4/2015Edition
Answers for industry.
Installation Instructions
Smart Valve Positioner
Integral Volume Booster
SIPART PS2
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E35229820
Ⓟ
04/2015 Subject to change
Copyright © Siemens AG 2015.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury
may
result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 3
Table of contents
1 Introduction ........................................................................................................................................ 5
1.1 Purpose of this documentation ................................................................................................ 5
1.2 History ..................................................................................................................................... 5
1.3 Purpose ................................................................................................................................... 5
1.4 Checking the consignment ...................................................................................................... 6
1.5 Transportation and storage ..................................................................................................... 6
1.6 Notes on Warranty .................................................................................................................. 7
2 Safety notes ....................................................................................................................................... 9
2.1 Warning Symbols .................................................................................................................... 9
2.2 Laws and directives ............................................................................................................... 10
2.3 Conformity with European directives ..................................................................................... 10
2.4 Loss of safety of device with type of protection "Intrinsic safety Ex i" .................................... 11
3 Theory of Operation.......................................................................................................................... 13
4 Installing/mounting ........................................................................................................................... 15
4.1 Basic Safety Instructions ....................................................................................................... 15
4.1.1 Improper Commissioning ...................................................................................................... 15
4.1.2 Exceeded maximum ambient or process media temperature ............................................... 16
4.1.3 Unsuitable Compressed Air .................................................................................................. 17
4.1.4 Prior to working on the control valve ..................................................................................... 17
4.1.5 Proper Mounting.................................................................................................................... 18
4.1.5.1 Incorrect mounting ................................................................................................................ 18
4.1.5.2 Loss of degree of protection .................................................................................................. 18
4.2 Integral Volume Booster ........................................................................................................ 18
4.3 Installation ............................................................................................................................. 20
4.4 Pneumatic Connections ........................................................................................................ 34
4.5 Device Setup ......................................................................................................................... 34
5 Service and maintenance.................................................................................................................. 37
5.1 Maintenance.......................................................................................................................... 37
6 Dimension drawings ......................................................................................................................... 41
6.1 Installation and Outline Drawings .......................................................................................... 41
Index ............................................................................................................................................... 43
Table of contents
Integral Volume Booster Installation Instructions
4 Hardware Installation Manual, 4/2015, A5E35229820-AB
Tables
Table 4- 1 Climate Class ............................................................................................................................. 19
Table 4- 2 Weight ........................................................................................................................................ 19
Figures
Figure 3-1 Single Acting Booster ................................................................................................................. 14
Figure 4-1 O-ring Gauge ............................................................................................................................. 30
Figure 4-2 O-ring Connection ...................................................................................................................... 31
Figure 4-3 Connecting Block ....................................................................................................................... 32
Figure 4-4 Gauge Connection ..................................................................................................................... 32
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 5
Introduction
1
1.1
Purpose of this documentation
These instructions are a brief summary of important features, functions and safety
information, and contain all information required for safe use of the device. Read the
instructions carefully prior to installation and commissioning. In order to use the device
correctly, first review its principle of operation.
The instructions are aimed at persons who mechanically assemble the device, connect it
electrically, and start it up.
To achieve optimum usage of the device, read the detailed version of the instructions.
See also
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)
Product information on SIPART PS2 in the Internet (http://www.siemens.com/sipartps2)
1.2
History
The contents of these instructions are regularly reviewed and corrections are included in
subsequent editions. We welcome suggestions for improvement.
The following table shows the most important changes in the documentation compared to
each previous edition.
Edition
Remarks
10/2014 First edition of Installation Instructions for the SIPART PS2 Integral Volume Booster.
4/2015 Second edition of Installation Instructions for the SIPART PS2 Integral Volume Booster.
This document replaces all previous instructions for use.
1.3
Purpose
The electropneumatic positioner is used for the continuous control of process valves with
pneumatic drives in the following industries.
● Chemicals
● Oil and gas
● Energy production
● Food and beverages
● Pulp and paper
Introduction
1.4 Checking the consignment
Integral Volume Booster Installation Instructions
6 Hardware Installation Manual, 4/2015, A5E35229820-AB
● Water/waste water
● Pharmaceutical industry
● Offshore plants
1.4
Checking the consignment
1. Check the packaging and the delivered items for visible damage.
2. Report any claims for damages immediately to the shipping company.
3. Retain damaged parts for clarification.
4. Check the scope of delivery by comparing your order to the shipping documents for
correctness and completeness.
WARNING
Using a damaged or incomplete device
Danger of explosion in hazardous areas.
• Do not use damaged or incomplete devices.
1.5
Transportation and storage
To guarantee sufficient protection during transport and storage, observe the following:
● Keep the original packaging for subsequent transportation.
● Devices/replacement parts should be returned in their original packaging.
● If the original packaging is no longer available, ensure that all shipments are properly
packaged to provide sufficient protection during transport. Siemens cannot assume
liability for any costs associated with transportation damages.
CAUTION
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
• Provide additional packaging as necessary.
Introduction
1.6 Notes on Warranty
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 7
1.6
Notes on Warranty
The sales contract contains the entire obligation of Siemens. The warranty contained in the
contract between the parties is the sole warranty of Siemens. Any statements continued
herein do not create new warranties or modify the existing warranty.
For warranty and non-warranty service, refer to Customer/Product Support in this
publication.
All product designations may be trademarks or product names of Siemens Industry, Inc. or
other supplier companies whose use by third parties for their own purposes could violate the
rights of the owners.
Siemens Industry, Inc. assumes no liability for errors or omissions in this document or for the
application and use of information in this document. The information herein is subject to
change without notice.
Procedures in this document have been reviewed for compliance with applicable approval
agency requirements and are considered sound practice. Neither Siemens Industry, Inc. nor
these agencies are responsible for product uses not included in the approval certification(s)
or for repairs or modifications made by the user.
Introduction
1.6 Notes on Warranty
Integral Volume Booster Installation Instructions
8 Hardware Installation Manual, 4/2015, A5E35229820-AB
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 9
Safety notes
2
This device left the factory in good working condition. In order to maintain this status and to
ensure safe operation of the device, observe these instructions and all the specifications
relevant to safety.
Observe the information and symbols on the device. Do not remove any information or
symbols from the device. Always keep the information and symbols in a completely legible
state.
2.1
Warning Symbols
Symbol
Explanation
Consult operating instructions
Hot surface
Dangerous electrical voltage
Corrosive materials
Toxic materials
Isolate the device from power using a circuit-breaker
Protect the device from impact otherwise loss of degree of protection
Protective insulation; device in protection class II
Safety notes
2.2 Laws and directives
Integral Volume Booster Installation Instructions
10 Hardware Installation Manual, 4/2015, A5E35229820-AB
2.2
Laws and directives
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation. These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)
● Canadian Electrical Code (CEC) (Canada)
Further provisions for hazardous area applications are for example:
● IEC 60079-14 (international)
● EN 60079-14 (EC)
2.3
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following
European guidelines:
Electromagnetic Comp
atibil-
i
ty EMC
2004/108/EC
Directive of the European Parliament and of the Council on the
approximation of the laws of the Member States relating to elec-
tromagnetic compatibility and repealing Directive 89/336/EEC.
Atmosphère explosible
ATEX
94/9/EC
Dire
ctive of the European Parliament and the Council on the
approximation of the laws of the Member States concerning
equipment and protective systems intended for use in pote
ntial-
ly explosive atmospheres.
LVD 2006/95/EC
Directive of the European Parliament and of the Council of the
harmoni
zation of the laws of Member States relating to electri-
cal equipment designed for use within certain voltage limits.
The applied standards can be found in the EC conformity declaration of the device.
WARNING
Improper device modifications
Danger to personnel, system and environment can result from modifications to the device,
particularly in hazardous areas.
• Only carry out modifications that are described in the instructions for the device. Failure
to observe this requirement cancels the manufacturer's warranty and the product
approvals.
Safety notes
2.4 Loss of safety of device with type of protection "Intrinsic safety Ex i"
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 11
Qualified personnel for hazardous area applications
Persons who install, connect, commission, operate, and service the device in a hazardous
area must have the following specific qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures,
aggressive, and hazardous media.
● They are authorized, trained, or instructed in carrying out work on electrical circuits for
hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the pertinent safety regulations.
WARNING
Unsuitable device for the hazardous area
Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and
labelled accordingly.
2.4
Loss of safety of device with type of protection "Intrinsic safety Ex i"
WARNING
Loss of safety of device with type of protection "Intrinsic safety Ex i"
If the device has already been operated in non-intrinsically safe circuits or the electrical
specifications have not been observed, the
safety of the device is no longer ensured for use
in hazardous areas. There is a danger of explosion.
• Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe
circuit.
• Observe the specifications for the electrical data on the certificate and/or in Chapter
"Technical data".
Safety notes
2.4 Loss of safety of device with type of protection "Intrinsic safety Ex i"
Integral Volume Booster Installation Instructions
12 Hardware Installation Manual, 4/2015, A5E35229820-AB
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 13
Theory of Operation
3
Input pressure from the positioner acting upon the effective area of the upper diaphragm,
produces a force which is opposed, in a 1:1 ratio, by the force from output pressure acting on
the lower diaphragm. A change in input pressure will create a differential requiring pilot
action to re-balance. An increase will depress the diaphragm assembly, opening the pilot
valve and admitting supply air to the output until balance is restored. Conversely, a decrease
will allow the diaphragm assembly to rise, opening the exhaust seat and lowering the output
to match input. These units incorporate a stabilizing bypass needle valve which allows input
to pass directly to output for small or gradual input changes. Since the booster is bypassed,
there is no loss of accuracy and, with proper needle valve setting, steady-state stability can
be maintained. The appropriate needle valve setting depends on the size of the actuator.
Typically, the larger the actuator, the more the needle valve can be closed and still maintain
stability.
Note
The Integral Volume Booster, as well as any other external volume booster, will change the
double acting SIPART PS2 operation upon loss of supply air.
Without the high flow option
module or external volume booster, the double acting PS2 traps output press
ure upon loss
of supply air.
With the Integral Volume Booster or external volume booster, the output
pressures are vented and the valve position cannot be determined upon loss of supply air.
The Integral Volume Booster has no effect on the SIPART PS2 ope
ration upon loss of
control signal or electrical power, see SIPART PS2 manual for details.
Theory of Operation
Integral Volume Booster Installation Instructions
14 Hardware Installation Manual, 4/2015, A5E35229820-AB
①
Input
⑤
Supply
②
Exhaust
⑥
Output
③
Exhaust Seat
⑦
Diaphragms
④
Supply Seat
⑧
Bypass Valve
Figure 3-1 Single Acting Booster
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 15
Installing/mounting
4
4.1
Basic Safety Instructions
4.1.1
Improper Commissioning
WARNING
Improper commissioning
These instructions are valid solely for the installation and commissioning of the Booster.
It is absolutely necessary that you follow the safety rules, notes and requirements of the
compact operating instructions before assembly, commissioning and also during operation
of the positioner. You can find the compact operating instructions on the supplied CD or on
the Internet under: http://www.siemens.com/processinstrumentation/documentation
(http://www.siemens.com/processinstrumentation/documentation)
WARNING
High operating force with pneumatic actuators
Risk of injury when working on control valves due to the high operating force of the
pneumatic actuator.
• Please observe the corresponding safety instructions for the pneumatic actuator in use.
WARNING
Lever for position detection
Danger of crushing and shearing with mounting kits which use a lever for position detection.
During commissioning and ongoing operation, severing or squeezing of limbs could occur
as a result of the lever. Risk of injury when working on control valves due to the high
operating force of the pneumatic actuator.
• Do not reach into the range of motion of the lever following mounting of the positioner
and mounting kit.
Installing/mounting
4.1 Basic Safety Instructions
Integral Volume Booster Installation Instructions
16 Hardware Installation Manual, 4/2015, A5E35229820-AB
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
• Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for
the device or enclosed with the accessory or spare part.
WARNING
It is possible to damage the cover gasket
If the cover gasket is not positioned correctly in the groove of the base plate, it could be
damaged when the cover is mounted and screwed tight.
• Therefore make sure that the gasket is seated correctly.
WARNING
Open cable inlet or incorrect cable gland
Danger of explosion in hazardous areas.
• Close the cable inlets for the electrical connections. Only use cable glands or plugs
which are approved for the relevant type of protection.
4.1.2
Exceeded maximum ambient or process media temperature
WARNING
Exceeded maximum ambient or process media temperature
Danger of explosion in hazardous areas.
Device damage.
• Make sure that the maximum permissible ambient and process media temperatures of
the device are not exceeded. Refer to the information in Chapter 4.2.
Installing/mounting
4.1 Basic Safety Instructions
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 17
4.1.3
Unsuitable Compressed Air
NOTICE
Caution
Use of process fluids other than instrument air is not recommended. No claim is made as to
the suitability of this product for use with other process fluids.
4.1.4
Prior to working on the control valve
CAUTION
Please note the following before working on the control valve and when attaching the
positioner
Danger of injury.
• Prior to working on the control valve, you must move the control valve into a completely
unpressurized. Proceed as follows:
– Depressurize the actuator chambers.
– Switch off the supply air PZ.
– Lock the valve in its position.
• Make sure that the valve has reached the unpressurized state.
• If you interrupt the pneumatic auxiliary power to the positioner, the unpressurized
position may only be reached after a certain waiting time.
• When mounting, observe the following sequence imperatively to avoid injuries or
mechanical damage to the positioner/mounting kit:
– Mount the positioner mechanically.
– Connect the electrical auxiliary power supply.
– Connect the pneumatic auxiliary power supply.
–
Commission the positioner.
WARNING
Mechanical impact energy
In order to ensure the degree of protection of the housing (IP66), protect the housing
versions of the positioners listed here from mechanical impact energy:
• 6DR5..3; not greater than 2 Joule
• 6DR5..0; not greater than 1 Joule
• 6DR5..1 with inspection window; not greater than 1 Joule
Installing/mounting
4.2 Integral Volume Booster
Integral Volume Booster Installation Instructions
18 Hardware Installation Manual, 4/2015, A5E35229820-AB
4.1.5
Proper Mounting
4.1.5.1
Incorrect mounting
NOTICE
Incorrect mounting
The device can be damaged, destroyed, or its functionality impaired through improper
mounting.
• Before installing ensure there is no visible damage to the device.
• Make sure that process connectors are clean, and suitable gaskets and glands are
used.
4.1.5.2
Loss of degree of protection
CAUTION
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection
specified on the nameplate is no longer guaranteed.
• Make sure that the device is securely closed.
4.2
Integral Volume Booster
The Integral Volume Booster (IVB) is an option for the SIPART PS2 positioner that provides
high flow capacity for use on control valve actuators that require very fast stroking speed. In
addition, it can respond to small or gradual input changes without jeopardizing steady-state
accuracy or stability. The design is based on field proven pneumatic booster relay
technology.
The IVB contains an integral stabilizing bypass valve. The bypass opening is controlled by a
screwdriver adjustment in the body of the booster which permits tuning for optimal dynamic
response. It is recommended that the bypass valve be opened 1/4-turn (counter-clockwise)
at initial start-up.
Installing/mounting
4.2 Integral Volume Booster
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 19
Specifications
Table 4- 1 Climate Class
Storage
1K5, but -40 …+80 °C (1K5, but -40 …+176 °F)
Transport
2K4, but -40 …+80 °C (2K4, but -40 …+176 °F)
Operation
4K3, but -30 …+80 °C (4K3, but -22 …+176 °F)
Note
SA = Single Acting, DA = Double Acting
Table 4- 2 Weight
Makrolon
Explosion Proof
With PS2
Kit only
With PS2
Kit only
Booster,
SA
4.0 kg (8.8 lbs) 2.9 kg (6.5 lbs) 7.9 kg (17.4 lbs) 3.3 kg (7.3 lbs)
Booster,
DA
5.3 kg (11.7 lbs) 4.3 kg (9.4 lbs) 9.3 kg (20.5 lbs) 4.7 kg (10.4 lbs)
Connections
● Pneumatic Connections - 1/2" NPT or G 1/2
● Gauge Connections: 1/8" NPT or G 1/8
Auxiliary Power (air supply)
Compressed air, carbon dioxide (CO2), nitrogen (N2) and noble gases
● Pressure
1.4...7 bar (20.3...101.5 psi)
● Air Supply to ISO 8573-1
● Air Consumption
1.2 x 10-2 Nm3/h (0.007SCFM)
Vibration Resistance
● Harmonic Oscillations compliant to ISA-S75.13
● Harmonic oscillations
150 m/s2 (492 ft/s2)
● Bumping (half-sine)
6ms, 1000 shocks/axis
Gauge
1/8" - 18 NPT or G 1/8 thread with Stainless Steel case in: Mpa, bar, psi. IP66 Rating
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
20 Hardware Installation Manual, 4/2015, A5E35229820-AB
Flow Capacity
Cv 2.0
Ordering Information
The booster can be ordered as a kit to add to an existing positioner in the field, or can
ordered as an option on a new unit.
Kit Numbers
6DR4004-1RK Single Acting for positioner with Makrolon enclosure, ½" NPT connections.
6DR4004-2RK Double Acting for positioner with Makrolon enclosure, ½" NPT connections.
6DR4004-1RQ Single Acting for positioner with flameproof enclosure, ½" NPT connections.
6DR4004-2RQ Double Acting for positioner with flameproof enclosure, ½" NPT connections.
6DR4004-1RJ Single Acting for positioner with Makrolon enclosure, G 1/2
6DR4004-2RJ Double Acting for positioner with Makrolon enclosure, G 1/2
6DR4004-1RP Single Acting for positioner with flameproof enclosure, G 1/2
6DR4004-2RP Double Acting for positioner with flameproof enclosure, G 1/2
Model Option Codes
R1K Single Acting for positioner with Makrolon enclosure, ½“ NPT connections.
R2K Double Acting for positioner with Makrolon enclosure, ½” NPT connections.
R1Q Single Acting for positioner with flameproof enclosure, ½” NPT connections.
R2Q Double Acting for positioner with flameproof enclosure, ½” NPT connections.
R1J Single Acting for positioner with Makrolon enclosure, G 1/2
R2J Double Acting for positioner with Makrolon enclosure, G 1/2
R1P Single Acting for positioner with flameproof enclosure, G 1/2
R2P Double Acting for positioner with flameproof enclosure, G 1/2
4.3
Installation
If the booster kit is to be stocked, stored, or shipped to another location prior to piping, make
sure that the factory installed plastic plugs are in the ports to prevent entry of moisture, dirt,
or other contaminants.
Required Tool List
● Allen Wrench (supplied)
● Adjustable Wrench
● 10mm Deep Socket and Socket Wrench
● 5mm Hex Wrench
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 21
Mounting the IVB (if not factory installed) Makrolon Positioner Housing (double acting shown)
1. Remove extension shaft from the kit.
2. When assembling extension shaft to positioner, be sure the shaft on the positioner is fully
inserted and setscrew is tightened against flat of positioner shaft. Verify shaft is secure.
①
Flat
②
Short threaded end goes into the positioner.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
22 Hardware Installation Manual, 4/2015, A5E35229820-AB
3. Hand-tighten the four studs into the four mounting holes around the positioner shaft.
Studs will be tightened later. Before assembling booster module, rotate positioner shaft
so set-screw is pointing towards positioner exhaust port (bronze sintered screen).
4. Slide the "booster module" over the studs and secure with lock washers and nuts on the
four studs. Torque to 3 Nm (2.2 ft lbs). Do not exceed 5 Nm (~3.7 ft lbs) maximum.
WARNING
Pinch Warning
Can cause severe personal injury.
Keep hands and fingers clear.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 23
5. Before adding gauge block be sure pneumatic plastic plugs are removed from all ports.
Attached the gauge block with two bolts and lock washers. Make sure the O-rings are
installed in the block before attaching it to the positioner. For single acting there are 2
large O-rings for the PS2 ports. For the double acting there are 3 large O-rings for the
PS2 ports. Lightly compress the lock washers; the bolts will be fully tightened later.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
24 Hardware Installation Manual, 4/2015, A5E35229820-AB
6. Attach the connecting block with two bolts and lock washers into the booster and two
bolts and lock washers into the gauge block. Make sure all six O-rings are installed in the
connecting block before attaching it to the booster and the gauges block (see figure
below). Lightly compress the lock washers; the bolts will be fully tightened later.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 25
7. Tighten the gauge block bolts to the positioner. Tighten the connecting block bolts to the
booster. Lastly tighten the connection block to gauge block bolts.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
26 Hardware Installation Manual, 4/2015, A5E35229820-AB
8. Attach the mounting bracket to the booster with 4 lock washers and nuts. Torque to 5 Nm
(3.7 ft lbs) maximum.
Note
The mounting bracket is not part of this kit. The mounting solution for the specific actuator
must be specified separately. Additional mounting holes are available behind the booster
which match the additional holes also available in the SIPART PS2 itself. Some brackets,
especially those for linear application, require these holes for mounting
Note
In certain linear applications when using a low clearance lever it will be necessary to
extend the shaft. PN16152
-
3028 Shaft Extender is included. Refer to installation drawing
A5E34908432B (16230
-160) in Appendix A for examples.
9. Mount positioner on actuator.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 27
Mounting the IVB (if not factory installed) Ex d Flameproof Housing (double acting shown)
1. Remove extension shaft from the kit.
2. When assembling extension shaft to positioner, be sure the shaft on the positioner is fully
inserted and setscrew is tightened against flat of positioner shaft. Verify shaft is secure
①
Flat
②
Short threaded end goes into the positioner.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
28 Hardware Installation Manual, 4/2015, A5E35229820-AB
3. Screw the studs into the four mounting holes around the positioner shaft. Do NOT rotate
studs to bottom of holes. Only rotate studs a minimum of 5 full rotations, max 9 full stud
rotations. Studs will be tightened later. Before assembling booster module, rotate
positioner shaft so set-screw is pointing towards positioner conduit entry.
WARNING
Pinch Warning
Can cause severe personal injury.
Keep hands and fingers clear.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 29
4. Slide the "booster module" over the studs such that the 4 M8 threaded holes align with
the 4 M8 threaded holes on the positioner. Secure with lock washers and nuts on the four
studs (max. torque 40" lbs).
5. Before adding gauge block be sure pneumatic plastic plugs are removed from all ports.
Assemble O-rings to gauge and connecting blocks with two bolts and lock washers.
Loosely attach the gauge block with two bolts and lock washers. Make sure the O-rings
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
30 Hardware Installation Manual, 4/2015, A5E35229820-AB
are installed in the block before attaching it to the positioner. There are 3 large O-rings for
the PS2 ports. The bolts will be fully tightened later.
Figure 4-1 O-ring Gauge
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 31
Figure 4-2 O-ring Connection
Note
Important
Follow bolt tightening sequence procedure carefully.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
32 Hardware Installation Manual, 4/2015, A5E35229820-AB
6. Secure the connecting block with two bolts and lock washers into the booster (refer to
Connection Block figure). Make sure six O-rings are installed in the block before attaching
it to the positioner. There are 3 O-rings for the booster and 3 O-rings for the gauge block.
Now secure connecting block to gauge block (refer to Gauge Connection figure).
Figure 4-3 Connecting Block
Figure 4-4 Gauge Connection
7. Tighten the gauge block bolts to the positioner.
Installing/mounting
4.3 Installation
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 33
8. Attach the mounting bracket to the booster with 4 lock washers and nuts.
Note
The mounting bracket is not part of this kit. The mounting solution for the specific actuator
must be specified separately. Additional mounting holes are available behind the booster
which match the additional holes also available in the SIPART PS2 itself. Some brackets,
es
pecially those for linear application, require these holes for mounting.
Note
In certain linear applications when using a low clearance lever it will be necessary to
extend the shaft. PN16152
-3028 Shaft Extender is included. Refer to installation drawing
A5E34908432B (16230
-160) in Appendix A for examples.
9. Mount positioner on actuator.
Mounting the SIPART PS2/IVB (factory installed)
1. Attach the mounting bracket to the booster with 4 lock washers and nuts.
2. Mount positioner on actuator.
Installing/mounting
4.4 Pneumatic Connections
Integral Volume Booster Installation Instructions
34 Hardware Installation Manual, 4/2015, A5E35229820-AB
4.4
Pneumatic Connections
Refer to installation drawing (assembly with dimensions) for the locations of the pneumatic
connections. The supply and output connections are 1/2" NPT or G 1/2. Ideally the SIPART
PS2/IVB assembly should be close coupled to the actuator. Tubing of 1/2" O.D. or larger is
recommended for piping. Blow out all piping before connections are made to prevent the
possibility of dirt or chips entering the relay. Use pipe sealant sparingly, and then only on the
male threads. A non-hardening sealant is strongly recommended. Connect the relay to a
source of clean, dry, oil-free instrument air. See Instrument Air Requirements.
NOTICE
Caution
Pressure in excess of 7 bar (101.5 psi)i to any connection may cause damage to the relay.
In any event, maximum actuator pressure should never be exceeded.
Instrument Air Requirements
NOTICE
Caution
Use of process fluids other than instrument air is not recommended. No claim is made as to
the suitability of this product for use with other process fluids.
NOTICE
Caution
Synthetic compressor lubricants in the air system at the instrument may cause the
instrument to fail.
There are many types of synthetic compressor lubricants. Some may not be compatible with
materials used in construction of the relay. Wetting of these materials with such an oil mist or
oil vapor, etc., may cause deterioration and may ultimately result in the failure of the
instrument. Refer to Specifications for a list of materials.
The requirements for a quality air supply can be found in the International Organization for
Standardization (ISO) 8573-1.
4.5
Device Setup
The Integral Volume Booster must be setup BEFORE initializing the SIPART PS2 valve
positioner. The “NOINI” (no initialization) mode, see display example below, can be used to
perform this setup. The NOINI mode will appear once proper electrical power is applied to a
brand-new SIPART PS2 valve positioner.
Installing/mounting
4.5 Device Setup
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 35
If the high flow option module is being retrofitted to an initialized SIPART PS2 valve
positioner, follow steps 1 through 6 to activate the NOINI mode:
1. Press and hold [HAND] button to enter configuration mode.
2. The configuration parameter number will appear in the lower left hand corner of display.
3. Toggle the [HAND] button until parameter “4.INITA” appears on the bottom of display.
4. Press and hold the [ - ] minus button until “no” appears on the top of the display.
5. Press and hold [HAND] button to exit configuration mode.
6. Display will be similar to the following (numerical value will vary).
Note
Once all pneumatic connections are made, and the a
ppropriate supply pressure is the
applied, moving the valve assembly throughout the entire valve stroke can be
accomplished using the: Plus [+] and/or Minus [
-] button/s.
– Turn needle valve(s) ¼ turn open.
– Pressing one button delivers air slowly to the actuator.
– Pressing and holding one button and then pressing and holding the other button will
deliver air quickly to the actuator.
To move valve assembly in the opposite direction reverse pushbutton sequence.
– If the valve assembly doesn’t move, it may be possible that the valve assembly is at
the actuator end-stop position. Therefore, alternate pushbutton sequence to deliver
air in the opposite direction.
7. Using [+] plus and [-] minus buttons, move valve assembly to each end-travel position.
Since numerical value on display is an un-calibrated value, use a mechanical indicator on
valve assembly to determine actual valve position.
8. Release pushbuttons to hold valve assembly to some mid-travel position. Once
pushbuttons are released valve assembly should not move.
If valve assembly continues to move, adjust high flow needle valve/s a quarter turn
counter-clockwise.
9. Repeat step 8 until valve assembly can be stopped at any travel position.
If step 9 cannot be accomplished, check for air leaks in valve assembly.
10.Setup of High flow option module is complete once valve assembly can be stopped at any
travel position by releasing pushbuttons.
11.Using SIPART PS2 leaflet instructions or manual, initialize SIPART PS2 valve positioner.
Installing/mounting
4.5 Device Setup
Integral Volume Booster Installation Instructions
36 Hardware Installation Manual, 4/2015, A5E35229820-AB
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 37
Service and maintenance
5
5.1
Maintenance
These instruments do not normally require any routine maintenance.
NOTICE
Caution
Before disassembling the unit, make sure all air pressure to the unit is turned off
Screens
The screens are located in the air supply and output connections. A screen must be
removed from its seat to be cleaned. Screens can be damaged during removal, and spare
screens should be on hand (P/N A5E35246369).
1. Turn supply air off.
2. Remove a screen with a scribe by carefully pulling on and around the edge of the screen.
3. Clean the screen by blowing through in the reverse direction with compressed air. Soak in
solvent or clean mechanically if necessary.
4. Insert the screen until it bottoms using an object, such as the eraser end of a pencil,
which will not cause damage.
Shipping and Storage
If the booster kit is to be stocked, stored, or shipped to another location prior to piping, make
sure that the factory installed plastic plugs are in the ports to prevent entry of moisture, dirt,
or other contaminants.
Customer/Product Support
This section provides the Internet site addresses, e-mail addresses, telephone numbers, and
related information for customers to access Siemens product support.
Service and maintenance
5.1 Maintenance
Integral Volume Booster Installation Instructions
38 Hardware Installation Manual, 4/2015, A5E35229820-AB
When contacting Siemens for support:
● Please have complete product information at hand:
– For hardware, this information is provided on the product nameplate (part number or
model number, serial number, and/or version).
– For most software, this information is given in the Help > About screen.
● If there is a problem with product operation:
– Is the problem intermittent or repeatable? What symptoms have been observed?
– What steps, configuration changes, loop modifications, etc. were performed before the
problem occurred?
– What status messages, error messages, or LED indications are displayed?
– What troubleshooting steps have been performed?
– Is the installation environment (e.g. temperature, humidity) within the product’s
specified operating parameters? For software, does the PC meet or exceed the
minimum requirements (e.g. processor, memory, operating system)?
● A copy of the product Service Instruction, User’s Manual, or other technical literature
should be at hand. The Siemens public Internet site (see the table) has current revisions
of technical literature, in Portable Document Format, for downloading.
● To send an instrument to Siemens for repair, request a Return Material Authorization
(RMA).
NOTICE
Important
An instrument must be thoroughly cleaned (decontaminated) to remove any process
materials, hazardous materials, or blood borne pathogens prior to return for repair. Read
and complete the Siemens RMA form(s)
Support is available through an online Support Request service; a link is provided in the
table below.
Service and maintenance
5.1 Maintenance
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 39
For support and the location of your local Siemens representative, refer to the table below for
the URL of the Process Instrumentation (PI) portion of the Siemens public Internet site. Once
at the site, click Support in the right column and then Product Support. Next select the type
of support desired: sales, technical (see the table below), documentation, or software.
Online Support Request http://www.siemens.com/automation/support-
request
(http://www.siemens.com/automation/support-
request)
Technical Support 1-800-333-7421; 8 a.m. to 4:45 p.m. eastern
time, Monday through Friday (except holidays)
Customer Service & Returns
1-800-365-8766 (warranty and non-warranty)
Public Internet Site http://www.usa.siemens.com/pi
(http://www.usa.siemens.com/pi)
Technical Publications in PDF Click the above link to go to the Siemens Internet
site and then click Process Instrumentation. In
the column to the right, click Support > Manuals.
In the column to the left, select the product line
(e.g. Pressure or Temperature or Controllers) to
open navigation and search panes. Note: Naviga-
tion may change as the site evolves.
Service and maintenance
5.1 Maintenance
Integral Volume Booster Installation Instructions
40 Hardware Installation Manual, 4/2015, A5E35229820-AB
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 41
Dimension drawings
6
6.1
Installation and Outline Drawings
The following installation drawings are used with this device:
A5E34493397A Rev AB - Installation Drawing, PS2 Double Acting Booster (16230-171)
A5E34493297A Rev AB - Installation Drawing, PS2 Single Acting Booster (16230-172)
A5E34493407A Rev AB - Installation Drawing, PS2 Double Acting Booster, FP (16230-173)
A5E34493368A Rev AB - Installation Drawing, PS2 Single Acting Booster, FP (16230-174)
A5E34908432B Rev AB - Installation Drawing, Layout, PS2 Shaft Extender Use (16230-160)
Dimension drawings
6.1 Installation and Outline Drawings
Integral Volume Booster Installation Instructions
42 Hardware Installation Manual, 4/2015, A5E35229820-AB
Integral Volume Booster Installation Instructions
Hardware Installation Manual, 4/2015, A5E35229820-AB 43
Index
A
Auxiliary Power, 19
C
Certificates, 10
Connections, 19
Correct usage, (See improper device modifications)
Customer Support, 37
D
Drawings
Installation and Outline, 41
F
Flow Capacity, 20
G
Gauge, 19
H
Hazardous area
Laws and directives, 10
History, 5
I
Improper device modifications, 10
Industries, 5
Installation Procedures, 20
Instrument Air Requirements, 34
Integral Volume Booster, 18
K
Kit numbers, 20
M
Maintenance and Service, 37
Model Option Codes, 20
N
NOINI Mode, 34
O
Ordering Information, 20
P
Pneumatic Connections, 34
Q
Qualified personnel, 11
S
Scope of delivery, 6
Screens
Cleaning, 37
Shipping and Storage, 37
Specifications, 19
Symbols, (Refer to warning symbols)
T
Test certificates, 10
Theory of Operation, 13
V
Vibration Resistance, 19
W
Warning symbols, 9
Warranty, 7
Subject to change without prior notice
Order No.: A5E353229820
Lit. No.: A5E353229820-AB
04.2015
All rights reserved
Printed in USA
© 2015 Siemens Industry, Inc.
Siemens Industry, Inc.
Industry Automation Division
Valve Positioner
Spring House, PA 19477
USA
www.siemens.com/processautomation
For more information
www.siemens.de\sipartps2
