Siemens SIPART PS2 (6DR5) Modules

Technical Dossier

Product Details And Specifications

Siemens SIPART PS2 Series: Comprehensive Module Range and Technical Overview

The Siemens SIPART PS2 series, identified by the 6DR5 order number prefix, is one of the most widely deployed intelligent electropneumatic positioner families in global heavy industry. Installed across petrochemical complexes, nuclear power stations, offshore platforms, LNG terminals, and crude oil refineries, the SIPART PS2 platform has accumulated a multi-decade installed base that spans every major process automation architecture — from legacy HART 5 networks to modern PROFIBUS PA and FOUNDATION Fieldbus H1 topologies.

In chemical processing plants operating under IEC 61511 SIL 2 requirements, the SIPART PS2 is routinely specified for its certified partial stroke testing (PST) capability, which allows safety-instrumented shutdown valves to be tested online without process interruption. In nuclear auxiliary systems, the series' EMC-hardened housing and wide operating temperature range (−40 °C to +80 °C) make it the positioner of choice for safety-class instrumentation loops. Refineries operating Distributed Control Systems from Emerson DeltaV, Honeywell Experion, and ABB 800xA rely on the SIPART PS2's multi-protocol communication stack to integrate valve diagnostics directly into the DCS historian.

The series covers both linear and part-turn actuator configurations, supports single-acting and double-acting pneumatic circuits, and is available in standard, explosion-proof (Ex d / Ex ia), and stainless-steel enclosure variants. Its self-calibration algorithm (AUTO RUN) eliminates manual span and zero adjustment, reducing commissioning time to under five minutes per valve.

The Evolution of SIPART PS2 Architecture

The SIPART PS2 lineage traces to the early 1990s, when Siemens introduced the first-generation SIPART PS intelligent positioner to replace pneumatic-only positioners on modulating control valves. The original platform used a proprietary serial interface and analog 4–20 mA command input exclusively.

The transition to the 6DR5 platform (SIPART PS2) in the late 1990s introduced a dual-wire HART communication overlay on the 4–20 mA loop, enabling remote diagnostics without additional wiring. This generation established the core mechanical architecture — a non-contact inductive position sensor, a 5/3-way piezo valve block, and a microprocessor-based control board — that remains the foundation of the series today.

The second architectural milestone was the introduction of PROFIBUS PA and FOUNDATION Fieldbus H1 variants (6DR5510, 6DR5520 sub-families), which replaced the analog command signal entirely with a digital fieldbus token. These variants enabled the positioner to function as a full fieldbus device node, reporting valve signature data, travel accumulation, and torque profiles to the DCS asset management layer.

The third generation introduced SIL 2-capable variants with hardware-redundant solenoid outputs and certified PST routines, addressing the growing adoption of IEC 61511 in process safety. Simultaneously, Siemens introduced the HART 7 revision across the analog sub-family, adding burst mode and enhanced device description (DD/EDD) support.

As of 2024, the SIPART PS2 series is in its mature/sustained phase. Siemens continues to manufacture and supply the full 6DR5 range, but the platform is not receiving new feature development. End users operating legacy PROFIBUS PA segments should note that Siemens' long-term roadmap favors migration toward PROFINET-based valve control via the SIMATIC PCS 7 and PCS neo ecosystems. For sites with 10+ year maintenance horizons, stocking critical 6DR5 spare modules — particularly the piezo valve block assembly and the position sensor module — is a standard lifecycle management practice.

Compatibility note: The 6DR5 electronics module is not backward-compatible with the original SIPART PS (6DR4) housing. Mechanical retrofit kits exist for common actuator yoke patterns (VDI/VDE 3845 Namur), but the pneumatic block dimensions differ between generations.

SIPART PS2 Full Catalog & Functionalities (SKU List)

The following SKUs represent the core SIPART PS2 product matrix. Models are organized by communication protocol and actuator type. Each entry reflects a distinct orderable configuration.

Analog / HART — Single-Acting (Linear Actuator)

• 6DR5010-0NG00-0AA0: SIPART PS2 basic, 4–20 mA/HART, single-acting, standard enclosure, no Ex rating, aluminum housing.
• 6DR5013-0FN00-0AA3: SIPART PS2 with HART, single-acting, stainless steel enclosure, IP66, suitable for offshore and wash-down environments.
• 6DR5010-0EN00-0AA0: SIPART PS2 HART, single-acting, Ex ia (intrinsically safe) certified, Zone 1/21, ATEX/IECEx.
• 6DR5010-0NN00-0AA0: SIPART PS2 HART, single-acting, Ex d (flameproof) enclosure, Zone 1, heavy-duty cast aluminum.

Analog / HART — Double-Acting (Linear & Part-Turn Actuator)

• 6DR5020-0NG00-0AA0: SIPART PS2 basic, 4–20 mA/HART, double-acting, standard enclosure, no Ex rating.
• 6DR5020-0EN00-0AA0: SIPART PS2 HART, double-acting, Ex ia certified, Zone 1/21, ATEX/IECEx.
• 6DR5020-0NN00-0AA0: SIPART PS2 HART, double-acting, Ex d flameproof enclosure, Zone 1.
• 6DR5023-0FN00-0AA3: SIPART PS2 HART, double-acting, stainless steel enclosure, IP66, corrosion-resistant for marine applications.

PROFIBUS PA — Single-Acting

• 6DR5510-0NG00-0AA0: SIPART PS2 PROFIBUS PA, single-acting, standard enclosure, non-Ex, full fieldbus device profile.
• 6DR5510-0EN00-0AA0: SIPART PS2 PROFIBUS PA, single-acting, Ex ia Zone 1/21, ATEX certified.
• 6DR5510-0NN00-0AA0: SIPART PS2 PROFIBUS PA, single-acting, Ex d Zone 1, flameproof housing.

PROFIBUS PA — Double-Acting

• 6DR5520-0NG00-0AA0: SIPART PS2 PROFIBUS PA, double-acting, standard enclosure, non-Ex.
• 6DR5520-0EN00-0AA0: SIPART PS2 PROFIBUS PA, double-acting, Ex ia Zone 1/21, ATEX/IECEx.

FOUNDATION Fieldbus H1

• 6DR5610-0NG00-0AA0: SIPART PS2 FF-H1, single-acting, standard enclosure, ITK 6.x compliant, supports function block execution.
• 6DR5620-0NG00-0AA0: SIPART PS2 FF-H1, double-acting, standard enclosure, ITK 6.x compliant.

Accessories & Spare Modules

• 6DR4004-8V: Replacement piezo valve block assembly for 6DR5 single-acting variants — the highest-frequency wear component in the series.
• 6DR4004-6J: Non-contact inductive position sensor module, compatible across the full 6DR5 range.
• 6DR4004-8D: Limit switch / binary output module, adds two configurable SPDT relay outputs for end-position signaling.

Sourcing Hard-to-Find & Obsolete SIPART PS2 Parts

Although Siemens continues to manufacture the core 6DR5 range, several early-production variants and accessory modules have been discontinued or assigned extended lead times exceeding 20 weeks. The most commonly affected items include early-revision Ex d housings with legacy cable entry thread patterns (PG thread vs. M20), first-generation display boards with the 4-button keypad interface, and PROFIBUS PA variants manufactured before the 2012 firmware revision that introduced enhanced diagnostic blocks.

DriveKNMS maintains a dedicated inventory of new-old-stock (NOS) and professionally refurbished SIPART PS2 units sourced from decommissioned process plants, engineering contractors, and authorized distributor overstock. Our procurement team cross-references Siemens' order number matrix against customer-supplied tag lists to identify exact replacement units, including cases where the original order number has been superseded by a revised part number.

For end users operating SIPART PS2 positioners on safety-instrumented systems (SIS), DriveKNMS provides documentation packages that include the original Siemens functional safety certificate reference, firmware version confirmation, and a test report demonstrating correct PST function — supporting the customer's SIL maintenance records without requiring a Siemens service contract.

Quality Control for the SIPART PS2 Range

The SIPART PS2 presents specific quality verification challenges due to its integrated pneumatic-electronic architecture. A positioner that passes basic electrical continuity checks may still exhibit faults in the piezo valve block, the position feedback sensor, or the internal PID control loop that only manifest under live pneumatic load.

DriveKNMS applies a multi-stage test protocol to every SIPART PS2 unit prior to dispatch:

• Stage 1 — Visual and Mechanical Inspection: Housing integrity check, cable entry seal condition, pneumatic port thread inspection (1/4" NPT or G1/4"), and actuator mounting interface verification against VDI/VDE 3845 Namur bracket dimensions.
• Stage 2 — Electronics Bench Test: 4–20 mA input simulation across full range, HART communication handshake verification using a Fluke 710 HART calibrator, and display/keypad function check. For PROFIBUS PA units: segment coupler connection test and GSD file compatibility verification.
• Stage 3 — Pneumatic Functional Test: Live air supply at 1.4–7 bar (20–100 psi) connected to the supply port. Valve travel simulation using a mechanical stroke simulator fixture. Verification of AUTO RUN self-calibration sequence completion. Leakage test on all pneumatic connections at 6 bar for 60 seconds.
• Stage 4 — Control Loop Performance Test: Step response test at 0%, 25%, 50%, 75%, and 100% setpoint. Deadband and hysteresis measurement recorded against Siemens factory specification (≤0.1% of travel range). Results logged to a unit-specific test certificate issued with each shipment.
• Stage 5 — Final Documentation: Serial number recording, firmware version logging, and packaging in anti-static, moisture-barrier material with desiccant for international freight.