Siemens SIPART DR22, 6DR2210 User Manual

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Page 1

Manual Edition12/2006

Controller

SIPART DR22

6DR2210

sipart

Page 2

Page 3

SIPART DR22 6DR2210

Edition 12/2006

Manual

SIPART DR22 6DR2210 C79000-G7476-C154-03

Page 4

Block diagram

AE1

AE2

AE3

AE4

AE5

BE1

BE4

L+

Options

1/20

1/19

1/22

1/21

1/24

1/23

2/4 2/3 2/2 2/1

3/4

3/3

3/2

3/1

1/15

1/16

1/17

1/18

1/3

1/2

1/1

I,U

I,U,R UNI,

P, T, V

Slot 2

I,U,R UNI,

P, T, V

Slot 3

24 V



6DR2210-4 24 V UC 6DR2210-5 115/230 V AC switchable

bE01

bE02

bE03

bE04

–

S10

AE1A

S11

AE2A

S12

AE3A

S13

AE4A

S14

AE5A

+24V

+5V

REF

S20

drawn: S4 = 0 at S4 = 1 freely connectable

S212 to S217 FE7 FE8 FE9 FE10 FE11 FE12

User program memory for:

onPA on AdAP line

oFPA FdEF FCon off FPoS line APSt FPST

S15

Standard

FE1

settings

S16

Analog inputs

FE2

Assembly

S17

Slot 5 and 6

FE3

Digital inputs

Setpoint command

S18

Control algorithm

FE4

Y switching

Y display

S98

Analog outputs

FE5/6

Digital outputs

Limit value alarms

Restart conditions

Serial interface

S0 to S4

S5 to S21,

S200 to S217

S22, S23

S24toS48,

S218 to S228

S49toS53

S54toS60

S61toS66

S67toS68

S69toS75,

S247 to S257

S76toS93,

S258 to S266

S94toS98,

S267 to S268

S99, S100

S101 to S107

r o n

0000

o d u

l e

24 V I

3AE 1AA y

hold

5BE 4BA24V +2BE 2BA Rel. 3AO/3BE

Slot 6

3AE 1AA y

hold

5BE 4BA 24V +2BE 2BA Rel. 3AO/3BE

Slot 5

RS 232

RS 485

PROFIBUS

Slot 4

Slot Terminal

1/12

1/13

1/14

1/4

1/5

1/6

1/7

1/8

1/9

1/10

1/11

6/6 6/5 6/4 6/3 6/2 6/1

Options

5/6

5/5

5/4

5/3

5/2

5/1

4/2

4/7

4/8

4/3

AA1

AA2

AA3

BA1

BA8

Options

SIPART DR22 6DR2210

C79000-G7476-C154-03

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Manual

Classification of safety--related notices

This manual contains notices which you shouldobserve toensure your own personalsafety, 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 situation 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.

NOTICE

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

ment or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

Siemens AG Automation and Drives Postfach 48 48 90437 NÜRNBERG DEUTSCHLAND

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.

Disclaimer of Liability We have checked the contents of this manual for

agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed.

e Siemens AG 2006 Technical data subject to change.

SIPART DR22 6DR2210 C79000-G7476-C154--03

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Trademarks

SIMATICR,SIPARTR,SIRECR, SITRANSR registered trademarks of Siemens AG. Third parties using for their own purposes any other names in this document which refer to trade-

marks might infringe upon the rights of the trademark owners.

SIPART DR22 6DR2210

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Manual Contents

Conents

Page

1 Technical Description 7...................................................

1.1 Safety notes and scope of delivery 7..................................................

1.2 Range of Application 8..............................................................

1.3 Design (Hardware) 9...............................................................

1.4 Function principle 12................................................................

1.4.1 Standard controller 12.................................................................

1.4.2 Description of the option modules 13....................................................

1.4.3 CPU self-diagnostics 20...............................................................

1.4.4 Data storage, User program memory 21.................................................

1.5 Functional description of the structure switches 22.......................................

1.5.1 Analog input signal processing permanently connected 22..................................

1.5.2 Analog input signal processing freely connected (S4 = 1) 25.................................

1.5.2.1 Arithmetic Ar1 to Ar6 27...............................................................

1.5.2.2 Function transmitter Fu1 and Fu2 27....................................................

1.5.2.3 Maximum value selection MA1 to MA3 27................................................

1.5.2.4 Minimum value selection Mi1 to Mi3 28...................................................

1.5.2.5 Correction computer for ideal gases rE1 28...............................................

1.5.2.6 Switch for analog variables AS1 to AS5 33...............................................

1.5.2.7 Comparator with adjustable hysteresis Co1, Co2 33........................................

1.5.2.8 AND NOT function (NAND) nA1, nA2 33.................................................

1.5.2.9 OR NOT function (NOR) no1, no2 33....................................................

1.5.3 Digital input signal processing 34.......................................................

1.5.3.1 Digital inputs BE1 to BE14 34..........................................................

1.5.3.2 Assignment and direction of effect of the digital inputs 35....................................

1.5.3.3 Linking the digital inputs BE1 bis BE14 to the control signals via the SES 35...................

1.5.3.4 Functional explanation of the digital control signals 39......................................

1.5.4 Controller types (S1, S49 to S53) 40.....................................................

1.5.4.1 General, recurrent functions 40.........................................................

1.5.4.2 S1 = 0: Fixed setpoint controller with 2 independent setpoints 48...........................

1.5.4.3 S1= 1: Fixed setpoint controller with 2 dependent setpoints 51.............................

1.5.4.4 S1 = 2: DDC fixed setpoint controller 52................................................

1.5.4.5 S1 = 3: Follow-up controller, synchronized controller, SPC-controller 58.....................

1.5.4.6 S1 = 4: commanded ratio controller 64.................................................

1.5.4.7 S1 = 5: Cascade control 69..........................................................

1.5.4.8 S1 = 6: Ratio-cascade control 74......................................................

1.5.4.9 S1 = 7/8: Override control 77...........................................................

1.5.4.10 S1 = 9: Process display 83...........................................................

1.5.4.11 S1 = 10: Fixed setpoint controller with 1 setpoint (control system coupling) 84.................

1.5.4.12 S1 = 11: Follow-up controller without Int/Ext switching (control system coupling) 85.............

1.5.4.13 S1=12: Double fixed setpoint/follow-up controller 86......................................

1.5.5 Control algorithm, parameter control, adaptation 89........................................

1.5.5.1 Control algorithm 89..................................................................

1.5.6 Controller output structures (S2, S61 to S68) 99...........................................

1.5.6.1 S2 = 0: Continuous (K) controller 99...................................................

1.5.6.2 S2 = 1: Three-position step (S) -controller with internal feedback 104.........................

1.5.6.3 S2 = 2: Three-position step (S) -- controller with external feedback 107.......................

1.5.7 Analog output signal processing (S69 to S75, S247 to S257) 120..............................

1.5.8 Digital output signal processing (S76 to S93 and S258 to S266) 121...........................

1.5.9 Limit value alarms (S94 to S100, S267 to S268) 124........................................

1.5.10 Restart conditions (S99, S100) 126.......................................................

1.5.11 Serial interface and PROFIBUS-DP (S101 to S107) 126.....................................

1.6 Technical Data 127...................................................................

1.6.1 General data 127......................................................................

1.6.2 Standard Controller 129................................................................

1.6.3 Technical data of the options modules 133.................................................

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2 Installation 143.............................................................

2.1 Mechanical Installation 143............................................................

2.2 Electrical Connection 143.............................................................

2.2.1 Connection standard controller 147.......................................................

2.2.2 Wiring of option modules 150............................................................

2.2.3 Alternative connection for I- and U-input 158...............................................

2.2.4 Connection of the interface 163..........................................................

3 Operation 167..............................................................

3.1 Process operation 167................................................................

3.2 Selection level 169...................................................................

3.3 Configuring level (parameterization and structuring mode) 172..............................

3.3.1 Paramterization 172...................................................................

3.3.2 Parameterization mode onPA (online parameters) 173.......................................

3.3.3 Parameterization mode AdAP (Adaptation) 175.............................................

3.3.4 Structuring mode oFPA (offline Parameters) 182............................................

3.3.5 Structuring mode PASt (parameter control) 184.............................................

3.3.6 Structuring mode StrS (structure switches) 186.............................................

3.3.7 Structuring mode FdEF (define functions) 201..............................................

3.3.8 Structuring mode FCon (connect functions, connection) 202..................................

3.3.9 Structuring mode FPoS (position functions) 205............................................

3.3.10 Structuring mode FPSt (Functions Preset, factory setting) 209................................

3.3.11 Structuring mode APSt (All Preset, factory setting) 210......................................

3.3.12 Set structuring mode CAE4/CAE5 -- UNI module(s) 211.....................................

3.3.12.1 Measuring range for mV (SEnS=Mv.) 212.................................................

3.3.12.2 Measuring range for U, I (SEnS=Mv.) 212.................................................

3.3.12.3 Measuring range for thermocouple with internal reference point (SEnS=tc.in) 213................

3.3.12.4 Measuring range for thermocouple with external reference point (SEnS=tc.EH) 213..............

3.3.12.5 Measuring range for PT100-4-wire and PT100-3-wire connection (SEnS=Pt.3L/PT.4L) 213........

3.3.12.6 Measuring range for PT100-2-wire connection (SEnS=Pt.2L) 214.............................

3.3.12.7 Measuring range for resistance potentiometer

(SEnS=r._ for R < 600 W, SEnS=r. for R< 2.8 kW) 214......................................

ManualContents

4 Commissioning 215........................................................

4.1 Adapting the controller direction of effect to the controlled system 215........................

4.2 Setting the split range outputs and the actuating time in K-controllers (S2 = 0) 217.............

4.3 Adaptation of the S-controller to the actuating drive 218....................................

4.4 Setting the filter and the response threshold 219..........................................

4.5 Automatic setting of control parameters 220..............................................

4.6 Manual setting of the control parameters 224.............................................

4.7 Manual setting of the control parameters 225.............................................

5 Maintenance 227...........................................................

5.1 General information and handling 227...................................................

5.2 Spare parts list 231...................................................................

6 Ordering data 233..........................................................

7 Application examples for configuring the controller 235.......................

8 Configuring tool 241........................................................

9 Explanation of abbreviations 253............................................

Index 259........................................................................

SIPART DR22 6DR2210

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Manual 1 Technical Description

1.1 Safety notes and scope of delivery

1 Technical Description

1.1 Safety notes and sco p e of delivery

D Scope of delivery

When the controller is delivered the box contains: 1 Controller as ordered

1 three-pin plug at 115/230 V AC or special plug at 24 V UC 2 Clamps, pluggable 1 Assembly and installation instructions

Order number C79000-M7474-C38

WARNING

This device is electrically operated. When operating electrical equipment, certain parts of this equipment automatically carry dangerous voltages. Failure to observe these instructions could therefore lead to serious injury or material damage. Only properly trained and qualified personnel are allowed to work on this equipment. This personnel must be fully conservant with all the warnings and commissioning measures as described in this user’s guide. The perfect and safe operation of this equipment is conditional upon proper transport, proper storage, installation and assembly as well as on careful operation and commissioning.

D Basic equipment

The following variants of the SIPART DR22 are available:

Order number Power Supply

6DR2210-4 6DR2210-5

D Option modules

Signal convertors have separate ordering and delivery items. For handling reasons basic equipment and signal convertors which were ordered at the same time may be delivered by separate mail.

D Documentation

This user’s guide is available in the following languages:

English C79000-G7476-C154 German C79000-G7400-C154

SIPART DR22 6DR2210 C79000-G7476-C154-03

24 V UC 115/230 V AC, switchable

Page 10

1.2 Range of Application

Manual1 Technical Description

D Subject to change

The user’s guide has been compiled with great care. However, it may be necessary within the scope of product care to make changes to the product and its operation without prior notice which are not contained in this user’s guide. We are not liable for any costs ensuing for this reason.

1.2 Range of Application

The SIPART DR22 is a digitally operating device in the top class range. Its program memory contains a large number of prepared function blocks for calculating, controlling, regulating in technical processes which the user can implement without programming knowledge and additional tools.

In addition a robust adaptation procedure is available in this device which makes it much easier to commission even critical controlled systems. The controller determines the optimized control parameters independently on request without the user being expected to have any prior knowledge of how the control loop may respond. The applied procedure is suitable for systems with compensation and aperiodic transient behavior; even greater dead times are taken into account.

For more complicated applications the fixed connection of the individual functions can be canceled in the input range and replaced by a free structuring. The user can easily add extra analog function blocks and connect them to each other and to the interfaces of the input range with the software. This achieves optimum adaptation even to complex problems.

The named programming possibilities guarantee a great flexibility in the use of the controller and allow fast, easy adapting of the device to the problem so that the SIPART DR22 can be used universally for control jobs in processing engineering, e.g. as

-- fixed setpoint controller for one, two or three-component control, optionally with two setpoints

-- DDC fixed setpoint controller for one-, two- or three-component control

-- follow-up controller (synchronized controller, SPC controller) with internal/external switching

-- fixed or commanded ratio controller with Internal/External switching

-- cascade controller (double controller)

-- ratio-cascade controller (double controller)

-- override controller with Min or Max selection of the manipulated variable (double controller)

-- double controller with two independent control channels

The extensive hardware equipment of the instrument by which numerous interfaces are available for connecting the field cables is of advantage for the universal utilization. The instrument can also be connected to master systems via a plug-in serial interface or operated and monitored centrally by a Personal Computer.

The SIPART DR22 can be used alternatively as a continuous controller with a current output signal or as a three-position step controller for controlling electric motor drives without changing the hardware equipment.

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Manual 1 Technical Description

1.3 Design (Hardware)

The process controller SIPART DR22 has a modular structure and is therefore maintenance friendly and easy to convert and retrofit. Other signal convertors can be installed in the generously equipped, fully functional standard controller to expand the range of application. These modules are inserted in backplane slots of the enclosed instrument (Fig. 1-2, page 11).

The standard controller consists of

-- the front module with the control and display elements

-- the main board with CPU and terminal strips

-- the plastic casing with an interface board

-- the power supply unit.

The electrical connections between the modules are made by an interface board screwed into the casing. The main board is pushed into rear slot 1 and locked. It holds a 10-pin and a 14-pin terminal strip to which all inputs and outputs of the standard controller are connected. Five other slots can be equipped with option modules if the number of terminals to the process available in the standard controller are not sufficient for the planned task.

The standard controller always has three permanently installed analog inputs (AE) with electronic potential isolation which can be wired alternatively with standardized voltage signals (0/0.2 to 1 V or 0/2 to 10 V) or current signals (0/4 to 20 mA). There are also four digital inputs (BE, 0/24 V) and eight digital outputs (BA, 0/24 V, 50 mA) which can be used for different functions depending on the configuration.

The SIPART DR22 also has three analog outputs (AA) which can all supply a current signal from 0 to 20 mA or 4 to 20 mA and be assigned to different variables. A short-circuit-proof L+--output (DC 24 V, 100 mA) is available for supplying transmitters.

The power supply unit is located in a fully enclosed metal casing and is screwed tightly to the plastic casing of the controller. This power supply is available in two different versions so that two types of SIPART DR22 are available:

6DR2210-4 for power supply connection UC 24 V 6DR2210-5 for power supply connection AC 230 V, switchable to AC 115 V

Many applications can be implemented with the three permanently available analog inputs of the standard controller alone. Two additional input modules can be inserted in slots 2 and 3 for complex jobs or for the connection of other input signals. These input modules are available in addition to for processing normalized current and voltage signals for the direct connection of resistance thermometers Pt100 and all common thermocouples and resistance sensors or potentiometers. In addition a module with 3 analog inputs (equipment as in the standard controller) can be inserted in slots 5 and 6. This increases the number of inputs to a total of 11.

Slot 4 serves to accommodate an interface module (SES) with V.28-point-pointoutput or SIPART bus interface for serial communication with a master system. A PROFIBUS interface module can be equipped optionally here.

SIPART DR22 6DR2210 C79000-G7476-C154-03

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1.3 Design (Hardware)

The slots 5 and 6 can accommodate signal convertors of different functions and can be equipped optionally with modules for expanding digital inputs or digital outputs.

The following assemblies are possible:

2 relays 4 digital outputs/2 digital inputs 5 digital inputs 3 analog outputs/3 digital inputs 1 analog output with digital fault output (y

function) with remote supply

hold

3 analog inputs

Manual1 Technical Description

Figure 1-1 Front view of the SIPART DR22

1 Power supply unit 2Casing 3 Front module

SIPART DR22 6DR2210

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Manual 1 Technical Description

Legend:

1 PE conductor -- contact spring 2Slot6 3Slot5 4 Slot 1 (basic board) 5Slot2 6Slot3 7 Slot 4 (SES: RS 232/

RS 485, Profibus DP) 8 Grounding screw 9 DIN rail (delivered with the

interface relay) 10 Selector switch Mains voltage 11 Mains plug 12 Power supply unit

1.3 Design (Hardware)

7 6 5 4

Figure 1-2 Rear view of the SIPART DR22

SIPART DR22 6DR2210 C79000-G7476-C154-03

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1.4 Function principle

1.4.1 Standard controller

Manual1 Technical Description

1.4 Function principle

1.4.1 Standard controller

The standard controller consists of three function blocks:

-- Power supply unit

-- Front module

-- Main board

Power supply unit

Primary clocked power supply plug with high efficiency for AC 115/230 V (switchable) or for UC 24 V. It generates the secondary internal supply voltages +24 V and +5 V from the power supply. The metal body is mounted on PE conductors (protection class I). The power supply and internal supply voltages are isolated from each other by safe separation by a protective shield. The internal supply voltages are functional extra-low voltages due to overvoltage cutoff in the event of an error. Since no other voltages are generated in the instrument, these statements apply for all field signal cables (used standards, see chapter 1.6, page 127). A total of 450 mA are available for the outputs L+, AA and BA due to the design for a high power output.

Front module

The front module contains the control and display elements and the appropriate trigger components for the displays.

All display elements are designed in LED technology which provides a longer service life and higher light density as well as a good viewing angle. The control elements are short-stroke switches with a tangible ”pressure point” and high return force.

Main board

The main board contains the field signal conditioning of the standard controller, the CPU (Central Processing Unit) and the connections (through the interface board) to the module slots.

The field signals are fed through protective circuits for external static or dynamic overvoltages and then adapted to the signal levels of the CPU by the appropriate circuits. This adaptation is performed for the analog inputs, the analog outputs and the digital outputs by modern thick-film circuits.

The microcontroller used has integrated AD- and DA converters and operates with 32k batterybacked RAM. The user-specific configuration is stored in an user program memory with a serial 4k EEPROM. When replacing the main board the user memory can be plugged from the old onto the new module. The whole CPU is designed in C-MOS technology.

A process image is generated at the start of every routine. The analog and digital inputs and actuation of the front buttons is included and the process variables received from the serial interface are accepted. All calculations are made with these input signals according to the configured functions. Then the data are output to the display elements, the analog outputs and the digital outputs as well as storage of the calculated variables on standby for the serial interface transmitter. The interface traffic runs in interrupt mode.

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Manual 1 Technical Description

1.4.2 Description of the option modules

1.4 Function principle

A large number of prepared functions for controlling processing plants as well as machines and apparatus is stored in the set value memory of the SIPART DR22. The user programs the instrument himself by selecting the desired functions by setting structure switches. The total functioning of the instrument is given by the combination of the individual structure switches. Programming knowledge is not necessary for the settings. All settings are made without an additional programming unit exclusively through the front panel of the SIPART DR22 or through the serial interface. The job-specific program written in this way is saved in the non-volatile user program memory.

1.4.2 Description of the option modules

The following option modules are described in this chapter

6DR2800-8A Module with 3 AE, U- or I-input 6DR2800-8J I/U module 6DR2800-8R R module 6DR2800-8V UNI module 6DR2805-8A Reference junction terminal 6DR2805-8J Measuring range for TC, internal connector 6DR2801-8D Module with 2 BA (relays) 6DR2801-8E Module with 2 BE and 4 BA 6DR2801-8C Module with 5 BE 6DR2802-8A Analog output module with y-hold function 6DR2802-8B Module with 3AA and 3BE 6DR2803-8P Serial interface PROFIBUS-DP 6DR2803-8C Serial interface RS 232 / RS 485 6DR2804-8A Module with 4 BA relays 6DR2804-8B Module with 2 BA relays

6DR2800-8A Module with 3 AE, U- or I-input

D Inputs for current and voltage

To expand the analog inputs. For a description of the module and technical data, see chapter 1.6.2, page 129 (Inputs standard controller).

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1.4 Function principle

1.4.2 Description of the option modules

Manual1 Technical Description

6DR2800-8J I/U module

D Input variables current 0/4 to 20 mA or voltage 0/0.2 to 1 V or 0/2 to 10 V

The input amplifier of the module is designed as a differentiating amplifier with jumperable gain for 0 to 1 V or 0 to 10 V input signal. For current input signals the 49.9 Ω 0.1 % impedance is switched on by plug-in bridges on the module. The start value 0 mA or 4 mA or 0 V or 0.2 V (2 V) is defined by configuration in the standard controller. The differentiating amplifier is designed for common mode voltages up to 10 V and has a high common mode suppression. As a result it is possible to connect the current inputs in series as for electrical isolation when they have common ground. At voltage inputs this circuit technique makes it possible to suppress the voltage dips on the ground rail by two--pole wiring on non floating voltage supplies. We refer to an electronic potential isolation.

6DR2800-8R R module

D Input for resistance or current potentiometer

Potentiometers with rated values of 80 Ω to 1200 Ω can be connected as resistance potentiometers. A constant current of Is = 5 mA is fed to the potentiometer wiper. The wiper resistance is therefore not included in the measurement. Resistances are switched parallel to the potentiometer by a slide switch on the module and a rough range selection made. Range start and end are set with the two adjusting pots on the back of the module.

This fine adjustment can be made by the displays on the front module (with the appropriate structuring). For adjustment with a remote measuring instrument, the analog output can be assigned to the appropriate input.

The external wiring must be changed for resistance potentiometers which cannot withstand the 5 mA wiper current or which have a rated resistance

> 1kΩ. The constant current is then not

fed through the wiper but through the whole resistance network of the potentiometer. A voltage divider measurement is now made through the wiper. Coarse adjustment is made by a remote parallel resistor to the resistance potentiometer.

This module can also be used as a current input with adjustable range start and full scale. The load is 49.9 Ω and is referenced to ground.

6DR2800-8V UNI module

D Direct connection of thermocouple or Pt100 sensors, resistance of mV transmitters

Measured value sensors such as thermocouples (TC), resistance thermometers Pt100 (RTD), resistance potentiometers (R) or voltage transmitters in the mV range can be connected directly. The measuring variable is selected by configuring the controller in the HdeF level (AE4/AE5); the range and the other parameters are set in the CAE4/CAE5 menu. The sensorspecific characteristics (linearization) for thermocouples and Pt100 resistance thermometers are stored in the contoller’s program memory and are automatically taken into account. No settings need to be made on the module itself.

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Manual 1 Technical Description

1.4.2 Description of the option modules

1.4 Function principle

The signal lines are connected by a plug terminal block with screw terminals. When using thermocouples with internal reference junction terminal, this terminal block must be replaced by the terminal 6DR2805-8A. With the measuring for TC, internal connector 6DR2805-8J in place of the terminal block, the measuring range of the direct input (0/20 to 100 mV) can be extended to 0/2upto10Vor0/4upto20mA.

The UNI module operates with an AD converter with 18 bit resolution. The measuring inputs and ground of the standard controller are electrically isolated with a permissible common mode voltage of 50 V UC.

6DR2805-8A reference junction terminal

D Terminal with internal reference junction terminal for thermocouples

This terminal is used in connection with the UNI module for temperature measuring with thermocouples at an internal reference junction terminal. It consists of a temperature sensor which is preassembled on a terminal block and plated to avoid mechanical damage.

6DR2805-8J measuring for TC, internal connector

D measuring for TC, internal connector for current 0/4 to 20 mA or voltage 0/2 to 10 V

The measuring for TC, internal connector is used in connection with the UNI module to measure current orvoltage. The input variable is reduced to 0/20 to 100 mV by a voltage divider or shunt resistors in the measuring for TC, internal connector.

Wiper resistors with 250 Ω or 50 Ω are available optionally at 2 different terminals for 0/4 to 20 mA signals.

The electrical isolation of the UNI module is retained even when the measuring for TC, internal connector is used.

6DR2801-8D Module with 2 BA relays

D Digital output module with 2 relay contacts

To convert 2 digital outputs to relay contacts up to 35 V UC.

This module is equipped with 2 relays whose switching contacts have potential free outputs. The RC combinations of the spark quenching elements are respectively parallel to the rest and working contacts.

In AC consumers with low power the current flowing through the capacitor of the spark quenching element when the contact is open may interfere (e.g. the hold current of some switching elements is not exceeded). In this case the capacitors (1 μF) must be removed and replaced with low capacitance capacitors.

The 68 V suppressor diodes parallel to the capacitors act additionally to reduce the induced voltage.

SIPART DR22 6DR2210 C79000-G7476-C154-03

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1.4 Function principle

1.4.2 Description of the option modules

Manual1 Technical Description

WARNING

The relays used on the digital output module are designed for a maximum rating up to UC 35 V. The same applies for the air and creep lines on the circuit board. Higher voltages may therefore only be switched through appropriately approved series connected circuit elements under observance of the technical data and the pertinent safety regulations.

6DR2801-8E Module with 2 BE and 4 BA

D Digital signal module with 2 digital inputs and 4 digital outputs

The module serves to extend the digital inputs and digital outputs already existing in the standard controller.

The inputs are designed for the 24 V logic and are non-floating. The functions are assigned to the inputs and outputs by the configuration of the controller.

The digital outputs are short-circuit-proof and can drive commercially available relays or the interface relays 6DR2804--8A/8B directly.

6DR2801-8C Module with 5 BE

D Digital input module with 5 digital inputs

The module serves to extend the digital inputs already existing in the standard controller.

The inputs are designed for the 24 V logic and are non-floating. The function is assigned to the input by the configuration of the controller.

6DR2802-8A Analog output module with y-hold function

For auxiliary control device function when servicing and for extending the analog outputs AA1 to AA3 existing in the standard controller.

Can be inserted in slot 5/6, S22/S23=4 to be set in the structure mode StrS, Start value of the outputs S72/S249 can be set in StrS.

The y

module contains a microprocessor which maintains serial data communication with the

hold

processor on the main board through the Rxd/Txd lines. The processor feeds the U/I converter and the CPU fault message output St

through its analog output. The module can be externally supplied through an auxiliary voltage input which is OR--linked with the controller power supply. The analog output of the module is freely available.

-- y

-function

hold

If data communication to the y

processor is interrupted, the analog output receives its last

hold

value. The processor reads the current variable first when data traffic is recovered. The output current is maintained if:

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Manual 1 Technical Description

1.4.2 Description of the option modules

1.4 Function principle

-- the self diagnostics of the CPU (see chapter 1.4.3, page 20) responds.

-- the supply voltage of the SIPART DR22 fails and the y

-- all modules except the power supply unit are removed (if the y

-module is powered externally.

hold

module is powered

hold

externally).

-- the y

module is removed (Attention: electrostatically sensitive module! Observe the

hold

safety precautions!), if it is powered externally (error message on the front module oP. *.6 Err/oP.*.5, see chapter 5, page 227). *.6 Err/oP.*.5, see chapter 5).

In this way it is possible to perform all maintenance work right up to replacing the instrument whilst maintaining the controller controlled variable. Handling during module replacement, see chapter 5 ”Maintenance”.

Fault message output

-- S t

This digital output is always high when there is no error and becomes low in the event of an error. It responds when:

-- the self diagnostics of the CPU (see chapter 1.4.3, page 20) responds.

-- the controller power supply fails,

-- the Y

module is removed,

hold

-- the main board is removed.

6DR2802-8B Module with 3AA and 3BE

To extend the analog outputs (0/4 to 20 mA) and digital inputs can be inserted in slot 5: AA7, AA8, AA9 BE5, BE6, BE7

and in slot 6: AA4, AA5, AA6 BE10, BE11, BE12

6DR2803-8P Serial interface PROFIBUS-DP

The module 6DR2803-8P is a PROFIBUS-DP interface module with RS 485 driver and electrical isolation to the controller. It operates as an intelligent converter module and adapts the private SIPART to the open PROFIBUS-DP protocol.

This optional card can be inserted in all SIPART-DR controllers in slot 4. The following settings must be made with the appropriate configurations for the serial interface:

-- Interface on

-- Even parity

-- LRC without

-- Baud rate 9600

-- Parameters/process values writable (as desired)

-- Station number according to selection 0 to 125

Make sure that the station number is not assigned double on the bus. The PROFIBUS module serves to connect the SIPART controllers to a master system for control and monitoring. In addition the parameters and configuring switches of the controller can be read and written. Up to 32 process variables can be selected and read out cyclically by configuration of the PROFIBUS module.

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1.4 Function principle

1.4.2 Description of the option modules

Manual1 Technical Description

The process data are read out of the controller in a polling procedure with an update time < 300 ms. If the master writes process data to the slave, these become active after a maximum 1 controller cycle.

The description and the controller base file (*.GSD) can be downloaded from Internet under www.fielddevices.com

A technical description including the controller base file (*.GSD) is available for creating a master-slave linking software for interpreting the identifications and useful data from and to the SIPART controller.

The programs SIPART S5 DP and S7 DP are offered for certain hardware configurations.

6DR2803-8C Serial interface RS 232 / RS 485

D Serial interface for RS 232 or RS 485 with electrical isolation

Canbeinsertedinslot4.

For connecting the controller SIPART DR22 to a master system for control and monitoring. All process variables can be sent, the external setpoint, tracking variable, operating modes, parameters and configurations sent and received.

The interface traffic can take place as follows:

RS 232 as point-to-point connection SIPART Bus

The SIPART bus is no longer available. Therefore please implement multipoint connections via RS 485 or PROFIBUS DP.

RS 485 As a serial data bus with up to 32 users.

The interface module 6DR2803-8C offers electrical isolation between Rxd/Txd and the controller. Switching can be performed between RS 232, SIPART bus and RS 485 with a plug-in bridge.

A detailed technical description of the telegram traffic is available for creating an interface software.

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Manual 1 Technical Description

1.4.2 Description of the option modules

Txd

24 V

+7.5 V

-7.5 V

+7.5V

-7.5 V

RS 232

SIPART bus

24 V

Txd

Rxd

+7.5 V

1.4 Function principle

RS 485 + 150R

+7.5 V

RS 485

Rxd/ Txd A

Rxd/ Txd B

Rxd

-1

Figure 1-3 Block diagram serial interface

for RS 232 / SIPART BUS

-7.5 V

Other connections: NC

Rxd

Rxd/ Txd

NC2, 7

Other connections: NC

Figure 1-4 Block diagram serial interface for

RS 485

6DR2804-8A Module with 4 BA relays 6DR2804-8B Module with 2 BA relays

D Interface relay module with 2 or 4 relays

To convert 2 or 4 binary outputs to relay contacts up to 230 V UC.

The module can be snapped onto a mounting rail on the back of the controller. The mounting rail is delivered with the interface relay module.

One or two relay modules with 2 relays each are installed depending on the version. Every relay has a switching contact with spark quenching in both switching branches. In AC consumers with a very low power, the current flowing (e.g. hold current in contactors) through the spark quenching capacitor (33nF) when the contact is open interferes. In this case they should be replaced by capacitors of the same construction type, voltage strength and lower value.

The switching contact is fed to the plug terminals with 3 poles so that rest and working circuits can be switched. The relays can be controlled directly from the controller’s digital outputs by external wiring.

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1.4 Function principle

1.4.3 CPU self-diagnostics

Manual1 Technical Description

WARNING

The relays used on the interface relay module are designed for a maximum rating of AC 250 V in overvoltage class III and contamination factor 2 according to DIN EN 61010 Part 1. The same applies for the air and creep lines on the circuit board. Resonance increases up to twice the rated operating voltage may occur when phase shift motors are controlled. These voltages are available at the open relay contact. Therefore such motors may only be controlled under observance of the technical data and the pertinent safety conditions via approved switching elements.

1.4.3 CPU self-diagnostics

The CPU runs safety diagnostics routines which either can only after a reset or cyclically. The CPU is familiar with two different types of reset.

-- Power on reset

Power-On-Reset always takes place when the 5-V supply drops below 4.45 V, i.e. the power supply is interrupted for longer than specified in the technical data. All parameters and configurations are reloaded from the user program memory into the RAM.

At S100 = 1 the digital x-display flashes as indication after a Power-On-Reset, it is acknowledged by the Shift key (12).

Flashing is suppressed by S100 = 0.

-- Watch dog reset

When a watch-dog-reset occurs the parameters and configurations from the user program memory are reloaded into the RAM. The current process variables and the status signals are read out of the RAM for further processing. There are no flashing signals on the front module.

CPU-tESt appears in the digital displays dd1 and dd2 for a maximum 5 s after every reset. Every error detected by the self-diagnostics leads to a flashing error message on the digital displays dd1 and dd2 with defined states of the analog and digital outputs. The fault message output St

of the y

module becomes low. The reactions listed in the table are only possible of

hold

course (since this is a self-test) if the errors occur in such a way that the appropriate outputs or the front module can still be controlled properly or the outputs themselves are still functioning.

There are other error messages for the input range which indicate defective structurings within this range (see chapter 1.5.6 ”Error messages”, page 99). In addition error messages are output in the adaptation (see chapter 3.3.2 ”Parameterization mode AdAP”, page 173).

The digital displays flash in the case of error messages.

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Manual 1 Technical Description

sages

gofg

Errorcause/

CPU

RAM

0last

0mA00

memor

)

municatio

cyclic0

operatingwith

tin

matchtheplugged

1.4 Function principle

1.4.4 Data storage, User program memory

All data are written in the RAM first and then transfered to the user program memory (EEPROM) when returning to the process operation mode (manually or via the SES).

Writing time

The writing time after leaving the parameterization and configuring modes is up to 30 s. Then the data are stored in a non-volatile memory.

Error messages of the CPU

Reactions

Error

mes-

dd1 dd2

CPU Err

MEM Err

Monitoring

EEPROM,

EPROM

User program memor

Monitoring

time

Power On-Reset

Watch Dog-Reset

Power On-Reset

Watch Dog-Reset

hold

AA4/7

with

last value

-module

AA4/7

without

0mA

last value

0mA

last value

when storing

continues operating with current

oP.5.*.

oP.*.6.

Data communication μP-slot 5

Data communication μP-slot 6

cyclic 0

pulled last value

defective,

pulled 0mA

undefined

Also double error display oP.5.6 possible, * means digit dark.

At BE5 to 9 and BE10 to 14 the effect of the digital inputs (after inversion) are set to 0 in the event of an error.

Standard controller

AA1

to 3

data

continues operating with current data

Options

BA1

to 8

BA9

to 12

0 0 0

continues

operating with

current data

last state or undefined

continues operating with current data

BA13

to 16

continues operating with current data

last state or undefined

Primary

Error cause

Remedy

Monitored components of the CPU defective/change main board

User program memory not plugged or defective/plug or change

Monitored components of the CPU defective/change main board

User program memory not plugged or defective/plug or change

Option not plugged, defective or setting in hdEF oP5 does not match the plugged option. Plug option or replace or correct oP5

Option not plugged, defective or setting in hdEF oP5 does not match the plugged option. Plug option or replace or correct oP6

Table 1-1 Error message of the CPU

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1.5 Functional description of the structure switches

1.5.1 Analog input signal processing permanently connected

Manual1 Technical Description

1.5 Functional description of the structure switches

(S0 to S107, S200 to S268)

In the factory setting (setting when the device is delivered) most of the structure switches are set to 0. This corresponds to the most usual setting of the individual functions so that only few structure switches need to be set selectively during commissioning. However, it is recommendable to compare the individual structure switch settings with the task.

With structure switch S0 the user program can be identified by a number from 1 to 254 in the structuring mode Strs. The setting 0 corresponds to the factory setting and is regenerated automatically in the APSt function (All Preset). All changes in parameters or structures in relation to the factory setting automatically set S0 from 0 to 1.

The structure switches S1 and S2 are fundamentally significant. With S1 the controller type is set and thus the processing of command variable, main controlled variable and auxiliary controlled variables up to control difference generation determined. With S2 the controller output structure is set and thus the processing of the automatic-, manual-, safety- and follow--up variables as well as the manipulated variable output determined as a K- or S-output.

1.5.1 Analog input signal processing permanently connected

(S3 to S21, S200 to 205)

In the structure switch setting S4=0 the analog input range is permanently connected (see figure 1-5, page 24). With S4=1 the permanent connection is canceled and converted into a freely connectable input range (see chapter 1.5.2, page 25).

Every one of the maximum 11 analog inputs is fed through an AD converter which performs the 50 or 60 Hz interference suppression by averaging over 20 or 16 2/3 ms. After this the signal range 0 to 20 mA or 4 to 20 mA is normalized to 0 to 100% calculated value per channel with S5 to S9 or S200 to S205.

At the same time it is decided with S5 to S9 or S200 to S205 whether operation is to take place with or without range monitoring (transmitter fault). The monitor signals per channel on dropping below --2.5 % or exceeding +106.25 % with a hysteresis of 0.25 % to the digital x and w display. By an OR link of all single messages the group transmitter fault MUF is formed which can be assigned to the digital outputs and negated optionally (see chapter 1.5.8, page 121). Only the analog inputs selected with the transmitter fault monitor are monitored, displayed on the front panel (the appropriate position stays dark in the case of analog inputs not selected with transmitter fault) and signaled with the OR link. The error message is acknowledged with the Shift key (12). The fault message signal via the OR link is available until the appropriate analog inputs are back in the working range.

After the range monitoring the 11 analog inputs are fed through a 1st order filter which can be set by the parameters tF1 to tFb in the range of oFF, 0.1 to 1000 s in the parameterization mode onPA. The factory setting is 1 s.

With S10 to S14 or S206 to S211 every channel can now be root extracted optionally. After root extraction, the 11 analog inputs are available for further processing as AEA1 to AEbA.

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Manual 1 Technical Description

1.5.1 Analog input signal processing permanently connected

1.5 Functional description of the structure switches

The function inputs FE1 and FE3 are preceded by a linearizer which enables non-linear process variables to be displayed physically correctly (for operating method see chapter 1.5.2, page 25) function block Fu, setting of the 13 vertex values, see chapter 1.5.4, figure 1-19, page 45 to figure 1-23, page 46).

The outputs of the analog inputs AE1A to AEbA are now assigned to the function inputs FE1 to FE12 by the structure switches S15 to S19 or S212 to S217. The outputs AE1A to AEbA and the function inputs FE1 to FE12 are available for the assignment to analog outputs, the limit value alarm and the parameter control and can be read through the SES. With this input structure most control tasks can be solved in connection with the different controller types and controller output structures.

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1.5 Functional description of the structure switches

1.5.1 Analog input signal processing permanently connected

Manual1 Technical Description

see fig. 1-24 (pg. 48) to fig. 1-44 (pg. 83)

FE1

FE2

see fig. 1-50

(pg. 90)

FE3

see fig. 1-58 (pg. 102) to

fig. 1-62 (pg. 109)

FE4

FE5Zy

FE6

FE7

FE12

function inputs

S20

--1 .1

to 11.1

S15

AE1A

AE2A

...

AE3A

AEbA

AE1A

AE2A

S21

--1 .3

to 11.3

S16

...

AE3A

AEbA

S17

...

AE1A

AE2A

AE3A

AEbA

S18

AE1A

AE2A

AE3A

AEbA

1, 2

...

S19

...

AE1A

AE2A

AE3A

AEbA

S212

...

AE1A

AE2A

AE3A

AEbA

S217

...

AE1A

AE2A

AE3A

AEbA

connectable

AE7A

AE8A

AE1A

S4 = 1 drawn

at S4 = 1 freely

AE2A

AE3A

AE4A

AE5A

AE6A

AE9A

AEAA (AE10A)

AEbA (AE11A)

Outputs of the

tF1

1/20

analog outputs

AE1

0, 1

AE1A

S10

AE2A

S11

AE3A

S12

AE4A

S13

AE5A

S14

AE6A

S206

AEbA

(AE11A)

S211

...

tF2

2, 3

0, 1

4bis20mA

1/19

I, U

1/22

AE1

1/21

I, U

tF3

2, 3

0, 1

4to20mA

1/23

1/24

AE1

I, U

tF4

2, 3

0, 1

4to20mA

Slot 2

AE4

I, U, R,

P, T

tF5

2, 3

0, 1

4to20mA

Slot 3

AE5

I, U, R,

P, T

tF6

...

S200

2, 3

4to20mA

2, 3

0, 1

...

4bis20mA

Slot 6

AE6

I, U

AE7

I, UAAE8

Slot 5

I, U

AE9

tFb

S205

2, 3

0, 1

4to20mA

AE10

I, UAAE11

I, U

Figure 1-5 Analog input signal processing permanently connected (S4 = 0)

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Manual 1 Technical Description

1.5.2 Analog input signal processing freely connected (S4 = 1)

1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

The structure switch setting S4=1 cancels the permanent connection at S4=0 in the analog input range and replaces it with a freely connectable input range. The freely connectable input range basically represents a multifunctional unit, configuring takes place according to the same rules.

Up to the outputs AE1A to AEbA (AE11A), the signal processing is identical to that described in chapter 1.5.1, page 22. The function inputs FE1 to FE12 also operate in the same way with the difference that FE5 (follow-up input) and FE6 (position feedback input) can be used in parallel and with the difference that FE5 (follow--up input) and FE6 (position feedback input) can be used in parallel and connected with different signals.

Nine different function blocks which occur with different frequency can now be connected absolutely freely between the outputs AE1A to AEbA and the function inputs FE1 to FE12. The outputs AE1A to AEbA represent data sources whilst the function inputs FE1 to FE12 are data sources. Parallel to the outputs, 15 connectable linear parameters are arranged with a setting range of -1.999 to 19.999 (corresponding to -199.9 % to 1999.9 %), a number of normal constants as well as other variables gained from the controller as data source.

The function blocks have a different number of inputs (data sinks) and 1 output each (data source) depending on the function depth.

The function blocks ”function transmitter” and ”correction computer” have assigned parameters which can be set in the structuring mode oFPA. The connectable parameters P1 to P15 are set in the parameterization mode onPA.

By structuring on the front module the necessary functions are selected or defined (structuring mode FdEF), connected (structuring mode FCon) and correctly positioned in time in the cycle (structuring mode FPoS), see chapter 3.3.7, page 201 to 3.3.9, page 205. Connection is absolutely free, i.e. any data source can be connected with any data sink. The operating effort is minimized by fading the data sources and sinks from undefined function blocks. In addition the data sinks which are not obliagatory for a function are pre--occupied by constants which can be overwritten. The inputs pre--occupied with ncon (not connected) are absolutely essential for the function and must be connected. This very variable connection facility in the analog input range also enables complex control tasks to be solved.

No distinction is made between analog and digital signals. Digital inputs have a threshold value of 0.5. Digital outputs supply a value of 0 % (0) or 100 % (1).

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1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

Data sources Data sinks Data sources Data sinks

Manual1 Technical Description

AE1

AE2

AE3

AE4

AE5

AE6

AE11

Connectable parameters

Constants

Digital inputs

Fault message

AE1.A

AE2.A

AE3.A

AE4.A

AE5.A

AE6.A

AEb.A

P01

P15

--1,0 .

1.05

BE01

BE09

AE1

AE5

Ar .F

Ar .1

Ar .2

Ar .3 Ar .4

Ar .5

Fu .F

Fu .1

Parameter: Vertex value at -10, 0, 10 to 90, 100, 110

MA .F MA .1

MA .2

MA .3

Mi .F Mi .1

Mi .2

Mi .3

rE1 .F

rE1 .1

rE1 .2

rE1 .3

Parameter. tA, tE, PA, PE

Ar1 to Ar6

E1 E2

E1 · E2+E3-E4

E3 E4 E5

Fu1, Fu2

MA1 to MA3

E1 E2 E3

Mi1 to Mi3

E1 E2 E3

rE1



ΔP



f(E2·E3)

Max

Min.

Ar .6

Fu .2

MA .4

Mi .4

rE .4

FE1

FE2

FE3

FE4

FE5

FE6

FE7

FE8

FE9

FE10

FE11

FE12

Analog signals

Analog or digital signals

Alarms A1 to A4

AS .F

AS .1

AS .2

AS .3

AS1 to AS5

E1 E2 E3

Status message

Setpoints w1/w2

Manipulated variable y *)

Serial analog value

Int1 Int2

SPI1 SPI2

SP1 SP2

yI yII

SAA1

SAA4

Co .F Co .1

Co .2

Co .3

nA .F

nA .1

nA .2

nA .3

no .F

no .1

no .2

no .3

Co1, Co2

nA1, nA2

E1 E2 E3

no1, no2

E1 E2 E3

≥1

Figure 1-6 Analog input signal processing freely connectable (S4=1)

AS .4

Co .4

nA .4

no .4

SPI 1/2: internal setpoint

SP 1/2: active setpoint

*) y1: Manipulated value

*) y2: Manipulated value

controller 1/2

controller1/2

y controller 1

y controller 2 (for S1 = 12)

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Manual 1 Technical Description

1.5.2 Analog input signal processing freely connected (S4 = 1)

1.5 Functional description of the structure switches

The individual function blocks are described below.

1.5.2.1 Arithmetic Ar1 to Ar6

Ar1toAr6

ncon ncon

0.000

1.000

Ar .F Ar .1

Ar .2

Ar .3 Ar .4

Ar .5

E1 E2

E1 · E2+E3-E4

Figure 1-7 Function block Arithmetic Ar1 to Ar6

-- With this function block the four basic arithmetic functions are implemented with appropriate assignment of inputs 0 and 1 respectively. The preset E3=E4=0, E5=1 gives A = E1×E2.

-- Typical process-technical applications are dosing or evaluation (E1×E2), range fade-outs (E1×E2+E3) or differentiations (E3 - E4).

Ar .6

E1 · E2 + E3 - E4

E5 is limited to values ≥0.5 %.

1.5.2.2 Function transmitter Fu1 and Fu2

Fu1, Fu2

Fu .F

ncon

Fu .1

-10, 0, 10 bis 90, 100, 110oFPA

Fu .2

A=f(E)

Figure 1-8 Function block function transmitter

The function transmitter assigns every value of the input variable E in the range from -10 % to +110 % an output variable A in the range from -199,9 % to +199,9 % with the function entered by the user: A = f(E). The function is entered by the parameters ”vertex value 1 to 13” for -10 % to +110 % of E in intervals of 10 %. Parabolae are set by the computing program between these vertex values which interlink tangentially the vertex values so that a constant function is produced. The vertex values at -10 % and +110 % of E are required for the overflow. The last rise remains constant in the case of further overmodulation of E. When used as a linearizer for the displays, the linearization function is entered by the 13 vertex values so that the series circuiting of the sensor function gives a linear equation with the linearization function (see chapter 1.5.4, figure 1-20 to figure 1-23, page 46).

1.5.2.3 Maximum value selection MA1 to MA3

MA1.F to MA3.F

ncon ncon

0.050

MA .F MA .1

MA .2 MA .3

E1 E2 E3

Max

MA .4

A = max (E1,E2, E3)

The greatest of the three input values is connected through to the output.

Figure 1-9 Function block maximum value selection

With the preset the greater value of E1 or E2 is connected through to A and at the same time limited to the value of E3 (-5 %). Typical applications are maximum value selection circuits and minimum value limitings.

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1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

Manual1 Technical Description

If only 2 inputs are required, the 3rd input must be set outside the working range of the two inputs to a minimum value otherwise minimum value limiting takes place.

1.5.2.4 Minimum value selection Mi1 to Mi3

Mi1.F to Mi3.F

ncon ncon

1.050

Mi .F Mi .1

Mi .2

Mi .3

E1 E2 E3

Min.

Figure 1-10 Function block minimum value selection

With the preset the smaller value of E1 or E2 is connected through to A and at the same time limited to the value of E3 (105%). Typical applications are minimum value selection circuits. If only 2 inputs are required, the 3rd input must be set outside the working range to a maximum value, otherwise a maximum value limiting takes place.

Mi ..4

A = min (E1, E2, E3)

The smallest of the three input values is connected through to the output.

1.5.2.5 Correction computer for ideal gases rE1

rE1

rE1 .F

1.000 ncon ncon

rE1 .1

rE1 .2

rE1 .3

E2 E



ΔP



f(E2·E3)

Figure 1-11 Function block correction computer rE1 for ideal gases

The rooted signal of the active pressure must be applied at input c**.1. The measuring ranges are normalized to the calculation state with the parameters PA, PE, tA, tE (correction quotients start/end for pressure and temperature).

Range of Application

The correction computer is used to calculate the flow of gases from the active pressure Δp depending on pressure and temperature. The medium must be in pure phase, i.e. so that no liquid separations may take place. This should be noted particularly for gases close to the saturation point.

rE .4

A = Δp·f(E2,E3)

f(E2, E3) =

(oFPA)tA, tE, PA, PE



(PE – PA) E2 + PA

(tE – tA) E3 + tA

Errors due to fluctuating status variables of the medium (pressure, temperature) are corrected by the flow correction computer here.

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Manual 1 Technical Description

1.5.2 Analog input signal processing freely connected (S4 = 1)

1.5 Functional description of the structure switches

Pressure p Temperature t

Kp/cm

Figure 1-12 Active pressure measuring method, Principle

Active pressure Δp

Measured value transmission

Δp

Calculation

Function block rE

Physical notes

The active pressure measuring method is based on the law of continuity and Bernoulli’s energy equation. According to the law of continuity the flow of a flowing liquid in a pipe is the same at all places. If the cross-section is reduced at one point, the flow speed at this point should increase. According to Bernoulli’s energy equation the energy content of a flowing material is made up of the sum of the kinetic energy (due to the speed) and the potential energy (of the pressure). An increase in speed therefore causes a reduction in pressure. This drop in pressure, the so-called ”active pressure” Δp is a measure of the flow q.

The following applies:

q = c· Δp



with c as a factor which depends on the dimensions of the pipe, the shape of the constriction, the density of the flowing medium and some other influences. The equation states that the active pressure generated by the constriction is in the same ratio as the square of the flow.

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1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

Δp

1.00

0.81

0.49

0.25

0.09

Manual1 Technical Description

Figure 1-13 Relationship between flow q and active pressure Δp

0.3 0.70.5 0.9 1.0 q

To measure the flow, a choke is installed at the measuring point which constricts the pipe and has two connections for tapping the active pressure. If the properties of the choke and the measuring material are known to the extent that the equation specified above can be calculated, the active pressure is a measure of the flow.

If you have chosen a certain choke, the flow can be described in the calculation state or operation state.

= K· ρ



· Δpor q = K· ρ· Δp



Since the density is included in the measuring result according to the above equation, measuring errors occur when the density in the operating state differs from the value based on the calculation of the choke. Therefore a correction factor F is introduced for the density in operating condition.

with V=

as specific volume.

In order to be able to perform the correction with the factor F, the current specific volume must be determined first. For the dry gases the densities change according to the laws for ideal gases:

The correction factor is then given as:V = R

F =



·p

·T

with p as absolute pressure and T as absolute temperature.

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Manual 1 Technical Description

1.5.2 Analog input signal processing freely connected (S4 = 1)

1.5 Functional description of the structure switches

m3/kg

to P

abs.A

to Â

Figure 1-14 Display of the correction range

abs.E

Correction range

Range of pressure of the transmitter Range of temperature of the transmitter

E _C

abs.A

abs.B

abs.E

abs.

bar

qFlow

ρ Density Δp Active pressure

p Pressure Â Temperature (_C) T Temperature (K) V Specific volume R Gas constant F Correction factor f (p, T)

Indices:

AStart EEnd B Calculation state abs Absolute variable m Ground v Volume

This gives for the corrected flow

·p

q = F·K· ρ



· Δp= K· ρ



The factor contained in the formula

· Δp·

K· ρ



·T

is already taken into account in the measurement of

the active pressure and can therefore be ignored by the computer.

Related to the correction factor it follows:



A = Δp

·f(E2,E3)with F = f(E2, E3)=

(PE − PA) E2 + PA



(tE − tA) E3 + tA

The measuring ranges are normalized to the calculation state with the parameters PA, PE, tA, tE (correction quotients start/end for pressure and temperature).

Mass flow computer, m

A=qm,E2=p,E3=Â

PA =

tA =

absA

,PE=

,tE=

T T

absE

with T

[K]

A∕E∕B

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1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

Manual1 Technical Description

Volume flow computer related to the operating status q

Since the volume is reciprocally proportional to the density, a volume flow computer can be made out of this mass flow computer by changing the inputs E2 and E3.

A=q

PA =

tA =

Volume flow computer related to the standard status q

,E2=Â,E3=p

,PE=

absA

,tE=

absE

with T

A∕E∕B

[K],

Since the output signal is now related to the volume flow in the standard status, TN= 273. 15 K,

= 1.01325 bar

A=q

tA =

PA =

,E2=p,E3=Â

,tE=

absA

,PE=

and no longer to the operating state, it must be corrected accordingly.

abs

with T

absE

A∕E∕B

[K],

The following applies for all computers:

p T

absA

to T

to p

absE

Transmitter range absolute pressure (bar) Transmitter range absolute temperature (K)

is formed from the transmitter range Â

to ÂEby conversion:

T(K) = 273, 15 + Â (_C)

B,TB

Pressure and temperature range of the calculation state of the measuring panel (absolute values)

and TBmust be within the range of the transmitter; and may not be more than the factor 100

away from the range limits.

PA, tA = 0.01 to 1

PE, tE = 1 to 99.99

The input rE1.1 Δp is limited to values ≥0.

If the adjustable ranges for PA, PE, tA, tE are not sufficient a linear equation can be switched in front of the appropriate input for adaptation (function block Ar).

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.2 Analog input signal processing freely connected (S4 = 1)

1.5.2.6 Switch for analog variables AS1 to AS5

E3 A 0(<0,5)

≥0,5)

E1 E2

ncon ncon

0.0

1.5.2.7 Comparator with adjustable hysteresis Co1, Co2

(two-position switch, e.g. limit value sensor)

Inputs Output A E1≥(E2 + H/2)

E1<(E2 -- H/2)

1H=E3 = hysteresis) 0

ncon ncon

0.050

1.5.2.8 AND NOT function (NAND) nA1, nA2

A=E1∧ E2 ∧ E3 =E1∨ E2 ∨ E3 with default: A = E1 (Negation of E1)

E1 E2 E3 A

0 0 0 1 100 1 010 1 110 1

0 0 1 1 101 1 011 1 111 0

nA1.F to nA2.F

ncon

1.0

AS1.F to AS5.F

AS .F AS .1

AS .2

AS .3

E1 E2 E3

Co1.F to Co2.F

Co .F Co .1

Co .2

Co .3

nA .F nA .1

nA .2

nA .3

E1 E2 E3

AS .4

Co .4

nA .4

1.5.2.9 OR NOT function (NOR) no1, no2

A=E1∨ E2 ∨ E3 =E1∧ E2 ∧ E3 with default: A = E1 (Negation of E1)

E1 E2 E3 A

0 0 0 1 100 0 010 0 110 0

0 0 1 0 101 0 011 0 111 0

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no1.F to no2.F

ncon

0.0

no .F no .1

no .2

no .3

E1 E2 E3

≥1

no .4

Page 36

1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

Manual1 Technical Description

1.5.3 Digital input signal processing

(S24 to S48, S219 to S230)

1.5.3.1 Digital inputs BE1 to BE14

The inputs BE1 to BE4 are located on the basic board. BE5 to 9 and 10 to 14 are connected to the module 6DR2801-8C at the slots 5 or 6. The digital output modules 6DR2801-8E also contain another two digital inputs in addition to the outputs so that in this case the two digital inputs BE5/BE6 or BE10/BE11 can be used.

24 V

Slot 5 3AA + 3BE 6DR2802--8B

BE5 BE5

5/1

5/2

5/3

6/1

6/2

6/3

24 V

BE6

BE7

S22 = 6

Slot 6 3AA + 3BE 6DR2802--8B

BE10

24 V

BE11

BE12

S23 = 6

5/1

5/6

6/1

6/6

Slot 5 4BA + 2BE 6DR2801-8E

BE6

S22 = 1

Slot 6 4BA + 2BE 6DR2801-8E

BE10

BE11

S23 = 1

24 V

1/15

1/16

1/17

1/18

5/1

5/2

5/3

5/4 5/5

6/1

6/2

6/3

6/4 6/5

BE1

BE2

BE3

BE4

Slot 5 6DR2801--8C 5BE

24 V

BE5

BE6

BE7

BE8 BE9

S22 = 2

Slot 6 6DR2801--8C 5BE

24 V

BE10

BE11

BE12

BE13 BE14

S23 = 2

bE01

bE02

bE03

bE04

bE05

bE06

bE07

bE08

bE09

bE10

bE11

bE12

bE13

bE14

Figure 1-15 Input function digital inputs

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

1.5.3.2 Assignment and direction of effect of the digital inputs

see fig. 1-16, page 37 The control signals CB, He ...+yBLII, -yBLII are assigned by the structure switches S24 to S38 and S219 to S228 to the digital inputs BE1 to BE14 or the status Lo. In the assignment of CB (S24), CBII (S219), PI (S30), PII (S31), wSLI (S225) and wSLII (S226) the High status (S** = --1) is also possible. The control signals can be negated optionally by the structure switches S39 to S46 and S229 to S230.

The digital inputs BE1 to BE4 of the standard controller can be extended with the option modules 6DR2801-8C, 6DR2801-8E, 6DR2802-8B in slot 5 and in slot 6.

When using option modules in slots 5 and 6 the structure switches S22 and S23 must be set according to the assembly, otherwise it will lead to error messages (see chapter 1.4.3, page

20). All digital inputs can be read by the SES.

1.5.3.3 Linking the digital inputs BE1 bis BE14 to the control signals via the

SES

(S47 to S49, S101)

see fig. 1-17, page 38 The control signals CB and N may be available optionally as static signals or as a pulse (key operation on consoles) at the digital inputs. The setting is made by S47 for CB and S48 for N. On selecting the pulse input, every positive edge flips the flip-flop. In the following descriptions the output status of the flip--flop is assumed as CB or N.

All control signals except

Δw and Δy can also be preset by the SES at S101 = 2, 3, 4, 5

and OR linked with the appropriate control signals through the digital inputs. The incremental adjustment of w or y by the SES is not advisable on account of the bus run times. Since the top operation hierarchy in a computer link should be with the autarcic single controller, the control signals can be switched off by the SES by rounding with RC = Int key (2) of the controller or via CB

(optionally time-monitored) or via CBBE(central Computer

∧CB via the Internal/External

Fail line).

In addition the internal flip-flop can be activated at S101 = 2 to 5 parallel to pressing the keys

ES.

via Int

The CB signal is formed at S101 = 2, 4 as an OR function of CB

via a digital input so that operation can take place optionally with one signal.

via the serial interface and

At S101 = 3, 5 the OR function is replaced by an AND function so that the CB set by the SES can be reset via a central Computer Fail line.

The function RC = Int

∧CB (computer operation) also controls the command variable switching in all controller types, i.e. also in SPC-mode or manipulated variable switching in DDC mode (see chapter 1.5.4, page 40). The two controller types S1 = 10/11 operate without command variable switching. The Internal key and the control signal CB are available with the link RC Int∨CB

for locking operation through the serial interface (e. g. when coupling to control sys-

tems).

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1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

Manual1 Technical Description

At S47 = 0 static switching takes place due to the logic function RC = Int∧CB. In the case of thepresettoInt

(Internal LED (1) off) you can switch statically with CB between controller values and computer values (command and manipulated variables). The computer standby CB is displayed negated by the C the controller is signaled negated as a message signal RB signaled negated as a message signal RC

-LED (3) (C =CB,CB=1=CLED off). The computer standby of = Int. The computer mode is also

= Int∧CB .

At S47 = 1 static switching with acknowledgement takes place. Every time the computer is recovered (CB from 0 ! 1) the internal flip--flop is set to 1 (Internal LED on, C the computer mode RC = Int∧CB

only becomes active after pressing the Internal key (Int=0).

LED off) so that

With S49 the Internal/External key can be switched out of function and only internal or external operation preselected.

The control signal H is generated as an OR-function by the Manual-/Automatic key (9) with subsequent flip-flop (Hi) and the control signal He whereby He can be preset by the SES or the digital inputs in the way described above.

With the structure switch S64 Automatic-/Manual switching can be blocked in the positions only Automatic (H = 0) or only Manual (H = 1). The Manual LED (8) always indicates the active status (see also chapter 1.5.6, page 99).

At S64 = 0 to 2, He is connected statically by both the SES and the digital inputs. At S64 = 3/4 the connection is made dynamically, i.e. every positive edge causes manual-automatic-manual opeeration switching. Additionally interlocking of He

with RC =Int∨CB is canceled at

structure switch S64 = 4.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

assignment with

S**

--1

BE01 1 BE02 2 BE03 3 BE04 4

BE05 5 BE06 6 BE07 7 BE08 8 BE09 9

BE10 10 BE11 11 BE12 12 BE13 13 BE14 14

FE09 15 FE10 16 FE11 17 FE12 18

S24

--1

S25

S26

--1

S27

--1

S28 S29 S30

--1

S31

--1

S32 S33

--1

S34

--1

S35

--1

S36

--1

S37

--1

S38

--1

S218 S219

--1

S220

--1

S221

--1

S222

--1

S223

--1

S224

--1

S225

--1

S226

--1

S227

--1

S228

--1

S39

0 1

S40

0 1

S41

0 1

S42

0 1

S43

0 1

S43

0 1

S44

0 1

S44

0 1

S45

0 1

S45

0 1

S46

0 1

S46

0 1

S39

0 1

S40

0 1

S41

0 1

S42

0 1

S229

0 1

S229

0 1

S230

0 1

S230

0 1

S46

0 1

S46

0 1

PII

+Δw

--Δw

+Δy

--Δy

+ybL

--ybL

CBII

HeII

NII

SiII

/tSI

/tSII

wSLI

wSLII

+ybLII

--ybLII

accordingtofig.1-17, Page 38

bLS

bLPS

PAU

according to fig. 1-17, Page 38

bLb

accordingtofig.1-17, Page 38

Figure 1-16 Assignment and direction of effect S24 to S38 and S218 to S228

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1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

Manual1 Technical Description

+Δw

-Δw

+Δy

-Δy

S64

from fig. 1-16, p. 37

0/2/3/4

HeBE(I/II)

SiBE(II) bLb

bLS

bLPS

P I

PII

PAU

+ybLBE(II)

-ybL

tSHI

tSHII

WSLI

WSLII

(II)

**)

bLb bLS bLPS

tSHII

onlyactiveinCB∧Int

CB∧Int

S48

3 3

2/3(4/5)

0/1 S101

S64

0/1/2

S64 0/1/2

3/4

≥

2/3(4/5)

0/1

S101

2/3(4/5)

S101

0/1

2/3(4/5)

S101

0/1

2/3(4/5)

S101

0/1

S47

≥

S49

2/3/ 4/5

SES

CBBE(II)

0/1

S101

2/3/4/5

S101

0/1

2/3/4/5

0/1

S101

≥

0/2

S47

Int

IntII

*) as of software version --D06 **) as of software version --C09

3/5

0/1 2/4

S271*)

S101

-1

Figure 1-17 Linking the digital inputs BE1 to BE14 with the control signals via the SES

(S47, S48, S49, S101)

+Δw

-Δw +Δy

-Δy

≥

0/1/3/4

S64

H (II)

Si (II)

≥

bLb bLS bLPS P I PII PAU +ybL (II)

≥

-ybL (II) tSHI tSHII WSLI WSLII

≥

N(II)

active control signals for the switching functions in the controller

CB (II)

RC=Int∧CB (single controller) RC=Int II∧CB (cascade)

RB=Int (single controller)

or Int II (cascade)

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.3 Digital input signal processing

1.5.3.4 Functional explanation of the digital control signals

bLb Blocking operation

Blocking the entire device operation and configuring. Exception: Display of circuit

bLS Blocking structuring

With this signal the controller only allows switching to the online parameterization levels outside process operation. In this way the parameters for adapting the instrument to the process and the necessary settings for the adaptation can be selected. Structuring is blocked.

bLPS Blocking parameterization and structuring

The entire configuring of the device is blocked, this means the parameterization as well. Only the normal process operation according to the preselected controller type is permitted.

CB Computer standby

Depending on the controller type this digital signal together with the Internal/External key effects either switching in the setpoint range or DDC operation begins. Central computer fail line in SPC and DDC operation.

He Manual external

This signal blocks the output of the controller and enables direct manual adjustment of the manipulated variable on the front control panel.

N Follow-up

With this signal the output of the K--controller and the three-position step controller with external position feedback is followed up to the follow-up signal yN.

Si Safety operation

In K-controllers and three-position step controllers with external position feedback, the manipulated variable adopts the parameterized safety value. In three-position step controllers with internal position simulation, the manipulated variable runs defined to 0 or 100 %.

tSHI/II Setpoint ramp/Setpoint changes

Setpoint changes via the setpoint ramp can be stopped by a binary input.

I/II External setpoint -- preselection

Preselect whether external setpoint via analog input or SES/incremental.

PI P-operation controller I

With this signal the controller I (parameter set I) is switched to P-operation.

PII P-operation controller II

With this signal the controller II (parameter set II) is switched to P-operation.

PAU Parameter switching

The programmable controller types include single controllers and double controllers (meshed controllers). Single controllers operate with the parameter set I and can be switched by this digital signal to the parameter set II. Double controllers are permanently assigned to the parameter sets I and II;the switching possibility is then omitted.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Δw Incremental setpoint adjustment

External setpoint or nominal ratio preset for incremental adjustment via digital inputs

Δy Incremental manipulated variable adjustment

External manipulated variable default for incremental adjustment through digital inputs in follow-up operation.

ybL Direction-dependent blocking of the manipulated variable

Direction-dependent limiting of the manipulated variable by external signals, e.g. from the limit switches of the actuating drives. This limiting is effective in every operating mode.

Signals with identification II relate logically to controller II at S1 = 12. Corresponding SES signals are only effective when CBII=1 and IntII=0.

1.5.4 Controller types (S1, S49 to S53)

1.5.4.1 General, recurrent functions

Manual1 Technical Description

-- Manual setpoint preset wi or nominal ratio preset wvi on the control front panel.

The internal setpoint can always be adjusted with the

Δw-keys (6 Fig. 3-1) when the green

internal LED (1) lights up. The adjusting facility is marked by ↗ in the tables. Exceptions to this rule are expressly mentioned in the individual controller types. The adjustment operates incrementally, in the first step with a resolution of 1 digit and then an adjustment progression so that major changes can also be performed fast enough. After every interruption in the adjustment by releasing the keys, the progression starts again with the smallest adjustment step.

-- Setpoint preset wi or nominal ratio preset wvi by the SES

Every time the internal setpoint can be adjusted by the keys (6) on the control front panel, it is also possible to make a preset with the SES. Since only absolute and not incremental adjustment is possible with the SES, it is advisable to use the setpoint ramp tS to avoid steps.

In addition the control signal Int and the automatic/manual switching can be preset with the manual manipulated variable adjustment with the SES so that a complete parallel process operation is possible with the SES (see also chapter 1.5.6 ”Controller output structure”, section ”Control system coupling via the serial interface” on page 113).

-- Source for the external setpoint S53 and S101

The external setpoint w

E can come from a maximum of three different sources in the differ-

ent controller types:

external setpoint as an absolute value via the analog inputs (w external setpoint incremental via the control signals external setpoint as an absolute value via the SES (w In double controllers (S1 = 12) you can switch between w control signal w

SLI

or w

SLII

Δw(w

ES) SES (w

)

EΔ

)

Selection with S53

)selection with S101

and wEArespectively with

-- Setpoint ramp tS

(accordingly tSII at S1 = 12) With the parameter tS (oFPA) the adjusting speed of the effective setpoint w (in ratio control-

ler S1 = 4 the effective nominal ratio) can be set in the range of oFF, 0.1 to 9984 min over

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

0 to 100%. At the same time, tS presets the floating time for 0 to 100% change in incremental setpoint adjustment via the control signals

Δw. At tS = oFF the adjustment speed goes

to 1.

With the setpoint ramp, setpoint switchings can be effected to non-followed-up variables SH and wi, w

EΔ,wES

at S52 = 1 and w

if the supplying controller has not been followed up

not suddenly but with the set ramp.

Δw

S H

external Setpoint

Figure 1-18 Setpoint switching with ramp

safe Setpoint

tan α =

tw=

100 %

Δw·tS

100 %

Δw

With the control signals tS and tSII the set setpoint ramps can be switched off.

-- Setpoint limits SA, SE

(accordingly SAII,SEII at S1 = 12) With the parameters SA and SE (oFPA) the effective setpoint w can be limited to minimum

value (SA) and maximum value (SE) in the range from -10 to 110 %. Exception: Ratio controller (S1 = 4) and ratio cascade, commanded ratio controller (S1 = 6)

-- Follow-up of the ineffective setpoint to the active setpoint (S52)

(accordingly S235 at S1 = 12) Normally the ineffective setpoint is followed up to the effective setpoint so that the setpoint

switching is bumpless. The internal setpoint (wi), the external setpoint incrementally adjustable via Δw(w The safety setpoint SH cannot be followed up. The external setpoint w

) and the external setpoint via the SES (wES) can be followed up.

EΔ

via the analog

inputs can only be followed up indirectly by following up the supplying device on the output side. To do this the effective w is used as a follow-up variable, assigned to an analog output and as a follow--up control signal the OR-operation H∨N∨Si, assigned to a digital output.

At S52 = 1 the follow-up is suppressed. This switch setting is always required especially in follow-up controllers if the internal setpoint represents a kind of safety function or if multiple setpoint operation is to be run in follow-up controller (S1 = 3).

-- x-tracking (S50)

(accordingly S233 at S1 = 12) With the structure switch S50 = 1, x-tracking (ratio controller xv-tracking) can be switched

on. This means that the setpoint is followed up to the actual value or the nominal ratio is followed up to the actual ratio and therefore a control difference xd is reset to 0. The follow up always takes place when there is no automatic operation (A). This is the case in manual mode (H), follow-up mode (N), DDC mode and in operation with safety manipulated variable (Si): A

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=H∨N∨Si

Page 44

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

x-tracking in direction-dependent blocking operation is not possible because the P-step produced by resetting the driving control error to blocking direction would immediately cancel the blocking.

x-tracking takes place without the set setpoint ramp tS. By following up the setpoint to the actual value (nominal ratio to actual ratio), the control difference xd = 0 and automatic operation starts absolutely bumplessly. Since one can usually assume in manual mode and DDC mode that the actual value has been driven to the desired value, the followed up setpoint corresponds to the rated value.

x-tracking only takes full effect if the follow-up of the inactive setpoint is locked onto the active setpoint (S52 = 0) so that not only the active setpoint w but also the setpoint source which is supplying after switching to automatic operation is followed up.

Manual1 Technical Description

At S52 = 1 (without follow-up) the control difference is 0 during the A

-operation but after switching to the automatic mode the old non-followed up setpoint is immediately active again. With the setpoint ramp tS this step-shaped setpoint change takes place via a time ramp.

This combination is always useful when it is not guaranteed during A

-operation (especially in safety mode) that the actual value will be driven to the desired rated value by the actuating manipulation and the follow-up variable would not be correct in full x-tracking.

-- Constants c1 to c7

In the individual controller types the process variables are partially linked with each other whereby the constants c1 to c3 are used for the controlled variable links and constants c4 and c5 for the command variable links. The constants are set in the parameterization mode onPA in the range from -1.999 to 9.999.

The constants c6, c7 serve to dose the disturbance variable connection to the controller output yI or yII (see chapter 1.5.5.1, figure 1-50, page 90 and figure 1-51, page 91). They can be set in the parameterization mode onPA in the range from -19.99 to 19.99.

-- Control signals for the setpoint switching

If available in the single controller types, the setpoint switching takes place depending on the control signals Int (Internal/External key) and CB (Computer standby) as an AND function RC = Int indicated by the C

∧CB and its negation. The status of the control signal CB and the Internal key (2) is

LED (3) and the Internal LED (1).

With S49 the Internal/External key (2) can be set out of function and can block in the positions Internal or External (see chapter 1.5.3, figure 1-17, page 38). The factory setting is S49 = 0 only Internal. With S24 the CB signal can be set to Lo or Hi or a digital input assigned, (see chapter 1.5.3, figure 1-16, page 37). The factory setting is S24 = -1, CB = 1.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

The setpoint switching can be varied freely with these structuring possibilities:

Switching to Int S49 CB S24 active active

Dependence on setpoint w setpoint w

S1=3,4,5,6,7,8 S1=0/1

Int and CB 0∨12 0∨1 1 to 14 wi (SH) or w only Int 0∨12 1 -1 wiorw only CB 0 1 0∨1 1 to 14 wi (SH) or w

only external 0 1 1 -1 w only internal 1 0 any any wi wi2

Table 1-2 Possibilities of setpoint switching depending on S24 and S49

no Switching

E wi1 or wi2

wi1 or wi2

wi1

-- Actual value and setpoint display

A red and a green analog display with 1.7% resolution and a red and a green 4

/2digit digital display are arranged on the front panel. The green displays are assigned to the setpoint, the red displays to the actual value. In addition there is a 3-digit yellow digital display for the y-display. The corresponding adjustment keys and status-LED’s are assigned in color and position to the displays.

The two analog displays always indicate the active actual value. The difference between the two displays is the control difference xd or the control error xw = --xd. The digital actual value display also indicates the current actual value except in the ratio controllers (ratio controller: actual ratio). The digital setpoint display indicates the setpoint before the setpoint ramp except in ratio controllers (ratio controller: nominal ratio before the setpoint ramp).

Depending on the controller type the displays, the Internal/External-key (2) and the Δw-adjustment keys (6) are switched by the Shift key (12) controller I/controller II.

The following symbols are used in the block diagrams below to simplify the representation:

Adjustable display range (digital displays only)

Parameter set dP, dA, dE, I or II for setting the display format

Display level I or II, no identification means only 1 level or both levels the same

0000

Displayed variables x, w, xv or wv Display type Digital display

0000

↗ Analog display

↗ Digital and analog display

0000

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Display range

The digital displays are four-digit 7-segment displays, the display range of which can be set in double controllers and process displays (S1

>4) for the x- and w-display together, for the

two display levels I and II separately, with the parameter dP (decimal point), dA (start value) and dE (full scale) in the structuring mode oFPA.

In single controllers (S1 ≤4) the parameters of the display level II arefolloweduptothe parameters of the display level I and are not adjustable.

With dAI or dAII the numeric value is set which is to be displayed at arithmetic value 0 (corresponding to 0 % display in the analog displays). With dEI or dEII the numeric value is set which is to be displayed at arithmetic value 1 (corresponding to 100 % display in the analog displays). With dPI or dPII the decimal point is set as a fixed point. If the starting point is set less than the full scale, a rising display is given with increasing arithmetic values and vice versa. The numeric range for the start and end values goes from -1999 to 19999, beyond these numbers -oFL and oFL is displayed in the case of overmodulation in the process operation level. The factory setting is 0.0 to 100.0 %.

With the refresh rate parameter dr (onPA) the digital displays can be calmed down in the case of restless process variables. Non-linear process variables can be represented physically correctly by the linearization.

Manual1 Technical Description

The display range set with dP, dA and dE is transferred depending on the controller type (S1) to the parameters and setpoints which can be assigned to the displayed variable:

S1 Display format accordingly Parameter range

-1.1 to

11.1

0 1 2 3 4 5 6 7 8

9 10 11 12

Table 1-3 Display format of parameters and setpoints assigned to the displays

d*I

# #

d*I

d*II

% d*I d*I d*I d*I d*I d*I

-1.3 to

11.3 d*I

# #

d*I

% d*II d*II d*II

d*II

SA, SE,

SH d*I

# # #

d*I d*II d*II

d*I

-d*I d*I d*I

Sb wi/wiI wiII

-d*II d*II

d*I

# # # # # # #

d*I

-d*I d*I d*I

d*II d*II

d*II

referenced to

dE*-dA* = 100 %

-10%to110%

# #

-10%to110%

-199.9 to 199.9 %

-10%to110%

-199.9 to 199.9 %

-10%to110%

With the appropriate asisgnment, this also applies to the limit value alarms A1 to A4, see chapter 1.5.9, page 124.

The analog displays have a fixed display range of 0 to 100 %. The overshoot or undershoot is displayed by the flashing 100 % or 0 %-LED. Display is by one or two alternately flashing LEDs. The center of the illumination field represents the ”pointer”. This display technique doubles the resolution. If a falling characteristic is set for the digital displays (d*E<d*A), the analog displays are switched in direction of effect except for the ratio controllers.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Setting of the linearizer at S4 = 0

Set start and end of measuring with dA* and dE* and the decimal point dP* in the structuring mode oFPA for the display. Divide measuring range U

to UEincluding 10 % overflow in 10 % sections and determine

partial voltages.

E-UA

= n+UAwith n = -1 to 11

h10

Determine the respective physical value from the appropriate function tables for every Un or graphically from the corresponding curve (interpolate if necessary) and enter the value for the respective vertex value (-1* to 11*) in physical variables in the structuring mode oFPA.

[mV]

nUn[mV]Vertext[_C]

value

110

100

-10

11 52.732

UE=48,33 mV

UA=4,31 mV

0 100 200 300 400 500 600 700 800 900 1,000 1,200

10 48.33

9 43.928

8 39.526 ! 8*900

7 35.124

6 30.722

5 26.32

4 21.918

3 17.516

2 13.114

1 8.712

04.31

-1 -0.092

t[_C]

!11

! 10

! 9

! 7

! 6

! 5

! 4

! 3

! 2

! 1

! 0

! -1

1,048

1,000

951

846

790

729

664

593

514

420

300

Figure 1-19 Example of linearization of a thermocouple type B Pt30Rh/Pt6, measuring range 300 to

1000 _C

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Setting the function transmitter for linearizing at S4 = 1

Manual1 Technical Description

Phys.

eIntInt

--1 0 t o 11 0

d**

0000 0000

x1(l)

Figure 1-20 Using the function transmitter to

linearize non-linear process variables for the display and control

The vertex values of the function transmitters are given in % and not physically here because of their free utilization.

Setting takes place in the structure mode oFPA in the range from --199.9 to +199.9 %.

The vertex values 0 and 100 are set with 0 % or 100 % so that x standard variable and the reference junction terminals for determining the display range of the digital display are correct. The display range is set with the parameters dA*, dE* and dP* according to the physical measuring range.

Vertex values

110 100

--1 0

x1[%]

100

80 70

60 50

40 30

20 10

4020

1,0006002000 1,4001,600 1,800

10080

[%]

Phys.

˚C

Measuring range 200 to 1600 ˚C

Figure 1-21 Sensor function, e.g. from table

(l) is available again as a

To determine the vertex values, apply the sensor function as shown in fig. 1-21 and divide the range into 10% steps (x

--10to110onthex

x1(l) [%]

100

0 2040 6080100

Figure 1-22 Linearization function

-axis and enter one after the other in the structuring mode oFPA.

phys

in %). Then read off the % values in the vertex positions

phys

x1(l) [%]

100

x1[%]

Vertex values

1000600200

1,400 1,600 1,800

Figure 1-23 Linearized controlled variable

x1(l)

˚C

Phys

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Function inputs FE1 to FE12

0 Fixed setpoint controller

2 independent setpoints

1 Fixed setpoint controller

2 dependent setpoints

2 DDC fixed setpoint

controller

3 Follow-up,

synchronized, SPC controller

4 Ratio controller x1 commanded

5 Cascade control x1II main controlled

6 Ratio cascade control xII main controlled

7/8 Override control x1I main controlled

9 Process display xI process variable 1 -- xII process variable2

10 Fixed setpoint controller

(control system coupling)

11 Follow-up controller

(control system coupling)

x1 main controlled

FE1

(linearizable)

x2 auxiliary controlled

variable

” ” ”

” ” wEexternal command

x2 commanded

process variable

x2II auxiliary control variable master controller

x2I commanding variable master controller

x2I auxiliary controlled variable main controller

x2 auxiliary controlled variable

variable

FE2 FE3 (linearizable)

variable

process variable

variable master controller

process variable slave controller

variable Main controller

variable

” wEexternal command

x3 auxiliary controlled

variable

wvEexternal command

variable for ratio factor

xI controlled variable slave

controller

x1I commanded process

variable slave controller

xII controlled variable

limiting controller

x3 auxiliary controlled

variable

12 Double controller x1I main controlled

variable

wEAI external setpoint x1II main controlled variable

Table 1-4 Control technical function of the inputs FE1 to FE3

Function inputs FE4 to FE12 have the following control-technical function:

FE4 disturbance variable connection (z) for the D-element or for the manipulated variable

y (selection by S55)

FE5 Follow-up input (y

) for the manipulated variable follow--up in K-controllers (S2 = 0)

and in S-controllers with external follow-up (S2 = 2)

FE6 Manipulated variable feedback supply (y

nal feedback (S2 = 1) or the manipulated variable feedback input (y

) for the y display in S-controllers with inter-

) in S-control-

lers with external feedback (S2 = 2); Process display (S1 = 9) with XIII FE7 Manipulated variable connection (z) selection S57 FE8 External setpoint

wEII

FE9 Follow-up input yNII FE10 Manipulated variable feedback supply y

FE11 manipulated variable connection setpoint

The function inputs FE1 to FE3 have different control-technical functions depending on the controller type (S1).

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.2 S1 = 0: Fixed setpoint controller with 2 independent setpoints

Manual1 Technical Description

000

FE1

FE2

FE3

FE4

wi1

wi2

0000 0000

INT∧CB

x = x1+c1· (x2-c2·x3+c3)

PID

ya+c6 · z

Figure 1-24 Principle representation S1 = 0

This controller type can be used as a fixed setpoint controller with 2 independent setpoints (two batch mode) or as a fixed setpoint controller with 1 setpoint, by blocking the Internal/External switching (factory setting). By linking the inputs x1, x2, x3 with the constants c1, c2, c3, it can be used as a three-component controller.

Switching between the two internal setpoints which are adjustable on the front separately as one, two or three component takes place depending on the control signals Int and CB according to table 1-5. Signaling of the active setpoint takes place on the LEDs Internal and C

. As soon as

a LED lights, wi2 is active.

Control commands Message signals Digital Effective w

Digital inputs Front Front LED outputs at S50= Explanations

H∨N∨Si CB internal internal C RB RC 01

01000 00 wi1wi1(n) 00001 01 wi2wi2(n)mit CB, Int=0 with Int,CB=1 01110 112)wi2 wi2 (n) 00111 11 wi2wi2(n)

11000 00 wi1x 10001 01 wi2x with CB,Int=0 with Int,CB=1 11110 112)wi2 x 10111 11 wi2x

follow up takes place at S52 = 0 and S50 = 1 to the controlled variable x, follow--up does not apply for the switching wi1/wi2 at S52 = 1automatic mode starts with wi=x (xd=0), theactive setpoint runs to the old set value via the possibly setsetpoint ramp tS

factory setting, fixed setpoint controller with 1 setpoint (S49 = 0: only Internal, Int = 1, S24 = -1: CB = 1) RB =Int RC

=Int∧CB = Int∨CB

Table 1-5 Switching between wi1 and wi2

switching switching

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

With the Shift key (12) the digital w display can be switched in the display level II to the inactive setpoint and the digital x display to the main controlled variable x1 (display range I must be set, display range II is automatically set the same). The active setpoint and the active actual value x are still shown on the analog displays.

Selection by

Shift key

effective wi

LED

controller I

LED

controller II

displayed w

displayed x

digital analog digital analog

III

via CB and Int accordingly 5

only if there is no x-tracking

0.5 = flashing rhythm 1:1

↗ = adjustable

only at C8 ≠0

wi1 wi1 wi2 wi2

wi1 or wi2 0 0 wI wI

1 0 1 0

0.5

wi1 ↗

wi2 ↗ wi2 ↗ wi1 ↗

wi1 wi1 wi2 wi2

x x

x x x

x x

Table 1-6 Switching the display levels

The setpoint displayed with the digital w-displays can also be set with the Δw-adjustment keys (6.1/6.2 Fig. 3-1, p. 168). The LEDs Controller I/ Controller II signal the display level. Flashing light signals that the displayed setpoint is not identical with the active setpoint.

Steady light signals that the displayed and active setpoints are identical.

If switching between wi1 and wi2 is blocked via S49 (Int) and S24 (CB), switching of the digital w display to the display level II is omitted. Only the digital x-display is switched over. Signaling of the display level II is with a steady light.

With the constants c8 and c9 a disturbance variable connection of FE11 can be made in the setpoint branch.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

SES

see Fig. 1-5, page 24

wi1

wi2

wi1

n o

0/1

S101

2/3/4/5

0/1

S101

2/3/4/5

wi2

n o

FE11

FE1

FE2

FE3

Int

∧CB

S52

wI--c 8 · ( wST+c9)

0000

w=wi+c8⋅

c1, c2, c3

x =x1+c1 · (x2-c2 · x3+c3)

factory setting c1=c2=c3=0

tFI

+c9)

Adaptation

d*I

0000

S50

0000

SA,SE

A=H∨N∨Si H=Hi∨He

0000

III

d*I

xdI

0000

see Fig. 1-50, page 90

Figure 1-25 Block diagram S1 = 0, fixed setpoint controller with 2 independent setpoints

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.3 S1= 1: Fixed setpoint controller with 2 dependent setpoints

0000

INT∧CB

wi1

wi2=wi1 · c4+c5

FE1

FE2

FE3

FE4

Figure 1-26 Principle representation S1 = 1

x=x1+c1 · (x2 - c2·x3+c3)

0000

PID

ya+c6⋅z

000

This controller type is always used when for example in two batch mode the second setpoint needs to be in a specific ratio to the first. The ratio is set by the constants c4 and c5.

Factory setting is c4 = 1 and c5 = 0.

The switching and display functions are the same as at S1 = 0. Only the internal setpoint (wi1) can be adjusted if it is displayed.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

wi1

SES

see Fig. 1-5, page 24

wi1

0/1

2/3/4/5

n o

S101

FE1

FE2

FE3

c4, c5

wi1 · c4+c5

factory setting c4=1, c5=0

x=x1+c1 · (x2 - c2 · x3+c3)

Int∧CB

wi1

wi2

c1, c2, c3

factory setting c1=c2=c3=0

tFI

Int∧CB

∧CB

Int

Adaptation

w-c5

d*I d*I

0000

SA,SE

S50

0000

=H∨N∨Si

H=Hi∨He

0000

S5 2

xdI

0000

see Fig. 1-50, pg. 90

Figure 1-27 Block diagram S1 = 1, fixed setpoint controller with 2 dependent setpoints

1.5.4.4 S1 = 2: DDC fixed setpoint controller

The DDC controller has the job of taking over the control circuit as bumpless as possible in the case of a computer failure. During the DDC operation the process computer takes over the control function, the controller is on standby, i.e. it is followed up to the computer manipulated variable; the control difference is reset to zero for absolutely bumpless switching by x-tracking if necessary.

In K-controller circuits, the actuating current can be output parallel by the computer periphery to achieve full redundancy. In this case the actuating current of the K-controller is switched off during computer operation (S66 = 1). If the actuating current of the computer is also to be switched off during controller operation, the two currents simply need to be added by OR diodes. This OR diode is integrated in the current outputs of the SIPART controllers.

If the UI-converter of the K-controller is to be used during computer operation to feed the final control element, the actuating current cutoff must be canceled (S66 = 0).

The DDC mode corresponds to follow-up mode of the other controller types with the difference that the switching to follow-up mode takes place not via the control signal N but as a function of

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

the control signal CB and the Internal/External key: DDC operation ≙ RC=Int

∧CB = 1

0000 0000 000

x-TRACKING

FE1

FE2

FE3

FE4

FE5

x=x1+c1 · (x2-c2·x3+c3)

Figure 1-28 Principle representation S1 = 2

PID

ya+c6 · z

INT∧CB

YES

SES

The DDC mode is signaled like the follow-up mode in the other controller types by the lit y-External LED. The status of the control signal CB and the Internal/External key is displayed by the LEDs C

and Internal. During the DDC mode the setpoint is prepared by follow-up to the computer failure. The setpoint is always displayed which would become active after the computer failure.

With S50 a choice is made between x-tracking and wi, with S51 the safety setpoint is preset.

With S61 the priority between DDC-mode and manual mode is determined. If DDC-mode has priority over manual mode, you can select with the manual-automatic switching whether operation is to continue after a computer failure in automatic or manual mode. If manual intervention is necessary in computer operation, switching to Internal operation is necessary in addition to switching to manual operation; the LEDs Internal (1) and Manual (8) light, the LED y-External (10) goes out, the dark LED C

(3) stil indicates computer standby.

If manual mode has priority over DDC-mode you can switch directly from computer operation to manual operation. Then the manual LED (8) lights, the y-External LED (10) goes out, the dark LEDs Internal (1) and C

(3) still indicate computer standby of the controller or computer

standby.

Automatic mode is always switched to here in the event of a computer failure.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

Table 1-7 DDC controller, S1 = 2, DDC operation has priority over manual operation S61 = 0

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Table 1-8 DDC controller, S1 = 2, manual operation has priority over DDC operation S61 = 1

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

manual operation can be achieved by

Control signals

Message signals

Manual1 Technical Description

digital

input He

0 1 0 1

Table 1-9 Generation of the control signal H = Hi∨He

In DDC mode the actuating current of the controller is switched off at S66 = 1. The source for yEat S62=0isy lated variable is followed up which is fed in via Δy(y

) the feeding controller must be followed up.

The table is shown for static computer switching without acknowledgement, S47 = 0.

By OR linking of the digital output H with the control signal Si no computer standby or computer operation can be signaled in manual or safety mode.

0.5 = Flashing rhythm 1 : 1

0,9 = Flashing rhythm 0.1 off, 0.9 on

Front

0 0 1 1

(FE5)oratS62=1y

Front

manual

LED

0.9 1 1

(Δy),ifS101 < 2. At S101=2 yESis active (SES).The external manipu-

digital

output

1 1 2 2

) and via the SES (yES). When feeding in via FE5

(↗) = adjustable

(n) = is followed up to the value active before switching, therefore bumpless switching.

The control signal Follow up (N) has no function in DDC controllers. The tables apply for S52 = 0 (with follow up of the inactive setpoint to the active setpoint). At S52 = 1 (without follow-up) and x-tracking automatic operation starts with wi = x (xd = 0), the active setpoint runs to the old set value wi via the possibly set setpoint ramp tS.

With the Shift key (12) the digital x display can be switched to the main controlled variable x1 in the display level II. Signaling of the display levels takes place via the LEDs Control I/Control II by a steady light.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

see fig. 1-50, page 90

xdI

0000

SA,SE

Int

d*I d*I

d*I

S61

S52

S50

0000

H=Hi∨He

S101

2/3/

wi1

SES

S50

4/5

S51

wi1

Figure 1-29 Block diagram S1 = 2, DDC fixed setpoint controller

SIPART DR22 6DR2210 C79000-G7476-C154-03

c1, c2, c3

x=x1+c1⋅(x2-c2⋅x3+c3)

FE1

FE2

see fig. 1-5, page 24

FE3

Factory setting

c1=c2=c3=0

Adaptation

Page 60

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

1.5.4.5 S1 = 3: Follow-up controller, synchronized controller, SPC-controller

000

SES

Δw

FE3

FE1

FE2

FE4

x=x1+c1 · x2+c3

wE=c4 · wE+c5

0000 0000

INT

∧CB

PID

ya+c6 · z

Figure 1-30 Principle representation S1 = 3

In this controller type you can switch between the internal setpoint wi and the external setpoint

depending on the control signals CB and the Internal-/External key (2) (see table 1--11,

page 61 and table 1--12, page 62).

The external setpoint can be preset via the analog output FE3 (w Δw as an incremental setpoint (w

) (selection via S53) or via the SES (wES) (selection by

EΔ

) or via the digital signals

S101). The active setpoint w can be fed back by an appropriately assigned analog output to the feeding controller for follow up when using w

EA or for displaying when using wEΔ .

This controller type is used for cascade controls with 2 separate controllers (master and follow-up controllers), for synchronized controls, fixed setpoint controls with external setpoint preset (e.g. under console conditions via the incremental Δw-inputs) and SPC-controls (setpoint control). This controller type attains special importance when coupled with the SIPART software for operation and monitoring. Here this controller type is used for fixed setpoint control with external setpoint preset (w the input y

(see chapter 1.5.6, page 99).

) and Automatic/Manual switching via the follow-up signal NESand

-- SPC controls

Here a process computer takes over the setpoint command during computer operation RC = Int

∧CB = 1, in the event of a computer failure (CB from 1 ! 0) the controller takes over either the last computer setpoint (followed up wi) or the safety setpoint SH (selection via S51).

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Cascade control

A command controller, e.g. a fixed setpoint controller (with the main controlled variable) feeds the external setpoint of a slave controller with its manipulated variable (with the auxiliary controlled variable, disturbance variable) and this the actuator. This gives faster control of the main controlled variable in the event of changes in the auxiliary controlled variable, e.g. furnace temperature control (furnace temperature, main controlled variable) with different flow of the medium to be heated (auxiliary controlled variable).

-- Synchronized controls

A master controller feeds several synchronized controllers simultaneously whose individual setpoints can be set in a ratio to each other by the constants c4 and c5 and then drag the controlled variables accordingly (controlled variable synchronization).

-- Internal/External switching

The setpoint switching takes place via a logic link RC = Int

∧CB and its negation (see table 1--11, page 61 and table 1--12, page 62). Both control signals can be set statically to 1 or 0 (int via S49, CB via S24) in addition to their normal functions as Shift key or control signal with the states 1 and 0, see chapter 1.5.3 fig. 1-16, page 37 and fig. 1-17, page 38. The factory setting is Int = 1 (S49 = 0) and CB=1 (S24 = -1), so that in the factory setting

the internal setpoint wi is always active and cannot be switched!

With this setting facility it is possible to perform the switching only dependent on Int (S49=2, S24= -1) or only dependent on CB (S49=1, S24=1 to 14) as a slave controller with Internal/ External-switching. If the switching facility is blocked in External position (S49=1, S24=-1), the controller operates as a follow-up controller without Internal/External-switching (see table 1-2, page 43).

-- Display of the external setpoint w

With the Shift key (12) the digital w-display can be switched to the external setpoint wE and the digital x-display to the main controlled variable x1 in the display level II (display range I must be set, display range II is automatically set the same). The active setpoint and the active actual value are still indicated on the analog displays.

The LEDs Controller I/Controller II signal the display level.

Flashing signals that the displayed external setpoint is not identical with the active setpoint. Steady light signals that the displayed and active setpoints are identical.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

Selection

by Shift

active

LED

controller

via CB and Int according to table 1--11 and 1-- 12

0.5 = flashing rhythm 1:1

only if there is no x-tracking

wi/SH

0 1 0

LED

controller

0.5 0 1

displayed w

displayed x

digital analog digital analog wi/SH

w w w

wi/SH

E E E

wi/SH

x1 x x1

x x x

Table 1-10 Switching the display level

If the switching possibility between internal and external setpoint is blocked through S49 and S24, switching of the digital w-display to the display level II is no longer used. Only the digital x-display is switched. The display level II is signaled by a steady light.

-- Operation with 2 or 3 setpoints

If follow-up of the inactive setpoint to the active setpoint is blocked with S52 = 1, a multiple setpoint operation (switching between wi, w

and SH is achieved (see table 1--12, page 62).

-- Controlled variable processing

A 2-component control is implemented (disturbance variable connection). With factors c1 and c3 the main controlled variable x1 can connect the auxiliary controlled variable x2 with weighting.

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Manual 1 Technical Description

Explanation

puter

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Control signals Message signals

S50=1 S51=0

active w at

S50=0 S51=1

(n)

wE(n)

wi(n,

↗)

S50=1 S51=1

lanations

Automatic mode, SPC mode

Automatic mode, computer switched off, computer in SPC standby

Automatic mode, computer on standby, controller not in SPC

standby

Automatic mode, computer switched off, controller not in SPC standby

Com-

uter

fail

Digital

inputs

∨N

∨Si

Front Front

CB1)In-

ter-

nal

Inter-

nal

LED

Digital

outputs

RB4)RC

S50=0

S51=0

0 1 0 0 0 0 0 wE(n)

0 0 0 0 1 0 1 wi(n,↗)

0 1 1 1 0 1 1 wi(n,↗) wi(n,↗)

0 0 1 1 1 1 1 wi(n,↗) wi(n,↗)

1 1 0 0 0 0 0

(n)

1 0 0 0 1 0 1

1 1 1 1 0 1 1

1 0 1 1 1 1 1

The table is shown for static computer switching without acknowledgement (S47 = 0).

Source for wEatS53=0iswEA(FE3)oratS53=1w The external setpoint fed in via Δw(w via FE3 (w

SH can only be reached after wEif Int = 0 and CB goes from 1 → to 0 (computer failure). If CB = 0 and Int is switched from 1 → 0, wi is still active. Since SH is not followed up, switching over to SH can take place with the setpoint ramp tS.

By OR-linking with the digital outputs H, N and the control signal Si no computer standby or computer operation can be signaled in manual, follow-up or safety operation.

Factory setting

) the feeding controller must be followed up.

(n,

↗)

(n,

↗)

(n,

↗)

) and via the SES (wES) is followed up. When feeding in the external setpoint

(n,

or wi

↗)

Manual, follow up or safety mode

(Δw), when S101 < 2. At S101 = 2 wESis active (SES).

(n) followed up to the value active before switching, therefore bumpless switching

↗ adjustable

Table 1-11 Follow-up/synchronized/SPC controller with Internal/External switching S1 = 3 with follow up

of the inactive setpoint

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1.5 Functional description of the structure switches

Explanation

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

Control signals

Digital

inputs

∨N

Front Front

CB1)Inter-

nal

∨Si

0 1 0 0 0 0 0 w

0 0 0 0 1 0 1 wi(↗)

Message signals

Inter-

nal

LED

Digital

outputs

RB4)RC

S50=0 S51=0

S50=1 S51=0

active w at

S50=0 S51=1

wi(

lanations

S50=1 S51=1

↗)

Automatic mode

0 1 1 1 0 1 1 wi(↗) wi(↗) 0 0 1 1 1 1 1 wi(↗) wi,↗) 1 1 0 0 0 0 0 w

1 0 0 0 1 0 1 wi(↗) x

x w

wi(

↗)

Manual, follow up or safety

mode

1 1 1 1 0 1 1 wi(↗) x wi(↗) x 1 0 1 1 1 1 1 wi(↗) x wi(↗) x

The table is shown for static computer switching without acknowledgement (S47 = 0).

Source for wEatS53=0iswEA(FE3)oratS53=1w The external setpoint fed in via via FE3 (w

By OR--linking with the digital outputs H, N and the control signal Si no computer standby or computer operation can be signaled in manual, follow-up or safety operation.

Factory setting

) the feeding controller must be followed up.

¦Δw(w

) and via the SES (wES) is followed up. When feeding in the external setpoint

( ¦Δw), when S101 < 2. At S101 = 2 wESis active (SES).

(n) followed up to the value active before switching, therefore bumpless switching

↗ adjustable

Table 1-12 Follow-up/synchronized/SPC controller with Internal/External switching (SPC controller),

S1 = 3 without follow-up of the active setpoint to the active setpoint S52 = 1, 2 or 3 setpoint operation

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

see chapter 1.5.5, figure 1-50, page 90

xdI

0000

=H∨N∨Si A

H=Hi∨He

S50

+c9)

+c8⋅

c4, c5

=c4⋅we+c5

c4=1, c5=0

Factory setting

d*I d*I

SA,SE

0000

+c9)

wI--c 8⋅

wi1

+c9)

w+c8⋅

Int

S52

S510

0000

d*I d*I

0000

factory setting

S101

0/1

4/5

2/3

S53

c1, c3

c1=c2=c3=0

Factory setting

FE1

x=x1+c1⋅ x2+c3

FE2

+Δw

FE3

FE11

EAwST

--Δw

wi1

w- -c5

S101

2/3

4/5

0/1

wi1

SES

see chapter 1.5.1, figure 1-5, page 24

Figure 1-31 Block diagram S1 = 3 slave controller, synchronized controller, SPC controller

SIPART DR22 6DR2210 C79000-G7476-C154-03

Adaptation

Page 66

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.6 S1 = 4: commanded ratio controller

Manual1 Technical Description

w=v⋅x2+c5

v = vA to vE v=wv·(vE-vA)

+vA

ist

SES

Δw

FE3

FE2

FE1

FE4

wvi

Int⋅CB

Figure 1-32 Principle representation S1 = 4

00000000

x1 - c5

x w

000

PID

ya+c6⋅z

In a ratio control the commanding process variable x2 is evaluated with the adjustable ratio factor and a basic value c5 added if necessary and forms the setpoint w for the following controlled process variable x1:

w=v⋅ x2 + c5

With xd = w - x1, xd = v ⋅ x2+c5--x1isgiven

In the controlled status (xd = 0), the following is given

and at c5 = 0

behaves according to the set ratio factor v.

x1 -- c5

i.e. in the controlled status

A typical application are combustion rules where a fuel volume x1 beongs to every air volume x2 to guarantee optimum combustion. The ratio factor range v = vA to vE is determined with the parameters vA and vE in the structuring mode oFPA in the range from 0.0 to 9.999 (factory setting vA = 0, vE = 1). In addition a basic value c5 (parameterization mode onPA) can be connected in the range from -1.999 to 9.999 (factory setting = 0.0).

The standardized nominal ratio wv (wvi or wv

) in the range from 0 to 1 is converted to the ratio

factor range.

v=wv(vE--vA)+vA

With w=v⋅ x2 + c5 , w = wv [(vE -- vA) + vA] x2 + c5 is given.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

In the ratio controller the standardized nominal ratio wv and the standardized actual ratio xv are displayed on the digital w and x displays respectively. Via d*I a physical display is possible. The controlled variable x1 and the evaluated commanding procesan be switched to the external nominal ratio (display level II) (display level I must be set, display level II is automatically set the same). Signaling of the display levels, see S1 = 3, fos variable w are displayed on the analog x and w displays respectively so that a direct control difference monitoring is possible at all times.

With the Shift key (12) the digital w-display cllow-up controller. The digital x-display shows the actual ratio xv in both display levels.

The actual ratio is gained by back calculating the ratio formula with the current process variables x1, x2:

ist

= xv (vE -- vA) + vA gives for

xv =

--v A

vE--vA

xv =

x1--c5

vE--vA

-vA

x1--c5

xv is displayed and is required for x-tracking mode. For the xv-display, x1 and x2 are limited to +0,5 % so that the display does not become too restless for small x1 and x2 or flip from positive to negative in the case of negative x2. The linearizers can be used for linearization of the commanding process variable x2 (via FE2 in the freely connectable input range) and the following process variable x1 (via FE1 also in permanently connected input range).

The linearization then acts on the analog displays and the ratio formation and therefore indirectly on the digital displays for nominal and actual ratio. The ratio controller has no nominal ratio limiting because the ratio factor range already marks the limit. The commanding process variable x2 can be limited by the freely connectable range (S4 = 1) if necessary.

The ratio controller behaves like slave controller S1 = 3 in switching of the setpoint ratio wv so that the information and tables there apply accordingly. The variables wi and w replaced by wvi and wv

. This controller type can also be used as a ratio controller with fixed

must be

ratio (manually adjustable) or with commanded ratio factor.

A fixed ratio factor is used for example in simple combustion rules, (see example in figure 1-33) where the ratio factor is reset manually if necessary for varying fuels. If it is possible to measure the effects of the ratio factor (combustion quality, pollutants in the flue gas) a commanded ratio controller is used. Here a master controller adjusts the ratio factor (ratio cascade) with the combustion quality as a control variable.

Another application for ratio cascades are concentration controls, e.g. pH-value controls. The pH-value is the controlled variable of the master controller, the flow of alkali and acid the commanded process variable and the following (controlled) process variable of the ratio controller.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Example of a ratio control

Manual1 Technical Description

Figure 1-33 Control diagram ratio control

c

GAS

AIR

In a combustion control the air-/gas flow should be in a constant ratio. The command variable (commanding process variable) is the air flow Q

12,000 m is the gas flow Q

/h as a signal 4 to 20 mA. The controlled variable (following process variable)

with a measuring range 0 to 3,000 m3/h which is also available as a

whichispresetintherange0to

4 to 20 mA signal. In an ideal combustion the air/gas ratio is

« ideal

==4.

⋅ λ

The air factor λ is then 1 and should be adjustable in the range from 0.75 to 1.25 on the controller.

The ratio factor v (bei xd = 0) is determined partly by the transmission factors K of the transmitter (measuring ranges).

1=QG

x2=Q

⋅ K

with the values from the example

⋅ K

v= =

⋅ λ

⋅

with

⋅ λ

100 %

3,000 m

100 %

12,000 m

With the values from the example

gives

K K

⋅

100 % ⋅ h ⋅ 12,000 m

⋅

3,000 m3⋅ 100 % ⋅ h

i.e. the choice of the transmitter ranges has been made so that

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

The desired adjustment range of λ gives:

vA = =

=0.8

vE = =

0.75

= 1.333

vA and vE are set in the structuring mode oFPA. By setting the nominal ratio wv from 0 to 1 the ratio factor v can now be adjusted from 0.8 to 1.33 or the air factor λ from 1.25 to 0.75.

1.33

0.75 1,3

0.8

1.2

0.9

1.1

1.2

1.25

0.9

0.8

0.2 0.6

0.80.40

Figure 1-34 Relationship ratio factor v and air factor λ to standardized nominal ratio wv

If the combustion is also to take place at small flow volumes with excess air, the constant c must be set negative. Figure 1-35 shows the gas/air ratio in the controlled state at different air factors λ andc=0aswellasatλ = 1 and c <0, i.e. with excess air.

Gas m3/h

V=1.33 λ=0,75

%mA

120

110

100

3,500

3,000

2,500

2,000

1,500

1,000

500

0 2,000 4,000 6,000 8,000 10,000 12,000 m

0102030405060708090100 %

4681012141618 20 mA

constant gas/air ratio

gas/air ratio with additional air excess

Figure 1-35 Display of gas/air ratio in controlled status

V=1 λ=1

V=0.8 λ=1.25

V=1, c<0

/h air

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

I+II

0000

S236=1/2

I+II

0000

seefig. 1-50, page 90

xd I

Manual1 Technical Description

x I

d*I

0000

S236=0/2

d*I

0000

d*I

0000

⋅

vA, vE, c5

w=v x2+c5

Factory setting

vA=0, vE=1, c5=0

S50

v=vA to vE

When adjusting wvi the

setpoint ramp is not active

x1--c5

actual

v=wv (vE- -vA)+vA

--vA

actual

vE--vA

wvi

S52

wi1

Int

S51

S101

2/3

A=H∨N∨Si

H=Hi∨He

0/1

4/5

S53

Factory setting

Adaptation

tF I

2/3

4/5

0/1

--Δw

+Δw

wvi

SES

Figure 1-36 Block diagram S1 = 4 commanded ratio controller

FE3

FE2

see fig. 1-5, page24

FE1

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.7 S1 = 5: Cascade control

000

yaI+c6⋅z

yaI

PID

wIxI

SLAVE CONTROLLER = CONTROLLER I

0000 0000

INT

wi I

yII=w

PID

wII

xII

wIΙ

wII

xIΙ

xII

wII

0000 0000

⋅

INTII∧CB

MASTER CONTROLLER = CONTROLLER II

II II

x=x1+c1x2+c3

wiII

x1II

x2II

SES

±Δw

Figure 1-37 Principle representation S1 = 5

SIPART DR22 6DR2210 C79000-G7476-C154-03

FE8

FE1

FE2

FE3

FE4

Page 72

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

In this controller type a master controller (Controller II) and a follow-up controller (Controller I) are interconnected in one controller in a cascade (application, see S1 = 3).

-- Master controller (controller II)

With respect to the setpoint switching the master controller has approximately the same structure as the follow-up controller S1 = 3. It is therefore a fixed setpoint controller with the possibility of external setpoint preset via analog signal, the serial interface or as an incremental setpoint via the control signals Δw. Selection is made with w

II and S101. In

computer coupling it is also possible here, in the case of a computer failure (CB from 1 ! 0) to continue working with the last computer setpoint (followed-up wi) or with the safety setpoint SH (selection by S51). The master controller cannot be switched to manual operation but the slave controller can be switched to the internal setpoint.

Follow-up of the inactive setpoint to the active setpoint can be switched off with S52 = 1.

-- Follow-up controller (controller I)

The follow-up controller can be switched for disconnecting the cascade for startup procedures via the Internal/External key (2) (Int I) between the internal setpoint wiI and the external setpoint w

EI which is equal to the manipulated variable of the master controller (yaII).

The internal operation of the follow-up controller corresponds to manual operation of the master controller.

Manual1 Technical Description

Setpoint limiting of the follow-up controller can be implemented by the y-limiting of the master controller. The follow-up of the master controller in internal operation of the follow-up controller and x-tracking (A controller in external operation and x-tracking (A

) and the follow-up of the internal setpoint of the follow-up

) always takes place so that the switching

Internal/External is bumpless.

-- Display and operating level switching

With the Shift key (12) the digital and analog x- and w-displays and the function of the Internal/External key (2) including the Internal LED (1) and the Δw-adjustment keys (6) are switched to the selected controller. The y-display (14), the Manual/Automatic key (9) and

the Δy-adjustment keys (13) are permanently assigned to the follow-up controller.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

The LED’s Controller I/Controller II signal the display and operating level:

Selection by Controll. II Controll. I LED LED LED LED displayed adjustable

Shift key Master Slave C

controller controller Controll.

Internal Controll. IControll. II is wi

Int Int according 1 0 1 II wi II ↗ Controller II Ext Int to CB 0 0 0.5 II -Master contr. Int Ext 1 0 0.5

Ext Ext C=CB001II --

IntInt0110I wi I ↗ Controller I Ext Int 0 1 0.5 0 I wi I ↗ Slave contr. Int Ext 0 0 0.5

ExtExt0010 I

only if there is no x-tracking

0.5 = flashing rhythm 1:1

Table 1-13 Switching the display levels

0 I

II wi II ↗

Flashing light signals that the status displayed by the Internal LED is identical with that in the unselected controller.

Steady light signals that the status displayed by the Internal LED is not identical with that in the selected controller.

Normally the display level switch will be in the position Controller II (master controller) so that the main controller variable xII can be monitored. The display level I is only used for startup procedures. The Automatic/Manual switch for the slave controller is possible in both display levels, depending on the selection of the display level the main controlled variable xII or the auxiliary controlled variable xI can be monitored. The display range of the digital x and w display can be adjusted separately for both controllers by the parameters d*I and d*II if necessary in connection with the linearizers so that both controllers can be displayed physically correctly.

-- x-tracking

With S50 =1, x-tracking is selected for both controllers together (S50). The slave controller follows up the internal setpoint or the controller output to the auxiliary controlled variable xI

-operation. The master controller triggers this function in A-operation or Internal of the

in A follow-up controller (Int I corresponds like A

SIPART DR22 6DR2210 C79000-G7476-C154-03

to disconnected cascade).

Page 74

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

via the SES.

Δ (±Δw), at S101=2 w

Δ,ifIntII=0 and CB go from 1 to 0 (computer failure). If CB=0 and Int is switched from 1 to 0, wiIΙ is still active. Since SH is not

IΙ at S101< 2 ist w

followed up, you can switch to SH with the setpoint ramp tS.

The table is shown for static computer switching without acknowledgement (S47=0).2)Source for w

SH can only be reached after w

By OR-linking with the digital outputs H, N, IntI and the control signal Si no computer standby or computer operation can be signaled at disconnected cascade.5)When selecting controller I is C LED = 06)Manual operation or operation with external manipulated variable is always possible irrespective of the selection Controller I/ControllerΙI.7)Switching only possible in the respective selected controller. Operating states are retained.

At S52=1 (without follow-up of the inactive setpoint to the active setpoint) the (n) is omitted at wII. If x-tracking is switched on (S50=1) automatic operation of the master

controller begins with w=x (xd=0), via the set setpoint ramp tS, the active setpoint runs to the old set value of w.

(n) followed up to the value active before switching, therefore bumpless switching

↗ adjustable

Table 1-14 Cascade control S1 = 5 with follow-up of the inactive setpoint to the active setpoint S52=0

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Controller I, see figure 1-50, page 90

xdI

Adap-

tation

Follow-up controllerMaster controller

A=H∨N∨Si

H=Hi∨He

0000

wIxI

0000

IntI

wiI

wII

d*II

S50

IntI

yaII=w

S101

PID

controller II

4/5

0/1

2/3/

wiI

xdII

xII

, tv, AH, YA, YE

Controller II see

Fig. 1-51, page 91,

Control parameter II

vv,cP,tn,Y

xII

0000

d*II

S50

A∨IntI

A∧Int

IntII

S52

S51

0/1

wiII

S101

2/3

0/1

S101

2/3

4/5

0000

xII wII

xII

4/5

xII=x1II+c1⋅x2II+c3

Adaptation

tFII

Factory setting c1=c3=0

--Δw

+Δw

x1ΙI

x2II

wiII

FE1

FE2

FE8

FE3

SES

Figure 1-38 Block diagram S1 = 5 cascade control

SIPART DR22 6DR2210 C79000-G7476-C154-03

see fig. 1-5, page 24

Factory setting

Page 76

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.8 S1 = 6: Ratio-cascade control

000

yaI=c6⋅z

PID

w Ix I

w I

Manual1 Technical Description

yaI

x I

0000 0000

wII xII wII

wI=v⋅x2+c5

wi I

IntI

w II

IntII∧CB

wiII

SES

wΔ

v=wv(vA--vE)+vA

v=vA to vE

PID

x II

FE1

FE8

Follow-up controller = Controller I

Master controller= Controller II

x2I

x1I--c5

xII

x2I

FE2

x1I

FE3

FE4

Figure 1-39 Principle representation S1 = 6

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

In this controller type a master controller (Controller II) and a follow-up controller as a commanded ratio controller (Controller I) are interconnected in a ratio cascade. (Applications see S1 = 4)

-- Master controller

The master controller has the same structure with respect to the setpoint switching as the follow-up controller S1 = 3. It is therefore a fixed setpoint controller with the possibility of external setpoint preset via the analog signal, the serial interface or as an incremental setpoint via the control signals

Δw. Selection is made with w

II and S101. In computer coupling it

is also possible here, in the case of a computer failure (CB from 1 ! 0) to continue working with the last computer setpoint (followed-up wi) or with the safety setpoint SH (selection by S51). The master controller cannot be switched to manual operation but the follow-up controller can be switched to the internal setpoint. x-tracking in A

-operation is possible by selection with S50 = 1. The follow-up of the inactive setpoint to the active setpoint can be switched off by S52 = 1.

-- Follow-up controller

The follow-up controller is a ratio controller as described under S1 = 4. To disconnect the cascade the Internal/External key (2) (Int I) can be used to switch between the internal ratio factor wvi and the external ratio factor wv

, which is equal to the manipulated variable of the

master controller (yaII). The internal operation of the follow-up controller corresponds to manual operation of the master controller.

xv-tracking is possible in A

-operation by selection with S50 = 1. Setpoint limitings can be performed via limiting of the manipulated variable of the master controller and possibly by limiting the commanding process variable x2 I in the freely connectable input range (S4 = 1). The follow-up of the master controller and xv-tracking in A internal ratio factor wvi in external operation and in x-tracking (A

-operation and the follow-up of the ) always takes place so that

switching is bumpless.

Table 1-14, page 72 and the statements on x-tracking of the cascade controls apply accordingly when wi is replaced by wvi and w

by wvE.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Controller I, see figure 1-50, page 90

xdI

Adaptation

Manual1 Technical Description

I+II

0000

I+II

0000

xvwv

d*I

S236=1/2

0000

vA, vE, c5

wI=v⋅x2+c5

S50

IntI

S236=0/2

d*I

Follow-up controllerMaster controller

x2I

x1I--c5

x2I

tFI

--vA

ist

vE--vA

xv=

Factory setting

vA=0, vE=1, c5=0

v=vA to vE

v=wv (vE--vA)+vA

x1I

yaII=wv

A=H∨N∨Si

H=Hi∨He

0/1

2/3/ S101

wvi

4/5

wvi

wII

d*II

0000

S101

d*II

0/1

4/5

SA,

S50

A∨IntI

A∧Int

Int

IntII

S52

S51

2/3

PID

controller II

xdII

xII

, tv, AH, YA, YE

Controller II see

Fig. 1-51, page 91,

Control parameter II

vv,cP,tn,Y

xII

xII wII

0000

=H∨N∨Si

H=Hi∨He

Adaptation

tFII

wiII

S101

2/3

4/5

0/1

wiII

SES

+Δw

Figure 1-40 Block diagram S1 = 6 ratio cascade control

xII

--Δw

FE8

x2I

FE1

see fig. 1-5, page 24

FE2

x1I

FE3

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Factory setting

Page 79

Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.9 S1 = 7/8: Override control

SES

Δw

FE8

FE1

FE2

FE3

x1I

x2I

xII

wSLI

xI=x1I+c1⋅x2I+c3

0000 0000

∧CB

INT

wII

0000 0000

xII

000

YEYEYA

yaI

yaII

Main controller

wII

xII

wII

PID-controller I

Min selection Max

PID-controller II

Limiting controller

Figure 1-41 Principle representation S1 = 7/8

In the override control (limiting control, disconnecting control) two controllers are connected parallel, the main controller (Controller I) and the limiting controller (Controller II) which act on a common actuator. The manipulated variables of both controllers are mutually limited by the in this case controlled parameters YA (S1=7) or YE (S1=8). This gives a controlled variable limiting related to the setpoint set or active in both controllers.

One of the two controllers -- preferably the main controller -- is always intervening and controls the process. The non-intervening controller then has a control difference which controls it to the limited manipulated variable. In this case all further integration is prevented so that no integral saturation takes place. Disconnection always takes place at the latest when the control diffrence in the non-intervening controller reverses. Changes in the controlled variable in the direction of the control difference reversal also lead to disconnection via the P-part (possibly also D-part). This gives a particularly good dynamic behavior.

By the arrangement of two controllers, better adaptation to the different time behaviors of the two controlled systems is achieved than with a Minimum- or Maximum selection of the control differences. The possible implementation by Minimum or Maximum selection of the manipulated variables can lead to dynamic problems due to integral saturation of the non-intervening controller.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

- Example: Core temperature control with maximum casing temperature limiting

The core temperature of a reactor is to be controlled without the cooled casing of the reactor exceeding a specific temperature (limiting setpoint Sb).

In error-free operation the main controller (Controller I) controls the core temperature to the set setpoint w

. Since the casing temperature is below the critical limiting setpoint Sb, the

core

limiting controller (Controller II) has a positive control difference. The manipulated variable of the main controller is fed -- increased by 1% -- to the limiting controller as a maximum limiting variable and forms its maximum manipulated variable. The limiting controller is driven to this limit by the positive control difference.

Its manipulated variable is also fed to the main controller as a maximum manipulated variable limit but remains ineffective because it is an increase of 1% above the manipulated variable of the main controller.

In this situation the main controller can set its manipulated variable totally independently of the limiting controller and control the core temperature of the reactor.

Sb=w

case

Controller II

Casing temperature controller (Limiting controller)

Manual1 Technical Description

core

Figure 1-42 Core temperature control with max. casing temperature limiting

Controller I

S1=8

Core temperature controller (Main controller)

If the casing temperature rises above the set limiting value Sb, e.g. due to failure of the cooling water, the limiting controller gets a negative control difference. As a result its manipulated variable is released from the forced limit and the heating performance is reduced. The limiting controller then forces the reduced manipulated variable on the main controller as a maximum manipulated variable limit. Due to the reduced heating performance the main controller receives a positive control difference which drives it to the manipulated variable limit. Now the limiting controller controls the process to constant casing temperature.

When the cooling is reinstated, the casing temperature drops. The limiting controller will now increase the heating performance and maintain the casing temperature. With increasing heating performance the core temperature also increases and the control difference of the main controller becomes negative.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

As a result the main controller controls down its manipulated variable and with it the heating performance and imposes the manipulated variable limit on the main controller. The case temperature drops below the limiting setpoint and the limiting controller drives to the manipulated variable limit via the now positive control difference. It is controlled to a constant core temperature.

The disconnection therefore always takes place when the controlled variable of the non-intervening controller becomes more positive than the set setpoint (xd negative), then the manipulated variable limited to maximum is dropped below, i.e. a maximum value limiting of the controlled variables takes place. The manipulated variable maximum value limiting corresponds in this example to a minimum value selection of the manipulated variables.

Depending on the structure switch position (S1 = 7 or 8) and the set controller direction of effect (normal: +Kp or reversed: -Kp) the limiting direction of the controlled variables is reversed (Minimum- or Maximum value limits):

Manipu-

lated

varia

limiting

direction

7 yA Max

8 yE Min

7 yA Max

8 yE Min

Table 1-15 Limiting direction of the controlled variables depending on S1 = 7/8 and controller direction

corres-

ponds

selec-

of effect

Controller direction

of effect

oy-

tion

Main

control-

ler I

norm +Kp norm +Kp xdI >0, xI<wI xdII >0, xII <Sb

rev -Kp rev -Kp xdI <0, xI >wI xdII <0, xII >Sb

norm +Kp norm +Kp xdI <0, xI >wI xdII <0, xII >Sb

rev -Kp rev -Kp xdI >0, xI <wI xdII >0, xII <Sb

norm +Kp rev -Kp xdI >0, xI <wI xdII <0, xII >Sb

rev -Kp norm +Kp xdI <0, xI >wI xdII >0, xII <Sb

norm +Kp rev -Kp xdI <0, xI >wI xdII >0, xII <Sb

rev -Kp norm +Kp xdI >0, xI <wI xdII >0, xII >Sb

Limit ing

control-

ler II

Main controller

Disconnection at

Limiting

controller II

Limiting of the

controlled

variables to

xI xII

Min Min

Max Max

Min Min

Min Max

Max Min

Min Max

The direction of effect of the transmitter, actuator and controlled system are included in the determining of the controller direction of effect (see chapter 4.1, page 215). As a rule, limiting controllers and main controllers have the same direction of effect so that the second part of the table is irrelevant.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

-- Main controller I

The main controller has the same structure with respect to the setpoint switching as the follow-up controller (S1 = 3) with the difference that the external setpoint w

E cannot be preset

via the analog inputs as an absolute value. It is therefore a fixed setpoint controller with the possibility of external sepoint preset via the SES or as an incremental setpoint via the control signals Δw. Selection is made by S101. In computer coupling it is also possible here, in the case of a computer failure (CB from 1 ! 0) to continue working with the last computer setpoint (followed--up wi) or with the safety setpoint SH (selection by S51).

Manual1 Technical Description

x-tracking in A

-operation is posssible by selection with S50 = 1. The follow-up of the inactive

setpoint to the active setpoint can be switched off by S52 = 1.

-- Limiting controller II

The limiting controller has a normal fixed setpoint structure without x-tracking and setpoint switching possibilities. The limiting setpoint Sb is set physically in the structuring mode oFPA in the range from -10 to 110 % related to the display range dEII -dAII = 100 %.

-- Display and operating level switching

The display and operating level switching Controller I or Controller II takes place in all operating modes with the Shift key (12). The LEDs Controller I, Controller II signal which controller is displayed and which controller is intervening.

The digital and analog x- and w-displays are switched. In the operating level II the Internal key (2) is inactive, the LED Internal (1) is off and the Δw adjusting keys (6) are inactive.

The y-display, the Manual/Automatic key (9) and the Δy-adjusting keys (13) are always permanently assigned to the common controller output and active in both display levels.

Selection by

Shift key

Main controller I Limiting controller II Main controller I Limiting controller II

only if there is no x-tracking

0.5 flashing rhythm 1:1

↗ adjustable

active controller

Main controller I Main controller I Limiting controller II Limiting controller II

LED con-

troller I

1 0

0.5 0

LED con-

troller II

0.5 0 1

displayedisadjustable

setpoint

wi ↗

Table 1-16 Display level switching

Flashing of the Controller I/Controller II-LEDs signals that the displayed controller is not identical with the active controller. Steady light signals that the displayed controller is not identical with the active controller.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

The process can be monitored at any time by manual switching. As a rule the display level switch is in position I (main controller) so that the main controller variable x1I canbemonitored. Flashing of the Controller LED I signals that the limiting setpoint has been reached and requests switching to the display level II (limiting controller) with the controlled variable of the limiting controller.

The display range must be set separately for the digital x and w display for both controllers with the parameters d*I and d*II if necessary in connection with the linearizers so that both controllers can be displayed correctly.

-- Automatic/Manual switching

Since both controllers only generate one common automatic manipulated variable y

,the

Automatic/Manual switching of both controllers is also common. In manual-, follow-up-, safety- or blocking operation, both controllers are followed up to the active y. The manipulated variable limit which is only active in automatic operation via the parameters YAI and YEI represents an absolute manipulated variable limit in automatic operation. The mutual follow-up of YA or YE can only take place up to the set limits. By setting YAI and YEI,YAII and YEII are set to the same value automatically on leaving the parameterization mode onPA.

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Controller I, see figure 1-50, page 90

Manual1 Technical Description

yE yA

PID controller I

see

chapter 1.5.5,

Figure 1-50,

xdI

Main controller

Page 90

yE yA

PID controller II

see

chapter 1.5.5,

Figure 1-51,

Page 91

Limiting controller

xd*II

xII

Adaptation

tFII

wII

d*II

0000

d*I

d*II

0000

xII

S52

0000

=H∨N∨Si A

SA,SE

Int

S51

S50

Int

H=Hi∨He

d*I

0000

Factory setting

S101

wiI

FE3

0/1

2/3

4/5

wiI

SES

Figure 1-43 Block diagram S1 = 7/8, Override control

S101

0/1

2/3

4/5

--Δw

+Δw

FE8

see fig. 1-5, page 24

I +c3

⋅

c1, c3

x=x1+c1x2II

x1I

x2I

FE1

FE2

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Factory setting c1=c3=0

tFI

FE4

Adaptation

Page 85

Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.10 S1 = 9: Process display

d*II

xII

gn (w)

0000

d*I

rt (x)

0000

FE3

FE1

FE6

xIII

S67

ge (y)oFF,0,1

S68

000

Figure 1-44 Block diagram, process display

The process display provides the possibility of displaying three process variables (xI to xIII).

The process variables xI and xII are indicated on the x- and w-display whereby the digital and analog displays are connected in parallel. With the parameters d*I and d*II, if necessary in connection with the linearizers, both process variables can be displayed separately physically correctly. The switching possibility of the display level is disabled. The LEDs Controller I/Controller II are dark.

The process variable xIII is indicated by the y-display and can be switched off by the structure switch S67 in the oFF position. The display range here is 0 to 100 %, according to the position of S68 mit rising or falling characteristic. The display overrun is -10 to 110 %. Alarm messages are possible by assigning the limit value alarms A1 to A4 to FE1, FE3 or FE6 (see chapter

1.5.9, page 124).

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.11 S1 = 10: Fixed setpoint controller with 1 setpoint (control system coupling)

S52

wI--c8(wST+c9)

Manual1 Technical Description

SES

wi1

Int∨

FE11

FE1

FE2

FE3

wi1

n o

0/1/3

0/1

2/3/4/5

S64

S101

2/4

x=x1+c1⋅ (x2-c2 · x3+c3)

factory setting c1=c2=c3=0

w=wI1+c8⋅ (w

+c9)

c1, c2, c3

tFI

d*I

0000

S50

Adaptation

SA,SE

A =H∨N∨Si H=Hi∨He

d*I

0000

xdI

see Fig. 1-50, page 90

Note: S64 = 3 is recommended for this controller type

Figure 1-45 Block diagram S1 = 10, fixed setpoint controller for control system coupling

This fixed setpoint controller is designed specially for coupling to the control system. The control interventions by the signals Int and CB which cannot be used otherwise in this controller type are available for locking the control system operation via the SES.

With Int∨CB

the setpoint signal wiESis separated and the manual intervention via HeESat

S64 = 3 suppressed.

S64 = 3 is expressly recommended for this connection. The other connection of the input function is almost identical with the structure S1 = 0.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

1.5.4.12 S1 = 11: Follow-up controller without Int/Ext switching (control system coupling)

This follow-up controller is designed specially for the control system coupling. It differs from the structureS1=3inthatthesetpointswitchingtow control signals are available for locking the control system operation via the SES. With Int∨CB the manual intervention via HeESat S64 = 3 is suppressed. S64 = 3 is expressly recommended for this connection.

Disconnection of a cascade control is made by manual manipulation at the master controller. The other functions are unchanged in relation to S1 = 3.

see fig. 1-50, page 90

via Int and CB is omitted and thus these

xdI

0000

SA,SE

w-c5

d*I

I/II

S52

+c5

c4. c5

=c4⋅w

Factory setting

c4=1, c5=0

S53

d*I

I/II

xx1

0000

d*I

I/II

0000

Factory setting

Adaptation

⋅

c1, c3

x=x1+c1 x2+c3

Factory setting c1=c3=0

tF I

--Δw

+Δw

FE3

see fig. 1-5, page 24

FE1

FE2

Figure 1-46 Block diagram S1=11 Follow-up controller for control system coupling

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

1.5.4.13 S1=12: Double fixed setpoint/follow-up controller

At S1=12, 2 independently operating controllers with fixed setpoint/follow-up controller function are available. With the Shift key the operating and display levels are switched completely between the two controllers.

Controller 1

SES

FE2

FE1

FE4

SES

FE8

0000 0000

wiI

wesI

wSLI

wiI

∧CB(I)

INT

xIwI

PID

ya+c6 · z

000

Controller 2

000

yII

wiII

0000 0000

wiII

INT

∧CB(II)

wSLII

xIIwII

PID

ya+c7 · z

FE3

FE7

xII

Figure 1-47 Principle representation S1 = 12 double controller

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

see fig. 1-50, page 90

xdI

d*I

0000

=H∨N∨Si A

SA,SE

H=Hi∨He

S50

Int

wiI

S52

S510

Adaptation

S101

2/3/

4/5

wiI

SES

Figure 1-48 Block diagram controller I at S1=12

I w

w 0

see fig. 1-5, page 24

FE2

tF I

FE1

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1.5 Functional description of the structure switches

1.5.4 Controller types (S1, S49 to S53)

Manual1 Technical Description

see fig. 1-50, page 90

S235

xdII

wII

xII

wII

dII

tSII

xII

dII

0000

xII

0000

=HII∨NII∨SiII A

SAII,SEII

AII

HII=HiII∨HeII

S233

IntII

Int

wiII

CBII

S2340

CBII

Adaptation

wiII

S101

2/3/

4/5

wiII

SES

Figure 1-49 Block diagram controller II at S1=12

II w

FE8

see fig. 1-5, page 24

tF I

FE3

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Manual 1 Technical Description



axd1

1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

(S54 to S60)

1.5.5.1 Control algorithm

The PiD control algorithm of controller I and II is implemented as an interaction-free parallel structure and follows the ideal controller equations whilst neglecting the filter constants and the cycle time.

-- P-controller

ya = Kp ⋅ xd = yo or

-- Pi-controller

=  Kp

ya = Kp (xd + xd dt) +yo(t) or =  Kp (1 + )

jω Tn

-- D-part (zD-part)

The D-part can be added optionally.

= Kp

jω Tv

1+jω

The input variable E for the D-part is xd, x, -z, or +z depending on the setting of S55 or S57.

-- zy-part

The z-part can be added optionally to the controller output ya.

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1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

see fig. 1-58, page 102 to fig. 1-63, page 110

see chapter 1.5.3,

figure 1-17, page 38

PII

Manual1 Technical Description

S231

YAI,YEI

0/2

--p

--(Kp⋅xd+c6⋅zy)

Controller structure I

tn I

c6⋅zy

S54

--1

tF I

xdI

tv I

vv I

KpI

S54

--1

S55

--1

At S55=2.3, zy=0 %!

0/1

zΔ

S55

2/3

Figure 1-50 Block diagram controller structure I

FE4

see fig. 1-25, page 50 to fig. 1-49, page 88

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Manual 1 Technical Description

see fig. 1-64, page 115 to fig. 1-68, page 119 or Fig. 1-38 page 73 and fig. 1-40, page 76

seefigure1-17

PII

YAII,YEII

1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

S231

0/2

II--p

II--(kp⋅xd+c7⋅zy)

Controller structure II

tnII

c7⋅zyII

KpII

S56

AHII

tFII

xdII

--1

tv II

vv II

KpII

S56

--1

S57

--1

xII

--1

At S57=2.3, zy=0 %!

zyII

0/1

zΔ

S57

2,3

Figure 1-51 Block diagram controller structure II

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see fig. 1-25, page 50 to fig. 1-49, page 88

FE7

Page 94

1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

Manual1 Technical Description

Controller direction of effect

The controller direction of effect is set with S54 (controller I) or S56 (controller II), it must always have an opposite behavior (reverse coupling) to the controlled system (including actuator and transmitter) S54/56= 0, normally acting controller (+Kp, rising x causes falling y) for normally acting systems (rising y causes rising x) S54/56=1, reversing controller (--Kp, rising x causes rising y) for reversing systems (rising y causes falling x).

Operating point yo for P-controller

-- The operating point yo of the P-controller can be set either automatically or as a parameter

(onPA).

-- Automatic operating point (Yo = Auto)

Whenever there is no automatic operation (manual, follow-up, safety or blocking operation) the operating point yo is followed up so that switching to automatic operation is bumpless.

This gives an automatic setting of the operating point yo in manual mode: yo = y

yo = y If the actual value in manual mode (x

ate manual manipulated variable (y nipulated variable (y

yo = y

 Kp(w--xH)c6⋅zyII in controller II or

 Kp(w--xH)c6⋅zyin controller I

) is driven to the desired setpoint (w) by the appropri-

), the operating point (yo) is identical to the manual ma-

or yo = yHc6⋅zy.

-- Set operating point (Yo = 0 to 100 %)

-- The controller operates in all operating modes with the operating point set as a permanent

parameter.

Bumpless switching to automatic mode

If there is no automatic operation (manual, follow-up, safety or active blocking operation) the I-part or the operating point yo (only at Yo = Auto) is followed up so that the switching to automatic operation is bumpless. Any still active D part is set to zero.

P-PI switching

With the control signal P*=1 the controller is switched from Pi to P-behavior, at Yo=Auto the switching is bumpless.

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

Manipulated variable limiting yA, yE (yAII,yEII at S1=12)

The manipulated variable limiting with the parameters YA and YE is active in automatic operation in any case. The limits of these parameters are at --10 and +110 %. However, it should be taken into account that the controllers neither output negative actuating currents nor detect any negative position feedback signals.

If the manipulated variable y

reaches one of the limits YA or YE in automatic mode, further in-

tegration is aborted to avoid integral saturation. This ensures that the manipulated variable can be changed immediately after reversing the polarity.

In manual-, follow-up- (DDC) or safety operation the manipulated variable y can be driven out of the limiting range (only at S245=0 or S246=0). When switching to automatic mode the last manipulated variable is transfered bumplessly, then only changes in the manipulated variable in direction of the range YA to YE are executed. In controller I the manipulated variable limiting is only possible in K-controllers and three-position step controllers with external position feedback (S2=0 and S2=3).

Adaptive filter

The control difference xd is fed through an adaptive filter. By adjusting tFI or tFII (onPA) from oFF to 1 s the filter is switched on. By further increases to tF* the filter can be adapted to a lowfrequency disturbance frequency (seconds to hours time constant). Within a band in which changes repeatedly take place, changes are seen as disturbances by the filter and are filtered with the preset time constant tF*; Changes in a direction leading out of the band are passed unfiltered to the Pi(D) algorithm to enable fast control. If the disturbance level changes in time, the filter is automatically adapted to the new level.

Figure 1-52 Effect of the adaptive non-linear filter

The factory setting of tFI and tFII is 1 s. In controllers with D-part it should be set as great as possible because of the input noise amplified by vv ·Kp and in the adaptation (see chapter 4.4, page 219).

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1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

Manual1 Technical Description

Response threshold AH

The response threshold AH (dead zone element) is in the control difference connected after the adaptive filter.

xdoutput

-AH

input

Figure 1-53 Effect of the dead zone element

The dead zone element lends the controller a progressive behavior, at small control differences the gain is low or even 0, at larger control differences the specified Kp is reached. It should be taken into account that the remaining control difference can adopt the value of the set response threshold AH. The factory setting of AH is 0 % and can be set up to 10 % in the parameterization mode onPA.

In S-controllers the minimum necessary setting of AH is given by the minimum Δx=ks⋅Δy (see chapter 4.3, page 218) and can be increased for further calming of the controlled system. In K-controllers a small threshold value is advisable for calming the control circuit and reducing wear.

Parameter switching

The single controllers, i.e. fixed setpoint controllers with two independent setpoints, fixed set-point controllers with two dependent setpoints, DDC-fixed setpoint controllers, follow-up controllers (synchronized controllers, SPC-controllers) and ratio controllers operate with the parameter set I and can be switched via the control signal PAU = 1 to the parameter set II . Both parameter sets are separately adjustable in the parameter mode onPA. Every parameter set contains the parameters vv, cP, tn tv, AH, Yo, YA and YE with the ID I or II. The switching facility is conceived for 2-batch mode and should be performed manually since it cannot be bumpless in automatic operation.

Double controllers (cascade control, ratio cascade control and override control) operate with the separately adjustable parameter sets I and II for the controllers I and II. There is no longer a possibility of parameter switching by the control signal PAU.

Parameter control

With the structure switch S59 the parameter sets I or II can be replaced by a controlled parameter set except for YA and YE. In double controllers one of the two controllers can operate with controlled parameters. In single controllers the controlled parameter set can be used for operation and additionally it can be switched to a fixed parameter set by the control signal PAU. The

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Manual 1 Technical Description

1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

parameters cP (Kp), tn, tv, AH and Yo are controlled by a straight line with 5 vertex points at 10 %, 30 %, 50 %, 70 % and 90 % of the controlling variable. The controlling variable is selected by S60. All control-relevant, controller-internal variables are available.

S59 PAU active parameter set

0 0

1 1

2 2

Table 1-17 active parameter sets for single controllers

0 1

depending on S59 and control signal PAU

Parameter set I Parameter set II

controlled parameter set Parameter set II

Parameter set I controlled parameter set

The parameters are set manually per vertex point (identified by the suffix 1, 3, 5, 7, 9 for 10 %, 30 %, 50 %, 70 %, 90 % of the controlling variable in structuring mode PAST. Beyond the marginal vertex points 10 and 90 % the set values remain constant. (Exception: Yo can be controlled over the whole range 0 to 100 %.)

For parameters which do not need to be controlled, same values are set for all vertex points. The derivative action gain vvc is not controllable but can be set in the range from 0.1 to 10.

When controlling tv a supplementary condition must be satisfied: tv.1 to tv.9 must either be all = oFF (Pi or P controller) or all ≠ oFF (PID or PD controller). Otherwise the error message tv/Err appears when jumping out of the structuring mode PAST with the Exit key (see chapter

3.3.3, page 175).

Yo is controllable in the range from 0 to 100 % and then acts like a ”fixed set” operating point. Yo = Auto can also be set, in this case no parameter control takes place but the operating point is set automatically in non--automatic operation (see operating point in P-controller).

Yo.1 to Yo.9 must either be set all = Auto or all ≠ Auto. Otherwise the error message Yo/Err appears when jumping out of the structuring mode PASt with the Exit key (see chapter 3.3.3, page 175).

Typical controlling variables are the control difference xd (it acts as 10jxdj) for progressive controls and x or y for operating point dependent controls (non-linear controlled systems). If S60 = 17 is set, a controling variable of 10% is simulated in Pi operation and a controlling variable of 30% in P operation. In this way you can work with large Kp (cP.3) for example in P operation (control signal P=1) to reach the operating point quickly. After switching to Pi operation (control signal P=0) a reduced Kp (cP.1) is active for a stable control. The parameter values and the value of the controlling variable can be gained by adaptation (see section ”Adaptation” on the next page).

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1.5.5 Control algorithm, parameter control, adaptation

cP=Kp

cP.9

cP.7

cP.5

cP.3

cP.1

Manual1 Technical Description

-9 -7 -5 -3 -1 +1 +3 +5 +7 +9 % xd

Figure 1-54 Example of a Kp control with 10jxdj as a controlling variable for progressive control

10 30 50 70 90 % SG=10

jxdj

Adaptation (S58)

The adaptation procedure represents a reliable and easy to operate commissioning tool. The adaptation procedure is far superior to manual optimization especially in slow controlled systems and in PIC controller types. It is activated by the operator and can be aborted at any time in the event of danger. The parameters determined by the adaptation can be changed and accepted specifically by the user. Non-linear control lines can also be mastered in connection with the parameter control.

In the parameterization mode AdAP which is only accessible at S58 ≠0, the following presettings are made for the adaptation procedure:

tU Monitoring time dPv Direction of step command dY Amplitude of step command

With the structure switch S58 the choice of the control behavior (with or without overshoot) is made. The adaptation principle is divided into line identification and controller design.

-- Line identification

The controller is driven to the desired operating point manually. By pressing the Enter key the set manual manipulated variable is changed by a step adjustable in the direction (dPv) and amplitude (dY). The y-step is output at the end of 10 % of the set monitoring time (tU) if there was a fixed state of the controlled variable during this time. Otherwise there is an error message with abortion of the identification (see chapter 3.3.3, table 3--2, page 177).

The step response of the controlled system is then accepted with a max. 84 value pairs (time and amplitude). The respective main controlled variable of the different control types is

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1.5 Functional description of the structure switches

1.5.5 Control algorithm, parameter control, adaptation

filtered adaptively -- (see figures 1-25, page 50 to figure 1-43, page 82) to use for controlled variable measurement. The measured values are read in with a scanning rate according to the cycle time. The noise level is suppressed by the adaptive filter. The storage procedure operates with cyclic data reduction and subsequent refilling so that slow controlled systems can be entered.

After the start ID has been run through (the controlled variable x must have left the start ID band within 50% of the set monitoring time tU), 95% of the full range must have been

reached at the latest at

/3of tU. The set monitoring time (tU) must be ≥ 2 T95 of the controlled system with safety reserve. The remaining time is required for the full scale identification. The full scale identification can also take place immediately after the start

identification, but

/3of the performed measurements are always required for the full scale

identification. Recording of the measured value pairs is ended on identifying the full scale.

A comparison with the recorded transient function is now made based on the stored Ptn models with n = 1 to 8 and equal time constants T by variation of n and T. The determined line gain ks is transfered to the line models. The comparison is made over the minimum error area F (n, T)

Additionally a special entry of real dead times is made which then shifts the identified control line to higher orders.

Control lines with compensation and periodic transient of 1st to 8th order with a transient time T95 of 5 s to 12 h can be identified. Dead time parts are permissible. In S-controllers the transient time T95 should be twice the positioning time Ty.

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Model curve x

F(n,T)=min

x measuring process

Δy

Δx=ks⋅Δy

manual

Manual1 Technical Description

67 %

Start ID

ID fixed state

Start of adaptation

Figure 1-55 Time curve of an adaptation without error messages in which tU = 2×T95

Full scale ID

100500-10

Error checks are made during line identification in order to be able to prematurely abort the identification. There are 13 control steps altogether which are displayed by flashing on the digital x- and w- displays when errors occur. As soon as an error message appears, the line identification is aborted and it must be restarted after correcting the presettings in the parameterization mode AdAP if necessary. Acknowledgement of the error messages, see table 3-2 ”Error messages of the adaptation procedure”, page 177.

-- Controller design

The controller is designed according to the amount optimum method (S58=2). This setting method is very robust and also allows variation of the line amplification. However, it generates an overshoot of approx. 5 % in the event of changes in the command variables. If this is not wanted, you can also work with the controller design without overshoot (S58 = 1), Kp is reduced here to 80 %.

% tU

The controller is designed for PI and PID behavior, therefore kp, tn and for PID tv are calculated, whereby the derivative action gain is fixed at 5. A prerequisite is that the D-element is connected with xd or x (S55 = 0 or 1).

In S-controllers the response threshold AH is calculated in addition to kp, tn, tv. The parameters tA, tE and tY must be set beforehand according to the actuating drives used (see chapter 4.3, page 218). If the transient time T95 is near to 2 tY (floating time) overshooting may also occur in controller designs with D-part at S58=1.

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