioner is used to adjust and control pneumatic actuators. The

controller operates electropneumatically with compressed air as an
energy supply.

Purpose For example, the positioner can be used to control valves as follows:
S with linear actuator or
S with part-turn actuator VDI/VDE 3845 (figure 1-1, page 13)
Different mounting types are available for linear actuators:
S NAMUR or IEC 534
S integrated mounting to ARCA
S integrated mounting to SAMSON (non-explosion-proof version)
This means the positioner can be installed and operated on all common
actuator systems.

Versions The positioner is available for the following actuators:

S double-acting and
S single-acting
For following applications:
S potentially explosive or
S not potentially explosive applications.

Housing The electronics with display, position feedback and valve block are
integrated in the housing.
The housing is available in three versions:
S Plastic housing for single and double-acting actuators
S Metal housing for single-acting actuators
S Explosion proof housing for single and double-acting actuators

Series 6A Manual
A5E00756809--01 11
Introduction

Degree of The device is designed with IP65/NEMA4x degree of protection.

protection

Explosion The intrinsically safe version can be used in hazardous areas in zone 1
Protection or zone 2.
The explosion proof version can be used in hazardous areas in zone 1
or zone 2.

SIL applications The SIPART PS2 positioners in the variations 6DR501*, 6DR511*,
6DR521* and 6DR531* (i.e. with 0/4 up to 20 mA control signal in the
single--acting design) are also suitable for positioning on fittings with
pneumatic actuators, which satisfy the special requirements for safety
devices up to SIL 2 to IEC 61508/ IEC 61511--1. For this, the SIL safety
instructions (see ”SIPART PS2 SIL safety manual” A5E00442120) must
be followed.

Options The positioner can be expanded with various options modules (chapter
2.7, page 27). The following modules are available in all:
S Jy-module: Two--wire current output 4 to 20 mA for position feed-
back
S Alarm module: 3 digital outputs and 1 digital input
S SIA module: one digital output for fault messages, two digital out-
puts for limit value alarms

Accessories S Manometer block: 2 or 3 manometers for single and double-

acting positioners
S Connection block (NAMUR) for safety valve block
S Mounting kits for linear and part-turn actuator
For decentralized installation of the positioner and position sensor:
S External position detection system
S Non-Contacting Position Sensor (NCS)

Environmental Only environmentally friendly materials have been used in the

Protection construction of the positioner.
The technical manual is printed on chlorine-free bleached paper.

Series 6A Manual
12 A5E00756809--01
 Introduction

3 1

1 Positioner double-acting in plastic housing

2 Part-turn actuator
3 Manometer block, double-acting

Figure 1-1 Positioner mounted on part-turn actuator (double-acting)

Series 6A Manual
A5E00756809--01 13
Introduction

Series 6A Manual
14 A5E00756809--01
 Design and Functional Principle

Design and Method of Operation

2
The following chapter describes the mechanical and electrical design,
the instrument components and method of operation of the positioner.

2.1 Overview

Introduction The electropneumatic positioner forms a control system in connection

with an actuator. The current position of the actuator is detected by a
servo potentiometer and fed back as actual value x. The setpoint and
actual value are output simultaneously on the display.
The setpoint w is formed by a current fed to the positioner which at the
same time serves to supply the positioner in two-wire operation. In 3 /
4-wire operation the supply comes from a 24 V voltage input.
The positioner operates as a predictive five--point switch by the output
variable ±∆y of which the integrated actuating valves are controlled with
pulse length modulation.
These actuating signals cause fluctuations in pressure in the actuator
chamber(s) and thus adjustment of the actuator until the control error is
zero.
Operation (manual) and configuration (structuring, initialization and pa-
rameterization) is effected by three keys and a display with the housing
cover removed.
The standard controller has one digital input (DI1). This can be configu-
red individually and can be used for blocking the operating modes for
example.
With the Iy option module, the current actuator position can be output
as a two wire signal Iy = 4 to 20 mA.
In addition the actuator can be monitored for two programmable limit
values which respond on exceeding or dropping below the stroke or
angle of rotation.
The limit value alarms are output by the alarm option module which can
monitor and report the function of the positioner and the actuator addi-
tionally through a fault message output. The value of the control diffe-
rence dependent on the travel time is monitored in automatic mode.
The fault signal is always set when the control error cannot be leveled
after a certain time because for example the valve is blocked or the
mains pressure is insufficient. The three digital outputs are implemen-
ted as semiconductor outputs and are error self--reporting, i.e. the out-

Series 6A Manual
A5E00756809--01 15
Design and Functional Principle

puts respond even when the power supply fails or the electronics are
defective.
The actuator can also be blocked or driven to its final positions depen-
ding on the configuration for example by an external event via a digital
input (DI2) on the alarm module.
If you require electrically independent limit value messages from the
standard controller, you will have to use the SIA module with the slot
initiators instead of the alarm module.
Communication with the controller is possible via the optional HART
interface.
To be able to use the positioner with a variety of different part-turn and
linear actuators, it has a friction clutch and switchable gearing.
The switchable gearing allows you to adjust the positioner for small and
large lifts. You can switch using the yellow switch (8, Fig. 2-2) between
33_ (as delivered) and 90_.
The friction clutch (9, Fig. 2-2) allows you to set the working range, par-
ticularly for linear actuators, after installation. You thus do not have to
ensure symmetrical mounting during the installation.
As it is not allowed to open the housing of an explosion--proof version
in a potentially explosive atmosphere, the shaft has an externally fitted,
additional friction clutch (8, Fig. 2-3, page 18).

NOTICE
for the explosion--proof version:
Only adjust the outer friction clutch (8, Fig. 2-3, page 18). The internal
friction clutch (9, Fig. 2-2 page 17) is fixed and, for the explosion--proof
version, must not be adjusted.

Series 6A Manual
16 A5E00756809--01
 Design and Functional Principle

2.2 Design Rating Plate

(1) (9) (8)

(2)
(3)

(4)

(5) (6) (7)

(1) Manufacturer (6) Serial number

(2) Product name (7) Information address
(3) Order number (8) Protection class
(4) Technical data (9) Observe manual
(5) Place of manufacture

Figure 2-1 Design rating plate, example with protection class EEx ia/ib

2.3 Instrument Components

14 3

15

2W 3/4 W 90°
33 O

2
4...20 mA

0/4...20 mA

1
13

DI1
O
90

4
33°

12

6.1 6.2
11 10 9 8 7 6 5

1 Input: Supply air 8 Transmission ratio selector

2 Output: Actuating pressure Y1 9 Adjusting wheel for frichtion clutch
3 Display 10 Motherboard
4 Output: Actuating pressure Y2 *) 11 Terminals options modules
5 Operating keys 12 Dummy plug
6 Restrictor 13 Screw--type cable gland
6.1 Restrictor Y1 14 Terminal plate on cover
6.2 Restrictor Y2 *) 15 Purging air switch
7 Silencer
*) in double--acting actuators

Figure 2-2 View of the positioner in normal version (cover open)

Series 6A Manual
A5E00756809--01 17
Design and Functional Principle

9 3 6.1 2 1 12 7

138
9
10

238
--
+

10 5 6.2 4 8

1 Input: Supply air 7 Transmission ratio selector

2 Output: Actuating pressure Y1 (only possible with positioner open)
3 Display 8 Adjusting wheel for friction clutch
4 Output: Actuating pressure Y2 *) 9 Terminals standard controller
5 Operating keys 10 Terminals options modules
6.1 Restrictor Y1 12 Safety catch
6.2 Restrictor Y2 *)
*) in double--acting actuators

Figure 2-3 View of the explosion proof version of the positioner

2.3.1 Motherboard

The motherboard contains all the electronic elements such as the CPU,
memory, A/D converter. It also contains the display and the operating
keys.
In addition, the terminal strips for connecting the options modules are
also on the motherboard.

2.3.2 Electrical Connections

The terminals of the standard controller, the Iy and alarm-option module

are arranged at the left--hand front edges and offset against each other
in staircase form.
A module cover protects the modules from being pulled out and pre-
vents incorrect installation.

Series 6A Manual
18 A5E00756809--01
 Design and Functional Principle

2.3.3 Pneumatic Connections

The pneumatic connections are on the right hand side of the positioner
(figure 2-4 and figure 2-5).

2
3

1 Actuating pressure Y1 in single-- and double--acting actuators

2 Feedback shaft
3 Supply air Pz
4 Actuating pressure Y2 in double--acting actuators
5 Exhaust air output E with silencer on the bottom of the instrument

Figure 2-4 Pneumatic connection in normal version

2
3

1 Restrictor Y2 *) 5 Actuating pressure Y1

2 Restrictor Y1 6 Exhaust air output E
3 Actuating pressure Y2 *) 7 Housing ventilation (2x)
4 Supply air PZ
*) in double--acting actuators

Figure 2-5 Pneumatic connection in explosion proof version

In addition, there are pneumatic connections on the back of the positio-

ner for integrated installation in single--acting linear actuators.
S Actuating pressure Y1
S Exhaust air output E (not in explosion proof version)
In the ex--factory state, these connections are sealed by screws (see
figure 3-1, page 39, figure 3-3, page 40 and figure 3-4, page 41).
The exhaust air output E can be provided for supplying dry instrument
air to the tapping chamber and spring chamber to prevent corrosion.

Series 6A Manual
A5E00756809--01 19
Design and Functional Principle

Figure 2-6, page 21 shows the pneumatic connection variants for the
different actuator types, the positioning action and the safety position
after power failure.

Series 6A Manual
20 A5E00756809--01
 Design and Functional Principle

Positioning Safety position after power failure

pressure Actuator type
Connection electrical pneumatic
In part-turn actuators the
direction of rotation
counterclockwise looking
Y1 onto the actuating shaft of
Closed Closed the valve is usually defined
as ”Open”.
Closed Open

Y1

Open Open
Open
Closed

Y2

Open Closed Open

Y1
Closed Open Last position
(before power
Y1 failure)

Closed
Y2

Closed Open

Y1 up

down
Down Down

Y1

up

down
Up Up

Y2
Y1 up

down
Up

up down
Last position
(before power
Y1 failure)
Y2 up
Down
down

Figure 2-6 Pneumatic connection positioning

2.3.4 Mounting Kit

The positioner can be mounted on almost all actuators with the appro-
priate mounting kit.

Series 6A Manual
A5E00756809--01 21
Design and Functional Principle

2.3.5 Purge air switching (not in the explosion proof version)

The purge air switch is accessible above the pneumatic terminal strip
with the housing open (figure 2-7). In the IN position the inside of the
housing is purged with very small amounts of clean, dry instrument air.
In the OUT position the purge air is fed directly to the outside air.

Figure 2-7 Purge air switch on the valve block, view of the positioner onto pneumatic connection side
with cover open

2.3.6 Restrictors

In order to achieve travel times of > 1.5 s in small actuators, the air rate
can be reduced with the restrictors Y1 and Y2 (figure 2-8, in explosion
proof version, see figure 2-5, page 19). By turning to the right the air
rate is reduced up to shutting off. To set the restrictors it is advisable to
close them and then open them slowly (see initialization RUN3).
In the case of double-acting valves make sure that both chokes are set
approximately equal.

Hexagon socket 2.5 mm

Y1 Y2

Figure 2-8 Restrictors

2.4 Method of Operation

The electropneumatic positioner forms a control circuit with the

pneumatic actuator in which the actual value x is the position of the
actuator bar in linear actuators or the position of the actuator shaft in
part-turn actuators and the command variable w is the actuating current
of a controller or a manual control station of 4 to 20 mA.

Series 6A Manual
22 A5E00756809--01
 Design and Functional Principle

The stroke or part-turn movement of the actuator is transferred by the

appropriate mounting accessories, the feedback shaft and a play--free
switchable gearwheel to a high quality conductive plastic potentiometer
and to the analog input of the microcontroller.
This may correct the angle error of the stroke tap, compares the
potemtiometer voltage as actual value x with the setpoint w fed in at
the terminals 3 and 7 and calculates the manipulated variable
increments Δy. Depending on the size and direction of the control
error (x-w) the piezo--controlled supply air or exhaust air valve is
opened. The volume of the actuator integrates the positioning
increments to actuating pressure y open which moves the actuator bar
or actuator shaft approximately proportionally. These positioning
increments change the actuating pressure until the control error
becomes zero.
The pneumatic actuators are available in single and double-acting
versions. Only one pressure chamber is aerated or deaerated in the
single-acting version. The resulting pressure operates against a spring.
In the double-acting version, two pressure chambers are counteractive.
In this case the one volume is deaerated when the other volume is
aerated. See the block diagram figure 2-10, page 25.
The control algorithm is an adaptive predictive five--point switch (see
figure 2-9, page 24).
The valves are controlled with continuous contact at large control errors
(fast step zone). At medium control errors the valve is controlled by
pulse length modulated pulses (short step zone).
No actuating pulses are output in the small control error zone (adaptive
dead zone). The dead zone adaptation and the continuous adaptation
of the minimum pulse lengths in automatic operation cause the best
possible control accuracy to be achieved at the lowest switching fre-
quency. The start parameters are determined during the initialization
phase and stored in a non--volatile memory. These are basically the
real travel with the mechanical limit stops, the travel times, the size of
the dead zone etc.
In addition the number of fault messages, changes in direction and the
number of strokes are determined and stored every 15 minutes during
operation. These parameters can be read out and documented by the
communication programs such as PDM and AMS. Conclusions as to
the wear on the fitting can be drawn (diagnostic function) especially by
comparing the old value with the currently determined values.
Figure 2-10, page 25 shows the block diagrams for single-- and
double--acting actuators with the linear actuator as an example.

Series 6A Manual
A5E00756809--01 23
Design and Functional Principle

. NOTE
The exhaust air valve is always open when there is no current.

Figure 2-9 Method of operation five--point switch

Series 6A Manual
24 A5E00756809--01
 Design and Functional Principle

1
HART
2 3
Supply
Zuluft air
BE1 _ y
3V
pZ
_ + y
+
I W+
Exhaust
Abluft air
+24 V
+5 V p1
p1
W A
D p2
Micro-
I W- controller p2
A
y0 D
+U
Abluft
Exhaust
+ _ air

W
4
x0 x
U
U
I
6
5
BE2 A1 A2

I I

8 9

7 p2

A1 A2 p1 p1
stroke
stroke

1 Motherboard with microcontroller and input circuit

2 Control panel with LC-display and momentary action switch
3 Piezo--valve unit, always built--in
4 Valve unit with double-acting positioner always built--in
5 Iy-module for electro-pneumatic positioner
6 Alarm module for three alarm outputs and one digital input
7 SIA-module (Slot Initiator-Alarm-module)
8 Spring--loaded pneumatic actuator (single-acting)
9 Spring--loaded pneumatic actuator (double-acting)

Figure 2-10 Block diagram of the electro-pneumatic positioner, functional diagram

. NOTE
Alarm module (6) and SIA module (7) can only be used alternatively.

Series 6A Manual
A5E00756809--01 25
Design and Functional Principle

2.5 HART-function

Function The positioner is also available with built--in HART-functions. The

HART protocol allows you to communicate with your instrument with a
handheld communicatorR, PC or programming unit. This enables you
to configure your instrument comfortably, save configurations, call dia-
gnostic data, display online measured values and much more. Commu-
nication takes place as frequency modulation over the existing signal
lines for the command variable from 4 to 20 mA.
The SPART PS2 is integrated in the following parameterization tools:
S Handheld communicatorR
S PDM (Process Device Manager)
S AMS (Asset Management System)
S Cornerstone (without diagnostic values/--functions)

. NOTE
Operation on the positioner has priority over the settings via the HART
intetrface.
Communication is aborted by a power failure at the positioner.

2.6 State as supplied

There are no mechanical mounting accessories on the controller in the

state as supplied. These must be ordered and installed according to
the “operating instructions” depending on the application.
The respective connections for single or double-acting versions are
prepared at the factory as ordered.
The pneumatic connections on the rear are sealed.

Series 6A Manual
26 A5E00756809--01
 Design and Functional Principle

2.7 Options modules

2.7.1 Installation of options modules in normal and intrinsically safe

versions

The following option modules are available for the positioner in the
standard and the intrinsically safe version:
-- Iy module
-- Alarm module
-- SIA module
-- Mechanical limit switch module
-- EMC filter module

Installation The option modules are secured by a assembly covering ((1), see fi-
gure 2-11, page 28) and mechanically fixed.

. NOTE
The housing must be opened to install the options modules. The
degree of protection IP65 is not guaranteed as long as the positioner is
open.

Opening the To open the positioner, the four screws of the housing cover must be
instrument loosened with a Phillips screwdriver.
Disconnect or isolate the power supply cables.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.

. NOTE
To prevent premature wearing of the fixture by the self--tapping screws
(1.1), the following method of mounting the module cover (1) has
proven effective.
1. Turn the screws counterclockwise until you feel them snap into the
thread
2. Tighten both screws carefully in clockwise direction

Series 6A Manual
A5E00756809--01 27
Design and Functional Principle

6 1 1.1

2.1

1.1 2.1

12

10

4
7 11

7.1 7.2 7.3 8 9

1 Module cover 7 SIA-module and mechanical limit switch module

1.1 Fixing screws 7.1 Special screw
2 Motherboard 7.2 Actuating disc for A1 (terminals 41 and 42)
2.1 Fixing screws 7.3 Actuating disc for A2 (terminals 51 and 52)
3 Iy-module with ribbon cable (6) 8 Adjusting wheel for friction clutch
4 Alarm module with ribbon cable (5) 9 Transmission ratio selector
5 Ribbon cable for alarm module 10 Insulating cover
6 Ribbon cable for Iy-module 11 Valve block
12 Actuating disc bearings

Figure 2-11 Installation of Options Modules

Series 6A Manual
28 A5E00756809--01
 Design and Functional Principle

2.7.2 Installation of options modules in explosion proof version

The following option modules are available for the positioner in the
explosion--proof version:
-- Iy module
-- Alarm module

Installation The options modules are protected and mechanically fixed by a module
cover ((1), see figure 2-12, page 31).

. NOTE
The housing must be opened to install the options modules. The
degree of protection IP65/NEMA4x is not guaranteed as long as the
positioner is open.

WARNING
! In areas in which the atmosphere may be potentially explosive, the
explosion--proof positioner may only be supplied with electrical
auxiliary power when the housing is closed and when built--in,
approved electronics are used.
The feed--though openings for the electronic connections must be
sealed with EEX-d certified cable glands or EEx-d certified plugs or an
ignition lock must be mounted at a maximum distance of 46 cm
(18 inches) when using the “conduit”--system.

Open the positio- See figure 2-12, page 31. Disconnect or isolate the power supply ca-
ner bles first.
To open the positioner, the safety catch (12) must be opened and the
screw--on cover unscrewed.
After loosening the four fixing screws (13.1) the complete rack (13) can
be removed. The actuator may have to be turned so that the clutch can
be easily disengaged.
Remove the module cover (1). To do this, the two screws (1.1) must be
removed with a screwdriver.

Series 6A Manual
A5E00756809--01 29
Design and Functional Principle

. NOTE
To prevent premature wearing of the fixture by the self--tapping screw
(1.1) next to the display, the following method of mounting the module
cover (1) has proven effective.
1. Turn the screws counterclockwise until you feel them snap into the
thread.
2. Tighten both screws carefully in clockwise direction.

Series 6A Manual
30 A5E00756809--01
 Design and Functional Principle

1.1

1
13.1

1.1
2

11
4
3

12
10

13.1 7 5 6
13

1 Module cover 7 Transmission ratio selector

1.1 Fixing screws 8 Adjusting wheel for friction clutch
2 PA module 10 Housing
3 Iy module with ribbon cable 11 Screw--on cover
4 Alarm module with ribbon cable 12 Safety catch
5 Ribbon cable for alarm module 13 Rack
6 Ribbon cable for Iy module 13.1 Fixing screws

Figure 2-12 Installation of the options modules in the explosion proof version

2.7.3 Iy module

Function With the Iy-option module, the current actuator position can be output
as a two wire signal Iy = 4 to 20 mA – potentially isolated from the
standard controller. The dynamic control of the Iy module makes it also
error self--reporting.

Series 6A Manual
A5E00756809--01 31
Design and Functional Principle

Installation The Iy module (3) is pushed in to the bottom compartment of the mo-
dule rack up to the stop and connected by the enclosed 6-wire ribbon
cable (6) to the motherboard (see figure 2-11, page 28).

2.7.4 Alarm module

The alarm module contains

S 3 digital outputs and
S 1 digital input

Function The digital outputs serve to output fault messages and alarms. The
configuration is described in chapter 4.4, page 94, with the parameters
44 to 54.
By an external signal applied at digital input (DI2) the actuator can be
blocked or driven to its limit positions for example depending on the
configuration. The configuration is described in chapter 4.4, page 94,
with the parameters 43.
The alarm module is available in two versions:
S explosion protected for connecting to switching amplifier DIN 19234
S non--explosion protected for connection to voltage sources with a
maximum 35 V
The semiconductor outputs of the alarm module report an alarm (signal
state Low) by switching off with high resistance. They are conductive in
the High state (without alarm). The dynamic control makes them error
self--reporting.
The outputs are potentially isolated from the basic circuit and each
other.
The digital input is double.
S one potential isolated for voltage level
S one not potential isolated for floating contacts
These two inputs are designed as logic OR links.

Installation The alarm module (4) is pushed in underneath the motherboard into the
module rack up to the stop and connected by the enclosed 8-wire rib-
bon cable (5) to the motherboard (see figure 2-11, page 28).

Series 6A Manual
32 A5E00756809--01
 Design and Functional Principle

2.7.5 SIA module

The SIA module contains three digital outputs.

Function A collected fault message (see alarme module) is output via a digita-
loutput. The floating digital output is implemented as a self error repor-
ting semiconductor output.
The other two digital outputs are used for reporting two mechanically
adjustable limit values (L1, L2) by slot initiators. The two binary outputs
are electrically independent of the rest of the electronics.

Installation (Slot Initiator Alarm module) Proceed as follows for installation:

1. Remove all the electrical connections from the motherboard (2).
2. Loosen the two fixing screws (2.1) of the motherboard.
3. Snap out the motherboard by carefully bending the four holders.
4. Insert the SIA-module (7) from above up to the top pcb rail of the
container.
5. Push the SIA module in the pcb rail of the container about 3 mm to
the right.
6. Screw the special screw (7.1) through the SIA module into the axle
of the positioner (Torque: 2 Nm):

CAUTION
The pin pressed into the actuating disc bearing (12) must be adjusted
to just before touching with the special screw. The actuating disc bea-
ring and the special screw must then be turned simultaneously so that
the pins slot into the special screw.

7. Place the insulating cover (10) over the SIA module underneath
the surface of the motherboard at the container wall on one side.
The recesses in the insulating cover must slot into the correspon-
ding lugs on the container wall. Place the insulating cover on the
SIA module by carefully bending the container walls.
8. Snap the motherboard into the four holders and screw it tight again
with the two fixing screws (2.1).
9. Make all the electrical connections between the motherboard and
the options with the ribbon cables provided and between the mo-
therboard and potentiometers with the potentiometer cable.
10. Fix the enclosed module cover instead of the standard version with
the two screws (1.1).

Series 6A Manual
A5E00756809--01 33
Design and Functional Principle

11. Select the plates which already exist on the standard version of the
module cover from the set of plates enclosed. Stick the selected
plates according to the standard version to the mounted module
cover. In the case of the version which doesn’t feature explosion
protection, stick the warning sign (figure 2) onto the side of the
ground plate opposite the typeplate.
12. Make the electrical connections.

Setting the two limit values:

. NOTE
Connect a suitable display instrument such as the Initiator--Tester type
2/Ex made by Peperl+Fuchs to the terminals 41 and 42 or terminals 51
and 52 of the SIA module to be able to see the switching state of the
slot initiators.

13. Drive the actuator to the first desired mechanical position.

14. Adjust the top actuating disc (7.2) by hand until the output signal
on terminals 41 and 42 changes.
15. Drive the actuator to the second desired mechanical position.
16. Adjust the bottom actuating disc (7.3) by hand until the output si-
gnal on terminals 51 and 52 changes.

. NOTE
If you turn the actuating disc beyond the switching point up to the next
switching point, you can set a high-low or a low-high change.
To avoid the actuating discs being accidentally adjusted during opera-
ting, they are relatively sluggish. The following remedy might be of help
if you are having trouble with the adjustment: open and close the ac-
tuator several times while holding the actuating discs. This temporarily
reduces the friction. This allows an easier and finer adjustment.

2.7.6 Mechanical limit switch module

The mechanical limit switch module contains the following:

S A binary output for the output of a group error message)
S Two switches for signaling two limit values that can be set mechani-
cally. These two switches are electrically independent from the rest
of the electronic system

Series 6A Manual
34 A5E00756809--01
 Design and Functional Principle

Installation The installation has to be carried as follows (figure 2-11, page 28):

WARNING
! When the mechanical limit switch module is run with AC > 16 V or
DC > 35 V (low voltage), the housing must be protected against
mechanical actions of > 1 Joule, since otherwise the proper functioning
of the IP66 protective system is not guaranteed.

DANGER
! When the module is supplied with low voltage, you must observe the
basic safety rules before beginning work on the device, such as:
1. Deenergizing the module by disconnecting it via the disconnecting
device located directly upstream from the module
2. Securing it against being turned on again
3. Ensuring that the module is disconnected from the voltage supply

CAUTION
The following maximal values only refer to the clamps 41 and 42 as
well as the clamps 51 and 52.
Maximal voltage (not Ex) AV 250 V or DC 24 V
Maximal current (not Ex) AC/DC 4 A
Maximal voltage (Ex) DC 30 V
Maximal current (Ex) DC 100 mA
When you supply one circuit breaker with extra--low voltage (AC
< 16 V or DC < 35 V) and the other with low voltage, you ensure that
the cable insulation is doubled.
When operating the switch with low voltage, you must position the low
voltage circuits so that they are separated from the extra--low voltage
circuits.

Follow the instructions below for installation:

1. Remove all electrical connections on the motherboard (2).
2. Loosen carefully both fixing screws (2.1) for the motherboard.
3. Snap put the motherboard (2) by carefully bending the four
holders.
4. Insert the limit switch module (7) from above until it reaches the
upper printed circuit board rail of the container.
5. Push the mechanical limit switch module (7) in the printed circuit
board rail of the container ca. 3 mm towards the right
6. Screw the special screw (7.1) through the mechanical limit switch
module into the axle of the positioner (torque: 2 Nm).

Series 6A Manual
A5E00756809--01 35
Design and Functional Principle

CAUTION
The pin pressed into the actuating disc bearing (12) must be adju-
sted just before it touches the special screw (7.1) In order that the
pin slot into the special screw, you must then turn the actuating
disc bearing and the special screw simultaneously

7. Place the insulating cover (10) over the mechanical limit switch
module underneath the surface of the motherboard onto the con-
tainer on the wall. The recesses in the insulating cover must slot
into the corresponding lugs on the container wall. Place the insula-
ting cover on the mechanical limit switch module by carefully ben-
ding the container walls.
8. Snap the motherboard board into the four holders and screw it tight
again with the two fixing screws (2.1).
9. Make sure all electrical connections between the motherboard and
the options using the ribbon cables provided and between the mo-
therboard and potentiometer using the potentiometer cable.
10. Fix the enclosed module cover (1) instead of the standard version
using the two screws (1.1).

. NOTE
To prevent premature wearing of the fixture by the self--tapping screws
(1.1), the following method of mounting the module cover (1) has pro-
ven effective:
S Turn the screws counterclockwise until you feel them snap into the
thread.
S Tighten both screws carefully in a clockwise direction

. NOTE
Before connecting up the limit contact module, ensure that:
S only qualified personnel connect and set the limit contact module.
S all cables are de--energized.
S the cables are stripped so that the insulation is flush with the termi-
nal when plugging in the wires.
S the ends of stranded wires have sleeves
S the connection cables are insulated according to the permitted cur-
rent load.
S the permissible working temperature of the cables exceeds the ma-
ximal ambient temperature by minimum 25 _C.
S the Ex--version is only allowed to be operated in intrinsically safe
circuits with approved switching amplifiers.

Series 6A Manual
36 A5E00756809--01
 Design and Functional Principle

Connection
1. Loosen the screw (1) on the cover (2).
2. Push the cover (2) till it reaches the front stop.
3. Screw each cable tight in the appropriate terminal.
4. Push the cover (2) till it stops at the motherboard.
5. Tighten the screw (1) of the cover (2).
6. Fix the cables of each switch in pairs on the mounting eye using
the cable binders provided (3).

Figure 2-13 Cable connection

Setting the two limit values:

1. Drive the actuator to the first desired mechanical position.
2. Adjust the top actuating disc (7.2) by hand until the output signal
on terminals 41 and 42 changes.
3. Drive the actuator to the second desired mechanical position.
4. Adjust the bottom actuating disc (7.3) by hand until the output si-
gnal on terminals 51 and 52 changes.

. NOTE
To avoid the actuating discs (7.2/7.3) being accidentally adjusted du-
ring operation, they are relatively sluggish. The following remedy might
be of help if you are having trouble with the adjustment: open and
close the actuator several times while holding the actuating discs. This
temporarily reduces the friction. This allows an easier and finer adjust-
ment.

Series 6A Manual
A5E00756809--01 37
Design and Functional Principle

2.7.7 Accessories

Y1

Y1
PZ

PZ Y2

Figure 2-14 Manometer block (left for single-acting, right for double-acting actuators)

Manometer block The manometer block for single-acting actuator contains two
manometers which are screwed to the lateral pneumatic connection of
the positioner with O-rings. The values for the input pressure (supply
air PZ) and output pressure (actuating pressure Y1) are displayed.
The manometer block for double-acting actuators contains three
manometers which are screwed to the lateral pneumatic connection of
the positioner with O-rings. The values for the input pressure (supply
air PZ) and output pressure (actuating pressure Y1 and Y2) are
displayed.

Series 6A Manual
38 A5E00756809--01
 Preparing for Operation

Preparing for Operation

3
This chapter describes all the preparations necessary for operating the
positioner.

3.1 Instrument identification (type key)

The order number of the positioner is printed on the rating plate and on
the packaging. Compare this with the order number in chapter 7.2,
page 136.
Installation of any modules required is described in chapter 2.7,
page 27 of this technical manual.

3.2 Dimensional drawings

60
50 x 4 x M6 Y1
29,5
7
2

Y1
65

E 33 PZ
37
80

95

72
29,5

Y2
48

9 deep
M8, 9 deep
29

23
All air connections 11,2
58 G 1/4 or 1/4” NPT
182

M20 x 1.5 or NPT-adapter

13,5
96,6

8
h9

1
15

7 14,5

38,5
88,5

Figure 3-1 Dimensional drawing version plastic housing 6DR5xx0

Series 6A Manual
A5E00756809--01 39
Preparing for Operation

90

79.5
3x 50
G 1/4 or
20.5

9.5
1/4” NPT

14

9
25
12
2xM6
29.5
58.75

82
M4
Thread depth 5.5
10

3.5
5

5
5.3
9.5

Figure 3-2 Dimensional drawing terminal strip for plastic housing

12
6.5
Y1
50 x 4 x M6
9 deep

29.5
Y1
2

84
29
65

29,5

59
7

E
34.5

27.5

14

M8, 9 deep
PZ
23
58 All air connections
G 1/4 or 1/4” NPT 11.2
182

M20 x 1.5 or NPT-adapter

13.5
96.5

8
h9

1
15

7 14.5

38.5
88.5

Figure 3-3 Dimensional drawing version metal housing 6DR5xx1

Series 6A Manual
40 A5E00756809--01
 Preparing for Operation

23 All air connections

M8, 14 deep (4x) G1/4 or 1/4”NPT

10.25
E

33.5
12

25
43

7
65

33.5
34

4.5
7.75

19,25
50
M6, 11 deep (4x)
1)
M6, 8 deep (2x)

∅
60 87.2
M20, M25 or 7.5 25.7 14,3
1/ ”NPT (2x)
2
129.5
3.5
1) Connection 238/Y2 only in
double action version

158.5
∅ 136.5

82,5

235,3
∅ 8 h9

Figure 3-4 Dimensional drawing for positioner with metal housing in explosion proof
version 6DR5xx5

3.3 Assembly

General

WARNING
! To avoid injury or mechanical damage to the positioner/mounting kit,
the following order must be observed for assembly:
1. Mechanical fitting of positioner this chapter
2. Connection of electric power supply see chapter 3.4, p. 55
3. Connection of pneumatic power supply see chapter 3.5, p. 69
4. Put into operation see chapter 3.6, p. 70
Please also observe the warning on page 56!

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. NOTE
The positioner will be equipped at the factory and delivered complete
with the necessary options at the customer’s request. Options modules
may only be retrofitted by our service technicians.
The positioner must be assembled – especially in a moist environment
– in such a way as to rule out freezing of the positioner axle at low
ambient temperature.
The operating keys must be covered to prevent liquid getting in.

WARNING
! In the combination of components it must be ensured that only
positioners and options modules are combined which are approved for
the respective area of application. This applies especially for safe
operation of the positioner in areas in which the atmosphere is
potentially explosive (zone 1 and 2). The instrument categories (2 and
3) of the instrument itself and those of its options must be observed.

In addition, you must always make sure that no water gets into an open
housing or screw--type gland. This may be the case for example when
the positioner cannot be finally assembled and connected immediately.
It generally applies that the positioner may only be operated with dry
compressed air. Therefore use the normal water traps. An additional
drying unit may even be necessary in extreme cases. This is
particularly important when operating the positioner at low ambient
temperatures. Please set the purge air switch (on the valve block
above the pneumatic terminals) additionally to the “OUT” position.
Use a sufficiently rugged console (e.g. plate thickness > 4 mm with
reinforcements) for part-turn actuators and the mounting kit “linear
actuator” or integrated connection for linear actuators.

3.3.1 Instructions for using positioners in a wet environment

This information gives you important instructions for the assembly and
operation of the positioner in a wet environment (frequent, heavy rain
and/or prolonged tropical condensation) in which the IP65 degree of
protection is no longer sufficient and especially when there is a danger
that water may freeze.
To prevent water getting into the instrument in normal operation (e.g.
through the exhaust air openings) or the display being poorly legible,
please avoid the unfavorable installation positions illustrated in
figure 3-5.

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Figure 3-5 Favorable and unfavorable installation positions

If conditions oblige you to operate the positioner in a unfavorable

installation position, you can take additional precautionary measures to
prevent penetration by water.

. NOTE
Never clean the positioner with a high pressure water jet because the
IP65 degree of protection is inadequate protection for this.

The necessary additional measures to prevent penetration by water

depend on the installation position chosen and you may additionally
require:
S screw--type gland with sealing ring (e.g. FESTO: CK –1 / 4–PK–6)
S plastic hose approx. 20 to 30 cm (e.g. FESTO PUN-- 8X1,25 SW)
S cable straps (number and length depends on local conditions)

Procedure
S Connect the pipes in such a way that rain water which runs along
the pipes can drip off before it reaches the terminal strip of the posi-
tioner.
S Check the electrical connections for perfect firm contact.
S Check the seal in the housing cover for damage and contamination.
Clean and replace if necessary.
S Mount the positioner if possible so that the sinter bronze silencer
faces downwards on the underside of the housing (vertical installa-
tion position). If this is not possible, the silencer should be replaced
by a suitable screw--type gland with a plastic hose.

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Assembly of the screw--type gland with plastic hose

S Unscrew the sinter bronze silencer from the exhaust air opening on
the underside of the housing.
S Screw the screw--type gland mentioned above into the exhaust air
opening.
S Mount the above mentioned plastic hose on the screw--type gland
and check the good fit.
S Fix the plastic hose with a cable strap to the fitting so that the
opening faces downwards.
S Make sure that the hose has no kinks and the exhaust air can flow
out unhindered.

3.3.2 Instructions for using positioners which are exposed to strong

accelerations or vibrations

NOTICE
for explosion--proof versions:
Only adjust the outer friction clutch (8, Fig.2-12, page 31). The internal
friction clutch (8, Fig.2-11 page 28 ) is fixed and, for the
explosion--proof version, must not be adjusted.

The electro--pneumatic positioner has a friction clutch and switchable

gearing and can thus be used universally for part-turn and linear actua-
tors. This means that, for part-turn actuators you don’t have to worry
about the zero point and for linear actuators, you don’t have to worry
about symmetrical mounting, as you can adjust the working range after
installation, with the help of the friction clutch. The switchable gearing
allows you to also adjust the positioner for small or large lifts.
Occasionally it can happen, that in the rough environment of process
systems (e.g. due to incorrectly fitted valves or if ”steam pulses” occur)
that the shaft to monitor the position of the positioner is exposed to ex-
treme acceleration, which far exceeds its specified load limits, and
which could result in an unwanted shift in the friction clutch or in the
gears in the position monitoring jumping briefly out.
For cases like this, as standard, the positioner is fitted with a locking
device for the friction clutch and you can also lock the setting of the
transmission ratio selector. This means that an unwanted change to the
position monitoring due to the above mentioned effects can be reliably
prevented.
Both of these locking options are labeled via additional tags inside the
device (see Figure 3-6, page 45). Note that these locks are only requi-
red if extreme acceleration or strong vibration might be present within
your process.

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Procedure After you have installed the positioner and put it fully into operation, you
can set the torque for the friction clutch as follows:
S On the module cover, insert an ordinary 4 mm wide screwdriver into
a slot on the yellow wheel.
S Now use the screwdriver to move the yellow wheel to the left, until
you can feel that it clicks in. This increases the torque of the friction
clutch.
S You can recognize a locked friction clutch by an approx. 1 mm wide
gap between the yellow and black wheels.
S If you have to set the zero pint e.g. after exchanging the actuator,
first reduce the torque by turning the yellow wheel to the right until
you hit the stop. After setting the zero point, you can refix the friction
clutch as described above.
Starting from the neutral setting (as delivered), you can lock the trans-
mission ratio selector as follows:
S Adjust the yellow wheel underneath the terminals with an ordinary
4 mm wide screwdriver to correspond to the setting that you would
like (33_ or 90_), turning to the left or right, until you can feel that it
clicks in.
S Please note that you can only adjust the transmission ratio selector
after releasing the fixing.
For this reason you first have to put the yellow ring into the neutral
position, if you have to adjust the transmission ratio selector e.g.
after exchanging the actuator).

(2)

90_
(3)
(1) 90
33

33_
(4)

(1) Transmission ratio selector interlock

(2) Open
(3) Friction clutch
(4) Close

Figure 3-6 Locking and fixing mechanisms

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External position Applications in which the measures described above are inadequate
displacement are also conceivable. This applies for instance with continuous and
sensor heavy vibration, increased or too low ambient temperatures and in the
case of nuclear radiation.
The separate attachment of position displacement sensor and
controller unit can help here. A universal component is available which
is suitable both for linear and part-turn actuators.

You require the following:

S The external position detection system (order no. C73451-

A430-D78). This consists of a positioner housing with integrated
friction clutch, built-in potentiometer and various dummy plugs and
seals.
S or a Non-Contacting Position Sensor (e.g. 6DR4004--6N)
S The controller unit, any positioner version.
S The EMC filter module, this is is a set together with cable clips and
M-20 screw--type cable gland and has the order number
C73451-A430-D23. The EMC filter module must be installed in the
positioner. The installation instructions enclosed with the EMC filter
module explain how to assemble the components.
S A 3-wire cable for connecting the components.
This EMC filter module should always be used for the controller unit
when any actuator-mounted potentiometer (resistance 10 kΩ) is to
be used instead of the position detection system C73451--A430--D78.

WARNING
! The explosion--proof version may not be run together with the external
position detection system.

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3.3.3 Mounting kit ”linear actuator” 6DR4004-8V and 6DR4004-8L

The scope of delivery of the mounting kit” linear actuator IEC 534
(3 mm to 35 mm)” are contained (ser. no. see figure 3-7, page 49):
Ser. no. pieces Designation Note
1 1 NAMUR mounting kit bracket Standardized connection for mounting console with
IEC 534 ledge, column or plane surface
2 1 Pick-up bracket Guides the roller with carrier pin and turns lever
arm
3 2 Clamping assembly Mounting of pick-up bracket on actuator spindle
4 1 Carrier pin Assembly with roll (5) on lever (6)
6 1 Lever NAMUR For stroke range 3 mm to 35 mm
For stroke ranges> 35 mm to 130 mm (special deli-
very), lever 6DR4004-8L is required additionally
7 2 U bolt Only for actuators with columns
8 4 Hexagon head screw M8 x 20 DIN 933-A2
9 2 Hexagon head screw M8 x 16 DIN 933-A2
10 6 Lock washer A8 -- DIN 127-A2
11 6 Flat washer B 8,4 -- DIN 125-A2
12 2 Flat washer B 6,4 -- DIN 125-A2
14 1 Spring washer A6 -- DIN 137A-A2
15 1 Lock washer 3.2 -- DIN 6799-A2
16 3 Spring washer A6 -- DIN 127-A2
17 3 Socket cap screw M6 x 25 DIN 7984-A2
18 1 Hexagon nut M6 -- DIN 934-A4
19 1 Square nut M6 -- DIN 557-A4
21 4 Hexagon nut M8 -- DIN 934-A4
Table 2-1 Scope of delivery of the mounting kit “linear actuator”

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3.3.4 Assembly procedure (see figure 3-7, page 49)

1. Mount clamping assembly (3) with hexagon socket cap screws

(17) and lock washer (16) on the actuator spindle.
2. Insert the pick--up bracket (2) into the recesses of the clamping
assembly. Set the necessary length and tighten the screws so that
the pick--up bracket can still be shifted.
3. Insert the pin in the lever (6) and assemble with nut (18), spring
washer (14) and washer (12).
4. The value of the stroke range specified on the actuator or if this
does not exist as a scaling value, the next greatest scaling value is
set. The center of the pin must be in line with the scaling value.
The same value can be set later under parameter 3.YWAY in
commissioning to display the way in mm after initialization.
5. Assemble the hexagon socket cap screw (17), spring washer (16),
washer (12) and square nut (19) on the lever.
6. Push the premounted lever onto the positioner axis up to the stop
and fix with the hexagon socket cap screw (17).
7. Fit the mounting bracket (1) with two hexagon head screws (9),
lock washer (10) and flat washer (11) on the rear of the positioner.
8. Selection of the row of holes depends on the width of the actuator
yoke. The roll (5) should engage in the pick-up bracket (2) as close
as possible to the spindle but may not touch the clamping
assembly.
9. Hold the positioner with the mounting bracket on the actuator so
that the pin (4) is guided within the pick-up bracket (2).
10. Tighten the pick-up bracket.
11. Position the mounting parts according to the type of actuator.
-- Actuator with ledge: Hexagon head screw (8), flat washer (11)
and lock washer (10).
-- Actuator with plane surface: Four hexagon head screws (8), flat
washer (11) and lock washer (10).
-- Actuator with columns: Two U bolts (7), four hexagon nuts (21)
with flat washer (11) and lock washer (10).
12. Secure positioner onto the yoke using the previously positioned
mounting parts.

. NOTE
Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke center as possible. You can use the
lever scale as orientation. It must be guaranteed that the horizontal
lever position is passed through within the stroke range.

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17
2

16
12

16
18
19 14
12

17
6
3

1)
4

Without explosion-proof version

11
10
9
1

11
10
9
3)

Explosion-proof version:

11
10
9

11
10
9
3)

Figure 3-7 Assembly procedure (linear actuator)

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1 11 10

8
10
8
Mounting on yoke Mounting on yoke
11 with ledge with plane surface

11 10

Mounting on yoke
with columns

21
4)
as required

Figure 3-7 Assembly procedure (linear actuator) continued

3.3.5 Mounting kit ”part-turn actuator” 6DR4004-8D

The scope of delivery of the mounting kit ”part-turn actuator” contains (ser. no. see figures 3-8
and 3-9):
Ser. no. Pieces Designation Note
2 1 Coupling wheel Mounting on position feedback shaft of the
positioner
3 1 Carrier Mounting on end of actuator shaft
4 1 Multiple plate Indication of actuator position, comprising 4.1
and 4.2
4.1 8 Scales Different divisions
4.2 1 Pointer mark Reference point for scale
14 4 Hexagon head screw DIN 933 -- M6 x 12
15 4 Lock washer S6
16 1 Fillister head screw DIN 84 -- M6 x 12
17 1 Washer DIN 125 – 6.4
18 1 Hexagon socket head screw Premounted with coupling wheel
19 1 Allen key For item 18
Table 2-2 Scope of delivery of the mounting kit “part-turn actuator”

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3.3.6 Assembly procedure (see figure 3-8 and figure 3-9)

1. Attach VDI/VDE 3845 mounting console ((9), actuator-specific,

scope of delivery actuator manufacturer) onto rear of positioner
and secure using hexagon head screws (14) and lock washers
(15).
2. Adhere pointer (4.2) onto mounting console in the center of the
centering hole.
3. Push the coupling wheel (2) onto positioner axis, pull back by
about 1 mm and tighten the hexagon socket head screw (18) with
the Allen key provided.
4. Place the carrier (3) onto the end of the actuator and secure using
Fillister head screw (16) and washer (17).
5. Carefully place positioner with mounting console onto the actuator
such that the pin of the coupling wheel engages in the actuator.
6. Align the positioner/mounting console assembly in the center of the
actuator and screw tight.
(Screws not included in delivery; they are part of the actuator
mounting console!)
7. Following startup as described in Chapter 3.6, page 70: Drive the
actuator to the end position and adhere scale (4.1) on the coupling
wheel (2) according to direction of rotation and part-turn actuator.
The scale is self--adhesive!

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15
14

2
18
9
1) 2)

16
17
3

3)

2
4.1
2

0%20 40 60 80 100%

4)
5)

Figure 3-8 Assembly procedure (part-turn actuator)

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15 14

1) 16
17
3
18

2) 2

3)

2
4.1
2
0%20 40 60 80 100%
3

5)
4)

Figure 3-9 Assembly procedure for explosion proof version (part-turn actuator)

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CUT A -- B
4.2 14, 15

15
positioner
14, 15

G 1/4
25

A B

part-turn actuator

3 16, 17 10 4.1 9

2 Coupling wheel 10 Feedback shaft

3 Carrier 14 Hexagon head screw M6 x 12
4 Multiple plate 15 Lock washer S6
4.1 Scale 16 Fillister head screw M6 x 12
4.2 Pointer mark 17 Washer
9 VDI/VDE 3845-mounting bracket 18 Hexagon socket head screw

Figure 3-10 Mounted positioner for part-turn actuator

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fastening level
Befestigungsebene
Stellungsregler
positioner

M6 4 +0,1

Schwenkantrieb
part-turn actuator

35

F05-Lkr.- 50

Figure 3-11 Attachment of part-turn actuator, mounting console (scope of delivery actuator manufacturer),
dimensions

3.4 Electrical Connection

. NOTE
Any necessary options modules must be installed before electrical
connection (see chapter 2.7, page 27).
N.B.: The transmission ratio selector can only be set when the
positioner is open. Therefore check this setting before closing the
controller.

WARNING
! The specifications of the examination certificate valid in your country
must be observed.
Electrical connection in hazardous areas
The national directives and laws which apply in your country for haz-
ardous areas, must be followed for electrical installations. In Germany
these are, for example:
-- Working reliability regulations
-- Regulations for installing electrical equipment in hazardous areas,
DIN EN 60079--14 (in the past VDE 0165, T1).
-- The EC type examination certificates

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! WARNING
If the intrinsically safe version is operated with a higher operating vol-
tage by mistake, the positioner must no longer be used for intrinsically
safe application.
The explosion-proof positioner may only be supplied with electrical
power in areas in which the atmosphere may be potentially explosive
when the housing is closed.
The feed-though openings in the explosion-proof version for the
electronic connections must be sealed with EEX-d certified cable
glands or EEx-d certified plugs or an ignition lock must be mounted at
a maximum distance of 46 cm (18 inches) when using the
“conduit”-system.

The plastic housing is metal lined to increase the electromagnetic

compatibility (EMC) against high frequency radiation. This screen is
connected electrically to the threaded bushes shown in figure 3-12,
page 56.
Please bear in mind that this protection can only be effective if you con-
nect at least one of these bushes with grounded fittings by electrically
conductive (blank) mounting parts.

Shield

Figure 3-12 Base plate

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. NOTE
Use standard M20 x 1.5 cable gland nuts to ensure leakage (IP--
protection of the housing) and for the necessary tensile strength use
only cables with a cable diameter ≥ 8 mm, or for smaller diameters
use a suitable sealing insert.

For the NPT version, the positioner will be delivered with an adapter.
Make sure that when fitting a part into the adapter, that the maximum
permissible torque of 10 Nm is not exceeded.

NOTE for use in zone 2:

Non-sparking equipment for Zone 2 may not be connected or discon-
nected under power in normal operation.
However, during installation or repair work the positioner may be con-
nected or disconnected even under power (see also certificate for zone
2).

NOTE for use in two-wire systems:

Never connect the current input (terminal 6 and 7) to a voltage source
as this could destroy the positioner.
Always use a current source with a maximum output current of 20 mA.
To maintain the power supply, the input current must be ≥3.6 mA.

3.4.1 Connection in non-intrinsically safe and explosion proof version

+ 4 to 20 mA E 6DR50x0-xNxxx
6 Positioner 6DR5011-xNxxx
A
7 6DR51x0-xNxxx
J 8 6DR5111-xNxxx
9 6DR50x5-xExxx
10 Digital input 1 6DR51x5-xExxx

Only for:
HART Communicator 6DR51x0-xNxxx
6DR5111-xNxxx
6DR51x5-xExxx

Figure 3-13 Two-wire connection

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2 Positioner 6DR53x0-xNxxx
+ 4 to 20 mA 6DR52x5-xExxx
3
6DR53x5-xExxx
4
5
J

E
6 A
7
8
9 Digital input 1
10

HART Communicator Only for:

6DR52x5-xExxx

Figure 3-14 Two-wire connection

+
Positioner 6DR53x0-Nxxx
2
18 to 30 V 6DR52x5-Exxx
3 6DR53x5-Exxx
4
U
5

0/4 to 20 mA
+ E
*) 6 A
*) 7
J 8
9
10 Digital input 1

HART Communicator Only for:

6DR52x5-xExxx

*) only for three-wire connection

Figure 3-15 Three-/four--wire connection

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Current output

+
61 E
UH ≤35 V
62 J
+
Iy module:
6DR4004-8J

Figure 3-16 Iy-module 6DR4004-8J

Digital inputs and outputs

Alarm module
6DR4004-8A

+13 V +
≤30 V 11
12 ≥1 Digital input 2
+4,5 V

21 +3 V
22
1K
+
35 V 31 Fault
32 message

1K
+
35 V 41 Limit value A1
42

+ 1K

35 V 51 Limit value A2
52

Figure 3-17 Alarm module 6DR4004--8A

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SIA module

SIA module
Switching amplifier according to DIN EN 60947--5--6 6DR4004-8G

2K1
+
8.2 V 31 Fault
10K
32 message

+
8.2 V 41 Limit value A1
42

+
8.2 V 51 Limit value A2
52

Figure 3-18 SIA module 6DR4004-8G

Mechnical limit switch module

Limit switch module

6DR4004-8K

2K1
+
max. DC 8.2 V 31
10K Fault message
32
=
+ max. AC 250 V
41
DC 24 V Limit value A1
42
 AC/DC 4 A

+ max. AC 250 V
51
DC 24 V Limit value A2
52
 AC/DC 4 A

Figure 3-19 Mechanical limit switch module 6DR4004--8K (not EEx)

3.4.2 Connection in intrinsically safe version

. NOTE
Only certified intrinsically safe circuits may be connected as power
supply, control and signal circuits.

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Standard controller

Non-hazardous Hazardous area zone 1 or zone 2

area

+ 4 to 20 mA E
EEx Positioner
6 6DR5010-xExxx
A
7 6DR5020-xExxx
J 8 6DR5011-xExxx
9
10 Digital input 1
Intrinsically
safe power
source

Figure 3-20 Two-wire connection, EEx i

Non-hazardous Hazardous area zone 1 or zone 2

area

2 Positioner 6DR5210-xExxx
EEx + 4 to 20 mA 6DR5220-xExxx
3
6DR5211-xExxx
4
5
J
E
Intrinsically 6 A
safe power 7
source
8
9
Digital input 1
10

HART Communicator

Figure 3-21 Two-wire connection, EEx i

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Non-hazardous Hazardous area zone 1 or zone 2

area

+ 18 to 30 V
EEx Positioner 6DR5210-xExxx
2
6DR5220-xExxx
3
6DR5211-xExxx
4
U
5

EEx + 4 to 20 mA E
6 A
*) *)
7
8
J
9
Digital input 1
Intrinsically 10
safe power
source

HART Communicator

*) Only for three-wire connection

Figure 3-22 Three-/four--wire connection, EEx i

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Split-range

Non-hazardous Hazardous area zone 1 or zone 2

area
Power supply
L+ Instrument 1
intrinsically safe feed sources

+18 to 30 V
EEx
Positioner
M 6DR5210-xExxx
U
6DR5220-xExxx
6DR5211-xExxx

Iy +0/4 to 20 mA
EEx setting range 1
I M

total setting Digital input 1

range Iy #

Instrument 2
Positioner
6DR5210-xExxx
6DR5220-xExxx
6DR5211-xExxx

setting range 2

Digital input 1
#

Figure 3-23 Series circuit of two positioners, e.g. split range (separate power supply), EEx i

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Current output

Non-hazardous area Hazardous area zone 1 or zone 2

+
EEx +
61 E
UH U 62 J
≤30 V J

Iy module
+
6DR4004-6J

Intrinsically safe power source

Figure 3-24 Iy module 6DR4004-6J, EEx i

Digital inputs and outputs

Non-hazardous area Hazardous area zone 1 or zone 2

Alarm module
6DR4004-6A

+
11
≤25.2 V
EEx 12 ≥1 Digital
input 2

21 + 3V
22
Intrinsically + 2K1
safe 31
switching am- 8.2 V 10K Fault
plifier to DIN EEx 32 message
EN 60947--5--6
2K1
+
41
8.2 V 10K Limit value A1
EEx 42

+ 2K1
51
8.2 V 10K Limit value A2
EEx 52

Figure 3-25 Alarm module 6DR4004-6A, EEx i

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SIA module

Non-hazardous area Hazardous area zone 1 or zone 2

SIA module
6DR4004-6G

+ 2K1
Intrinsically safe 31 Fault
8.2 V 10K
Switching ampli- EEx 32 message
fier to DIN EN
60947--5--6
+
41
8.2 V Limit value A1
EEx 42

+
8.2 V 51
Limit value A2
EEx 52

Figure 3-26 SIA module 6DR4004-6G, EEx i

Mechnical limit switch module

Non-hazardous area Hazardous area zone 1 or zone 2

Intrinsically safe
Switching ampli- Mechanical limit switch module
fier to DIN EN 6DR4004-8K
60947--5--6

2K1
+
max. DC 8.2 V 31
10K Fault
EEx 32 message

+
Umax DC 30 V 41
42 Limit value A1
= Imax 100 mA

+
Umax DC 30 V 51
52 Limit value A2
= Imax 100 mA

Figure 3-27 Mechnical limit switch module 6DR4004--8K (EEx i)

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3.4.3 Connection in type of protection “n” version

Standard controller

Non-hazardous area Hazardous area zone 2

+ 4 to 20 mA E
6 Positioner 6DR5010-xGxxx
A 6DR5020-xGxxx
7
6DR5011-xGxxx
J 8
9
10 Digital input 1

Figure 3-28 Two-wire connection, EEx n

Non-hazardous area Hazardous area zone 2

Positioner 6DR5210-xGxxx
+ 4 to 20 mA 2
6DR5220-xGxxx
3
6DR5211-xGxxx
4
5
J

E
6 A
7
8
9 Digital input 1
10

HART Communicator

Figure 3-29 Two-wire connection, EEx n

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Non-hazardous area Hazardous area zone 2

+
Positioner 6DR5210-Gxxx
2
18 to 30 V 6DR5220-Gxxx
3 6DR5211-Gxxx
4
U
5

0/4 to 20 mA
+ E
*) 6 A
*) 7
J 8
9 Digital input 1
10

HAR Communicator

*) Only for three-wire connection

Figure 3-30 Three-/Four-wire connection, EEx n

Current output

Non-hazardous area Hazardous area zone 1 or zone 2

+ +
61 E
UH
62 J
≤30 V

Iy module
+
6DR4004-6J

Figure 3-31 Iy module 6DR4004-6J, EEx n

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Digital inputs and outputs

Non-hazardous area Hazardous area zone 2

Alarm module
6DR4004-6A

+
11
12 ≥1 Digital
input 2

21 +3 V
22

+ 2K1

8.2 V 31
10K Fault
32 message

2K1
+
8.2 V 41
10K Limit value A1
42

+ 2K1
51
8.2 V 10K Limit value A2
52

Figure 3-32 Alarm module 6DR4004--6A, EEx n

SIA module

Non-hazardous area Hazardous area zone 2

SIA module
6DR4004-6G

+ 2K1
31
8.2 V 10K Fault
32
message

+
41
8.2 V Limit value A1
42

+
8.2 V 51
Limit value A2
52

Figure 3-33 SIA module 6DR4004-6G, EEx n

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3.5 Pneumatic Connection

WARNING
! For reasons of safety, the pneumatic power may only be supplied after
assembly when the positioner is switched to operating level P manual
operation with electrical signal applied (as--delivered state, see figure
4-4, page 90).

. NOTE
Note the air quality! Oil-free industrial air, solid content < 30 μm, pressure
dew point 20 K below the lowest ambient temperature (chapter 7 “Techni-
cal Data”, page 133).

S Connect a manometer block for supply air and actuating pressure if

necessary.
S Connection by female thread G 1/4 DIN 45141 or 1/4” NPT:
PZ Supply air 1.4 to 7 bar
Y1 actuating pressure 1 for single- and double-acting actuators
Y2 actuating pressure 2 for double-acting actuators
E exhaust air outlet (remove silencer if necessary)
see figure 2-4 and 2-5, page 19.
S .Safety position when the electric power supply fails:
single-acting: Y1 deaerated
double-acting: Y1 Max. Actuating pressure
(supply air pressure)
Y2 deaerated
S Connect actuating pressure Y1 or Y2 (only in double-acting actua-
tors) according to the desired safety position.
S Connect supply air to PZ.

. NOTE
In order for spring-loaded pneumatic actuators to be able to reliably
exploit the maximum possible travel, the supply pressure must be
sufficiently greater than the maximum required final pressure of the
actuator.
After installing the device, check the pneumatic connections of the entire
assembly for leakage. Any leakage would cause not only continuous
consumption of compressed air but also would cause the positioner to
continually endeavor to compensate for the variance in position, leading
in time to premature wear of the whole control mechanism.

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3.6 Commissioning

Once the positioner has been fitted to a pneumatic actuator, it must be

provided with electrical and pneumatic auxiliary power.
Then you can then adapt the position controller to the respective actua-
tor by parameterizing and initializing it.
Mode” operating mode (which can also if necessary be attained by
”PRST”) -- ”NOINI” will flash.
If the positioner has not been initialized it will be in the ”P Manual
Mode” operating mode (which can also if necessary be attained by
”PRST”) -- ”NOINI” will flash.
This initialization can be effected in three different ways:
S Automatic initialization
Initialization takes place automatically. Hereby the positioner deter-
mines the direction of action, the stem travel and the angle of rota-
tion, the travel times of the actuator one after the other and adapts
the control parameters to the dynamic behavior of the actuator.
S Manual initialization
The stem travel or angle of rotation of the actuator can be set ma-
nually, the other parameters are determined as in automatic initiali-
zation. This function is useful in actuators with soft limit stops.
S Copying initialization data (positioner exchange)
In the devices with HART function the initialization data of a positio-
ner can be read out and copied to another positioner. This enables a
defective device to be changed without having to interrupt an ongo-
ing process by initialization.
Only a few parameters need to be set in the positioner prior to initializa-
tion. The others are defaulted so that they do not normally need to be
adjusted. You will have no problems with commissioning if you observe
the following points.
The possible operating modes and parameters, together with the
adjustment capabilities and their effects are described in chapter 4
page 87 ”Operation”.

. NOTE
N.B.: The operating pressure should be at least one bar greater than is
necessary for closing/opening the valve during initialization.
N.B.: The transmission ratio selector can only be set when the
positioner is open. Therefore check this setting before closing the
housing.

3.6.1 Preparations for linear actuators

1. Assemble the positioner with the appropriate mounting kit (see

chapter 3.3.3, page 39).

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. NOTE
Particularly important is the position of the transmission ratio selector
(8, figure 2-2, page 17) in the positioner:

Stroke Lever Position of the transmission ratio

selector
5 to 20 mm short 33° (i.e. down)
25 to 35 mm short 90° (i.e. up)
40 to 130 mm long 90° (i.e. up)

2. Push the carrier pin (4, figure 3-7 (page 49) 2) onto the lever (6,
figure 3-7, 2) to the scale position corresponding to the rated
stroke or next highest position and screw the carrier pin tight with
the nut (18, figure 3-7, 2).
3. Connect the actuator and the positioner with the pneumatic lines
and supply pneumatic power to the positioner (figure 2-4 and 2-5,
page 19 ).
4. Connect a suitable current or voltage source (see figure 3-13,
page 57 and figure 3-20, page 61).
5. The positioner is now in the operating mode ”P-manual opera-
tion” The current potentiometer voltage (P) is displayed in percent
in the top line of the display, e.g.: ”P12.3”, and ”NOINI” flashes in
the bottom line:

6. Check the free running of the mechanics in the whole actuating

range by moving the actuator with the keys and and driving
to the respective end position.

. NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.

7. Now move the actuator to the horizontal position of the lever. A

value between P48.0 and P52.0 should be visible in the display. If
this is not the case, adjust the friction clutch (8, figure 2-11, page
28 or in frameproof enclosure 8, figure 2-12, page 31) until ”P50.0”
is displayed with a horizontal lever. The more accurately you hit
this value, the more exactly the positioner can determine the path.

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NOTICE
for the explosion--proof version:
Only adjust the outer friction clutch (8, Fig. 2-3, page 18). The internal
friction clutch (9, Fig. 2-2 page 17) is fixed and, for the explosion--proof
version, must not be adjusted.

3.6.2 Automatic initialization of linear actuator

If you can move the actuator correctly, leave it standing in a central po-
sition and start automatic initialization:

1. Press the operation mode key for longer than 5 s. This brings
you to the Configuration mode.
Display:

2. Switch to the second parameter by pressing the operation mode

key briefly.
Display:
or

. NOTE
It is vital that this value corresponds to the setting of the transmission
ratio selector (8, figure 2-2, page 17) (33° or 90°).

3. Switch on to the following display with the operation mode key :

You only need to set this parameter if you want to have the total
stroke in mm displayed at the end of the initialization phase. To do
this, select the same value in the display to which you have set the
carrier pin to the scale on the lever.

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4. Switch on to the following display with the operation mode key :

5. Start initialization by pressing the key for longer than 5 s.

Display:

During the initialization phase ”RUN1” to ”RUN5” appear one after an-
other in the bottom display (see also structograms figure 3-35, page 81
to figure 3-38, page 84).

. NOTE
The initialization process may last up to 15 minutes depending on the
actuator.

The initialization is complete when the following display appears:

The following display appears after pressing the operation mode key
briefly:

To exit the Configuration mode, press the operation mode key for
longer than 5 s. The software version is displayed after about 5 s. The
instrument is in manual operation after releasing the operation mode
key.

. NOTE
You can abort an ongoing initialization at any time by pressing the
operation mode key. Your previous settings are retained. All the para-
meters are reset to the factory setting only after performing a “Preset”.

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3.6.3 Manual initialization of linear actuator

The positioner can be initialized with this function without the actuator
being driven hard against the limit stop. The start and end positions of
the travel are set manually. The other initialization steps (optimization
of the control parameters) run automatically as in automatic initializa-
tion.

Manual initializa- 1. Make preparations as described in chapter 3.6.1, page 70 for

tion procedure in linear actuator. In particular, make sure by manually driving the whole
linear actuator travel that the displayed potentiometer setting moves
in the permissible range between P5.0 and P95.0.

Press the operation mode key for longer than 5 s. This brings
you to the Configuration mode.
Display:

3. Switch to the second parameter by pressing the operation key

briefly. One of the following displays appears:
or

. NOTE
It is vital that this value corresponds to the setting of the transmission
ratio selector (33_ or 90°).

4. Switch on to the following display with the operation mode key:

You only need to set this parameter if you want to have the total
stroke in mm displayed at the end of the initialization phase. To do
this, select the same value in the display to which you have set
the carrier pin to the scale on the lever or the next highest position
in intermediate positions.

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5. Switch on to the following display by pressing the operation

mode key twice:

6. Start initialization by pressing the increment key for longer

than 5 s.
Display:

7. After 5 s the display changes to:

(The display of the potentiometer setting is shown here and below

as an example only).
Now move the actuator to the position which you want to define as
the first of the two end positions with the increment and decre-
ment key. Then press the operation mode key . This accepts
the current position as end position 1 and switches on to the next
position.

. NOTE
If the message “RANGE” appears in the bottom line, the selected end
position is outside the permissible measuring range. There are several
ways to correct the error:
S Adjust the friction clutch until “OK” appears and press the operation
mode key again or
S move to another end position with the increment and decrement key
or
S abort initialization by pressing the operation mode key. You then have
to change to P manual operation and correct the travel and the posi-
tion detection according to step 1.

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8. If step 7 was successful, the following display appears:

Now move the actuator to the position which you want to define as
the second end position with the increment and decre-
ment key. Then press the operation mode key . This enters
the current position as end position 2.

. NOTE
If the message “RANGE” appears in the bottom line, the selected end
position is outside the permissible measuring range. There are several
ways to correct the error:
S move to another end position with the increment and decrement key
or
S abort initialization by pressing the operation mode key. You then have
to change to P manual operation and correct the travel and the posi-
tion detection according to step 1.

. NOTE
If the message “Set Middl” appears, the lever arm must be driven to
horizontal position using the increment and decrement key and then
the operation mode key pressed. This sets the reference point of the
sine correction in linear actuators.

9. The rest of the initialization now runs automatically. “RUN1” to

“RUN5” appear one after another in the bottom line of the display.
The following display appears on successful completion of initiali-
zation:

The first line additionally contains the determined stroke in millimeters if

the set lever length was specified with parameter 3 YWAY.
5 INITM appears in the bottom line again after pressing the operation
mode key briefly. This brings you back to the Configuration
operating mode.
To exit the Configuration mode, press the operation mode key for
longer than 5 seconds. The software version is displayed after about
5 seconds. The instrument is in manual operation after releasing the
operation mode key.

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3.6.4 Preparations for part-turn actuator

. NOTE
Very important: Switch the transmission ratio selector in the
positioner (8, figure 2-2, page 17) to position 90° (normal angle for
part-turn actuator).

1. Mount the positioner with the appropriate mounting kit (see chapter
3.3.5, page 50).
2. Connect the actuator and the positioner with the pneumatic lines
and supply pneumatic power to the positioner (figure 2-4 and 2-5,
page 19).
3. Connect a suitable current or voltage source (see figure 3-13,
page 57 and figure 3-20, page 61).
4. The positioner is now in the operating mode ”P-manual
operation” The current potentiometer voltage (P) is displayed in %
in the top line of the display, e.g.: ”P12.3”, and ”NOINI” flashes in
the bottom line:

5. Check the free running of the mechanics in the whole actuating

range by moving the actuator with the keys and and driving
to the respective end position.

. NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.

3.6.5 Automatic initialization of part-turn actuator

If you can move the actuator correctly through the actuating range,
leave it standing in a central position and start automatic initialization:

1. Press the operation mode key for longer than 5 s. This brings
you to the configuration operating mode.
Display

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2. Set the parameter with the -key to ”turn”

Display:

3. Switch to the second parameter by pressing the operation mode

key briefly. This has set automatically to 90°.
Display:

4. Switch on to the following display with the operation mode key :

5. Start initialization by pressing the key for longer than 5 s.

Display:

During the initialization phase ”RUN1” to ”RUN5” appear one after

another in the bottom display (see also structograms in figure 3-35,
page 81 to figure 3-38, page 84).

. NOTE
The initialization process may last up to 15 minutes depending on the
actuator.

The initialization is complete when the following display

appears:

The top value indicates the total angle of rotation of the actuator
(example 93.5°).

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The following display appears after pressing the operation mode key
briefly:

To exit the Configuration mode, press the operation mode key for
longer than 5 s. The software version is displayed after about 5 s. The
instrument is in manual operation after releasing the operation mode
key.

. NOTE
You can abort an ongoing initialization at any time by pressing the ope-
ration mode key. Your previous settings are retained. All the parame-
ters are set to the factory setting only after performing a “Preset”.

3.6.6 Manual initialization of part-turn actuators

The positioner can be initialized with this function without the actuator
being driven hard against the limit stop. The start and end positions of
the travel are set manually. The other initialization steps (optimization
of the control parameters) run automatically as in automatic initializa-
tion.

Manual initializa- 1. Make preparations as described in chapter 3.6.4, page 77 for

tion procedure in part-turn actuators. In particular, make sure by manually driving
part-turn actuators the whole travel that the displayed potentiometer setting
moves in the permissible range between P5.0 and P95.0.

2. Press the operation mode key for longer than 5 s. This brings
you to the Configuration mode.
Display:

3. Set the parameter YFCT to “turn” with the decrement key.

Display:

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4. Switch to the second parameter by pressing the operation mode

key briefly.
Display:

. NOTE
Make sure that the transmission ratio selector is in position 90 °!

5. Switch on to the following display by pressing the operation mode

key twice:

The following steps are identical with the steps 6) to 9) for initiali-
zation of linear actuators.
After successful initialization the determined part-turn range ap-
pears in the top display.
“5.INITM” appears in the bottom line again after pressing the op-
eration mode key briefly. This brings you back to the Configura-
tion mode.
To exit the Configuration mode, press the operation mode key
for longer than 5 seconds. The software version is displayed after
about 5 seconds. The instrument is in manual operation after re-
leasing the operation mode key.

3.6.7 Automatic initialization (structograms)

linear actuator part-turn actuator

Up Down Closed Open

Figure 3-34 Direction of action of the actuators

The initialization procedure should be taken from the following structo-

gram (figure 3-35 to figure 3-38). The terms Open/Closed and up/down
in the structogram refer to the direction of action of the actuators as
illustrated in figure 3-34.

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configure

start: press >5s

move the actuator

1 into the travel range
with:

piezo valve 1 opens continue with:

RUN 1

no no
dy > 4 % ? t > 60 s ?

yes yes

piezo valve 2 opens

no
dy > 4 % ? t > 60 s ?
no

yes
yes

2
manual intervention

Figure 3-35 Automatic initialization, part 1

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actuator moves
into closed
position

turn slip clutch

until 0 appears
no in the bottom line
tolerance band of the display
4% < dw < 10%
? continue with:
RUN 2

yes

actuator moves
into open
position

no
hard stop
up < 97 % ?

yes continue with: check

mechanics 1
no
span
up--dw > 25 % ?

continue with:
yes

3
manual intervention

Figure 3-36 Automatic initialization part 2 (in part-turn actuators)

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2
set lever arm vertical to stem with:

continue with:

actuator moves
into closed yes continue with:
position
no has friction
clutch been
continue with: moved?

correct height
adjustment or
turn friction clutch
no until 0 appears
tolerance band in the bottom line
4% < dw of the display
?
RUN 2

yes

actuator moves
into open
position

no set the next lowest travel

hard stop value on the lever and
up < 97 % ? check the setting of the 1
transmission ratio selector
yes continue with:

no set the next highest travel

span value on the lever and
up--dw > 25 % ? check the setting of the 1
transmission ratio selector
continue with:
yes
was the no
vertical position
(to stem) of the lever
driven through
?

yes

3
manual intervention

Figure 3-37 Automatic initialization part 2 (in linear actuators)

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continue with:
determine travel times
or

display travel times set restrictor(s) to

flashes change the travel
times
if setting of travel
alternating times is desired
RUN 3

yes flashes
within
alternating
5s? display of travel
times in s
no

yes actuator comes to standstill

after display of leakage
within in % / min
5s? 1 minute
no
if leakage test of
actuator is desired continue with:
RUN 4

determine minimum
positioning increments

optimizing of transient behavior and

RUN 5

determining of prediction horizon

display of stroke in mm
or
or angle of rotation in degrees,
is also the identification for
complete initialization
continue with:

configure

manual intervention

Figure 3-38 Automatic initialization, part 3

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3.7 Copying initialization data (positioner exchange)

With this function you have the possibility of starting up a positioner

without running the initialization routine. This allows for example a posi-
tioner to be changed on a running system in which automatic or manual
initialization cannot be performed without disturbing the process.

NOTICE
Initialization (automatic or manual) should be performed as soon as
possible afterwards because only then can the positioner be optimally
adapted to the mechanical and dynamic properties of the actuator.

Data are transmitted from the positioner to be replaced to the

replacement instrument via the HART®- communication interface.
The following steps must be performed to exchange a positioner:
1. Read in and save instrument parameters and initialization data
(determined in initialization) of the instrument to be replaced with
PDM (Process Device Manager). This step is unnecessary if the
instrument has been parameterized with PDM and the data have
already been stored.
2. Fix the actuator in its momentary position (mechanical or
pneumatic).
3. Read and note the current position actual value of the positioner to
be changed. If the electronics are defective, determine the current
position by measuring on the actuator or valve.
4. Disassemble the positioner. Mount the lever arm of the positioner
on the replacement instrument. Mount the replacement instrument
on the fitting. Move the transmission ratio selector to the same
position as the defective instrument. Copy the instrument data and
initialization data from the PDM or handheld.
5. If the displayed actual value does not match the noted value of the
defective positioner, set the correct value with the friction clutch.
6. The positioner is now ready to operate.
The accuracy and dynamic behavior may be restricted in relation
to correct initialization. The position of the hard stops and the rela-
ted maintenance data may show deviations in particular. Therefore
initialization must be performed at the earliest opportunity.

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Operation
4
The following chapter describes the operation of the positioner.

4.1 Display

The LC display has two lines whereby the lines have different
segmentation. The elements of the top line consist of 7, those of the
bottom line of 14 segments. The contents of the display depend on the
selected operating mode (see chapter 4.3, page 90)

. NOTE
If the positioner is operated in ranges with temperatures below --10 °C
the liquid crystal display becomes sluggish and the display refresh rate
is reduced considerably.

Figure 4-1 shows you the various display options. The meaning of fur-
ther display capabilities is detailed in chapter 4.6 page 119.

4.2 Input keys

The positioner is operated by three keys (figure 4-2) the function of

which depends on the selected operating mode. In the explosion proof
version of the positioner the input keys are underneath a key cover
which can be lifted up after loosening the cover screw.

. NOTE
The input keys of the explosion proof version must be covered to
prevent liquid getting in. The IP65/NEMA4x degree of protection is not
guaranteed when the housing is open or the key cover is open.

The housing cover must be removed to operate the keys in the normal
and intrinsically safe versions of the positioners.

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Operation

Figure 4-1 Meaning of the various display options

. NOTE
The degree of protection IP 65/NEMA4x is not guaranteed as long as
the positioner is open.

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 Operation

2 3 4

1 Display
2 Operation mode key
3 Decrement key
4 Increment key

Figure 4-2 Display and input keys of the positioner

Explanations of the input keys

S The operation mode key (manual key) serves to switch over the
operating mode and pass on parameters.

. NOTE
By pressing and holding the operation mode key and additionally
pressing the decrement key, you can select the parameters in reverse
order.

S The decrement key serves to select parameter values in

configuration and to move the actuator in manual operation.
S The increment key serves to select parameter values in
configuration and to move the actuator in manual operation.

Firmware version The current firmware state is displayed when you exit the configuration
menu.

Figure 4-3 Firmware version, example: C4

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Operation

4.3 Operating modes

The positioner can be operated in five operating modes.

1. P-manual mode (ex--factory state)
2. Configuration and initialization
3. Manual mode (MAN)
4. Automatic (AUT)
5. Diagnostic display
Figure 4-4 gives you an overview of the possible operating modes and
the change between them.

Figure 4-4 Change between the operating modes

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P-manual mode The display of the positioner shows you the current potentiometer
(ex--factory state) setting in the top line and ”NOINIT” flashes in the second line. You can
move the actuator with the decrement and increment key . In order
to adapt the positioner to your actuator, you have to change to the
Configuration menu. See also chapter 3.6, page 70 “Commissioning”.
Output of alarms and position feedback is possible after successful init-
ialization.

Configuration and To go to the Configuration menu, press the operation mode key for
initialization at least 5 seconds. In the Configuration menu you can adapt the
positioner individually to your actuator and start initialization. Only a few
parameters need to be set in the positioner prior to initialization. The
others are defaulted so that they do not normally need to be adjusted.
You can block the Configuration menu against manipulation by an
appropriately parameterized and activated digital input. Which
parameters you need to set and all other parameters are explained in
chapter 4.4, page 93 Parameters.
The configuration mode can be reported by outputting a
parameterizable fault message, a position feedback or output of limit
values A1 and A2 is not possible.

. NOTE
If the electric power supply fails during configuration, the positioner
switches back to the first parameter after recovering the power supply,
values which have already been parameterized are retained. When
doing this, please note that the new value will only be saved when
leaving the configuration menu or when another parameter is selected.
Without a power failure you re-enter the configuration menu at the
point you exited it when you call the Configuration menu again.

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Operation

at the same time at the same time

to
at the same time at the same time

Figure 4-5 Overview: Configuration

3-1
Manual mode In this operating mode you can move the actuator with the decrement
(MAN) ( ) and increment keys ( ) and the current position is held
regardless of the setpoint current and any leakages.

. NOTE
You can move the actuator quickly by pressing the other direction key
additionally whilst keeping the direction key selected first pressed.

The manual mode can be reported by outputting a parameterizable

fault message, a position feedback or output of limit values A1 and A2
is only possible in automatic mode.

. NOTE
The positioner switches over to automatic mode automatically after an
electrical power failure.

Automatic (AUT) The automatic mode is the normal mode. In this mode the positioner
compares the setpoint current with the current position and moves the
actuator until the control deviation reaches the parameterizable dead
zone. Error messages are output if this is not possible for various
reasons.

Diagnostic display In this operating mode you can have the current operating data (such
as number of strokes, number of changes in direction, number of faults
messages, etc.) displayed (see table 3-1, page 109).
From the automatic or manual mode you go to the diagnostic display
by simultaneously pressing all three keys for at least two seconds.
See chapter 4.5, page 108 for further information.

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. NOTE
The respective operating mode (MAN or AUT) of the positioner is retai-
ned when you switch to the diagnostic display, i.e. in automatic opera-
tion the specified setpoint is still used for controlling and in manual
operation the position last reached is retained.

4.4 Parameters

All the parameters of the positioner are listed in this chapter. Figure 4-6
shows an overview of the parameters.
The parameter name is shown once in plain text and once as it ap-
pears in the display. The function of the parameter is described briefly
in the ”Function” column. In addition, the possible parameter values,
the physical unit and the factory setting of the parameters are shown.

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Operation

Figure 4-6 Parameter table of the positioner

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The following configuration block diagram shows the effects of the pa-
rameters.

Figure 4-7 Configuration block diagram

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Operation

Normally adjustment of the first three following parameters is com-

pletely sufficient to enable a positioner to be operated by an actuator. If
you wish to become familiar with all details of the positioner, try out in-
crementally the effects of the remaining parameters by selective trials.

. NOTE
In particular if the positioner has previously been operated using a
different actuator, it must always be reinitialized in order to restore the
factory settings. Only in this way can the positioner matching process
start from known conditions. The parameter ”51 PRST” is provided for
this purpose.
This is also recommended if multiple parameters have been changed
in a single session, the effects cannot be assessed and unintended
consequences may result.

1.YFCT Positioning actuator type

This is to match the positioner with the respective actuator and where
necessary to the position sensor being used. The following adjustment
capabilities are provided:
S YFCT = turn
This adjustment is necessary for the part-turn actuator.
If ”turn” is selected, the following parameter ”2. YAGL” is automati-
cally set to 90_ and cannot be changed.
S YFCT = WAY (Factory setting)
This is necessary for a linear actuator. This allows the positioner to
compensate for the non-linearity that arises due to the conversion of
the linear movement of the linear actuator into the part-turn move-
ment of the feedback shaft. For this the positioner is factory set so
that it shows between ”P 49.0 and P 51.0” when the arm on the
feedback shaft is vertical to the linear actuator spindle.
S YFCT = LWAY
This must be adjusted, if an external linear potentiometer is to be
connected to a linear actuator.
TIP: use this adjustment also for part-turn actuators with reverse
direction of control action.
S YFCT = ncSt
Use this when an NCS is fitted to a part-turn actuator.
S YFCT = --ncSt
This must be set when an NCS is used with a part-turn actuator with
reverse direction of control action.
S YFCT = ncSL
This must be set when an NCS is used with a linear actuator.

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. NOTE
After ”LWAY, ncSt, --ncSt or ncSL” have been adjusted, both the
following parameters ”2. YAGL” and ”3. YWAY” will not be displayed.

2.YAGL Rated angle of rotation of the feedback shaft

In part-turn actuators, an angle of 90° is preset automatically by
1.YFCT = turn (see above). In linear actuators (1.YFCT = WAY) a
value of 33° or 90° can be selected depending on the stroke range:
S 33° for strokes ≤ 20 mm
S 90° for strokes > 20 mm
When using the lever up to 35 mm, both angles of rotation (33° and
90°) are possible.
The long lever (> 35 mm stroke) is only designed for an angle of
rotation setting of 90°. It is not part of the mounting kit set 6DR4004-8V
but must be ordered separately under order number 6DR4004-8L.

. NOTE
The setting of the transmission ratio selector on the positioner (see
figure 2-2, page 17 and figure 2-3, page 18) must correspond to the
angle value selected under “2.YAGL”.

3.YWAY Lever arm transmission

Selection of the lever arm range: serves to display the real stroke after
initialization. The use of this parameter is optional. You only need to set
this parameter if you want to have the way in mm displayed at the end
of the initialization.
If the parameter value ”oFF” is selected here, the real stroke is not
displayed after initialization.

. NOTE
The specification “YWAY” must match the mechanical lever arm trans-
mission. The carrier must be set to the value of the actuator stroke, if
this is not scaled to the next highest scaled value.

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Operation

4.INITA Automatic initialization (see chapter 3.6, page 70)

By selecting “Strt” and pressing the increment key for at least
5 seconds, automatic initialization is started. The initialization process
is displayed by “RUN 1” to “RUN 5” (see figure 3-35, page 81 to figure
3-38, page 84).

5.INITM Manual initialization

By selecting “Strt” and pressing the increment key for at least
5 seconds, manual initialization is started. The manual initialization
process is described in chapter 3.6.3, page 74 and chapter 3.6.6,
page 79.

. NOTE
If the positioner has already been initialized, for INITA and INITM it is
possible to transfer it to its non-initialized state without changing the
remaining parameters by pressing the decrement key for 5 s.

6.SCUR Current range of the setpoint

The selection of the current range depends on the connection type.
”0mA” (0 to 20 mA) is only possible in three-/four--wire connections
(see figure 3-23, page 63).

7.SDIR Setpoint direction (see figure 4-8, page 99)

The setting of the setpoint direction serves to reverse the direction of
action of the setpoint. It is used mainly for the split range mode and in
single--acting actuators with the safety position “up”.

8.SPRA Split range start (see figure 4-8)

and
9.SPRE Split range end (see figure 4-8)
The parameters “8.SPRA” and “9.SPRE” in connection with the
parameter “7.SDIR” serve to restrict the active setpoint range. In this
way split range tasks can be solved with the following characteristics.
S rising / falling
S falling / rising
S falling / falling
S rising / rising

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y=x
100 %

Positioner 1
6.SDIR = FALL

Total setting range

Positioner 2
6.SDIR = riSE

0%
100 %--SPRE 100 %--SPRA SPRA SPRE 100 % JW
Positioner 1 Positioner 2 [0 % to 100 %]
Setting range 1 Setting range 2

Figure 4-8 Example: Split range-operation with two positioners

10.TSUP Setpoint ramp UP

and
11.TSDO Setpoint ramp DOWN
The setpoint ramp is effective in automatic operation and limits the
speed of alteration of the active setpoint. When switching over from
manual operation to automatic the active setpoint is adjusted to the set-
point on the positioner with the setpoint ramp.
This bumpless manual/automatic switchover avoids excessive pressure
increases on long pipelines.
In the position TSUP = Auto the slower of the two travel times deter-
mined during initialization is used for the setpoint ramp. TSDO is then
ineffective.

12.SFCT Setpoint function (see figure 4-9, page 100)

Non--linear valve characteristics can be linearized with this function and
any flow characteristics simulated in linear valve characteristics.

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Operation

Six valve characteristics are stored in the positioner

S linear (12.SFCT = Lin, factory setting)
S equal percentage 1 : 25 (12.SFCT = 1:25)
S equal percentage 1 : 33 (12.SFCT = 1:33)
S equal percentage 1 : 50 (12.SFCT = 1:50)
S inverse equal percentage 25 : 1 (12.SFCT = n1:25)
S inverse equal percentage 33 : 1 (12.SFCT = n1:33)
S inverse equal percentage 50 : 1 (12.SFCT = n1:50)
S freely adjustable (12.SFCT = FrEE)

13.SL0 to 33.SL20 Setpoint turning points

A flow parameter can be assigned to the respective setpoint turning
value at an interval of 5 %. These points lead to a polygon chain with
20 straight lines which therefore represents a projection of the valve
characteristic.

Limit for tight closing Limit for tight closing

x Example: x Example:
39 YCLS = UP 39 YCLS = UP
100% 41 YCUP = 85.0 100%
41YCUP = 75.0

90 90

80 80

70 Setpoint turning point

Modulation range
70
Modulation range

Example:
18 SL5 = 45.0 12 SFCT = FrEE
60 60

50 50
9 SFCT = Lin
40 40

Limit for tight closing Limit for tight closing

30 Example: 30 Example:
39 YCLS = DO 39 YCLS = DO
20 40 YCDO = 15.0 20 40YCDO = 10.0

10 10
Setpoint Setpoint
0 w 0 w
0 10 20 30 40 50 60 70 80 90 100 % 0 10 20 30 40 50 60 70 80 90 100 %

SL 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Figure 4-9 Setpoint characteristic, manipulated variable standardization and tight closing function

The setpoint vertex values can only be input at 12.SFCT=FrEE. You

may only enter a strictly monotonous characteristic, and two consecu-
tive vertex values must differ by at least 0.2 %.

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34.DEBA Dead zone of the controller

At dEbA = AUto the dead zone in automatic operation is adapted con-
tinuously to the requirements of the control circuit. The dead zone is
gradually increased on detecting a control oscillation. The reverse
adaptation takes place by a time criterion.
In the other discrete settings the fixed value is used for the dead zone.

35.YA Manipulated variable limiting start (see figure 4-9 and 4-10)
and
36.YE Manipulated variable limiting end (see figure 4-9 and 4-10)
With the parameters “YA” and “YE” the mechanical actuating distance
(from stop to stop) is limited to the set values. In this way the mechani-
cal setting range of the actuator can be limited to the active flow and
the integral saturation of the commanding controller avoided.

. NOTE
YE must always be set to greater than YA.

37.YNRM Manipulated variable standardization (see figure 4-9 and 4-10)

With limiting of the manipulated variable (by “35.YA” and “36.YE”) two
different scalings are produced for the display and the position feed-
back via the current output (MPOS or FLOW).
The MPOS scaling shows the mechanical position (0 to 100%) be-
tween the hard stops of the initialization. This is not affected by the pa-
rameters “35.YA” and “36.YE”. The parameters “35.YA” and “36.YE”
are displayed in the MPOS-scale.
The FLOW-scale is the standardization (0 to 100%) to the range be-
tween “35.YA” and “36.YE”. The setpoint w (0 to 100%) is always re-
ferred to this range. This gives (also by using valve characteristics) a
quasi--flow--proportional display and position feedback Iy.
To calculate the control difference, the setpoint is also shown in the ap-
propriate scale on the display.

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YNRM = MPOS or YNRM = FLOW

Presetting: YA = 0% and YE = 100%
50%
Input current
(setpoint)
4mA 7.2mA 10.4mA 13.6mA 16.8mA 20mA
X display
W display
0% 20% 40% 60% 80% 100%
Mechan. Stroke
(actual value)
0mm 16mm 32mm 48mm 64mm 80mm
YA = 0% YE = 100%

Example:
YNRM = MPOS with YA = 10 % and YE = 80 %
50%
Input current
(setpoint)
4mA 7.2mA 10.4mA 13.6mA 16.8mA 20mA
X display
W display
0% 20% 40% 60% 80% 100%
Mechan. Stroke
(actual value)
0mm 16mm 32mm 48mm 64mm 80mm
YA = 10% YE = 80%

Example:
YNRM = FLOW with YA = 10 % and YE = 80 %
50%
Input current
(setpoint)
4mA 7.2mA 10.4mA 13.6mA 16.8mA 20mA
X display
0% 20% 40% 60% 80% 100% W display

Mechan. Stroke
(actual value)
0mm 16mm 32mm 48mm 64mm 80mm
YA = 10% YE = 80%

Figure 4-10 Dependence on the stroke of standardization and on YA and YE in the example of an 80 mm
linear actuator

38.YDIR Manipulated variable direction of action

The direction of action (rising or falling) of the display and the position
feedback (Iy) can be set with this.

39.YCLS Tight closing with manipulated variable (see figure 4-9, page 100)
With this function the valve can be driven to the seat with the maximum
actuating force of the actuator (continuous contact of the piezo--
valves). The tight closing function can be activated on one side or for
both limit positions. YCLS becomes active when the setpoint is below
the value set with parameter “YCDO” or above that set with parameter
“YCUP”.

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. NOTE
If the control function to close tightly is activated, for parameter ”49.
LIM” the monitoring of the control deviation in each overrun direction
(YCDO: < 0 %, YCUP: > 100 %) is disabled. This function is particu-
larly useful for valves with a soft seating. For long term monitoring of
the end--stop positions, we recommend activating the parameters
”52. ZERO” and ”53. OPEN”.

40.YCDO Value for tight closing, bottom

and
41.YCUP Value for tight closing, top

. NOTE
“40.YCDO” must always be set to less than “41.YCUP”. The tight
closing function has a fixed hysteresis of 1 %. ”40.YCDO” and
”41.YCUP” relate to mechanical stops and are independent of the
settings of ”7.SDIR” and ”38.YDIR”.

42.BIN1 Function digital input 1 (see figure 4-6, page 94)

and
43.BIN2 Function digital input 2 (see figure 4-6)
The parameters “BIN1” and “BIN2” can be set individually depending
on the purpose. The direction of action can be adapted to an NCC or
an NOC.
S BIN1 or BIN2 = on or --on
Digital messages of the periphery (e.g. pressure or temperature
switches) can be read out via the HART interface or lead to respon-
ding of the fault message output by OR linking with other messages.
S BIN1 = bLoc1
The Configuration operating mode is locked to prevent it being adju-
sted (e.g. by a wire jumper between terminals 9 and 10).
S BIN1 = bLoc2
If digital input 1 has been activated, manual operation is also locked
in addition to the Configuration operating mode.
S BIN1 or BIN2 = uP or doWn (contact closes) or --uP or --doWn (con-
tact opens).
The actuator drives the linear actuator to the upper or lower stop
when the digital input is activated with continuous contact.
S BIN1 or BIN2 (contact closes) = StoP or --StoP (contact opens).
With activated digital input the piezo--valves are blocked and the
actuator remains in the last position. Leakage messages can then
be executed without initialization function.

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Operation

S BIN1 or BIN2 = oFF (factory setting)

no function
special function of DI1: If the digital input 1 is activated in P manual
operation by a jumper between terminals 9 and 10, , when the ope-
rating mode key is pressed the firmware version will be displayed.
line of the display.
If one of the above named functions is selected with the parameters
“BIN1” and “BIN2” simultaneously, then “Blocking” has priority over
“Up” and “Up” priority over “Down”.

44.AFCT Alarm function

The actuator can report the exceeding (max.) or dropping below (min)
of a specified stroke or angle of rotation. The response of the alarms
(limits) is related to the MPOS-scaling (see figure 4-10, page 102). The
alarms are reported by the alarm module (order no. 6DR4004-6A or
-8A). In addition the alarms can be read out through the HART
interface (optional).
The direction of action of the digital outputs can be adapted from high
active to low active sequence systems.

Limit
Alarm module
A2 A1 A2
A1 = 48
AFCT = MIN / MAX
A2 = 52
A1 Travel = 45 Activated
Travel = 50
way Travel = 55 Activated

MIN MAX A1 = 48
A2 = 52 AFCT = --MIN / --MAX
Travel = 45 Activated
MIN MIN Travel = 50 Activated Activated
Travel = 55 Activated

MAX MAX A1 = 52
AFCT = MIN / MAX
A2 = 48
Travel = 45 Activated
--MIN --MAX Travel = 50 Activated Activated
Travel = 55 Activated

A1 = 52
--MIN --MIN AFCT = --MIN / --MAX
A2 = 48
Travel = 45 Activated
Travel = 50
--MAX --MAX Travel = 55 Activated

45.A1 Response threshold alarm 1

and
46.A2 Response threshold alarm 2
The alarm thresholds are related to the mechanical path (MPOS-scale).

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47. FCT Function of the fault message output

The fault message output serves as a group message for following
faults:
S Control error (e.g. by actuator fault, valve fault, compressed air fai-
lure) with the parameters “48. TIM” and “49. LIM”
S Positioner not in automatic mode
S Digital input activated (see parameter “42.BIN1” and “43.BIN2”)
S Exceeding of a limit value (e.g. way integral or valve seat, see para-
meter 50 to 54)
It also responds at:
S Power failure
S Processor fault
The direction of action of the digital outputs can be adapted from high
active to low active sequence systems.
For more information on error messages, see chapter 4.5.3 Online--
Diagnosis, page 113.

48. TIM Monitoring time for setting the fault messages

The set value (s) serves as a specification for the time within which the
positioner must have reached the controlled state. The corresponding
response threshold is specified with “49. LIM”.
The fault message output is set on exceeding the set time.

. NOTE
If the control function to close tightly is activated, for parameter ”49.
LIM” the monitoring of the control deviation in each overrun direction
(YCDO: < 0 %, YCUP: > 100 %) is disabled. This function is particu-
larly useful for valves with a soft seating. For long term monitoring of
the end--stop positions, we recommend activating the parameters
”52. ZERO” and ”53. OPEN”.
For more information on error messages, see chapter 4.5.3 Online--
Diagnosis, page 113.

49. LIM Response threshold of the fault message

Here a value (%) can be set for the permissible variable of control error
for releasing the fault message.
If the parameters 48 and 49 are both set to ”Auto” (factory setting), the
fault message is set if the short step zone is not reached within a
certain time. This time is 5 times the initialization travel time within 5 to
95% of the travel and 10 times this time outside 10 to 90% of the travel.

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50. STRK Limit value for monitoring the way integral

A limit value for the way integral can be set here. If the way integral
exceeds the limit value, the fault message output (optional) is activated.
This function enables a preventive maintenance of the fitting, see also
chapter 4.5 “Diagnostics”, page 108.
This monitoring function can be deactivated with the OFF setting
(factory setting).

51. DCHG Limit value for monitoring the changes of direction

A limit value for the direction change counter can be set here. If this
counter exceeds the limit value, the fault message output is activated.
This function enables a preventive maintenance of the fitting, see also
chapter 4.5 “Diagnostics”, page 108.
This monitoring function can be deactivated with the OFF setting
(factory setting).

52. ZERO Tolerance value for monitoring the bottom hard stop
With this value a limit value (in percent related to the total mechanical
distance) can be preset for the monitoring of the bottom hard stop. If
this tolerance value is exceeded or dropped below of, the fault
message output (optional) is activated.
This function detects when the bottom stop has changed by more then
the specified tolerance related to its initialization value. Monitoring
takes place when the valve is in tight closing bottom. Activation of the
tight closing bottom function (parameter “39.YCLS”) is therefore a
prerequisite.
The fault message remains activated until either a subsequent
monitoring remains within the tolerance or a new initialization is
performed.
This monitoring function can be deactivated with the OFF setting
(factory setting). See also chapter 4.5 “Diagnostics”, page 108.

53. OPEN Tolerance value for monitoring the top hard stop
With this value a limit value (in percent related to the total mechanical
distance) can be preset for the monitoring of the top hard stop. If this
tolerance value is exceeded or dropped below of, the fault message
output (optional) is activated.
This function detects when the top stop has changed by more than the
specified tolerance related to its initialization value. Monitoring takes
place when the valve is in tight closing top. Activation of the tight
closing top function (parameter “39.YCLS”) is therefore a prerequisite.
The fault message remains activated until either a subsequent
monitoring remains within the tolerance or a new initialization is
performed.
This monitoring function can be deactivated with the OFF setting
(factory setting).

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. NOTE
But the monitors of the bottom and top hard stop do not only react to
valve errors. Adjustment of the position feedback is also detected as
an error if the tolerance values are exceeded as a result.

54. DEBA Limit value for monitoring the dead zone adaptation
The automatic adaptation of the dead zone can be monitored with this
value (%). If the dead zone exceeds the set value, the fault message
output (optional) is activated.
Prerequisite for this function is the setting of the parameter“34.DEBA” =
Auto. This monitoring function can be deactivated with the OFF setting
(factory setting).

55.PRST Preset
Establishing the factory setting and resetting the initialization.

. NOTE
The positioner must be re--initialized after ”Preset”. All previously de-
termined maintenance parameters are cleared.

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Operation

4.5 Diagnosis

4.5.1 Diagnostic display

You go to the diagnostic display from automatic or manual operation by

simultaneously pressing all three keys for at least two seconds.
The following table shows an overview of the displayable values.
The diagnostic display has a similar structure to in the ”Configuration”
operating mode. the top line shows the value of the diagnostic variable,
the bottom line the number and abbreviation of the displayed variable.
The respective next diagnostic value can be selected with the operation
mode key . By pressing and holding the operation mode key and
additionally pressing the decrement key you can select the diag-
nostic values in reverse order.
Certain values can be set to zero by pressing the increment key for
at least 5 seconds. This is noted in the last column in the table.
Some diagnostic values may be greater than 99999. In this case the
display switches to exponential display. Example: the value 1234567 is
displayed as 1.23E6.
No. Abbrevia- Meaning Displayable Unit Rest
tion values poss.
1 STRKS Number of strokes 0 to 4.29E9 -- x
2 CHDIR Changes of direction 0 to 4.29E9 -- x
3 CNT Fault counter 0 to 4.29E9 -- x
4 A1CNT Alarm counter 1 0 to 4.29E9 -- x
5 A2CNT Alarm counter 2 0 to 4.29E9 -- x
6 HOURS Operating hours 0 to 4.29E9 Hours
7 WAY Determined travel 0 to 130 mm or _
8 TUP Travel time up 0 to 1000 s
9 TDOWN Travel time down 0 to 1000 s
10 LEAK Leakage 0.0 to 100.0 %
11 P0 Potentiometer value lower stop (0 %) 0.0 to 100.0 %
12 P100 Potentiometer value upper stop (100 %) 0.0 to 100.0 %
13 IMPUP Impulse length up 2 to 100 ms
14 IMPDN Impulse length down 2 to 100 ms
15 DBUP Dead Band Up 0.1 to 100.0 %
16 DBDN Dead Band Down 0.1 to 100.0 %
17 SSUP Short step zone up 0.1 to 100.0 %
18 SSDN Short step zone down 0.1 to 100.0 %
19 TEMP Current temperature --40 to 85 _C
20 TMIN Minimum temperature (”drag pointer”) --40 to 85 _C
21 TMAX Maximum temperature (”drag pointer”) --40 to 85 _C
22 T1 Number of operating hours in temperature range 1 0 to 4.29E9 Hours
23 T2 Number of operating hours in temperature range 2 0 to 4.29E9 Hours
24 T3 Number of operating hours in temperature range 3 0 to 4.29E9 Hours
25 T4 Number of operating hours in temperature range 4 0 to 4.29E9 Hours
26 T5 Number of operating hours in temperature range 5 0 to 4.29E9 Hours
27 T6 Number of operating hours in temperature range 6 0 to 4.29E9 Hours
28 T7 Number of operating hours in temperature range 7 0 to 4.29E9 Hours
29 T8 Number of operating hours in temperature range 8 0 to 4.29E9 Hours
30 T9 Number of operating hours in temperature range 9 0 to 4.29E9 Hours

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No. Abbrevia- Meaning Displayable Unit Rest

tion values poss.
31 VENT1 Number of cycles pre--controlvalve 1 0 to 4.29E9 --
32 VENT2 Number of cycles pre--controlvalve 2 0 to 4.29E9 --
33 STORE Store current values as ”last maintenance” -- --
(press increment key for 5 s)
34 PRUP Prediction up 1 to 40 --
35 PRDN Prediction down 1 to 40 --
36 WT00 Number of operating hours in distance class WT00 0 to 4.29E9 Hours x
37 WT05 Number of operating hours in distance class WT05 0 to 4.29E9 Hours x
38 WT10 Number of operating hours in distance class WT10 0 to 4.29E9 Hours x
39 WT30 Number of operating hours in distance class WT30 0 to 4.29E9 Hours x
40 WT50 Number of operating hours in distance class WT50 0 to 4.29E9 Hours x
41 WT70 Number of operating hours in distance class WT70 0 to 4.29E9 Hours x
42 WT90 Number of operating hours in distance class WT90 0 to 4.29E9 Hours x
43 WT95 Number of operating hours in distance class WT95 0 to 4.29E9 Hours x
44 mA Current setpoint 0.0 to 20.0 mA
Table 3-1 Overview diagnostic values

4.5.2 Meaning of the diagnostic values

1 STRKS Number of strokes

The actuator movements during operation are totaled and can be read
here as number of strokes. Unit: 100% stokes The value is written ev-
ery 15 minutes in a non--volatile memory. It can be reset to zero with
the increment key .

2 CHDIR Number of direction changes

Every change in direction leaving the dead zone is noted in the
controller and added to the number of changes of direction.
The value is written every 15 minutes in a non--volatile memory. It can
be reset to zero with the increment key .

3 CNT Fault counter

Every fault is noted in the controller and added to the number of fault
messages. The counter can be reset to zero with the increment key .

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4 A1CNT Alarm counter 1

and
5 A2CNT Alarm counter 2
Responses of alarm 1 and alarm 2 are counted with these two
counters. The prerequisite is the activation of the alarms with the
parameter “44.AFCT”. The counters can be reset to zero with the
increment key .

6 HOURS Operating hours

The operating hours counter is updated every hour as soon as the
positioner has been supplied with electrical power.

7 WAY Determined actuating way

This value indicates the actuating way determined during initialization
according to the display at the end of an initialization. Prerequisite in
linear actuator: Specification of the lever arm with the parameter
“3.YWAY”.

8 TUP Travel time up

and
9 TDOWN travel time down
These values show the travel times which have been determined dur-
ing initialization. The unit is seconds.

10 LEAK Leakage
If a leakage message has been output during initialization, the value of
the leakage can be read here in %/min.

11 P0 Potentiometer value bottom stop

and
12 P100 Potentiometer value top stop
These two values indicate the measured values of displacement mea-
surement (potentiometer) at the bottom and top hard stops as deter-
mined in automatic initialization. In manual initialization the values of
the manually reached limit positions are indicated here.

13 IMPUP Impulse length up

and
14 IMPDN Impulse length down
During initialization the smallest impulse lengths are determined with
which a movement of the actuator can be achieved. They are deter-
mined and displayed here for the “Up”-direction and the “Down”-direc-
tion.
These two parameter can be used for special applications (see chapter
4.7 page 123).

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15 DBUP Dead zone up

and
16 DBDN Dead zone down
Here the dead zone of the controller is displayed in “Up”-direction or in
“Down”-direction. The values correspond either to the manually set
value of the parameter“34.DEBA” or the value adapted automatically by
the instrument when “DEBA” has been set to ”Auto”.

17 SSUP Short step zone up

and
18 SSDN Short step zone down
The short step zone is the range of the controller in which pulse--
shaped control signals are output. The impulse length here is propor-
tional to the control error. If the control error is outside the short step
zone, the valves are controlled in continuous contact.
These two parameter can be tuned for special applications (see chap-
ter 4.7 page 123).

19 TEMP Current temperature

Current temperature in the positioner housing The sensor is on the
electronics board.
The temperature display can be switched between _C and _F by pres-
sing the decrement key.

20 TMIN Minimum temperature (drag pointer)

and
21 TMAX Maximum temperature (drag pointer)
The minimum and maximum temperature inside the housing is determi-
ned and stored continuously in a kind of drag pointer and can only be
reset in the factory.

22 T1 to Number of operating hours in temperature range T1 to T9

30 T9
Statistics how long operation takes place in which temperature ranges
is kept in the instrument. To do this, the measured temperature over
one hour respectively is averaged and incremented in the counter
which is assigned to the corresponding temperature range every hour.
This enables you to draw conclusions about the past operating condi-
tions and thus the whole fitting.
The temperature ranges are divided up as follows:
T1 T2 T3 T4 T5 T6 T7 T8 T9
Temperature ≥--30 ≥--15 ≥0 ≥15 ≥30 ≥45 ≥60 ≥75
range [_C] ≥--30 <--15 <0 < 15 < 30 < 45 < 60 < 75
[_F] ≥--22 ≥5 ≥32 ≥59 ≥86 ≥113 ≥140 ≥167
<--22 <5 < 32 < 59 < 86 < 113 < 140 < 167

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31 VENT1 Number of cycles pre--control valve 1

and
32 VENT2 Number of cycles pre--control valve 2
These two counters add up the control processes of the pre--control
valves.

33 STORE Store maintenance data

A store function is triggered by pressing the increment key for at
least 5 seconds. Here the diagnostic data 7 to 17 are stored in a non--
volatile memory as ”Data of the last maintenance”. These diagnostic
data are selected values, the changes of which can provide information
on the mechanical wear of the valve.
Normally this function is operated via PDM, menu item Instru-
ment!Store maintenance info. It is possible to compare the data of the
last maintenance with the current data via PDM.

34 PRUP Prediction up
35 PRDN Prediction down
see chapter 4.7 page 123).

36 WT00 to Number of operating hours in distance class WT00 to WT95

43 WT95
If the positioner is in automatic mode, statistics are constantly kept for
how long a valve or a flap has been operated in which section of the
setting range. To do this, the total setting range (0 to 100%) is divided
into 8 sections (distance classes). The positioner continuously registers
the current position and increments the operating hours meter assigned
to the corresponding section (distance class) every hour. This allows
returns to previous operating conditions and is particularly used to eva-
luate the control properties of the control circuit or the entire fitting.
The setting range is divided as follows:

WT00 WT05 WT10 WT30 WT50 WT70 WT90 WT95

Setting ≥5 % ≥10 % ≥30 % ≥50 % ≥30 % ≥90 % ≥95 %
range <5% < 10 % < 30 % < 50 % < 70 % < 90 % < 95 %
section

You can collectively set the 8 operating hours meters to zero by press-
ing the increment key (for at least 5 seconds).
TIP: As the distance classes at the end of the diagnostic menu have
the numbers 36 to 43, in addition to the operating mode key press the
decrement key repeatedly. This takes you quickly to the diagnostic
numbers 36 to 43.

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 Operation

44 MA Setpoint
You can display the current setpoint in mA here.

. NOTE
All diagnostic values are updated every 15 minutes to a non--volatile
memory, so that in the event of a loss of electrical power only the
events of at most the last 15 minutes will be lost.

4.5.3 Online-Diagnosis

Some important variables and parameters are monitored continuously

during operation. In the “Configuration” operating mode you can config-
ure this monitoring so that the fault message output is activated when a
certain event such as exceeding a limit value occurs.
Table 3-2, page 114 shows which events can activate the fault
message output, how the parameters must be set for this event to be
monitored, when the fault message disappears again and where the
possible causes of the fault lie.
In automatic and manual operation response of the fault message
output on the display shows which is the fault message trigger. The two
digits at the bottom left indicate the corresponding error code. If several
triggers occur at the same time, these are displayed cyclically. The
instrument status which also contains all fault messages can be called
via HART with the command #48.

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Operation

Error Event Parameter Fault message dis- Possible causes

code setting appears when ...
1 Remaining con- always active ... the control error has Compressed air missing,
trol error disappeared again actuator fault, valve fault
(e.g. blockade).
2 Instrument not 47. FCT= nA ... the instrument is The instrument is configured
in automatic or = nAB brought into automatic or is in manual operation.
mode mode
3 Digital input DI1 47. FCT= nAB ... the digital input is no The contact connected to
or DI2 active and digital function longer activated the binary input has become
BIN1 or BIN2 to active (e.g. stuffing box
”on” monitoring, excess
pressure, temperature
switch).
4 Limit value 50. STRK¸OFF ... the stroke counter is The total distance traveled
Number of stro- reset or the limit value by the actuator exceeded
kes exceeded increased the set limit value.
5 Limit value 51. DCHG¸OFF ... the change of direction The number of changes of
change of di- counter is reset or the limit direction exceeded the set
rection excee- value increased limit value.
ded
6 Limit value bot- 52. ZERO¸OFF ... the deviation of the stop Wear of the valve seat, de-
tom hard stop 39.YCLS = do or disappears or the posits or foreign bodies in
exceeded up do instrument is re--initialized the valve seat, mechanical
maladjustment, friction
clutch maladjusted.
7 Limit value 53. OPEN¸OFF ... the deviation of the stop Wear of the valve seat, de-
top hard stop 39 YCLS = up or disappears or the posits or foreign bodies in
exceeded up do instrument is re--initialized the valve seat, mechanical
maladjustment, friction
clutch maladjusted.
8 Limit value 54. DEBA¸OFF ... the limit value is Increased stuffing box
dead zone 34.DEBA = Auto dropped below again friction, mechanical lots of
adaptation ex- the position feedback
ceeded
Table 3-2 Events which can activate the fault message output

Explanations of column “Error codes”:

1 Monitoring of control error

In automatic operation the error between setpoint and actual value is
monitored continuously. The fault message is activated with unchanged
control error according to the setting of the parameters 48. TIM, moni-
toring time for setting the fault messages and 49 LIM, response thresh-
old of the fault message. As soon as the control error drops back below
the response threshold, the fault message is reset.

2 Monitoring automatic operation

A fault message is generated when the instrument is not in the auto-
matic mode at the appropriate parameter setting “47. FCT”. In this way
the control system can be warned for example when the instrument has
been switched to manual operation or Configuration on site.

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 Operation

3 Digital input DI1 or DI2 active

A fault message is generated when the digital input is activated at the
the corresponding setting of the parameter “47. FCT”, function of the
fault message output and the parameter “42.BIN1”, function digital in-
put 1. This may be a switch for stuffing box monitoring, a temperature
switch or a limit value switch for example.
Digital input 2 (on the alarm module option) can be configured in the
same way.

4 Monitoring of number of strokes

5 Monitoring of number of changes of direction
The two values number of strokes and number of changes of direction
are compared continuously with the limit values which are specified
with the parameters “50. STRK” and “51. DCHG”. The fault message
output responds when exceeded. Both functions can be deactivated
with the parameter setting ”OFF”.

6 Monitoring of the bottom hard stop (valve seat)

7 Monitoring of the top hard stop
Monitoring of the bottom hard stop is activated when the parameter
“52. ZERO” has a value¸OFF. Errors of the valve seat can be detected
with this function for example. Exceeding of the limit value may hint at
deposits or foreign bodies in the valve seat. Exceeding the limit value
may be caused by wear of the valve seat. Mechanical maladjustment of
the position feedback may also trigger this error message.
Monitoring takes place every time the valve is in tight closing position.
The current position is compared with the one determined during initiali-
zation as a bottom end stop. Activation of the tight closing bottom func-
tion (parameter “39.YCLS”) is therefore a prerequisite.
Example: 3% is set as a value. Normally the setting 0% is adopted
when closed. If a value >3% or <--3% is determined instead, a fault is
reported.
The fault message remains activated until either a subsequent
monitoring remains within the tolerance or a new initialization is
performed. The deactivation of the monitoring (“52. ZERO”=OFF) also
clears any existing fault message.
This monitoring function supplies no useful results when the stops have
not been determined automatically in initialization but the limits set
manually (manual initialization“5.INITM”).
An appropriate diagnosis is made for the top hard stop. The limit value
for this is set with the parameter . Activation of the tight closing top
function (parameter “39.YCLS”) is therefore a prerequisite.

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Operation

8 Monitoring of the dead zone adaptation

If the dead zone increases unproportionally in operation in automatic
adaptation of the dead zone (parameter DEBA = Auto) this points to an
error in the system (e.g. a marked increase in stuffing box friction, play
in the displacement detection, leakage). Therefore a limit value can be
specified for this value (”54. DEBA”, limit value for dead zone
monitoring) which activates the fault message output when it is
exceeded.

4.5.4 Fault correction

Diagnostics indicator

see Table

In which operating mode did the fault occur?

• Initialization 4
• Manual mode and automatic mode 5 6 7 8

Under which circumstances and conditions did the fault occur?

• Wet environment (e.g. heavy rain or constant condensation) 5
• Vibrating fittings 5 8
• Under impact or shock (e.g. steam jets or breakaway flaps) 4
• Damp (wet) compressed air 5
• Dirty (contaminated with solid particles) compressed air 5 6

When does the fault occur?

• Constantly (reproducibly) 4 5 6 7
• Sporadically (not reproducible) 8
• Usually after a certain operating period 5 6 8

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 Operation

Fault description Possible cause(s) Corrective actions

(symptoms)
• Positioner comes • Initialization started from the final • Up to 1 min. waiting time required
to a halt in RUN 1 stop and • Do not start initialization from an
• Reaction time of max. 1 min. not end stop
waited • Confirm network pressure
• Network pressure not connected or
too low
• Postioner comes • Transmission ratio switch and • Check settings:
to a halt in RUN 2 parameter 2 (YAGL) and true stroke • See leaflet: Figure Device view (7)
did not correlate and parameters 2 and 3
• Stroke on the lever incorrectly set • Check stroke setting on the lever
• Piezo valve(s) do not switch (see • see Table 5
Table 5)
• Positioner comes • Actuator positioning time too long • Open restrictor fully and/or set
to a halt in RUN 3 pressure PZ(1) to the highest
permissible value
• Use booster if necessary
• Positioner comes • Play in the positioner, actuator, • Linear actuator:
to a halt in RUN 5, fittings system Check seating of the stud screw of
does not reach the coupling wheel
FINISH (waiting • Part-turn actuator:
time > 5 min) Check seating of the lever on the
positioner shaft
• Correct any other play between the
actuator and the fittings
Table 4

Fault description Possible cause(s) Corrective actions

(symptoms)
• CPU test blinks in • Water in the valve manifold (from • At the early stages the fault can be
the display of the wet compressed air) corrected by subsequent operation
Postioner (ca. ev- with dry air (when necessary, in a
ery 2 secs) temperature cupboard at 50 to
• Piezo valve(s) do 70 °C)
not switch • Otherwise: Repair (see Chapter 5,
• Actuator cannot be • Dampness in the valve manifold page 125)
moved in manual
or automatic
mode, or only in
one direction
• Piezo valve(s) do • Screw between cover hood and the • Tighten screw, or release cause of
not switch (no soft valve manifold is not tight or the jamming when necessary
clicking can be hood is jammed
heard when the + • Dirt (swarf, particles) in the valve • Repair (see Chapter 5, page 125)
or -- keys are manifold or new device with integrated fine
pressed in manual filter which can be replaced and
mode) cleaned
• Deposits on the contact(s) between • Clean all contact surfaces with alco-
the electronics board and the valve hol: when necessary bend the valve
manifold can occur from abrasion manifold contact springs back into
through continuous stresses from place
strong vibrations
Table 5

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Operation

Fault description Possible cause(s) Corrective actions

(symptoms)
• Actuator does not • Compressed air < 1.4 bar • Set inlet air pressure to > 1.4 bar
move
• Piezo valve(s) do • Restrictor(s) closed down • Open restrictor screw(s) (see leaf-
not switch (al- (screw(s) at the right end stop) let, Figure “View of device (6)”) by
though a soft turning to the left
clicking can be
heard when the + • Dirt in the valve manifold • Repair (see Chapter 5, page 125)
or -- keys are or new device with integrated fine
pressed in filter which can be replaced and
manual mode) cleaned
• One piezo valve • Pneumatic leak in the positioner, • Fix leak in the actuator and/or
constantly actuator system, start leak test in supply line
switches in sta- RUN 3 (Initialization) !!! • If the actuator and supply line are
tionary automatic intact:
mode (constant Repair (see Chapter 5, page 125)
p
setpoint)) and in or new device
manual mode • Dirt in the valve manifold (see • See above
above)
Table 6

Fault description Possible cause(s) Corrective actions

(symptoms)
• The two piezo • Static friction on the packing glands • Reduce static friction or increase
valve constantly of the fittings or actuator too high dead zone of postioner (parameter
switch alternately dEbA) until the oscillating
in stationary auto-
auto movements stop.
matic mode • Play in the positioner, actuator, • Linear actuator:
(constant set- fittings system Check seating of the stub screw of
point), actuator the coupling wheel
oscillates around • Part-turn actuator:
a middle point Check seating of the lever on the
positioner shaft
• Correct any other play between the
actuator and fittings
• Actuator too fast • Increase positioning times by
means of restrictor screws
• If fast positioning times are
required, increase dead zone
(parameter dEbA) until the
oscillating movements stop.
• Positioner does • Supply pressure too low • Increase supply pressure
not drive the valve • Load of the supply controller or • Intermediate burden converter
up to the end stop system output too low; required • Select 3/4 wire operation
(at 20 mA) load potential.
Table 7

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 Operation

Fault description Possible cause(s) Corrective actions

(symptoms)
• Zero point • Such high accelerations have oc- • Shut off the cause of the shocks
shifts sporadi- curred through impact or shock that • Reinitialize the positioner
cally (> 3 %) the friction clutch has shifted (e.g.
through steam jets in the steam pipe-
lines)
• Device function • Insufficient electrical supply • Check electrical supply
breaks down • With very high continuous stresses
totally: no dis- by vibrations, the following can occur:
play
l
• Screws of the electrical terminals can • Tighten screws and secure with seal-
loosen ing varnish
• The electrical terminals and/or elec- • Repair at (see Chapter 5, page 125)
tronic modules can be shaken loose • Prevention: Mount the positioner on
rubber metal
Table 8

4.6 Meanings of other display texts

Notes on the tables:

nn stands for variable numerical values
Fault symbol
/ (slash): the texts to the left and right of the slash
flash alternately

Reports before initializing (first commissioning):

Meaning/Cause Actions
Lower
Upper

line
line

CPU x Report after connecting the electrical S Wait

START x auxiliary power
P nnn.n x Potentiometer voltage for non-initiali- S Check using the ”+” and ”--” keys
zed positioner (P manual mode) (Set- whether the overall travel can be tra-
ting actual value in % of measure- versed without ever ”P------” being dis-
ment range) played
S Perform initialization
P------ x Measurement range exceeded, po- S Set transmission ratio selector to 90
tentiometer is in the inactive zone, degrees, in particular for part-turn
transmission ratio selector or effec- actuators
tive lever arm are not matched to the S Match effective arm length for linear
travel actuators to measurement range
NOINI x Positioner not initialized S Start initialization

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Operation

Messages during initialization:

Meaning/Cause Actions

Lower
Upper
line

line
P---- x See above See above
RUN 1 x Initialization started, part 1 active S Wait
(direction of control action being de-
termined)
RUN 2 x Initialization part 2 active S Wait
(travel check and determination of
the end stops)
RUN 3 x Initialization part 3 active S Wait
(determination and display of positio-
ning times)
RUN 4 x Initialization part 4 active (determina- S Wait
tion the minimum positioning incre-
ment length)
RUN 5 x Initialization part 5 active (optimiza- S Wait until ”FINSH” is displayed (initia-
tion of the behavior on transients) lization completed successfully)
S Press ”operating mode” key briefly to
acknowledge or longer to quit confi-
guration mode
YEND1 x only during manual initialization S Move to first end position using the
first end position can be moved to ”+” or ”--” key
S Press ”operating mode” key to ack-
nowledge
YEND2 only during manual initialization S Move to second end position using
second end position can be moved the ”+” or ”--” key
to S Press ”operating mode” key to ack-
nowledge
RANGE x only during manual initialization S Using ”+” and ”--” keys move to the
End position or measurement span other end position and press ”operat-
are outwith the permitted measure- ing mode” key to acknowledge,
ment range or
S Adjust friction clutch until ”ok” is dis-
played and press ”operating mode”
key to acknowledge
or
S Interrupt initialization by pressing the
”operating mode” key, switch to P
manual mode and correct the travel
and position sensing
ok only during manual initialization S Press ”operating mode” key to ack-
permitted measurement range for nowledge, the remaining steps
end positions reached (”RUN1” to ”FINSH”) will run through
automatically
RUN 1/ x Fault in RUN 1 S Ensure compressed air is sufficient
ERROR no movement e.g. no compressed air S Open any choke(s)
S Re-start initialization
d___U x Bar display of the zero point S With friction clutch set to ”P 4.0” to
Zero point is outwith the tolerance ”P 9.9” ( >0< )
range S Continue using the ”+” or ”--” key
SEt x Friction clutch misaligned; ”P 50.0” S For linear actuators, use the ”+” and
MIDDL x no displayed when arm horizontal ”--” keys to bring the arm to the cor-
rect angle on the spindle
S Press ”operating mode” key briefly to
acknowledge (initialization will re-
sume)

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 Operation

Meaning/Cause Actions

Lower
Upper
line

line
UP > x ”UP” -- tolerance range exceeded or S Match effective arm length for linear
inactive zone of potentiometer ent- actuators to measurement range, or
ered set transmission ratio selector to 90
degrees
S Press ”operating mode” key briefly to
acknowledge
S Re-start initialization
90_95 x Only applies to part-turn actuators: S Use the ”+” and ”--” keys to move into
travel is not within range 90 to 95% the range of 90 to 95%
S Press ”operating mode” key briefly to
acknowledge
U--d> x Measurement span ”Up--Down” is in- S Reduce effective arm length for linear
sufficient actuators or set transmission ratio
selector to 33 degrees
S Press ”operating mode” key briefly to
acknowledge
S Re-start initialization
U nn.n x Display the positioning time ”Up” S Wait, or
D-->U x S To change the travel time interrupt
initialization with the ”--” key,
or
S Activate the leakage test with the ”+”
key
d nn.n x Display the positioning time ”Down” S Wait, or
U-->d x S To change the travel time interrupt
initialization with the ”--” key,
or
S Activate the leakage test with the ”+”
key
NOZZL x Actuator stationary (initialization inter- S Travel time can be adjusted by vary-
rupted with the ”--” key during actua- ing the choke(s)
tion speed display) S Use the ”--” key to repeat the deter-
mination of the positioning speed
S Continue using the ”+” key
TESt x Leakage test active initialization inter- S Wait 1 minute
LEAKG x rupted with the ”+” key during travel- S Continue with the ”+” key
speed display)
nn.n x Value and units of results of the leak- S Remove leakage if value is too high.
x age test S Continue with the ”+” key
_oMIN
nn.n x Initialization completed successfully, S Press ”operating mode” key briefly to
FINSH x with display of the travel or positio- acknowledge or longer to quit confi-
ning angle as appropriate guration mode

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Operation

Reports on leaving ”configuration” operating mode:

Meaning/Cause Actions

Manual
Upper

P manual
Lower

Auto-
matic

mode
line

line

mode
Cn x Software version S Wait
VER x
Error x Monoticity transgression of S Correct value
SLnn x the free characteristic line
at support point ”n”

Reports on leaving ”configuration” operating mode:

Meaning/Cause Actions
Manual
Upper

P manual
Lower

Auto-
matic

mode
line

line

mode

CPU x Message after applying S Wait

START x auxiliary electrical power
HW / x Fault in the hardware S Exchange electronics
ERROR
NOINI x x Positioner not initialized S Start initialization

nnn.n x x x Setting actual value [in %]

for initialized positioners.
Flashing decimal point in-
dicates communication
with a class 2 master
AUTnn x x Automatic mode (nn = set-
point)
MANnn x Manual mode (nn = setpo- S Press operating mode
int) key to change to auto-
matic mode
oFL / 127.9 x x x Display range exceeded. S Adjust friction clutch so
Possible causes: that when moving the
S Furiction clutch or actuator the actual value
S Transmission ratio display remains within
selector changed or 0.0 to 100.0 or
S Positioner installed wi- S Change transmission ra-
thout reinitialization,
tio selector or
having previously been
fitted to another actua- S Carry out factory setting
tor (preset) and initialization
EXSTP x x Actuator stopped by bi-
nary input
EX UP x x Actuator moved by binary
input to upper stop
EXDWN x x Actuator moved by binary
input to lower stop
HTCNF x x x x HART configuration is run-
ning

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 Operation

4.7 Optimization of the control data

The data automatically determined during initialization for control qua-
lity are optimized for short duration commands with small overshoots.
In special cases (e.g. extremely small and specially quick actuators or
when operating with boosters) it can however occur that these data
need to be revised to achieve quick responses or heavy damping. The
following six parameters are available for this purpose:

13 Pulse length up
14 Pulse length down

This determines for any sense of actuation the smallest drive move-
ment pulse length. The optimum value depends heavy on the volume
of the actuator.
Small values will lead to small actuation increments and frequent actua-
tor movements. Note that if the value is too small no movement will
result. If actuator volumes are large, then it is better to use larger ac-
tuation increments. Note also that large actuation increments will still
lead to large movements for small actuators.

17 Short step zone up

18 Short step zone down

The short step zone is the range in which the deviation from setpoint
varies between the fast step zone and the dead band. In this zone the
actuator is activated in pulses.
If the value is small, even small changes of setpoint will evoke relatively
large positioning speeds and can thus lead to overshoots. If the value
is large, the overshoots will be reduced, particularly on large changes
of setpoint but will lead to slow positioning speeds, particularly as the
target setpoint is approached.

34 Prediction up These parameters modify the damping factor, changing the control
35 Prediction down dynamics.
If the value is small, responses will be quick but with overshoots. If the
value is large, response will be slow but without overshoots.

During setup it is recommended that an automatic initialization is performed first, later changing
positioner parameters to match any special requirements.
TIP: So as to have a fixed reference value, it is advantageous for special control optimization
to set a fixed value for the dead zone (parameter DEBA) instead of ”Auto”.
The above parameters are usually selected from the diagnostics menu and activated for
general adjustment by pressing the increment or decrement key. Any adjustment to a
parameter will be immediately effective. This means the effect of the new values on the control
results can be immediately tested.
On leaving the diagnostic menu the activation of the parameter for adjustment will be deactiva-
ted again.

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Operation

Series 6A Manual
124 A5E00756809--01
 Care and Maintenance

Service and Maintenance

5
The positioner is largely maintenance--free. The positioners are fitted
with filters in the pneumatic connections as protection against coarse
particles of dirt. If the pneumatic energy supply contains particles of
dirt, the filters may clog and impair the function of the positioner. In this
case the filters can be cleaned as follows.

Positioner in metal housing and explosion proof version

1. Switch off the pneumatic power supply and remove the pipes.

2. Remove the metal filters carefully from the holes and clean (e.g.
with compressed air).

3. Insert the filters.

4. Re-connect the pipes and supply pneumatic energy.

Positioner in plastic housing

Removal

1. Switch off the pneumatic power supply and remove the pipes.

2. Unscrew the cover

3. Remove the three screws from the pneumatic connector strip.

4. Remove the filters and O-rings behind the connector strip.

5. Clean the filters (e.g. with compressed air).

Installation

6. First insert the filters in the recesses in the plastic housing and then
place the O-rings on the filters.

7. Align the pneumatic connector strip on the two lugs and screw tight
with the three self--tapping screws.

Important:
Make sure that the same thread is used. To do this turn the screws
counterclockwise until they snap into the thread audibly. Only then
should you tighten the screws.

Series 6A Manual
A5E00756809--01 125
Care and Maintenance

8. Replace the cover and screw it tight.

9. Re--connect the pipes and supply pneumatic energy.

DANGER
! Electrostatic charging must be prevented in hazardous areas. These
could be caused by example when cleaning the positioner in plastic
housing with a dry cloth.

Repair/Upgrade Faulty equipment should be sent to the repair department with details
of the fault and its origin. When ordering replacement equipment,
please specify the serial number of the original equipment. You will find
the serial number on the type plate.
Address of the responsible repair location, your contact, lists of spare
parts etc. can all be found on the Internet, under:
www.siemens.com/automation/services&support or
www.automation.siemens.com/partner

Series 6A Manual
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 Technical Data

Technical Data
6
General data for basic device 6DR50xx
6DR51xx
6DR52xx
6DR53xx
(see following pages)

Series 6A Manual
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 Technical Data

Series 6A(all versions) Vibration resistance

General data • Harmonic oscillations 3.5 mm (0.14 inch), 2 ... 27 Hz
(sine-wave) according to 3 cycles/axis
Travel range (linear actuators) 3 ... 130 mm (0.12 ... 5.12 inch) DIN EN 60062-2-6/05.96
(angle of feedback shaft 16 ... 90°) 98.1 m/s² (321.84 ft/s²),
27 ... 300 Hz, 3 cycles/axis
Angle of rotation (part-turn actua- 30 ... 100°
tors) • Bumping (half-sine) 150 m/s² (492 ft/s²), 6 ms,
to DIN EN 60068-2-29/03.95 1000 shocks/axis
Installation
• Noise (digitally controlled) 10 ... 200 Hz; 1 (m/s²)²/Hz
• On linear actuators Using attachment set to DIN EN 60068-2-64/08.95 (3.28 (ft/s²)²/Hz)
6DR4004-8V and where neces-
sary with an additional lever arm 200 ... 500 Hz; 0.3 (m/s²)²/Hz
6DR4004-8L on actuators (0.98 (ft/s²)²/Hz)
according to IEC 534-6 (NAMUR) 4 hours/axis
with ribs, bars or flat face
• Recommended continuous duty ≤ 30 m/s² (≤ 98.4 ft/s²) without res-
• On part-turn actuators Using attachment set range of the complete fitting onance sharpness
6DR4004-8D on actuators with
mounting plane according to Weight, basic device
VDI/VDE 3845 and DIN 3337: • Plastic casing Approx. 0.9 kg (0.90 kg)
The required mounting console • Metal casing, aluminium Approx. 1.3 kg (1.30 kg)
has to be provided on the actua- • Metal casing, stainless steel Approx. 3.9 kg (3.90 kg)
tor side; shaft with groove and • Metal casing EEx d version Approx. 5.2 kg (11.46 lb)
female thread M6
Dimensions See Dimension drawing
Controller
Climate class to DIN EN 60721-3-4 To IEC 721
• Five-point switch Self-adjusting
• Storage 1) 1K5, but -40 ... +80 °C
• Dead zone (1K5, but -40 ... +176 °F)
- dEbA = Auto Self-adjusting or can be set as
fixed value • Transport 1) 2K4, but -40 ... +80 °C
(2K4, but -40 ... +176 °F)
- dEbA = 0.1 ... 10% Self-adjusting or can be set as
fixed value • Operation 2) 4K3, but -30 ... +80 °C
(4K3, but -22 ... +176 °F)
A/D converter
• Scan time 10 ms Certificate and approvals
• Resolution ≤ 0.05% Classification according to pressure For gases of fluid group 1, com-
• Transmission error ≤ 0.2% equipment plies with requirements of
• Temperature effect ≤ 0.1%/10 K (≤ 0.1%/18 °F) directive (DRGL 97/23/EC) article 3, paragraph 3 (sound
engineering practice SEP)
Cycle time
• 20 mA/HART device 20 ms Pneumatic data
• PA device 60 ms Power supply (inlet air)
• FF device 60 ms (min. loop time)
• Pressure 1.4 ... 7 bar (20.3 ... 101.5 psi):
Binary input BE1 (terminals 9/10; Suitable only for floating contact; Sufficiently greater than max.
electrically connected to the basic max. contact load < 5 mA with drive pressure (actuating pres-
device) 3V sure)
Degree of protection IP65 to EN 60 529/NEMA 4x Air quality to ISO 8573-1
Mounting position Any; pneumatic connections and • Solid particle size and density Class 2
exhaust opening not facing up in
wet environment • Pressure dew point Class 2 (min. 20 K (36 °F) below
ambient temperature)
CE marking Conformity as regards EMC
Directive 89/336 EC in accor- • Oil content Class 2
dance with the following stan- Unthrottled flow
dards
• Inlet air valve 3)
EMC requirements EN 61326/A1 Appendix A.1 and - 2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm)
NAMUR NE21 August 98 - 4 bar (58 psi) 7.1 Nm³/h (31.3 USgpm)
Material - 6 bar (87 psi) 9.8 Nm³/h (43.1 USgpm)
• Housing • Outlet air valve 3)
- 6DR5..0-... (plastic) Glass-fiber-reinforced Macrolon - 2 bar (29 psi) 8.2 Nm³/h (36.1 USgpm)
- 6DR5..1-... (metal) GK AISi12 - 4 bar (58 psi) 13.7 Nm³/h (60.3 USgpm)
- 6DR5..2-... (stainless steel) Austenitic stainless steel mat. - 6 bar (87 psi) 19.2 Nm³/h (84.5 USgpm)
No. 1.4581 Valve leakage < 6⋅10-4 Nm³/h (0.0026 USgpm)
- 6DR5..5-... (metal, pressure- GK AISi12
Throttle ratio Adjustable up to ∞ : 1
proof)
Power consumption in the con- < 3.6⋅10-2 Nm³/h (0.158 USgpm)
• Pressure gauge block Aluminium AIMgSi, coated
trolled state
Types of actuators
• In plastic casing Single-action and double-action
• In aluminium casing Single-action
• In flameproof casing Single-action and double-action
• In stainless steel casing Single-action and double-action
1) During commissioning at ≤ 0 °C (≤ 32 °F) make sure that the valves are
flushed long enough with the dry medium.
2) At ≤ -10 °C the display refresh rate of the LCD is limited. Only T4 is per-
missible when using Iy module.
3) With EEx d version (6DR5..5-...) the values are reduced by approx. 20%

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128 A5E00756809--01
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Series 6A Basic device Basic device Basic device Basic device

without Ex protection with EEx-d protection with EEx ia/ib protection with EEx n protection
(flameproof casing)
Explosion protection to Without EEx d EEx ia/ib EEx n
EN 50014, EN 50020 and EN 50021 II 2 G EEx d II C T6 II 2 G EEx ia/ib II C T6 II 3 G EEx nA L [L] II C T6
Mounting location Zone 1 Zone 1 Zone 2
Permissible ambient temperature for -30 ... +80 °C T4: -30 ... +80 °C (-22 ... +176 °F)
operation (-22 ... +176 °F)
T5: -30 ... +65 °C (-22 ... +149 °F)
(for basic devices with EEX ia/ib and
EEx n protection the following applies: T6: -30 ... +50 °C (-22 ... +122 °F)
At ≤ -10 °C (+14 °F) the display refresh
rate of the LCD is limited. Only T4 is
permissible when using Iy module.)
Electrical data
Input
2-wire connection (terminals 6/8)
Rated signal range 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA
Current to maintain the power supply ≥ 3.6 mA ≥ 3.6 mA ≥ 3.6 mA ≥ 3.6 mA
Required load voltage
UB (corresponds to Ω at 20 mA)
• Without HART (6DR50..)
- Typical ≤ 6.36 V (corresponds to ≤ 6.36 V (corresponds to ≤ 7.8 V (corresponds to ≤ 7.8 V (corresponds to
318 Ω) 318 Ω) 390 Ω) 390 Ω)
- Max. ≤ 6.48 V (corresponds to ≤ 6.48 V (corresponds to ≤ 8.3 V (corresponds to ≤ 8.3 V (corresponds to
324 Ω) 324 Ω) 415 Ω) 415 Ω)
• Without HART (6DR53..)
- Typical ≤ 7.9 V (corresponds to – – –
395 Ω)
- Max. ≤ 8.4 V (corresponds to – – –
420 Ω)
• With HART (6DR51..)
- Typical ≤ 6.6 V (corresponds to ≤ 6.6 V (corresponds to – –
330 Ω) 330 Ω)
- Max. ≤ 6.72 V (corresponds to ≤ 6.72 V (corresponds to – –
336 Ω) 336 Ω)
• With HART (6DR52..)
- Typical – ≤ 8.4 V (corresponds to ≤ 8.4 V (corresponds to ≤ 8.4 V (corresponds to
420 Ω) 420 Ω) 420 Ω)
- Max. – ≤ 8.8 V (corresponds to ≤ 8.8 V (corresponds to ≤ 8.8 V (corresponds to
440 Ω) 440 Ω) 440 Ω)
• Static destruction limit ± 40 mA – –
Internal capacitance Ci
• Without HART – – ≤ 22 nF –
• With HART – – ≤ 7 nF –
Internal inductance Li
• Without HART – – ≤ 0.12 mH –
• With HART – – ≤ 0.24 mH –
For connection to power circuits with – – intrinsically safe Ui ≤ 30 V DC
Uo ≤ 30 V DC Ii ≤ 100 mA
Ik ≤ 100 mA
P≤1W

Series 6A Manual
A5E00756809--01 129
 Technical Data

Series 6A Basic device Basic device Basic device Basic device

without Ex protection with EEx-d protection with EEx ia/ib protection with EEx n protection
(flameproof casing)
3-/4-wire device (terminals 2/4
and 6/8) (6DR52.. and 6DR53..)
• Power supply UH 18 ... 35 V DC 18 ... 35 V DC 18 ... 30 V DC 18 ... 30 V DC
• Current consumption IH (UH - 7.5 V)/2.4 kW [mA] (UH - 7.5 V)/2.4 kW [mA] (UH - 7.5 V)/2.4 kW [mA] (UH - 7.5 V)/2.4 kW [mA]
• Internal capacitance Ci – – ≤ 22 nF –
• Internal inductance Li – – ≤ 0.12 mH –
• For connection to power circuits with – – intrinsically safe Ui ≤ 30 V DC
Uo ≤ 30 V DC Ii ≤ 100 mA
Ik ≤ 100 mA
P≤1W
Current input IW
Rated signal range 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA
Load voltage at 20 mA ≤ 0.2 V (corresponds to ≤ 0.2 V (corresponds to ≤ 1 V (corresponds to ≤ 1 V (corresponds to
10 Ω) 10 Ω) 50 Ω) 50 Ω)
Internal capacitance Ci – – ≤ 22 nF –
Internal inductance (Li) – – ≤ 0.12 mH –
For connection to power circuits with – – intrinsically safe Ui ≤ 30 V DC
Uo ≤ 30 V DC Ii ≤ 100 mA
Ik ≤ 100 mA
P≤1W
Electrical isolation between UH and IW between UH and IW between UH and IW between UH and IW
(2 intrinsically safe cir-
cuits)
Test voltage 840 V DC (1 s)
Connections
• Electric Screw terminals 2.5 Screw terminals 2.5 Screw terminals 2.5 Screw terminals 2.5
AWG28-12 AWG28-12 AWG28-12 AWG28-12
Cable gland M20 or EEx d certified cable Cable gland M20 or Cable gland M20 or
½“ NPT gland M20x1.5, ½“ NPT ½“ NPT ½“ NPT
or M25x1.5
• Pneumatic Female thread G1/4 DIN 45141 or ¼“ 18 NPT
External position sensor (potentiometer or NCS; as option)
• Uo – – <5V <5V
• Io – – < 75 mA < 75 mA
• Is – – <160 mA <160 mA
• Po – – <120 mW <120 mW
Maximum permissible external capaci- – – < 1 µF < 1 µF
tance Co
Maximum permissible external induc- – – < 1 mH < 1 mH
tance Lo

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130 A5E00756809--01
 Technical Data

■
Option modules Without Ex protection With Ex protection
Ex protection to EN 50 014 and EN 50 020 – II 2G EEx ia/ib II C T4/T5/T6 II 3G EEx nA L [L] II C T6
Mounting location – Zone 1 Zone 2
Permissible ambient temperature for opera- -30 ... +80 °C (-22 ... +176 °F) T4: -30 ... +80 °C (T4: -22 ... +176 °F)
tion
(For devices with Ex protection: Only in con- T5: -30 ... +65 °C (-22 ... +149 °F)
junction with the basic device 6DR5... -.E.... T6: -30 ... +50 °C (-22 ... +122 °F)
Only T4 is permissible when using Iy module)
Electrical data
Alarm module 6DR4004-8A (without Ex protec- 6DR4004-6A (with Ex protection) 6DR4004-6A (with Ex protection)
tion)
Binary alarm outputs A1, A2 and alarm output
Signal status High (not responded) Active, R = 1 kΩ, +3/-1%* ≥ 2.1 mA ≥ 2.1 mA
Signal status Low* (responded) Disabled, IR < 60 µA ≤ 1.2 mA ≤ 1.2 mA
(* Low is also the status when the basic
device is faulty or has not electric power sup- (* When used in the flameproof (Switching threshold with sup- (Switching threshold with sup-
ply) casing the current consumption ply to DIN EN 60947-5-6: ply to DIN EN 60947-5-6:
is limited to 10 mA per output.) UH = 8.2 V, Ri = 1kΩ) UH = 8.2 V, Ri = 1kΩ)
Internal capacitance Ci – ≤ 5.2 nF –
Internal inductance Li – Negligible –
Power supply UH ≤ 35 V – –
Connection to power circuits with – intrinsically safe switching Ui ≤ 15.5 V DC
amplifier DIN 19234
Uo ≤ 15.5 V DC
Ik ≤ 25 mA, P ≤ 64 mW
Binary input BE2
• Electrically connected to the basic device
- Signal status 0 Floating contact, open Floating contact, open Floating contact, open
- Signal status 1 Floating contact, closed Floating contact, closed Floating contact, closed
- Contact load 3 V, 5 µA 3 V, 5 µA 3 V, 5 µA
• Electrically isolated from the basic device
- Signal status 0 ≤ 4.5 V or open ≤ 4.5 V or open ≤ 4.5 V or open
- Signal status 1 ≥ 13 V ≥ 13 V ≥ 13 V
- Natural resistance ≥ 25 kΩ ≥ 25 kΩ ≥ 25 kΩ
Static destruction limit ± 35 V – –
Internal inductance and capacitance – Negligible –
Connection to power circuits – Intrinsically safe Ui ≤ 25.2 V Ui ≤ 25.2 V DC
Electrical isolation The 3 outputs, the input BE2 and the basic device are electrically isolated from each other
Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s
SIA module (not for EEx d version) 6DR4004-8G (without Ex protec- 6DR4004-6G (with Ex protec- 6DR4004-6G (with Ex protec-
tion) tion) tion)
Limit transmitter with slot-type initiators and 2-wire connection 2-wire connection 2-wire connection
alarm output
Ex protection Without II 2 G EEx ia/ib IIC T6 II 2 G EEx nA L [L] IIC T6
Connection 2-wire system to DIN EN 60947-5-6 (NAMUR), for switching amplifier to be connected on load side
2 slot-type initiators Type SJ2-SN Type SJ2-SN Type SJ2-SN
Function NC (normally closed) NC (normally closed) NC (normally closed)
Connection to power circuits with nominal voltage 8 V Intrinsically safe switching Ui ≤ 15.5 V DC
Current consumption: amplifier DIN EN 60947-5-6 Pi ≤ 64 mW
≥ 3 mA (limit value not Ui ≤ 15.5 V DC
responded) Ii ≤ 25 mA, Pi ≤ 64 mW
≤ 1 mA (limit value
responded)
Internal capacitance – ≤ 41 nF –
Internal inductance – ≤ 100 mH –
Electrical isolation The 3 outputs are electrically The 3 outputs are electrically The 3 outputs are electrically
isolated from the basic device isolated from the basic device isolated from the basic device
Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s
Alarm output See Alarm module See Alarm module See Alarm module

Series 6A Manual
A5E00756809--01 131
 Technical Data

Accessory modules Without Ex protection With Ex protection

Electrical data
Explosion protection to EN 50014 and – II 2G EEx ia/ib II C T4/T5/T6 II 3G EEx nA L [L] II C T6
EN 50020
Mounting location – Zone 1 Zone 2
Permissible ambient temperature for oper- -30 ... +80 °C (-22 ... +176 °F) T4: -30 ... +80 °C (-22 ... +176 °F)
ation
(For devices with Ex protection: Only in T5: -30 ... +65 °C (-22 ... +149 °F)
conjunction with the basic device T6: -30 ... +50 °C (-22 ... +122 °F)
6DR5... -.E.... Only T4 is permissible when
using Iy module. )
Iy module 6DR4004-8J (without Ex protec- 6DR4004-6J (with Ex protection) 6DR4004-6J (with Ex protection)
tion)
DC output for position feedback 2-wire connection 2-wire connection 2-wire connection
Nominal signal range i 4 ... 20 mA, short-circuit-proof 4 ... 20 mA, short-circuit-proof 4 ... 20 mA, short-circuit-proof
Total operating range 3.6 ... 20.5 mA 3.6 ... 20.5 mA 3.6 ... 20.5 mA
Power supply UH +12 ... +35 V +12 ... +30 V +12 ... +30 V
External load RB [kW] ≤ (UH [V] - 12 V) /i [mA] ≤ (UH [V] - 12 V) /i [mA] ≤ (UH [V] - 12 V) /i [mA]
Transmission error ≤ 0.3% ≤ 0.3% ≤ 0.3%
Temperature effect ≤ 0.1%/10 K (≤ 0.1%/18 °F) ≤ 0.1%/10 K (≤ 0.1%/18 °F) ≤ 0.1%/10 K (≤ 0.1%/18 °F)
Resolution ≤ 0.1% ≤ 0.1% ≤ 0.1%
Residual ripple ≤ 1% ≤ 1% ≤ 1%
Internal capacitance Ci – ≤ 11 nF –
Internal inductance Li – Negligible –
For connection to power circuits with Intrinsically safe: Ui ≤ 30 V DC Ui ≤ 30 V DC
Ii ≤ 100 mA; Pi ≤ 1 W (only T4) Ii ≤ 100 mA; Pi ≤ 1 W (only T4)
Electrical isolation Electrically isolated from the Electrically isolated from the Electrically isolated from the
basic device basic device basic device
Test voltage 840 V DC, 1 s 840 V DC, 1 s 840 V DC, 1 s
NCS sensor
(not for EEx d version)
Position range
• Linear actuator 3 ... 130 mm (0.12 ... 5.12 inch), 3 ... 130 mm (0.12 ... 5.12 inch), 3 ... 130 mm (0.12 ... 5.12 inch),
to 200 mm (7.87 inch) on request to 200 mm (7.87 inch) on request to 200 mm (7.87 inch) on request
• Part-turn actuator 30° ... 100° 30° ... 100° 30° ... 100°
Linearity (after correction by SIPART PS2)
• Linear actuator ± 1% ± 1% ± 1%
• Part-turn actuator ± 1% ± 1% ± 1%
Hysteresis ± 0.2% ± 0.2% ± 0.2%
Continuous working temperature -40 ... +85 °C (-40 ... +185 °F), -40 ... +85 °C (-40 ... +185 °F), -40 ... +85 °C (-40 ... +185 °F),
extended temperature range on extended temperature range on extended temperature range on
request request request
Degree of protection of casing IP68/NEMA 4X IP68/NEMA 4X IP68/NEMA 4X

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132 A5E00756809--01
 Scope of deliver

Scope of Delivery
7
The positioner and its options modules are delivered as separate units
and in different versions. Positioners and options modules for operation
in hazardous areas and non--hazardous areas are available. These ver-
sions are identified respectively by a special rating plate.

WARNING
! In the combination of components it must be ensured that only positio-
ners and options modules are combined which are approved for the
respective area of application. This applies especially for safe
operation of the positioner in areas in which the atmosphere is poten-
tially explosive (zone 1 and 2). The instrument categories (2 and 3) of
the instrument itself and those of its options must be observed.

Series 6A Manual
A5E00756809--01 133
 Scope of delivery

7.1 Ordering data

Series 6A - electropneumatic positioners

Product designation Order No.

Elektropneumatic Positioners 6A-6DR5 - 0 - 5 A

Design
2-wire, without HART (4 to 20mA) 0
2-wire, with HART, without explosion protection 1
2-, 3-, 4- wire with HART, with explosion protection 2
2-, 3-, 4- wire without HART, without explosion protection, 3
only with plastic casing
PROFIBUS PA connection (not with explosion protection 5
on version PROFIBUS plug M12)
FOUNDATION Fieldbus 6
For actuator
single-action 1
double-action 2
Housing
plastic 0
Aluminium; only single-action 1
Stainless steel; not FM/CSA 2
Explosion protection
without N
with explosion protection EEx ia/ib (CENELEC/FM/CSA) E
Connection thread (electric/pneumatic)
M20 X 1,5 / G1/4 G
1/2" NPT / 1/4" NPT N
M20 X 1,5 / 1/4" NPT M
1/2" NPT / G1/4 P
With PROFIBUS plug M12 / G1/4“ R
With PROFIBUS plug M12 / N1/4“ S
Limit monitor, built-in,
incl. 2nd cable gland
without 0
Alarm module; electronic (6DR4004-...A) 1
SIA module; slot initiators (6DR4004-...G) 2
Mechanical limit switch module (6DR4004-...K) 3
Option modules, built-in;
incl. 2nd cable gland
without 0
ly module for position feedback (4 to 20mA) 1
(6DR4004-...J)
EMC filter module for external position sensor 2
(C73451-A430-D23)
ly module and EMC filter module for external position sensor 3
Quick start guide
English/German/French/Spanish/Italian/Chinese K
Attached gauge block assembly
without 0
single G1/4 1
double G1/4 2
single NPT 3
double NPT 4
ex stock

Series 6A Manual
134 A5E00756809--01
 Scope of deliver

Series 6A - electropneumatic positioners

Product designation Order No.

Options
Alarm module, without explosion protection 6DR4004-8A
Alarm module, with explosion protection CENELEC 6DR4004-6A
Alarm module, with explosion protection FM 6DR4004-7A
Mechanical limit switch module 6DR4004-8K
SIA module, without explosion protection 6DR4004-8G
SIA module, with explosion protection CENELEC and FM 6DR4004-6G
ly module, without explosion protection 6DR4004-8J
ly module, with explosion protection CENELEC 6DR4004-6J
ly module, with explosion protection FM 6DR4004-7J
Accessories
Connection block for solenoid valve (mounting to IEC 534-6) 6DR4004-1B
Connection block for solenoid valve (mounting "SAMSON") 6DR4004-1C
Mounting kit for linear actuators up to 35 mm (1.38 inch) travel 6DR4004-8V
Mount. kit (without bracket) for lin. actuators up to 35 mm 6DR4004-8VK
Mount. kit (without bracket) for lin. actuators > 35 mm 6DR4004-8VL
Lever arm for travels from 35 to 130 mm 6DR4004-8L
Mounting kit for part-turn actuators (mounting bracket not included) 6DR4004-8D
Mounting kit for SAMSON actuator, type 3277 6DR4004-8S
Pressure gauge block, single-action 6DR4004-1M
Pressure gauge block, single-action, NPT 6DR4004-1MN
Pressure gauge block, double-action 6DR4004-2M
Pressure gauge block, double-action, NPT 6DR4004-2MN
EMC filter module for external position sensor C73451-A430-D23
NCS-Sensor for part-turn actuator, Ex ia/ib 6DR4004-6NN10
NCS-Sensor for part-turn actuator, without explosion protection 6DR4004-8NN10
NCS-Sensor for linear actuator (up to 14 mm), Ex ia/ib 6DR4004-6NN20
NCS-Sensor for linear actuator (up to 14 mm) without ex-protection 6DR4004-8NN20
NCS-Sensor for linear actuator (> 14 mm), Ex ia/ib 6DR4004-6NN30
NCS-Sensor for linear actuator (> 14 mm), without ex-protection 6DR4004-8NN30
HART modem 7MF4997-1DA 1)
1)
Export regulation: AL: N; ECCN: EAR99H

Series 6A Manual
A5E00756809--01 135
Scope of delivery

7.2 Scope of delivery of standard controller

Versions Housing Valve Ex-protection Order numbers

SIPART PS2 Plastic housing single action non Ex 6DR5010-xNxxx-0AA0
2L without Plastic housing double action non Ex 6DR5020-xNxxx-0AA0
HART Metal housing single action non Ex 6DR5011-xNxxx-0AA0
Plastic housing single action CENELEC/FM 6DR5010-xExxx-0AA0
SIPART PS2 Plastic housing double action CENELEC/FM 6DR5020-xExxx-0AA0
2L without Metal housing single action CENELEC/FM 6DR5011-xExxx-0AA0
HART Explosion proof housing single action CENELEC/FM 6DR5015-xExxx-0AA0
Explosion proof housing double action CENELEC/FM 6DR5025-xExxx-0AA0
Plastic housing single action non Ex 6DR5110-xNxxx-0AA0
SIPART PS2 Plastic housing double action non Ex 6DR5120-xNxxx-0AA0
2L with HART
Metal housing single action non Ex 6DR5111-xNxxx-0AA0
Plastic housing single action CENELEC/FM 6DR5210-xExxx-0AA0
Plastic housing double action CENELEC/FM 6DR5220-xExxx-0AA0
SIPART PS2 Metal housing single action CENELEC/FM 6DR5211-xExxx-0AA0
4L with HART
Explosion proof housing single action CENELEC/FM 6DR5215-xExxx-0AA0
Explosion proof housing double action CENELEC/FM 6DR5225-xExxx-0AA0

SIPART PS2 Plastic housing single action non Ex 6DR5310-xNxxx-0AA0

4L without
t out Plastic housing double action non Ex 6DR5320-xNxxx-0AA0
HART Metal housing single action non Ex 6DR5311-xNxxx-0AA0

2L corresponds to two-wire operation

4L corresponds to four--wire-operation
--x stands for sub--variant

7.3 Scope of delivery of options

Option Order number

SIA module non Ex 6DR4004-8G
SIA module Ex (CENELEC / FM)1)2) 6DR4004-6G
Alarm module non Ex 6DR4004-8A
Alarm module Ex (PTB)1) 6DR4004-6A
Alarm module Ex (FM)2) 6DR4004-7A
Jy-module non Ex 6DR4004-8J
Jy-module Ex (PTB)1) 6DR4004-6J
Jy-module Ex (FM)2) 6DR4004-7J
1) EC-type examination certificates
2) Approval Reports of Factory Mutual System

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136 A5E00756809--01
 Scope of deliver

7.4 Scope of delivery of accessories

Accessories Order number

Mounting kit set linear actuators IEC 534 -- 6 6DR4004-8V
including lever arm for 3 to 35 mm way
Additional lever for > 35 to 130 mm way 6DR4004-8L
Mounting kit part-turn actuators VDI/VDE 3845 6DR4004-8D
Solenoid valve block for SAMSON actuator (integrated mounting) 6DR4004-1C
Manometer block single acting 6DR4004-1M
Manometer block double acting 6DR4004-2M
Solenoid valve block single acting (NAMUR) 6DR4004-1B
Mounting set for SAMSON actuator (integrated mounting) 6DR4004-8S
NCS-Sensor 6DR4004-_ N_ _ 0
not explosion protected 6DR4004-8N
explosion-protected 6DR4004-6N
cable length 6 m 6DR4004-_NN
for part-turn actuators 6DR4004-_N_10
for linear actuators up to 14 mm 6DR4004-_N_20
EMC filter module C73451-A430-D23
External position detection system C73451-A430-D78
Operating software SIMATIC PDM on request

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A5E00756809--01 137
Scope of delivery

7.5 List of Spare Parts

Spare parts list: SIPART PS2 positioner

Description Order No. for version
Cover (plastic enclosure) with C73451--A430--D82 6DR4___
screws (4 pcs) and seal 6DR5___

Cover (metal enclosure) with screws C73451--A430--D83 6DR4___

(4 pcs) and seal 6DR5___

Motherboard, two--wire without A5E00082459 6DR50__--_N

HART, without explosion protection 6DR40__--_N *)
Motherboard, two--wire without A5E00082457 6DR50__--_E
HART, with explosion protection
Motherboard, two--wire HART, wi- A5E00082458 6DR51__--_N
thout explosion protection 6DR40__--_N *)
Motherboard, two--,three--,four--wire A5E00082456 6DR52__
HART, with explosion protection
Motherboard Two--,three--,four--wire A5E00102018 6DR53__--_N
without HART, without expl. protect. 6DR40__--_N *)
Motherboard PROFIBUS PA, wi- A5E00141523 6DR55__--_N..
thout explosion protection 6DR41__--_N
Motherboard PROFIBUS PA, with A5E00141550 6DR55__--_E
explosion protection 6DR41__--_E
Motherboard FIELDBUS Founda- A5E00215467 6DR56__
tion, without explosion proof
Motherboard FIELDBUS Founda- A5E00215466 6DR56__
tion, with explosion protection
Pneumatic block (Valve single acting C73451--A430--D80 6DR4___
incl. seals and screws) 6DR5___

Pneumatic block (Valve double ac- C73451--A430--D81 6DR4___

ting incl. seals and screws) 6DR5___

Potentiometer (complete) C73451--A430--D84 6DR4___

6DR5___

*) 6DR40.. can be used after having clarified whether application with two--wire or three--wire/four--wire
input
Note: For accesories and option modules see Catalog FI 01 ”Field In-
struments for Process Automation”

Series 6A Manual
138 A5E00756809--01
 Index

Index
8
A F
Accessories, 38 Filters, Cleaning the ~, 125
Alarm function, 104 Firmware version, 89
Alarm module, 32, 59, 64, 68 Four--wire connection, 58, 62, 67
Application
positioner in a wet environment, 42
under great accelerations and vibrations, 44 G
Assembly, 41 General information, 5
Screw--type gland with plastic hose, 44
Assembly procedure, 48, 51
linear actuator, 49
H
HART module, 26
part--turn actuator, 52, 53 Housing, 11
Automatic, Changing the operating mode, 92

B I
Initialization, 98
Base plate, 56 Automatic ~, Structogram, 81
Block diagram, Mode of operation, 25 automatic ~, 70, 72, 77, 80
changing the operating mode, 91
C copying ~, 70
manual ~, 70, 74, 79
Catalogs, 141
Commissioning, 70 Initialization data, Copying the ~, 85
Configuration, changing the operating mode, Input keys, 87
91 Installation positions, favorable and
Current output, Electrical Connection, 59, 64, unfavorable, 43, 45
67 Instrument identification, 39
Iy module, 31, 59, 64, 67

D L
Delivery, 10
Design Rating Plate, 17 Lever arm transmission, 97
Diagnosis, 108 Linear actuator
Online, 113 automatic initialization, 72
Diagnostic, Display, 108 manual initialization, 74
Diagnostic display, Changing the operating preparation, 70
mode, 92 Literature, 141
Diagnostic values, meaning of the ~, 109
Digital input, electrical connection, 59, 64, 68
Digital output, electrical connection, 59, 64, 68
M
Maintenance, 125
Dimensional drawings, 39
Manometer block, 38
Display, 87
Manual mode
Display texts, meanings, 119
Changing the operating mode, 92
distance class, 112
P manual mode, 91
double--acting, 13
Mechanical limit switch module, 34, 60
EEx i, 65
E Mechnical limit switch module, 65
Electrical connection, 18, 55 not EEx, 60

Series 6A Manual
A5E00756809--01 139
Index

Method of operation, 15, 22 Restrictors, 22

Mounting kit
linear actuator, 47
part--turn actuator, 50 S
Scope of Delivery, 133
Series circuit, of two positioners, 63
O Service, 125
Operating mode Setpoint, 113
AUT, 92 Setpoint characteristic, 100
MAN, 92 SIA module, 33, 60, 65, 68
Operating Modes, 90 Electrical Connection, 60, 65, 68
Operating modes, Change ~, 90 Split range, 63, 98
Operation, 87 Electrical Connection, 63
Options, 12, 27 Standard controller, 61, 66
Standards, 10
Structograms of automatic initialization, 80
P
Parameter table, SIPART PS2, 94
Parameters, 93 T
Part--turn actuator, 13, 54, 55 Technical data, 127
Automatic initialization, 77 Three--wire connection, 58, 62, 67
manual initialization, 79 Two--wire connection, 57, 58, 61, 66
preparation, 77 Type key, 39
PDM (Process Device Manager), 85, 112
Personnel, Qualification, 7
Pneumatic connection, 19, 69 U
Positioner exchange, 70, 85 Use as intended, 9
Positioning, 21
Preset, 107
Purge air switching, 22
V
Versions, 11
Vibrations, 44
Q View of the instrument, 17
Qualified Personnel, 7
W
R Warranty, 9
wet environment, 42
Reset, 107

Series 6A Manual
140 A5E00756809--01
CONTROLS
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A5E00756809-01
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