Siemens SIPART DR21 User Manual

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SIPART DR21 C73000-B7476-C143-08

SIPART DR21 6DR 210*--*

Edition 08/2010

Manual

SIPART DR21

C73000-B7476-C143-08

SIPART DR21 C73000-B7476-C143-08

Classification of safety--related notices

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

DANGER

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

Warnung

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.

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.

The reproduction, transmission or use of this document 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 Bereich Automatisierungs-- und Antriebstechnik Geschäftsgebiet Prozessinstrumentierung-- und Analytik D--76181 Karlsruhe

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 1999 Technical data subject to change.

SIPART DR21

C73000-B7476-C143-08

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 trademarks might infringe upon the rights of the trademark owners.

Controls and displays

3 4 5 6

19 20

1 Analog indication of actual value x 2 Analog indication of setpoint w 3 w/x digital display (other values can be displayed) 4 Signalling lamp w -- lights up if w is displayed 5 Signalling lamp x -- lights up if x is displayed 6 Selector pushbutton for w/x digital display,

acknowledgement pushbutton for flashing following return of power or pushbutton for entering selection mode

7 Pushbutton for adjustment of manipulated variable --

closed (open)

8 Pushbutton for adjustment of manipulated variable --

open (closed) 9 y digital display 10 Signalling lamps of Δy digital outputs with S controller 11 Switchover pushbutton Manual/Automatic or “Enter” pushbutton

from selection mode of configuring mode 12 Signalling lamp for manual mode 13 Signalling lamp for y--external mode

Modification of setpoint 14 Pushbutton for falling setpoint

15 Pushbutton for rising setpoint 16 Selector pushbutton for internal/external setpoint or “”Exit’”

pushbutton from configuring and selection modes to process

operation mode 17 Signalling lamp for internal setpoint 18 Signalling lamp for computer switched off (with w

ext

)

Further messages 19 Signalling lamp for adaptation procedure running

20 Signalling lamp for “Limit triggered”

. Note Operation can be blocked using the digital signal bLb;

exception: switching over o w/x digital display.

Display of actual value and setpoint

Modification of manipulated variable

SIPART DR21 C73000-B7476-C143-08

Block diagram

AI4A

S13

AI3A

S11

AI1A

AI3

Slot 1

Slot 2

I,U,R

AI4

Options

S18

DI1

DI2

24 V

L+

GND

+24 V

+5 V

REF

S14

S21

S57

DO7

DO8

24 V

S56

15 14 13

S22

Z S20

S19

/x3

S17

x2 S16

x1 S15

4DO 24V 2DI

2DO Rel

5DI

Slot 3

S84toS91

4/2

4/7

4/8

4/3

Slot 4

SES

DO2

DO1

+Δy

--Δy

AO/Jy

Options

Txd Rxd

1/4

1/3

1/2

1/1

2/4

2/3

2/2

2/1

3/6

3/5 3/4 3/3

3/2

3/1

∽

AI1

AI2

UNI

S8 to S10

S12

AI2A

249

Basic settings

S1 to S3

Analog inputs

S4 to S21

Configuration of slot 3

S22

Digital inputs

S23toS41

Setpoint tracking

S42toS45

Control algorithm

S46toS48

Y switchover

S49toS53

Y indicator

S54toS55

Analog output

S56

Switching output

S57

Digital outputs

S58toS75

Limit monitors

S76toS80

x/w indicator

S81

Restart conditions

S82toS83

Serial interface

S84toS91

SIPART DR21

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Manual Contents

SIPART DR21 C73000-B7476-C143-08

Contents

page

1 General Part -- Fundamental control technology terms 9....................

2 Technical Description 17...................................................

2.1 Safety notes and scope of delivery 17..................................................

2.2 Range of Application 18..............................................................

2.3 Features 19........................................................................

2.4 Design 24..........................................................................

2.5 Function principle 26................................................................

2.5.1 Standard controller 26.................................................................

2.5.2 Option module 28....................................................................

2.6 Technical Data 34...................................................................

2.6.1 General data 34......................................................................

2.6.2 Standard controller 36.................................................................

2.6.3 Option module 40....................................................................

3 Functional description of the structure switches 47..........................

3.1 General 47.........................................................................

3.2 Analog input signal processing (S3 to S21) 47..........................................

3.3 Digital input signal processing (S23 to S41) 50..........................................

3.4 Controller types (S1, S42 to S45) 55...................................................

3.4.1 General, recurrent functions 55.........................................................

3.4.2 Fixed setpoint controller with 2 independent setpoints (S1 = 0) 59............................

3.4.3 Slave controller, synchronized controller, SPC-controller 62.................................

3.4.4 DDC-Fixed setpoint controller (S1 = 2) 68................................................

3.4.5 Controlled ratio controller (S1 = 3) 75....................................................

3.4.6 Control unit/process display (S1 = 4) 80..................................................

3.4.7 Fixed setpoint controller with one setpoint (control system coupling) 89.......................

3.4.8 Slave controller without Int/Ext -switching (control system coupling) 90........................

3.5 Control algorithm 91.................................................................

3.6 Controller output structures (S2, S49 to S55) 94.........................................

3.7 Analog output signal processing (S56) 110...............................................

3.8 Digital output signal processing (S57 to S75) 111.........................................

3.9 Adaptation (S48) 113.................................................................

3.10 Other functions of the standard controller 115............................................

3.10.1 Adaptive filter 115.....................................................................

3.10.2 Response threshold AH 116............................................................

3.10.3 Limit value alarm (S76 to S80) 117.......................................................

3.10.4 Linearizer (S21, oFPA) 118.............................................................

3.10.5 Restart conditions (S82, S83) 120........................................................

3.10.6 Serial interface and PROFIBUS-DP (S84 to S91) 120.......................................

4 Installation 121.............................................................

4.1 Mechanical Installation 121............................................................

4.1.1 Work prior to installation 121............................................................

4.1.2 Installing the controller 124..............................................................

4.1.3 Installation of the options modules 125....................................................

4.2 Electrical Connection 126.............................................................

4.2.1 Warnings and block diagram 126.........................................................

4.2.2 Connection standard controller 130.......................................................

4.2.3 Connection of the options modules 133...................................................

4.2.3.1 Modules for analog measuring inputs 133.................................................

4.2.3.2 Connection examples for analog measuring inputs with the module 6DR2800-8J 137.............

4.2.3.3 Modules for expanding the digital inputs and digital outputs 142...............................

4.2.4 Connection of the interface module 6DR2803-8C 144.......................................

4.2.4.1 RS 232 point-to-point (END/END) 144....................................................

4.2.4.2 RS 485 bus 145.......................................................................

4.2.4.3 PROFIBUS-DP, 6DR2803-8P 146........................................................

ManualContents

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5 Operation 149..............................................................

5.1 General 149.........................................................................

5.2 Process operation mode 150..........................................................

5.3 Selection mode 152..................................................................

5.4 Configuration modes 154..............................................................

5.4.1 General, Online and Offline modes 154...................................................

5.4.2 Configuration mode online-parameters onPA 155..........................................

5.4.3 Configuration mode adaptation AdAP 156................................................

5.4.4 Configuration level offline parameters oFPA 163...........................................

5.4.5 Configuration mode structure switch StrS 165.............................................

5.4.6 Set UNI-module CAE3 173............................................................

5.4.6.1 Measuring range for mV (S8 = 0) 175.....................................................

5.4.6.2 Measuring range for U, I (S8 = 0) 175.....................................................

5.4.6.3 Measuring range for thermocouple with internal reference point (S8 = 1) 175....................

5.4.6.4 Measuring range for thermocouple with external reference point (S8 = 2) 176....................

5.4.6.5 Measuring range for PT100 four-wire and three-wire connection (S8 = 3,4) 176..................

5.4.6.6 Measuring range for PT100 two-wire connection (S8 = 5) 177.................................

5.4.6.7 Measuring range for resistance potentiometer (S8 = 6, 7) 177.................................

5.4.7 APSt (All Preset) Reset to factory setting 178..............................................

5.5 CPU self-diagnostics 179..............................................................

6 Commissioning 181........................................................

6.1 Adapting the direction of control action to the controlled system 181.........................

6.2 Setting of actuating time in K-controllers (S2 = 0) 183......................................

6.3 Adaptation of the S-controller to the actuating drive 183....................................

6.4 Setting the filter and the response threshold 185..........................................

6.5 Automatic setting of control parameters by the adaptation method 186.......................

6.6 Manual setting of the c ontrol parameters without knowledge of the plant behavior 189..........

6.7 Manual setting of the control parameters after the transient function 191......................

7 Application examples for configuring the controller 193.......................

7.1 General 193.........................................................................

7.2 Working with different setpoints 195.....................................................

7.3 Configuration examples 199...........................................................

7.4 Configuring tool, forms 216............................................................

8 Maintenance 223...........................................................

8.1 General information and handling 223...................................................

8.2 Exchanging components 224..........................................................

8.3 LED-test and software version 226......................................................

8.4 Spare parts list 227...................................................................

8.5 Ordering data 228....................................................................

9 General explanation of abbreviations for SIPART DR 229......................

Index 235........................................................................

1HL1Manual

SIPART DR21 C73000-B7476-C143-08

1 General Part -- Fundamental control technology terms

D Control loop

The function of a closed-loop control is to bring the output variable x of a controlled system to a predefined value and to retain this value even under the influence of disturbance variables z. The controlled variable x is compared with the command variable w. The resulting system deviation xd = w -- x is processed in the controller to the manipulated variable y which acts on the controlled system.

The controlled variable x is measured cyclically in a digital control.

w Command variable x Controlled variable xd System deviation y Manipulated variable z Disturbance variable

1 Controlled system 2 Control equipment

z1 z2 z3

Figure 1-1 Function diagram of control loop

D Sensors and transmitters

The controlled variable can be any physical variable. Frequently controlled variables in process engineering are pressure, temperature, level and flow.

In most process engineering applications, the process variables are measured using sensors and transmitters with a standardized signal output (0 to 20 mA or 4 to 20 mA). The standardized signal can be connected to several process process devices (loop between e.g. recorder/indicator/controller). Temperature sensors such as resistance thermometers or thermocouples, as well as resistance transmitters, can be connected directly to the controller using appropriate input cards (options).

D Final control elements and actuators

In process engineering applications, the manipulated variale y primarily acts on the controlled system via a valve, a butterfly valve or another mechanical means of adjustment. Three types of drive are possible for actuating such final control elements:

- Pneumatic actuators with compressed air as the auxiliary energy and electropneumatic signal converters or electropneumatic positioners. These have a proportional action and are driven by continuous controllers.

- Electric actuators, consisting of an electric motor and gear unit. These have an integral action and are driven by three-position step controllers. Electric actuators are also possible with an integrated (series-connected) positioner and then have a proportional action and can be driven by continuous controllers.

1 General Part -- Fundamental control technology terms Manual

SIPART DR21

C73000-B7476-C143-08

- Hydraulic actuators with electric oil pump and electrohydraulic positioner. These have a proportional action and are also driven by continuous controllers. These types of actuators can be used to implement continuous controls.

- Temperature control loops with diret electric or gas heating and/or cooling systems are driven by two-postion controllers (on/off controllers). The two-position controllers with the heating or cooling medium via relays, external contactors or thyristor controllers. The manipulated variable y is the on/off ratio. These are referred to as discontinuous controls.

D Controllers and control response

The controlled variable x is compared with the command variable w in the input circuit of the controller, and the system deviation xd is determined. This is processed with or without a time response into the output signal. The output signal of the amplifier can directly represent the manipulated variable y if e.g. proportional-action final control elements are to be driven by it.

In the case of electric actuators, the manipulated variable is produced by the actuator. The required positioning inrements are derived from the controller ouptut as a pulse-width-modulated signal by conversion.

Depending on the design of this circuit, the controller has a proportional action (P), a proportional-plus-derivative action (PD), a proportional-plus-integral action (PI) or a proportionalplus-integral-plus-derivative action (PID).

D Step function

If a step function is applied to the controller input, a step-forced response results at the output of the controller in accordance with its time response.

Figure 1-2 Step function

D P controller, step-forced response

Characteristic of the P controller are the proportional gain Kp and the working point y

.The working point is defined as the value of the output signal at which the system deviation is zero. If disturbance variables are present, a steady-state deviation may result depending on y

Kp · xd

Figure 1-3 Step-forced response of P controller

1 General Part -- Fundamental control technology termsManual

SIPART DR21 C73000-B7476-C143-08

D PD controller, step-forced response

In the case of the PD controller, the decaying D component is superimposed on the P component. The D component depends on the derivative action gain Vv and the derivative action time Tv.

Tv Vv

Kp · Vv · xd

Kp · xd

yO=0

Figure 1-4 Step-forced response of PD controller

D PI controller, step-forced response

In contrast to the P controller, a steady-state deviation is prevented in the PI controller by the integral component.

A characteristic of the integral component is the integral action time Tn.

Kp · xd

Figure 1-5 Step-forced response of PI controller

D PID controller, step-forced response

The PID controller results in improvement of the dynamic control quality as a result of the additional application of a D component.

Refer to the PD and PI controllers.

Kp · xd

Tv Vv

Figure 1-6 Step-forced response of PID controller

1 General Part -- Fundamental control technology terms Manual

SIPART DR21

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D Controller output signal

The controller ouptut signal must be adapted to the final control element. The following must be used according to the type of drive/final control element:

Type of drive/actuator

Controller output signal

Electric actuators Three-position step controllers

Pneumatic and hydraulic actuators Continuous controllers

Direct heaters/coolers Two-position controllers

D Three-position step controller with internal feedback

The three-position step controller switches the electric motor of the actuator to clockwise, stop or counterclockwise by means of relays or semiconductor switches. The rate of adjustment of the actuator can be influenced using different switch-on/pause ratios.

w Command variable x Controlled variable xd System deviation y Manipulated variable

1 Transmitter 2 Stepoint adjuster 3 Three-position switch 4 Feedback with time

response 5 Control amplifier 6 Actuator

0 to 20mA

(4 to 20mA)

Figure 1-7 Function diagram of three-position step controller

The output response to the three-position amplifier in conjunction with the integral-action actuator permits a “continuous” manipulated variable taking into account the response threshold.

1 General Part -- Fundamental control technology termsManual

SIPART DR21 C73000-B7476-C143-08

Kp Proportional gain Tn Integral action time xd System deviation Δy Manipulated variable of controller y Manipulated variable of motor

Kp · xd

Δy

Figure 1-8 Transient function and parameters of the three-position step controller

D Continuous controller

The controller output 0 to 20 mA or 4 to 20 mA acts on the final control element via an electropneumatic signal converter or an electropneumatic positioner.

0to20mA (4 to 20 mA)

0.2 to 1 bar

w Command variable x Controlled variable xd System deviation y Manipulated variable

1 Transmitter 2 Stepoint adjuster 3 Control amplifier 4 Electropneumatic signal

converter

5 Pneumatic actuator

Figure 1-9 Function diagram of continuous controller

This type of controller is preferentially used in the chemical industry.

1 General Part -- Fundamental control technology terms Manual

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D Two-position controller

The two-position controller (or three-position controller for heating/cooling) is used to activate relays, contactors or thyristor switches for electric heating or cooling.

- Two-position controller without feedback In the simplest version without feedback, two-position controllers operate an on/off switch. The controllers output is switched if the controlled variable violates the upper or lower limits of the switching hysteresis (x1 and x2). The controlled variable x is subject to permanent oscillation whose frequency and amplitude depend on the delay time of the system and the switching hysteresis of the controller.

1 Controller 2 Controlled system 3 Setpoint adjuster

x1 x2

w Command variable x Controlled variable y Manipulated variable ON/OFF z Disturbance variable

On Off

Figure 1-10 a) Function diagram b) Switching ouptupt and response of controlled variable

1 General Part -- Fundamental control technology termsManual

SIPART DR21 C73000-B7476-C143-08

- Two-position controller with feedback In modern two-position controllers with feedack -- such as the SIPAR T DR21 -- the switching response is determined by the period, the system deviation and the parameters. The period T is set as a fixed value in the controller. The system deviation xd in conjunctionw ith the parameters Kp/Tn/Tv determines the duty factor (ON/OFF ratio) within the period. Thus the switching response of the controller is not only triggered by changes in the controlled variable; appropriate selection of the parameters results in a largely constant controlled variable x.

1 Control amplifier 2 Controlled system 3 Setpoint adjuster 4 Pulse/pause converter

On Off

Duty factor 0 %

Duty factor 100 %

2 ¢ 100 %

-PeriodT

- System deviation xd

- Parameters Kp, Tn, Tv

w Command variable x Controlled variable y Manipulated variable Z Disturbance variable TPeriod

*) Duty factor (in % if period)

Figure 1-11 a) Function diagram b) Switching output and resosne of controlled variable

Adjustment of the period (separately for heating/cooling) permits the controller to be adapted to the special type of heater or the cooling unit. A compromise has to be made beween the control quality and the degree of wear.

Short period: Improved control quality, but increased wear on contact/heating valve.

Prime use with electric heaters.

Long period: Low wear on contact/heating valve, but poorer control quality. Prime

application with gas heaters or coolers.

1 General Part -- Fundamental control technology terms Manual

SIPART DR21

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2 Technical Description

2.1 Safety notes and scope of delivery

Manual

SIPART DR21 C73000-B7476-C143-08

2 Technical Description

2.1 Safety notes and scope of delivery

WARNING

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 personnelmust be fully conversant 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 Scope of delivery

When the controller is delivered the box also contains:

1 Controller as ordered 1 three-pin plug at 115/230 V AC or special plug at 24 V UC 2 Clamps, pluggable 2 Adhesive labels ”Power supply 115 V” (for 115/230 V-version). 1 CD ROM with documentation

D Standard controllers

The following variants of the SIPART DR21 are available:

Order number:

Output stage Power Supply

6DR2100-4 K/S-output 24 V UC 6DR2100-5 K/S-output 1 15/230 V AC, switchable

D Options modules (signal converters)

Signal converters have separate ordering- and delivery items. For handling reasons standard controllers and signal converters 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 C73000-B7476-C143 German C73000-B7400-C143

2 Technical Description

2.2 Range of Application

Manual

SIPART DR21

C73000-B7476-C143-08

D Subject to modifications

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.

2.2 Range of Application

D Application

The SIPART DR21 process controller is a digital instrument of the mid to upper performance class. It is used in control systems in process engineering for instance in the chemical and petrochemical industries, control- and power station engineering and in other fields of industry such as the food- and drink and tobacco industries.

The controller’ s great flexibility makes it suitable for use in simple or intermeshed control circuits. The wide setting range of the control parameters allow the SIPART DR21 to be used in process engineering both for fast (e.g. flow) and slow controlled systems (e.g. temperature). The controller determines the optimum control parameters independently on request without the user being expected to have any prior knowledge of how the control loop may respond. The applied adaptation procedure is suitable for systems with compensation and aperiodic transient behavior; Even greater dead times are taken into account. (Systems without compensation cannot be adapted by this method.)

D Controlling tasks

The input structure of the SIPART DR21 controller can be changed by configuring in such a way that the following controlling tasks can be solved.

- Fixed value controls, even with disturbance variables applied at the input

- Three-component controls

- Control circuits with up to two internal setpoints

- Follow-up-/synchronization controls

- Disturbance variables applied at the output

- Computer-controlled circuits in SPC- or DDC-operation

- Ratio controls with fixed or manipulated variables

SIPART DR21 can also be configured as a control unit, manual control unit, process display or resolver transmitter.

The SIPART DR21 controller can be used as a continuous controller with output 0/4 to 20 mA, as a stepper controller with a built-in relay for controlling motorized drives or as a two-position controller for heating/cooling systems.

Overlaid control functions or status- and alarm messages are possible through digital inputsand outputs.

2 Technical Description

2.3 Features

Manual

SIPART DR21 C73000-B7476-C143-08

2.3 Features

D General

Up to four signal converters can be added to the already generously and extensively equipped, fully functional standard controller to expand the range of application by plugging them into the slots at the back of the closed device.

SIPART DR21 offers the following features:

D Analog inputs

Two analog inputs for current 0/4 to 20 mA, without potential isolation

The SIPART DR21 controller can be expanded to a total of 4 analog inputs with signal converters.

The following signal converters are available:

Use as (on) Possible signal generators

UNImodule

AI3 (slot 1) TC/RTD/R/mV, with adapter plug also mA or V, electri-

cally isolated, permissible common mode voltage 50 V .

U/Imodule

AI3 (slot 1) AI4 (slot 2)

0/4to20mA,0/2to10V,0/0.2Vto1V Electronic potential isolation, permissible common mode voltage 10 V.

Rmodule

AI3 (slot 1) AI4 (slot 2)

Resistance potentiometer

In addition, the modules from the previous program (thermocouple/mV and Pt100) can be used (see SIPART DR20 user’s guide for wiring).

D Output structure

The SIPART DR21 controller has a y-analog output (manipulated variable) with a current signal of 0/4 to 20 mA and a switching output with two built-in relays which are interlocked. The relay lock can be released for a universal digital output. The relays are designed for AC 250 V, a spark quenching combination for wiring with contactors is provided.

The SIPART DR21 can be configured to operate as a continuous controller, a stepper controller for motorized drives or as a two-position controller.

When used as S-controllers, the analog output can be used for outputting x, w or xd for example.

2 Technical Description

2.3 Features

Manual

SIPART DR21

C73000-B7476-C143-08

WARNING

The relays are designed for a maximum switching voltage of AC 250 V/8 A in overvoltage class III and degree of contamination 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 three times 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 isolated switching elements.

D Voltage output

A voltage output L+ for feeding two-wire-transmitters or contacts for digital inputs.

D Slots for options

Four rear slots can be used for functional expansions. The options modules are slot coded so that wrong installation is largely ruled out. Slot assignment, see figure 2-2 Rear view, page 25.

D Power supply unit

The power supply unit is designed for the following voltages depending on the standard controller:

- 230 V/115 V AC, switchable by plug-in jumpers in the instrument.

-24VUC

2 Technical Description

2.3 Features

Manual

SIPART DR21 C73000-B7476-C143-08

D Digital inputs

Two digital inputs, potential-bound It can be upgraded to four or seven potential-bound digital inputs with signal converters. The digital inputs can be assigned to the following controller-internal switching signals.

bLb Blocking operation

Blocking the entire instrument operation and configuring. Exception: Switching the w/x-digital display

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 adaptation can be selected. Structuring is blocked.

bLPS Blocking parameterization and structuring

The entire configuring of the instrument 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 causes either switching in the setpoint range. In DDC-controllers, DDC-operation begins.

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 Tracking

With this signal the output of the K-controller and the three-position-step controller with external position feedback is tracked to the tracking signal y

Si Safety operation

The output of the K-controller or the three-position-stepper controller with external position feedback accepts the parameterized safety value. In three-position-stepper controllers with internal position feedback, the manipulated variable runs defined to 0 or 100 %.

P P-operation

Switching from PI (PID) to P (PD)-controller (i.e. switch off the I-part) This function simplifies automatic start-up of control circuits.

Switching off the setpoint ramp time

tSH Hold on setpoint change (setpoint ramp)

+yBL / --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.

2 Technical Description

2.3 Features

Manual

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D Digital outputs

Two digital outputs, active, potential-bound. It can be upgraded to four or six digital outputs with signal converters. The digital outputs are loadable up to 30 mA per output for direct tripping of relays. The digital outputs can also be used for the variable output, the relay outputs are then free for any digital signal output. The following controller-internal switching signals can be assigned to the digital outputs or relays.

Computer standby

Message that the controller can be switched to the external setpoint by the CB-signal.

Computer operation

Message that the controller is presently in computer operation or that it has been switched over to the external setpoint by the CB-signal.

H Manual mode

Message that the controller has been switched over to manual mode with the Manual/Automatic key.

Nw Tracking operation active

Message that the controller is in tracking operation.

A1 bis A4 Alarm output Alarm 1 to Alarm 4

MUF group alarm transmitter fault

The instruments’s analog input signals can be monitored for exceeding of the measuring-range. This signal gives a group alarm if an error is detected.

Δw Output of switching signals for setpoint adjustment

This function is only active when the controller is structured as a control unit (S1=4).

Δy Output of the incremental y-adjustment

Assignment is only possible on DO1, 2, 7 or 8 (S57).

The following signal converters are available for extending the digital inputs and outputs:

Use on Description

4 x DO/2 x DI Slot 3 4 binary outputs 24 V

2 binary inputs 24 V 5xDI Slot 3 5 binary inputs 24 V 2xrelays Slot 3 2 relay outputs 35 V

D Serial interface

An interface can be retrofitted with signal converters for RS 232/RS 485 or PROFIBUS DP.

2 Technical Description

2.3 Features

Manual

SIPART DR21 C73000-B7476-C143-08

D Others

Further functions are also possible. Examples:

Meaning see chapter

Adaptationprocedure

Automatic determining of the controller parameters by means of a robust adaptation method which also considerably simplifies commissioning of even critical controlled systems.

Configuring level AdAP; 3.9 (page

113) and 5.4.3 (page

156)

adaptive filter forxdFilter which dampens amplitude-dependent interference, the

value of the dampening is adapted automatically.

onPA-Parameter tF

3.10.1 (pg. 115) and

5.4.2 (page 155)

Setpoint ramp Prevents the setpoint or nominal ratio being changed too

fast. The desired adjustment speed can be set. The time for the change is set from 0 to 100 % here. The setpoint ramp is not active at x-tracking and digital signal tS

oFPA-Parameter tS;

3.4.1 (pg. 55) and

5.4.4 (pg. 163)

Filter for all inputs A 1st order filter can be connected to every analog input. onPA-Parameters t1

to t4; 3.2 (pg. 47) and 5.4.2 (pg. 155)

Root extractor for all controller inputs

A root extractor can be connected before every analog input. Structure switches

S11 to S14; 3.2 (pg.

47) and 5.4.5 (pg.

165)

Linearizer for an input variable

A linearizer with 13 (equidistant) support points and parabolic approximation can be assigned to one of the analog inputs AI1 to AI4 or to the controlled variable x1.

Structure switch S21; 3.10.4 (pg.

118) and 5.4.5 (pg.

165)

Initialization of the display x/w

The controlled variable x and the command variable w can be displayed in physical values.

oFPA-Parameter dA, dE; 3.4.1 (pg. 55) and 5.4.4 (pg. 163)

Limits for the setpoint w

The setpoint can be limited anywhere within the selected measuring range.

oFPA-Parameter SA, SE;

3.4.1 (pg. 55) and

5.4.4 (pg. 163)

Limits of the manipulated variable y

The manipulated variable y can be limited within the setting range –10% and +110 %. (Not in S-controllers with internal feedback)

onPA-Parameter YA, YE; 3.5 (pg. 91) and

5.4.2 (pg. 155)

x-Tracking The setpoint w is tracked to the controlled variable x in

manual-, tracking- and DDC-operation as well as at the safety setpoint.

Structure switch S43; 3.4.1 (pg. 55) and 5.4.5 (pg. 165)

Limit value alarms Any controller-internal variables or inputs can be monitored

for limit values. The output is by way of alarms A1 to A4.

Structure switches S76 and S77; 3.10.3 (pg. 117) and 5.4.5 (pg 165)

Transmitter monitoring

All or specific analog inputs can be monitored for dropping below- or- exceeding the range. In the event of a fault, the four-digit digital display outputs a message selectively for every input. A system fault can be output via the digital output MUF.

Structure switches S4 to S7, S66; 3.2 (pg. 47) and 5.4.5 (pg. 165)

Adaptation of the direction of action

SIPART DR21 operates with normal direction in the factory setting. The direction of the controller can be changed for reversing systems.

Structure switch S46; 3.5 (pg 91) and

5.4.5 (pg. 165)

Restart conditions After mains recovery the controller starts automatically with

the structured operating modes, setpoints and manipulated variables.

Structure switch S82; 3.10.5 (pg.120) and 5.4.5 (pg. 165)

2 Technical Description

2.4 Design

Manual

SIPART DR21

C73000-B7476-C143-08

2.4 Design

D Standard controller

The process controller has a modular structure and is therefore maintenance friendly and easy to convert- and retrofit. The standard controller consists of

- the front module with the control- and display elements

- the backplane module with the power supply unit

- the plastic housing with four slots for optional modules

D Front module

The front module accommodates the control- and display elements, the CPU (Central Processing Unit) and the connectors for the backplane- and options modules.

It is operated by a membrane keyboard with IP64 degree of protection. The front design is based directly on the SIPART DR 20/22/24-controller-family with color coded assignment of the display- and control elements.

For better monitoring of the process, SIPART DR21 has user-friendly analog displays for the setpoint- and actual value display, a four-digit digital display which can be set for setpoint, actual value and alarms (depending on the controller setting), a two-digit digital display for the manipulated variable y, numerous control keys and indicator diodes for various status signals.

The tag plate and the scales for the analog displays are replaceable.

D Backplane module with power supply unit

The following signal connections are accessible through the backplane.

- 2 analog inputs AI1, AI2, potential-bound to GND, 0/4 to 20 mA

- 1 analog output AO, potential-bound to GND, 0/4 to 20 mA

- 2 digital outputs + Δ y, - Δ y, potential-free via relay contacts

- 2 digital inputs DI1, DI2, for 24V-logic, function can be set

- 2 digital outputs DO1, DO2, for 24V- logic, function and direction can be set

- 1 Voltage output L+ to the transmitter supply

The power supply is located in a die-cast housing on the backplane module. The heat loss is transferred to the back of the controller by cooling fins.

A DIN rail can be mounted for connecting a powerful coupling relay module.

The power supply unit is high powered and offers a total 200 mA current for:

- supplying the analog output (0/4 to 20 mA)

- Active digital outputs (up to 6 digital outputs)

- L+-output for supplying two-wire-transmitters

- supplying the interface module

2 Technical Description

2.4 Design

Manual

SIPART DR21 C73000-B7476-C143-08

D Connection technique

The power supply is connected

- for 230 V/115 V AC by a three-pin plug

- for 24 V UC by a special two-pin plug.

On the standard controller the field lines (signal cables) are connected to three functionally combined plug-in screw-type terminals.

The options modules for analog inputs and digital inputs- and outputs have their own terminals which are also designed as plug-in screw-type terminals. The interface module is connected by its own plug.

Figure 2-1 Front view

1 Mains plug 2 Power supply unit 3 Slot1 AI3(I/U,R,P,T) 4 Slot2 AI4(I/U,R,P,T) 5 Slot 3 4DO,24 V or

2DO relay or

5DI 6 Slot 4 SES/PROFIBUS-DP 7DINrail

(scope of delivery of the relay module)

8 Terminal block 1

AI1toAI2(I)

9 Terminal block 2

AO1 DI1toDI2 DO1toDO2 24V L+; M

10 Terminal block 3

Digital outputs ±

Δy

3 4 5 6

Figure 2-2 Rear view

2 Technical Description

2.5 Function principle

Manual

SIPART DR21

C73000-B7476-C143-08

2.5 Function principle

2.5.1 Standard controller

D General

The SIPART DR21 controller operates on the basis of a modern, highly-integrated microcontroller in C-MOS-technology. A large number of functions for controlling processing plants are stored in the instrument’s ROM. The user can adapt the controller to the task himself by configuring it.

D Analog inputs AI1 and AI2.

The analog inputs of the SIPART DR21 are designed for 0/4 to 20 mA input signals. The inputs have an input load resistance of 248 Ω and are potential-bound. The start value 0 mA or 4 mA is determined by the structure switches S4 and S5.

D Outputs for the manipulated variable Y

The standard controller has the following outputs

K-output: switchable between 0 or 4 to 20 mA, potential-bound (S56) S-output: two relays, NOC, interlocked in factory setting, built-in spark quenching de-

signed for wiring with medium contactors. Other functions can be assigned to the relay outputs by configuration (structure switches S57 to S68), e.g. manipulated variable output ±Δy in S-controllers.

D Digital outputs DO1 and DO2

The digital outputs are short-circuit-proof and can drive commercially available relays or the interface relays 6DR2804-8A/8B directly. Different functions can be assigned to the digital outputs by configuration (structure switches S57 to S68).

D Digital inputs DI1 and DI2

The inputs are designed in 24-V-logic and are potential-bound. The function is assigned to the input by configuration of the controller (structure switches S23 to S33).

D CPU

The microcontroller used has integrated AD- and DA-converters and watchdog-circuits for cycle monitoring. The processor operates with a 64k EPROM (on a socket and therefore replaceable) and a 1k RAM.

The SIPART DR21 program runs with a fixed cycle time of 100 ms. A process image is generated at the start of every routine. The analog- and digital inputs, the operation of the front keyboard and the process variables received by the serial interface are acquired or accepted. All calculations are made according to the stored functions with these input signals. Then output to the display elements, the analog outputs and the digital outputs and

2 Technical Description

2.5 Function principle

Manual

SIPART DR21 C73000-B7476-C143-08

storage of the calculated variables for transmission mode of the serial interface take place. In S-controllers, the program run is interrupted every 5 ms to be able to switch off the S-outputs for better resolution. The interface communication also runs in interrupt mode.

D Power supply unit

A cast, overload-protected mains transformer for 115 V or 230 V AC built into a heat sink or a primary clocked plug-in type power supply unit for 24 V UC built into a heat sink generates the secondary internal supply voltages +24 V, +5 V and U

ref

from the power supply. The

metal body rests on protective conductors (protection class

I).

The power supply and internal supply voltages are isolated from each other by safe separation. The internal supply voltages are function low voltages. Since no other voltages are generated in the instrument, these statements apply to all field signal lines with the exception of relay connection lines (used standards see chapter 2.6 Technical data, page 34).

D Configuring

The controller has a large number of prepared functions for controlling processing plants. The user programs the instrument himself by selecting the desired functions or setting parameters by setting structure switches. The total functioning of the instrument is given by the combination of the individual structure switches or parameter settings. No programming knowledge is necessary (see Operation, chapter 5, page 149).

All settings are made without exception on the front operating panel of the SIPART DR21 or the serial interface.

The job-specific program written in this way is saved in the non-volatile user program memory.

The instrument is configured as a fixed value controller in the factory setting. This setting can be restored with the ”APSt”-function at any time.

The following parameterization- and structuring modes are available for configuring the SIPART DR21 controller.

onPA The transmission properties of the controller and with these the process course

are determined with the online-parameters. They can be changed during control operation (online)

oFPA The offline-parameters determine the basic functions such as display elements,

limit values, safety values. The controller is blocked (offline) while they are being set, the last value of the manipulated variable is held.

StrS The instrument structure, e.g. fixed value controller or follow-up controller is de-

termined with the structure switches. The controller is blocked (offline) while they are being set, the last value of the manipulated variable is held.

APSt The all preset-function restores the factory setting.

2 Technical Description

2.5 Function principle

Manual

SIPART DR21

C73000-B7476-C143-08

(AdAP) In the adaptation level the output conditions for automatic adaptation of the con-

troller parameters to the process is preset and adaptation started.

(CAE3) The measuring range is set and fine adjustment made if necessary here for the

UNI-module. The CAE3-menu is only displayed if it has been released in the structuring level (structure switch S6>3).

2.5.2 Option module

The following option modules are described in this chapter

6DR2800-8J I/U-module 6DR2800-8R R-module 6DR2800-8V UNI-module 6DR2805-8A reference point 6DR2805-8J measuring range plug 6DR2801-8D module with 2 DO (relay) 6DR2801-8E module with 2 DI and 4 DO 6DR2801-8C module with 5 DI 6DR2803-8P serial interface PROFIBUS-DP 6DR2803-8C serial interface RS 232/RS 485 6DR2804-8A module with 4 DO relays 6DR2804-8B module with 2 DO relays

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 module’s input amplifier is designed as a differentiating amplifier with shuntable 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. For voltage inputs this circuit technique makes it possible to suppress the voltage drops on the ground conductor by two-pole wiring on potential-bound voltage sources. 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 transmitters. A constant current of Is = 5 mA is fed to the potentiometer wiper. The wiper resistance is therefore not included in the measurement. Resistors are switched parallel to the potentiometer by settings on the module and a rough range selection made. Start of scale and -- full scale are set with the two adjusting pots on the back of the module.

2 Technical Description

2.5 Function principle

Manual

SIPART DR21 C73000-B7476-C143-08

This fine adjustment can be made on the displays on the front module (if structured appropriately). 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 transmitters which cannot withstand the 5 mA wiper current or which have a rated resistance >1 kΩ. 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- or 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 StrS-level (structure switches S6, S8, S9 and S10), the measuring range and the other parameters are set in the CAE3-menu. The sensor-specific 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.

The signal lines are connected by a plug terminal block with screw-type terminals. When using thermocouples with internal reference point, this terminal block must be replaced by the terminal 6DR2805-8A. With the measuring range plug 6DR2805-8J in place of the terminal block, the measuring range of the direct input (0/20 to 100 mV) can be extended to 0/2 up to 10 V or 0/4 up to 20 mA.

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.

The UNI-module can only be used at slot 1 (AI3).

6DR2805-8A Reference point

D Terminal with internal reference point for thermocouples

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

2 Technical Description

2.5 Function principle

Manual

SIPART DR21

C73000-B7476-C143-08

6DR2805-8J Measuring range plug

D Measuring range plug for current 0/4 to 20 mA or voltage 0/2 to 10 V

The measuring range plug is used in connection with the UNI-module to measure current- or voltage. The input variable is reduced to a signal range of 0/20 to 100 mV by a voltage divider or shunt resistors in the measuring range plug.

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 range plug is used.

6DR2801-8D 2 DO 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 restand 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.

CAUTION

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 2 DI and 4 DO

D Digital signal module with two 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 in 24-V-logic and are potential-bound. The functions are assigned to the inputs- and outputs by configuration of the controller. (Structure switches S23 to S33, S58toS68).

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

2 Technical Description

2.5 Function principle

Manual

SIPART DR21 C73000-B7476-C143-08

6DR2801-8C 5 DI

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 in 24-V-logic and are potential-bound. The function is assigned to the input by configuration of the controller (structure switches S23 to S33).

6DR2803-8P serial interface PROFIBUS-DP

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

This options card can be used in all SIPART-DR-instruments in slot 4. The following settings must be made with the appropriate structure switches for the serial interfaces.

- Interface on

- Even parity

- LRC without

- Baud rate 9600

- Parameters/process values writable (as desired)

- Station number of choice 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 structure 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.

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

A technical description including the controller-base-file (*.GSD) is available in Internet for creating a master-slave-linking software for interpreting the identifications and useful data from and to the SIPART-controller. Internet address: www.fielddevices.com [Edition: 05.2000])

The SIPART S5 DP and SIPART S7 DP programs are offered for DP-masters SIMATIC S5 and S7.

2 Technical Description

2.5 Function principle

Manual

SIPART DR21

C73000-B7476-C143-08

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

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

Can be used in slot 4, the structure switches S84 to S91 must be set for the transmission procedure.

For connecting the controller SIPAR T DR21 to a master system for control and monitoring. All process variables can be sent, the external setpoint, tracking variable, operating states, parameters and structurings sent and received via the interface.

Interface communication can take place:

RS 232 as a point-to-point connection

SIPART Bus The SIPART bus driver is no longer available.

Therefore, please realize multi--couplings 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 and RS 485 with a plug-in bridge.

A detailed technical description of the data communication for creating a linking software is available in Internet under www.fielddevices.com [Edition 05.2000].

Rxd/ Txd B

Rxd/ Txd A

24 V

Txd

Rxd

-1

+7.5 V

-7.5 V

+7.5V

-7.5 V

-7.5V

Rxd

Txd

Other connections: NC

24 V

Txd

Rxd

Other connections: NC

Rxd/ Txd

NC2, 7

+7.5 V

+7.5V

SIPART

bus

RS 485

RS 485+150R

RS 232

Figure 2-3 Block diagram serial interface in

RS 232/SIPART BUS

Figure 2-4 Block diagram serial interface at

Interface RS 485

2 Technical Description

2.5 Function principle

Manual

SIPART DR21 C73000-B7476-C143-08

6DR2804-8A module with 4 DO-relays 6DR2804-8B module with 2 DO-relays

D Coupling relay module with 2 or 4 relays

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

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

One or two relay modules are installed per version. Each of these modules consists of two relays with quench diodes parallel to the control winding. 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 the rest and working circuits can be switched. The relays can be controlled directly from the controller’s digital outputs by external wiring.

CAUTION

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 double 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.

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

2.6 Technical Data

2.6.1 General data

Installation position any

Climate class to IEC 721

Part 3--1 Storage 1k2 Part 3--2 Transport 2k2 Part 3--3 Operation 3k3

--25 t o + 7 5 _C

--25 t o + 7 5 _C 0to+50_C

Type of protection according to EN 60529

Front Housing Connections

IP64 IP30 IP20

Housing design

D Electrical safety

-- acc. to DIN EN 61 010 part 1,

-- Protection class I acc. to IEC 536

-- Safe disconnection between mains connection and field signals

-- Air and creep lines, unless specified otherwise, for overvoltage class III and degree of contamination 2

D EC Declaration of Conformity No. A5E00065058I--01

-- Conformity The product described above in the form as delivered is in conformity with the provisions of the following European Directives:

2004/108/EC EMC

Directive of the European Parliament and of the Council on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC

2006/95/EC LVD

Directive of the European Parliament and of the Council on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits.

D Spurious emission, interference immunity according to EN 61 326, NAMUR NE21 8/98

Weight, standard controller approx. 1.2 kg

Color

Front module frame Front surface

RAL 7037 RAL 7035

Material

Housing, front frame Front foil Backplanes, modules

Polycarbonate, glass-fiber reinforced Polyester Polybutylenterephthalate

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

Connection technique

Power Supply

1 15/230 V AC 24 V UC

Field signals

Three-pin plug IEC320/V DIN 49457A Special 2-pin plug Plug-in terminals for 1.5 mm

AWG 14

Installation depth necessary for changing the main board and modules

relay module 6DR2804-8A/B

Figure 2-5 Dimensions SIPART DR21, dimensions in mm

Number of Cut-out controllers width b

Under consideration of the permissible ambient temperature, tight installation one above the other is allowed

Figure 2-6 Panel cut-outs, dimensions in mm

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

2.6.2 Standard controller

Power Supply

Rated voltage 230 V AC 115 V AC 24 V UC

switchable

Operating voltage range 195 to

264 V AC

97 to 132 V AC

20 to 28 V AC

20 to 35 V DC

Frequency range 48 to 63 Hz -- -- --

External current I

Ext

200 mA

Power consumption

Standard controller without options without I

Ext

active power/apparent

power (capacitive) Standard controller with options

without I

Ext

active power/apparent

power (capacitive) Standard controller with options with

Ext

active power/apparent power

(capacitive)

5W/9VA

11 W/ 15 VA

15 W/19 VA

5W/9VA

11 W/ 15 VA

15 W/19 VA

4W/6VA

8.5W/12VA

12 W/17 VA

8.5 W

12 W

Permissible voltage breaks based on

0.85 U

and max. load

Time

≤20 ms ≤20 ms ≤20 ms ≤20 ms

including harmonic

current transmitted from L+, DO, AO to external loads

The load voltages of the AO are reduced hereby to 13 V, L+ to 15 V and the DO to 14 V

Table 2-1 Power supply standard controller

Analog inputs AI1 to AI2

Current

Rated signal range 0/4 to 20 mA Modulationrange -0.1to22mA Input resistance

Difference (load) 248 Ω ± 1%

Filter time constant 10 ms Zero error see AD-converter Full scale error see AD-converter Linearity error see AD-converter Temperature influence see AD-converter Static destruction limit ±40 mA Parameterizable transmitter fault message

AI1/2 0 mA to 20 mA

4mAto20mA

≤-0.5 %; ≤-2.5 %;

≥106.25 % ≥106.25 %

AI3/4 0/4 mA to 20 mA ≤-2.5 %; ≥106.25 %

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

Digital inputs DI1, DI2

Signal status 0 ≤ 4.5 V or open Signal status 1 ≥ 13 V Input resistance ≥ 27 kΩ Static destruction limit  35 V

NOTE

All error specifications refer to the rated signal range

Analog outputs AO

Rated signal range (0 to 100 %) 0 to 20 mA or 4 to 20 mA Modulation range 0 to 20.5 mA or 3.8 to 20.5 mA Load voltage from --1 to 18 V No-load voltage ≤ 26 V Inductive load ≤ 0.1 H Time constant 10 ms Residual ripple 900 Hz ≤ 0.2 % Resolution ≤ 0.1 % Load dependence ≤ 0.1 % Zero error ≤ 0.3 %

Full scale error ≤ 0.3 %

Linearity ≤ 0.05 % Temperature influence

Zero point Full scale

≤ 0.1%/10K ≤ 0.1%/10K

Static destruction limit --1 to 35 V

S-output (relay 230 V) DO7 and DO8

- Contact material Ag / Ni

- Contact load capacity

Switching voltage

AC DC

≤ 250 V ≤ 250 V

Switching current Contacts Contacts

locked

unlocked

AC DC

≤ 8A ≤ 2.5 A ≤ 8A ≤ 2.5 A

Rating

AC DC

≤ 1250 VA ≤30 W at 250 V ≤100 W at 24 V

Applies for interference acc. to IEC 801-3 to 3 V/m, with 10 V/m at 290 to 310 MHz ≤4.3 %

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

Service life

mechanical 230 V AC 8A electrical ohmic

2 ¢ 10

switching cycles

Spark quenching element Series circuit 22 nF/220 Ω parallel to it

varistor 420 V

rms

Digital outputs DO1 to DO2 (with wired-or diodes)

Signal status 0 ≤1.5 V Signal status 1 +19 V to 26 V load current ≤30 mA

Short-circuit current ≤50 mA Static destruction limit -1 V to +35 V

Measuring transmitter feed L+

Ratedvoltage +20to26V load current ≤ 60 mA, short-circuit-proof Short-circuit current ≤ 200 mA clocking Static destruction limit --1 to +35 V

CPU data

Cycle time 100 ms Minimum integration speed dy

kp ⋅ xd

0.1 ⋅ 0.1 % 10

A/D conversion except UNI module 6DR2800-8V

Procedure Successive approximation per input > 120

conversions and averaging within 20 or

16.67 ms Modulation range -5 % to 105 % of the modulation range Resolution 11 bits ≙ 0.06 % of the modulation range Zero error ≤ 0.2 % of the modulation range Full scale error ≤ 0.2 % of the modulation range Linearity error ≤ 0.2 % of the modulation range Temperature influence

Zero point ≤ 0.05 %/10 K of the modulation range Full scale ≤ 0.1 %/10 K of the modulation range

Setpoint- and manipulated variable adjustment

Setting With 2 keys (more - - less) Speed progressive Resolution wi

1 digit

0.1%ofratedrange0to20mA

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

Parameters

Setting With two keys (more -- less)

Speed progressive

Resolution

Linear parameters, % ≤0.1 % Linear parameters, physical 1 digit

Logarithmic parameters 128 values/octave Accuracy Time parameters 2%

All others Resolution accordingly, absolute

Display technique

-- x- and w-Digital display 4digit 7-segment LED

Color red

Digit height 7 mm

Display range Adjustable start and end

Number range --1999 to 9999

Overrun <--1999: --oFL

>9999: oFL Decimal point adjustable (fixed point) _.- ----- to -------Refresh rate Adjustable 0.1 to 9.9 s Resolution 1 digit but not better than AD-converter Display error corresponding to AD-converter and analog

inputs

-- x- and w-Analog display LED array vertical 30 LEDs

Color x

red

green Display range 0 to 100 % Overrun flashing first or last LED Refresh rate cyclic Resolution 1.7 % by alternate glowing of 1 or 2 LEDs,

the center of the illuminated field serves as

a pointer

-- y-display (digital) 2digit 7-segment-LED Color red Digit height 7 mm Display range 0 to 100 % Overrun -9 % to 109 %, display >99 % h0 to h9 Refresh rate Adjustable 0.1 s to 9.9 s Resolution 1 %

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

2.6.3 Option module

6DR2800-8J/R Analog inputs AI3 (slot 1), AI4 (slot 2)

Signal converter for

Order number:

Current

6DR2800-8J

Volta ge

6DR2800-8J

Resistance potentiomet er 6DR2800-8R

Range start

Min. span (100 %)

Max. zero point suppression Range full scale Dynamic range

0or4mA

20 mA

--4to115%

0Vor2V

or 199.6 mV

10 V, 998 mV

--4to115%

0 Ω

ΔR ≥ 0.3 R

RA ≤ 0.2 R

1.1 R

--4to115%

Transmitter fault message MUF --2,5 % ≥ MUF ≥ 106.25 % Input resistance

Difference

Common mode Permissible common mode voltage Supply current Line resistance

Three-wire-circuit

49.9 Ω 0.1 % 500 kΩ 0to+10V

200 kΩ ≥ 200 kΩ 0to+10V

5mA5%

per < 10 Ω Filter time constant 20 % 50 ms 50 ms 50 ms

Error

Zero point Gain Linearity Common mode

≤ 0.3 % ≤ 0.5 % ≤ 0.05 % ≤ 0.07 %/V

≤ 0.2 % ≤ 0.2 % ≤ 0.05 % ≤ 0.02 %/V

≤ 0.2 %

Influence of temperature

Zero point Gain

≤ 0.05 %/10 K ≤ 0.1%/10K

≤ 0.02 %/10 K ≤ 0.1%/10K

≤ 0.1%/10K

≤ 0.3%/10K

Static destruction limit

between the inp. referenced to M

40 mA  35 V  500 V

 35 V  35 V  500 V

 35 V

 500 V

Start of measuring by structuring

Without errors of A/D-converter

with R = RA +ΔR + RE adjustable in three ranges: R = 200 Ω, R = 500 Ω, R = 1000 Ω

Table 2-2 Technical data for module 6DR2800-8J/R

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

6DR2800-8V UNI-module Analog input AI3 (slot 1)

Analog input AI3

Pt100 R R

Slot 1 C R ≤ 600 Ω R ≤ 2.8 kΩ

StartofscaleMA Full scale ME

≥-175 mV

≤+175 mV

≥-175 mV

≤+175 mV

≥-200 C

≤+850 C

≥0 Ω

≤600 Ω

≥0 Ω

≤2.8 kΩ

Span Δ =ME--MA parameterizable 0 to Δmax

Min. recommended span 5mV 5mV 10 K 30 Ω 70 Ω

Transmitter fault message MUF

-2.5 % ≥ MUF ≥ 106.25 %

Input current ≤1 μA ≤1 μA -- -- --

Supply current -- -- 400 μA 400 μA 140 μA

Potential isolation

Test voltage 500 V AC

Perm. common mode voltage ≤50 V UC ≤50 V UC -- -- --

Line resistance

2L: RL1+RL4 ≤1kΩ ≤300 Ω ≤50 Ω -- --

3L: (RL1) = RL2 = RL4 -- -- ≤50 Ω -- --

4L: RL1 to RL4 -- -- ≤100 Ω -- --

Open loop signaling without ≥500 to

550 Ω

all

terminals

Open loop between

Terminal 2--3

Error

Transmission ±10 μV ±10 μV ±0.2 K ±60 mΩ ±200 mΩ

Linearity ±10 μV ±10 μV ±0.2 K ±60 mΩ ±200 mΩ

Resolution/noise ±5 μV ±2 μV ±0.1 K ±30 mΩ ±70 mΩ

Common mode ±1 μV/10 V ±1 μV/10 V -- -- --

Internal reference point -- ±0.5 K -- -- --

Temperature error

Transmission

±0.05 %/10 K

Internal reference point -- ±0.1K/10K -- -- --

Static destruction limit ±35 V ±35 V -- -- --

Cycle time 100 ms 200 ms 300 ms 200 ms 200 ms

Filter time constant adaptive

<1.5 s <2 s <2 s <1.5 s <1.5 s

20 mA, 10 V with measuring range plug 6DR2805-8J

Types, see structure switches, internal reference point (plug-in terminal block) 6DR2805-8A

Reference to parameterizable span Δ=ME--MA

In series with adaptive filter changeable by time constant t3 (onPA)

Table 2-3 Technical data for UNI-module 6DR2800-8V

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

6DR2805-8J Measuring range plug 20 mA/10 V

-- 20 mA

conversion to 100 mV

±0,3 %

Load terminal 1--2 50 Ω

1--3 250 Ω

Stat. destruction limit

±40 mA

-- 10 V

divider to 100 mV

±0,2 %

Input resistance 90 kΩ Statistical destruction limit

±100 V

6DR2801-8D 2DO Relay

35 V

Digital outputs DO3 and DO4 (slot 3)

-- Contact material Ag / Ni

-- Contact load capacity

Switching voltage

AC DC

≤ 35 V ≤ 35 V

Switching current

AC DC

≤ 5A ≤ 5A

Rating

AC DC

≤ 150 VA ≤ 100 W at 24 V ≤ 80 W at 35 V

-- Service life

mechanical 2x10

switching cycles

electrical

24 V/4 A ohmic 24 V/1 A inductive

2x10

switching cycles

2x10

switching cycles

-- Spark quenching element

Series circuit 1 μF/22 Ω parallel to it varistor 75 Vrms

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

6DR2801-8E 4DO 24 V, 2DI Digital outputs DO3 to DO6 and DI3 to DI4 (slot 3)

-- Digital outputs

Signal status 0 ≤ 1.5 V or open, residual current ≤ 50 μA Signal status 1 19 to 26 V load current ≤ 30 mA Short-circuit current ≤ 50 mA, clocking Static destruction limit --1 V to +35 V

-- Digital inputs

Signal status 0 ≤ 4.5 V or open Signal status 1 ≥ 13 V Input resistance ≥ 27 kΩ Static destruction limit  35 V

6DR2801-8C 5DI 24 V Digital inputs DI3 to DI7 (slot 3)

Signal status 0

≤ 4.5 V or open

Signal status 1

≥ 13 V

Input resistance

≥27 kΩ

Statistical destruction limit ±35 V

6DR2803-8P PROFIBUS-DP

Transmittable signals RS 485, PROFIBUS-DP-protocol Transmittable data Operating state, process variables, para-

meters and structure switches

Transmission procedure PROFIBUS-/ DP-protocol

According to DIN 19245, Part 1 and Part 3 (EN 50170)

Data rate 9.6 kbit/s to 1.5 Mbit/s

except 45.45 kBit/s Station number 0 to 125 Time monitoring of the data communication structurable on the controller in connection

with DP-watchdog Electrical isolation between Rxd/Txd-P/-N and

the controller 50 V UC common mode voltage Test voltage 500 V AC Repeater-control signal CNTR-P TTL-level with 1 TTL-load

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

Supply voltage VP (5 V) 5 V -0.4 V/+0.2 V; short-circuit-proof line lengths, per segment at 1.5 Mbit/s 200 m, see ET 200-Manual 6ES5 998-

3ES12 for further details

6DR2803-8C Serial interface

Transmittable signals RS 232, RS 485 or SIPART BUS *) shun-

table Transmittable data Operating state, process variables, para-

meters and structure switches Transmission procedure According to DIN 66258 A or B Character format 10 bits (start bit, ASCII-characters with

7 bits, parity bit and stop bit) Hamming-distance h 2 or 4 Data rate 300 to 9600 bit/s Transmission Asynchronous, semiduplex Addressable stations 32 Time monitoring of the data communication 1 s to 25 s or without Electrical isolation between Rxd/Txd

and the controller

max. common mode voltage Test voltage

50 V UC

500 V AC

RS 232 RS 485

Receiver input Rxd

Signal level 0 Signal level 1

Input resistance

0to+12V

-3 to -12 V

13 kΩ

UA>UB,+0.2to+12V

A<UB

,-0.2to-12V

12 Ω

Send output Txd

Signal level 0 Signal level 1

+5 to +10 V

-5 to -10 V

UA>UB,+1.5to+6V

A<UB

,-1.5to-6V

Load resistance ≤ 1.67 mA 54 Ω

Signal status 1 is the rest status

Input protected with 14 V Z-diode, higher voltages with current limiting to 50 mA possible.

Line capacitance and lengths

at 9600 bits/s

Line capacitance Reference values line lengths

Ribbon cable without shield Round cable with shield

RS 232 pointto-point

≤2.5 nF 50 m 10 m

RS 485 bus ≤250 nF 1,000 m 1,000 m

SIPART bus operation is no longer possible! The bus driver is no longer available!

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21 C73000-B7476-C143-08

6DR2804-8A/B Coupling relay 230 V

1 relay module 6DR2804-8B 2 relay modules 6DR2804-8A per relay module 2 relays with 1 switching contact each with

spark quenching element

- Contact material Silver-cadmium oxide

Switching voltage

AC ≤ 250 V DC ≤ 250 V

Switching current

AC ≤ 8A DC ≤ 8A

Rating

AC ≤ 1250 VA DC ≤30 W at 250 V

≤100 W at 24 V

- Service life

mechanical 2×10

switching cycles

electrical AC 220 V, ohmic 2×10

/I(A) switching cycles

- Spark quenching element Series circuit 22 nF/220 Ω parallel

plus varistor 420 V

rms

- Exciter winding

Voltage +19 to +30 V resistance 1.2 kΩ 180 Ω

- Electrical isolation between

Exciter winding -- contacts Relay module – relay module (6DR2805-8A)

Safe isolation

by reinforced isolation, air-

and creep lines for overvoltage class III

and degree of contamination 2

contact -- contact of a relay module

Safe isolation1)by reinforced insulation,

air- and creep lines for overvoltage class II

and degree of contamination 2

according to DIN EN 61010 Part 1

- Type of protection

Housing IP50 according to DIN 40050 Connections (in plugged state) IP20 according to DIN 40050

2 Technical Description

2.6 Technical Data

Manual

SIPART DR21

C73000-B7476-C143-08

- Housing material Polyamide 66

- Mounted on rail NS 35/7.5 DIN EN 50022

NS 35/15 DIN EN 50035

NS 32 DIN EN 50035

- Dimensioned drawing see fig. 2-7

3 2 1

8 7

NS 35/15

Center of the mounting rail

139

136

100

130

131.5

NS 32

NS 35/7.5

6 5 4

Figure 2-7 Dimensioned drawing coupling relay, dimensions in mm

3 Functional description of the structure switches

3.1 General

Manual

SIPART DR21 C73000-B7476-C143-08

3 Functional description of the structure switches

3.1 General

The controller is adapted to the respective job by structure switches. The factory setting corresponds to the most usual setting of the individual functions so that only few structure switches usually need to be set selectively during commissioning. However, it is recommendable to compare the compatibility of the individual structure switch settings with the task in any case.

The structure switches S1 and S2 are fundamentally important. 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 tracking variables as well as the manipulated variable output determined as a K- or S-output.

The functions of structure switches S3 to S81 correspond to the logical order of signal processing. S82 and S83 describe the restart conditions, S84 to S91 the transmission procedure of the serial interface.

The structure switches are described in this order in the following description.

NOTE

The control elements on the front are shown on page 5 and specified by the digits in the text in brackets. The structure switches are designated by S**.

3.2 Analog input signal processing (S3 to S21)

see fig. 3-1, page 49

Each of the maximum 4 analog inputs is fed through an AD-converter which performs the 50 or 60 Hz interference suppression (S3) by averaging over 20 or 16 2/3 ms. Then standardization to 0 to 100% calculated value takes place per channel of the signal range 0 to 20 mA or 4 to 20 mA. The UNI-module is structured with S6> 3 and S8 determines its input signal. S9 determines the thermocouple type when a thermocouple input is chosen. The temperature unit for PT100- or thermocouple signals is determined with S10.

At the same time S4 to S7 decide whether operation is to take place with or without range monitoring (transmitter fault). A separate AD-converter routine without averaging is responsible for monitoring so that the manual mode which is possible with S50 comes into action bumplessly in the event of a transmitter fault. The monitor signals per channel on dropping below -2.5% or exceeding +106.25 % with a hysteresis of 0.25 % on the digital x/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 figure 3-1, page 49 and chapter 3.8, page 111). 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 selected analog inputs are back in the working range.

3 Functional description of the structure switches

3.2 Analog input signal processing (S3 to S21)

Manual

SIPART DR21

C73000-B7476-C143-08

After range monitoring, the 4 analog inputs are each fed through a 1st order filter (parameters t1 to t4 can be set in the parameterization mode onPA). The factory setting is 1 s.

Now the root of every channel can be extracted with S11 to S14 and they can be linearized with S21. This allows non-linear process variables to be represented physically correctly as well (see chapter3.10.4 (page 118 for function principle) setting of the 13 vertex values, see fig. 3-35, page 1 19).

The controllers-, manipulated- or disturbance variables to be processed for the controller types (S1) can be acquired with S15 to S20 from the 4 analog inputs.

The disturbance variable z is connected either by the D-element or directly to the controller output (S47). y

serves as a tracking input for the manipulated variable in K-controllers (S2=0) or

S-controllers with external feedback (S2=3) and y

as a manipulated variable feedback in S-controllers with internal feedback (S2=2) or as a position feedback in S-controllers with external feedback (S2=3).

The controllers- or process variables are available for assignment to the analog output (S6) and the limit value signal (S76 to S80) and can be read in via the SES. With this input structure most control tasks can be solved in connection with the different controller types and controller output structures.

3 Functional description of the structure switches

3.2 Analog input signal processing (S3 to S21)

Manual

SIPART DR21 C73000-B7476-C143-08

Slot 1

S6< 4

4to20mA

0, 1

2, 3

S11

tF1

AI1

+1/2

--1/ 1

AI2

+1/4

--1/ 3

S21

4to20mA

0, 1

2, 3

S12

tF2

S21

4to20mA

0, 1

2, 3

S13

tF3

S21

S6≥4

S8, S9

Slot 2

4to20mA

0, 1

2, 3

50 Hz 60 Hz

S21

S14

S21

tF4

50 %

0,2

1,3

4,5

6,7

0,2

1,3

0,2

1,3

--3 106

x/w display

Transmitter fault-

signaling

1234

S21

0/1/2/3/4

S15

S16

S17

x3/w

S18

S19

S20

MUF

AI3

I, U, R

AI4

I, U, R

0/2/3/4/5

0/1/3/4/5

0/1/2/4/5

0/1/2/3/5

0, 2

UNI

AI1

AI2

AI3

AI4

AI2A

AI1A

AI3A

AI4A

Figure 3-1 Analog input signal processing

3 Functional description of the structure switches

3.3 Digital input signal processing (S23 to S41)

Manual

SIPART DR21

C73000-B7476-C143-08

3.3 Digital input signal processing (S23 to S41)

D Assignment and direction of effect of the digital inputs (S23 to S40)

see figure 3-2, page 52

The control signals CB, He ...bLS, bLPS, tSH are assigned by the structure switches S23 to S33, S92 to the digital inputs DI1 to DI7 or the Lo status. The High status is also possible when assigning CB (S23) and P (S27). The control signals can be negated optionally by the structure switches S34 to S40.

The digital inputs DI1 and DI2 of the standard controller can be extended by DI3 to DI7 for example with the option module 5DI (6DR2801-8C) in slot 3 (S22 = 2).

When using the module 4DO 24 V + 2DI (6DR2801-8E) it is possible to extend by two (DI3, DI4) inputs (S22=1).

When using option modules in slot 3, structure switch S22 must be set according to the assignment, otherwise there will be an error message (see chapter 5.5, page 179 ).

All digital inputs can be read by the SES.

D Linking the digital inputs DI1 to DI7 with the control signals via the SES.

(S41, S42, S51 and S85)

see figure 3-3, page 53

The control signal CB (S23) may be available at the digital input (S41) either as a static signal or as a pulse (key operation on control desk). Every positive edge trips the flip-flop when selecting the pulse input. In the following descriptions the output status of the flip-flop is assumed as CB.

All control signals (bLb as of software --B3, tSH as of software --B5) can also be specified in S85 = 2, 3, (4, 5)

via the SES and or-linked with the corresponding control signals by the digital inputs. Since the top operation hierarchy in a computer link should be with the autarchic single controller, the control signals can be switched off by the SES by rounding with RC = Int

∧ CB via the Internal/External key (16) of the controller or via CBES(optionally

time-monitored) or via CB

(central Computer Fail line) .

In addition the internal flip-flop can be activated at S85 = 2 to 5 parallel to pressing the keys via I nt

The CB-signal is formed at S85 = 2, (4)

as an OR-function of CBESvia the serial interface

and CB

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

as of software version --A5

3 Functional description of the structure switches

3.3 Digital input signal processing (S23 to S41)

Manual

SIPART DR21 C73000-B7476-C143-08

At S85 = 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.

At the same time, S85 switches over the sources for the external setpoint w

or wEAand

for the tracking manipulated variable y

or yN. The depth of intervention is determined additionally by the serial interface. This makes it possible to specify the process variables analogly for example and the corresponding status signals via the SES.

The function RC = Int

∧CB (computer operation) also controls the command variable switching in the controller types S1 = 0 to 4, i.e. also in SPC-operation or the disturbance variable switching in DDC-operation (see chapter 3.4, page 55).

The two controller types S1 = 5/6 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 linking to control systems).

At S41 = 0 a static switchover by the logic function RC = Int

∧CB takes place. In the case of the preset to Int (Internal LED (17) 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

-LED (18) (C =CB,CB=1≙ C LED off). The

computer standby of the controller is signaled negated as a message signal RB

= Int. Com-

puter operation RC is also signalled negated as a message signal RC =

Int

∧CB

At S41 = 1 static switching with acknowledgement takes place. Every time the computer is recovered (CB from 0 ! 1) If the internal flip-flop is set to 1 (internal LED on, C

LED off), so

that computer operation RC = Int

∧CB only becomes effective after pressing the internal key

(Int = 0).

With S42 = 0/2 the internal/external key is set out of order and only internal- or external operation is pre-selected.

The control signal H is generated as an OR-function by the Manual-/Automatic key (11) 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 S51 Automatic-/Manual switching can be blocked at the controller front (S51 =1 only Automatic or S51 = 2 only Manual. It is still possible to switch to manual operation by He in the ”Only Automatic” position. The Manual LED (12) always indicates the active status (see also chapter 3.6, page 94).

At S51 = 0 to 2, He is connected statically by both the SES and the digital inputs. At S51 = 3/4 the connection is made dynamically, i.e. every positive edge causes manual-automatic-manual operation switching. In addition, with structure switch S51 = 4 the locking of He

with RC =Int∨CB is released.

as of software version --A5

3 Functional description of the structure switches

3.3 Digital input signal processing (S23 to S41)

Manual

SIPART DR21

C73000-B7476-C143-08

3/1 3/2

3/3

3/4

3/5

1/5 1/6

3/1 3/6

DI1

DI3

DI4

DI5

DI6

DI7

DI3 DI4

Assignment with structure switches

1 2

3 4

5 6 7

3 4

5DI S22=2

4DO+2DI S22=1

Slot 3

S24

S25

S26

S27

S29

S30

S31

S32

S33

S23

iDI

-yBL

+yBL

S34

S35

S36

S37

S38

S39

S40

S28

bLb

bLS

bLPS

only for CB (S23) and P (S27)

as of software --B5

24 V

DI2

24 V

Structure-

switch setting

S92

tSH

S39

--1

Figure 3-2 Assignment and direction of action of the digital inputs S23 to S40

3 Functional description of the structure switches

3.3 Digital input signal processing (S23 to S41)

Manual

SIPART DR21 C73000-B7476-C143-08

0/2 (3/4)

S51

0/1

0,1,2,3

S51

2/3/(4/5)

S51

3/4

0/1/2

S51

3/4

0/1/2

2/3 (4/5)

S85

0,1

2/3 (4/5)

0/1

S85

S41

3/5

S85

02S42

0/1

2/3 (4/5)

S85

0,2

S41

≥

S51

0,1(3/4)

tSH

≥

Si bLb bLS bLPS P N tS PAU +yBL

-yBL

tSH

0/1

≥

2/3 (4/5)

S85

0/1

≥

2/3 (4/5)

S85

0/1

SES

bLb

bLS

bLPS

+yBL

-yBL

tSH

RC=Int∧CB not for S1 = 4 Control unit/processdisplay

≥

0/1/2/4

≥

RB =Int

--1

as of software version --A5

as of software version --B3

as of software version --B5

as of software version --C1

bLb

Int

S85

S84

0/1

Figure 3-3 Linking the digital inputs DI1 to DI7 with the control signals via the SES (S41, S42, S51, S85)

3 Functional description of the structure switches

3.3 Digital input signal processing (S23 to S41)

Manual

SIPART DR21

C73000-B7476-C143-08

D Functional explanation of the control signals

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 Tracking

With this signal the output of the K-controller and the three-position-stepper controller with external position feedback is tracked to the tracking signal y

Si Safety operation

In K-controllers and three-position-stepper controllers with external position feedback, the manipulated variable adopts the parameterized safety value. In three-position-stepper controllers with internal feedback the manipulated variable runs independently of the safety setting value to a defined limit position.

bLS Blocking structuring

The whole configuration is blocked with the exception of the online parameterization level.

bLPS Blocking parameterization and structuring

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

bLb Blocking operation

This signal blocks the entire front panel operation of the instrument.

P P-Operation controller

With this signal the controller is switched to P-operation.

setpoint ramp

The set setpoint ramp time can be made ineffective with this signal (tS

= High ≙ ramp switched off).

tSH setpoint hold (setpoint ramp)

The setpoint change is stopped with this signal. The setpoint change continues when the signal is reset.

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.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

3.4 Controller types (S1, S42 to S45)

3.4.1 General, recurrent functions

D 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 (14, 15) 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 quickly. After every interruption in the adjustment by releasing the keys, the progression starts again with the smallest adjustment step.

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

Every time the internal setpoint can be adjusted by the keys (7, 8) 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, the automatic-manual switching and the manual manipulated variable adjustment can be set via the SES. This makes a complete, parallel process operation via the SES possible (see also chapter 3.6, page 94 ).

D Source for the external setpoint (S85)

The external setpoint w

may come from two different sources depending on the controller

type.

External setpoint as an absolute value via the analog inputs (w

) S85 =0, 1, (4, 5)1)or

external setpoint as an absolute value via the SES (w

)S85=2,3

D Setpoint ramp tS

With the parameter tS (oFPA), the adjustment speed of the active setpoint w (in the ratio controller S1 = 3 the active nominal ratio) can be set over 0 to 100 %. At tS = oFF the adjustment speed moves towards 1. With the control signal tS

= 1 the set setpoint ramp is

switched off (the setpoint then changes suddenly).

With the setpoint ramp, sudden setpoint switchings to the untracked variables SH, wi, w

S45=1andw

can be avoided.

as of software version –A5

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

safe Setpoint

external Setpoint

Δw

tw=

tan

α =

100 %

Δw

Δw·tS

100 %

Figure 3-4 Setpoint switching with ramp

The setpoint change/setpoint ramp can be stopped with the control signal tSH. The setpoint change continues when the signal is reset.

D Setpoint limits SA, SE

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 = 3)

D Tracking of the ineffective setpoint to the active setpoint (S45)

Normally the ineffective setpoint is tracked to the effective setpoint so that the setpoint switching is bumpless. The internal setpoint (wi) and the external setpoint can be tracked via the SES (w

). The safety setpoint SH cannot be tracked.

The external setpoint w

through the analog inputs is only indirectly trackable by tracking

the feeding instrument to the internal setpoint.

At S45 = 1 the tracking 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 the fixed setpoint controller (S1 = 0).

D x-tracking (S43)

With the structure switch S43 = 1, x-tracking (ratio controller xv-tracking) can be switched on. This means that the setpoint is tracked to the actual value or the nominal ratio is tracked to the actual ratio and therefore a control difference xd is reset to 0. The tracking always takes place when there is no automatic operation (A

). This is the case in manual mode (H), tracking mode (N), DDC-mode and in operation with safety manipulated variable (Si): A

=H∨N∨Si

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 tracking the setpoint to the actual value (nominal ratio to actual ratio), the control difference xd = 0 and automatic operation starts absolutely bumplessly. Since it can normally be assumed that, especially in manual operation and in DDC-operation, the actual value has been driven to the desired value during manual- or DDC-operation, the tracked setpoint then corresponds to the rated value.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

x-tracking only takes full effect if the tracking of the inactive setpoint is locked onto the active setpoint (S45 = 0) so that not only the active setpoint w but also the setpoint source which is supplying after switching to automatic operation is tracked.

At S45 = 1 (without tracking) the control difference during the A

-operation is 0 but the old, untracked setpoint becomes effective again after switching to automatic operation. 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 tracking variable would not be correct in full x-tracking.

D Constants c1 to c7

Linking of the process variables with the constants is possible depending on the controller type, whereby the constants c1 to c3 are used for the control variable links, the constants c4 and c5 for the command variable links.

The constants are set in the parameterization mode onPA.

The constant c6 serves for proportioning the disturbance variable connection z to the controller output ya (see figure 3-7, page 62). It can be set in the parameterization mode onPA.

The constant c7 is used in P-controller operation as a factor for increasing the Kp-value. (P/PI-switchover, see figure 3-21, page 92).

D 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

∧ CB and its negation. The status of the control signal CB and the Internal key (16)

is indicated by the C

LED (18) and the Internal LED (17).

With S42 the Internal/External key (16) can be set out of function and can block in the positions Internal or External (see figure 3-3, page 53 ). The factory setting is S42 = 0 (only Internal).

With S23, the CB-signal can be set to Low or High or assigned to a digital input, (see figure 3-2, page 52). The factory setting is S23 = 8, CB = High.

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

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

D Actual value- and setpoint display

A red and a gree analog display with 1.7 % resolution are arranged on the front module. The green display is assigned to the setpoint, the red display to the actual value. A red, 4-digit digital display is used for displaying both the setpoint- and the actual value. Since only one display is available, the displayed variable is switched using the key (6). The scope of the display is controlled by the structure switch S81. The type of displayed variable is identified by the signal lamps (4) and (5).

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

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

Display type digital display

↗ analog display

0000

I... IV

0000

Display range adjustable with dP, dA,dE

Display levels of the digital display

displayed variables x, w, xv or wv

D Display range

The digital display for x or w is a four-digit 7-segment display. The display range for the x-and w-display is set together with the parameter dP (decimal point), dA (start value) and dE (end value) in the structuring mode oFPA.

With dA the numeric value is set which is to be displayed at arithmetic value 0 (corresponding to 0 % display in the analog displays). With dE the numeric value is set which is to be displayed at arithmetic value 1 (corresponding to 100 % display in the analog displays). With dP the decimal point is set as a fixed point. If the start value is set less than the end value, an increasing display is given with increasing arithmetic values and vice versa. The number range for the start- and end value respectively is from -1999 to 9999, outside these ranges,

--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 settled down in the case of restless process variables. Non-linear process variables can be represented physically correctly by the linearization.

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:

With the appropriate assignment, this also applies for the limit value alarms A1 to A4, see chapter 3.10.3, page 117.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

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. This is displayed by one or two, alternately lit LEDs. The centre point of the light field represents the ”pointer”. This display technique doubles the resolution. If a falling characteristic (dE<dA) is set for the digital displays, the analog displays are switched in direction of effect except for in the ratio controllers.

y-display

A 2-digit red digital display is available for the y-display additionally. The corresponding adjustment keys and status-LEDs are allocated to each other in color and space (see also chapter 3.6, page 94 ).

3.4.2 Fixed setpoint controller with 2 independent setpoints (S1 = 0)

ya+c6 S z

PID

wi2

wi1

INT∧CB

x=x1+c1S (x2 -c2Sx3+c3)

0000

Figure 3-5 Control principle 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 one-, two- or three-component controller.

Switching between the two setpoints which can be set separately on the front panel takes place dependent on the control signals Int and CB according to table 3-1, page 60. Signaling of the active setpoint takes place on the LEDs Internal and C

. As soon as a LED lights, wi2

is active.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Control commands Alarm signals Active w Digital inputs Front Front LED Digital outputs at S43= Explanations

H∨N∨Si CB

internal internal C RB RC 01

01000 00 wi1wi1(n)

switchover switchover

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

11000 00 wi1x

switchover switchover

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

tracking takes place at S45 = 0 and S43 = 1 to the control variable x, the tracking does not apply for switchover wi1/wi2 at S45 = 1 automatic mode starts with wi=x (xd=0), the active setpoint runs to the old set value via the possibly set setpoint ramp tS

Factory setting fixed setpoint controller with 1 setpoint (S42 = 0: only Internal, Int = 1, S23 = 8: CB = 1) RB =Int RC = Int∨

Factory setting

Table 3-1 Switching between wi1 and wi2

With the Shift key (6) the digital x/w-display can be switched between the display levels I to IV depending on the position of S81.

In display level II the active w can be displayed, in display level III the main control variable x1. The inactive setpoint is displayed in the display level IV . The displayed active or inactive setpoint can also be adjusted (see table 3-2).

The active setpoint- and actual value is displayed on the analog displays.

Structure

switches

Posi-

tion

Function

S81 Switching the w/x-digital display

Display order

I II III IV

[0] x/xv w/wv -- --

1 x/xv w/wv x1/xv -2 x/xv w/wi1/wv -- wE/wvE/wi2 3 x/xv w/wi1/wv x1/xv wE/wvE/wi2

4 x/xv -- -- -5 -- w/wv -- -6 -- -- x1/xv -7 xv wv x1 w

Identification of the displayed variables by the w- or x-signal lamp: 1 = steady light, 0.5 = flashing light, 0 = off

Display order

I II III IV

1 0 0.5 (0 at S81=6) 0 x-signal lamp 0 1 0 0,5 w-signal lamp

Table 3-2 Display levels (S81)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

S45

Int∧CB

S85

2/3/(4/5)

0/1

c1, c2, c3

S15

S16

S17

Factory setting c1=c2=c3=0

x=x1+c1 · (x2 - c2 · x3+c3)

SA,SE

wi1

n o

S43

Adaptation

SES

wi1

Int∧CB

Int

∧CB

=H∨N∨Si

IV II

0000 0000

H=Hi∨He

III

0000 0000

wi1/wi2

S85

2/3/(4/5)

0/1

wi2

n o

fig. 3-27, page 104

Note: S51=4 is recommended for this controller

as of software version --A5

fig. 3-1,

page 49

fig. 3-19, page 89

tS tSH

Figure 3-6 Block diagram S1 = 0, fixed setpoint controller with 2 independent setpoints

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

3.4.3 Slave controller, synchronized controller, SPC-controller

with Int/Ext-swtiching (S1 = 1)

SES

E=c4 · we+c5

x3/w

PID ya+c6 · z

0000

x=x1+c1 · x2+c3

Int∧CB

Figure 3-7 Control principle S1 = 1

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

depending on the control signals CB and the Internal-/External key (16) (see

table 3-4, page 65 and table 3-5, page 66).

The external setpoint can be set via the analog input w

or via the SES (wES) (selection by

S85).

This controller type is used for cascade controls with 2 separate controllers (master- and slave controllers), for synchronized controls, fixed setpoint controls with external setpoint preset under console conditions with external setpoint generator and SPC-controls (setpoint control).

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

D SPC-controls

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

∧CB = 1. In the case of computer failure (CB from 1 ! 0) the controller takes over

either the last computer setpoint (tracked wi) or the safety setpoint SH (selection via S44).

D Cascade controls

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) and this the final control element. 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).

D Slave controls

A command 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).

D Control signals for the setpoint switching

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

∧CB and its negation (see table 3-4, page 65 and table 3-5, page 66). 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 fig. 3-2, page 52 and fig. 3-3, page 53.

The factory setting is Int = 1 (S42 = 0) and CB=1 (S23 = 8), so that the internal setpoint

wi is always active and cannot be switched in the factory setting

With this setting option it is possible to make the setting only dependent on Int (S42=2, S23= 8) or only dependent on CB (S42=1, S23=1 to 7) as a slave controller with Internal/External-switching. If the switching option is blocked in External position (S42=1, S23=8), the controller operates as a slave controller without Internal/External-switching.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

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D Display of the external setpoint w

With the Shift key (6) the digital x/w-display can be switched between the display levels I to IV depending on the position of S81.

In display level II the active w can be displayed, in display level III the main control variable x1. The external setpoint w

is displayed in display level IV. The displayed active or inactive

setpoint can also be adjusted (see table 3-3).

The active setpoint- and actual value are displayed on the analog displays.

Structure

switches

Posi-

tion

Function

S81 Switching the w/x-digital display

Display order

I II III IV

[0] x/xv w/wv -- --

1 x/xv w/wv x1/xv -2 x/xv w/wi1/wv -- wE/wvE/wi2 3 x/xv w/wi1/wv x1/xv wE/wvE/wi2

4 x/xv -- -- -5 -- w/wv -- -6 -- -- x1/xv -7 xv wv x1 w

Identification of the displayed variables by the w- or x-signal lamp: 1 = steady light, 0.5 = flashing light, 0 = off

Display order

I II III IV

1 0 0.5 (0 at S81=6) 0 x-signal lamp 0 1 0 0,5 w-signal lamp

Table 3-3 Display levels (S81)

D Operation with 2 or 3 setpoints

If tracking of the inactive setpoint to the active setpoint is blocked with S45 = 1, a multiple setpoint operation (switching between wi, w

and SH is achieved (see table 3-4, page 65)

and table 3-5, page 66.

D 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.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

Control signals Message signals

Digital

inputs

Front Front

Digital

outputs

active w at

Com-

pu-

∨N

∨Si

CB1)In-

ter-

nal

In-

ter-

nal

LED

RB4)RC

S43=0 S44=0

S43=1 S44=0

S43=0 S44=1

S43=1 S44=1

Explanations

terfai-

lure

0 1 0 0 0 0 0 wE(n)

wE(n)

Automatic mode, SPC-mode

0 0 0 0 1 0 1 wi(n,↗)

wi(n,

↗)

Automatic mode, computer switched off, computer in SPC-standby

0 1 1 1 0 1 1 wi(n,↗) wi(n,↗)

Automatic mode, computer on standby, controller not in SPC-standby

0 0 1 1 1 1 1 wi(n,↗) wi(n,↗)

Automatic mode, computer switched off, computer in SPCstandby

1 1 0 0 0 0 0

(n)

1 0 0 0 1 0 1

(n,

↗)

or wi

(n,

↗)

Manual-, tracking- or safety mode

1 1 1 1 0 1 1

(n,

↗)

(n,

↗)

1 0 1 1 1 1 1

(n,

↗)

(n,

↗)

The table is shown for static CB-switching without acknowledgement (S41 = 0).

Source for wEat S85 = 0, 1, (4, 5 as of software version -A5) is wEAor at S85 = 2, 3 wES(SES). The external setpoint fed in through the SES (w

) is tracked. Tracking is not possible when the external setpoint is fed in via wEA.

SH can only be reached after wE, if Int = 0 and CB goes from 1 → 0 (computer failure). If CB = 0 and Int is switched from 1 → 0, wi is still active. Since SH is not tracked, 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-, tracking- or safety operation.

Factory setting

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

↗ adjustable

Factory setting

Table 3-4 Slave-/synchronized-/SPC-controller with Internal-/External switching S1 = 1 with tracking of

the inactive setpoint to the active S45 = 0

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Control signals

Message signals

Digital

inputs

Front Front

Digital

outputs

active w at

∨N

∨Si

CB1)Inter-

nal

In-

ter-

nal

LED

RB4)RC

S43=0 S44=0

S43=1 S44=0

S43=0 S44=1

S43=1 S44=1

Explanations

0 1 0 0 0 0 0 w

0 0 0 0 1 0 1 wi(↗)

wi(

↗)

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

x w

1 0 0 0 1 0 1 wi(↗) x

wi(

↗)

Manual-, tracking- 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 (S41 = 0).

Source for wEat S85 = 1, 2, (4, 5 as of software version -A5) is wEAor at S85 = 3, 4 wES. Switching between the setpoints 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-, tracking- or safety operation.

Factory setting

↗ adjustable

Factory setting

Table 3-5 Slave-/synchronized-/SPC controller with Internal-/External switching (SPC-controller), S1 =

1 without tracking of the active setpoint to the active setpoint S45 = 1, 2 or 3 setpoint operation

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

Factory setting

c1=c3=0

S85

2/3

100

Int

SA, SE

c1, c3

tFI

x3/w

S43

S44

S45

Adaptation

x=x1+c1 · x2+c3

w-c3

=c4·w

+c5

c4, c5

Factory setting

c4 = 1, c5 = 0

wi1

S85

wi1

SES

2/3/(4/5)

0/1

S17,

S15,

S16,

0/1/(4/5)

0000

III

xx1

0000

=H∨N∨Si

H=Hi∨He

Note: S51 = 4 is recommended for this controller

as of software version -A5

Figure

3-27,

page

104

Figure 3-1,

page 49

Figure

3-19,

page

tS tSH

Figure 3-8 Block diagram S1 = 1 slave controller, synchronized controller, SPC-controller

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

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3.4.4 DDC-Fixed setpoint controller (S1 = 2)

The DDC-controller has the job of taking over the control circuit as bumpless as possible in the case of a computer failure. During DDC operation- the process computer takes over the control function, the computer is in stand-by-mode and is tracked to the computer manipulated variable. If necessary the control difference is set to zero by x-tracking for absolutely bumpless switching.

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 (S52 = 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 U/I-converter of the K-controller is to be used during computer operation to feed the final control element, the actuating current cutoff must be cancelled (S52 = 0).

The DDC-mode corresponds to tracking mode of the other controller types with the difference that the switching to tracking mode takes place not via the control signal N but as a function of the control signal CB and the Internal/External key:

DDC-mode ≙ RC = Int

∧CB = 1

PID

x=x1+c1 · (x2 - c2 · x3+c3)

0000

ya+c6 · z

x - TRACKING

SES

Int∧CB

Figure 3-9 Control principle S1 = 2

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

The DDC-mode is signaled like the tracking 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 tracking to the com-

puter 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 S44 the safety setpoint is preset.

With S49 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 you need to intervene manually in computer operation, you have to switch to Internal-mode in addition to switching over to manual mode, then the LEDs Internal (17) and Manual (12) light up, the LED y-External (13) goes out, the non-lit LED C

(18) still 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 (12) lights, the y-External LED (13) goes out, the dark LEDs Internal (17) and C

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

standby.

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

D DDC-control unit

The DDC-control unit function is obtained with S49 = 0 and with S51 = 2 (manual mode only). In computer operation the manipulated variable is fed through y

, manual operation is always active after a computer failure. If you want to switch over to manual operation during computer operation, the computer operation must be switched off with the Internal key (16).

The actual value can be indicated on the actual value display.

SH as a flag pointer or wi can be indicated on the setpoint display.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Footnote explanation, see page 72

Table 3-6 DDC controller, S1 = 2, manual operation has priority over DDC operation S49 = 1

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

Footnote explanation, see page 72

Table 3-7 DDC controller, S1 = 2, manual operation has priority over DDC operation S49 = 1

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Notestotable3-9andtable3-7

Manual operation can be achieved by:

Control signals

Message signals

Digital input He Front Hi Front Manual LED Digital output H

0 1 0 1

0 0 1 1

0,9

1 1

0 1 1 1

Table 3-8 Generation of the control signal H = Hi∨He

In DDC-operation the setting current is switched off at S52 = 1. Source for yEat S85 = 0, 1,(4, 5 as of software version --A05), y is

.AtS85=2,3,yactsES(SES). The external

manipulated variable fed in through the SES (y

) is tracked. When feeding in via yNthe

feeding instrument must be tracked.

The table is shown for static computer switching without acknowledgement, S41 = 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

(

↗) = adjustable

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

The control signal Track (N) has no function in DDC-controllers. The tables apply for S45 = 0 (with tracking of the inactive setpoint to the active setpoint). At S45 = 1 (without tracking) 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.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

D Display levels

With the Shift key (6) the digital x/w-display can be switched between the display levels I to IV depending on the position of S81.

In display level II the active w can be displayed, in display level III the main control variable x1. The inactive setpoint is displayed in the display level IV. The displayed active or inactive setpoint can also be adjusted (see table 3-9).

The active setpoint- and actual value is displayed on the analog displays.

Structure

switches

Posi-

tion

Function

S81 Switching the w/x-digital display

Display order

I II III IV

[0] x/xv w/wv -- --

1 x/xv w/wv x1/xv -2 x/xv w/wi1/wv -- wE/wvE/wi2 3 x/xv w/wi1/wv x1/xv wE/wvE/wi2

4 x/xv -- -- -5 -- w/wv -- -6 -- -- x1/xv -7 xv wv x1 w

Identification of the displayed variables by the w- or x-signal lamp: 1 = steady light, 0.5 = flashing light, 0 = off

Display order

I II III IV

1 0 0.5 (0 at S81=6) 0 x-signal lamp 0 1 0 0,5 w-signal lamp

Table 3-9 Display levels (S81)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

S44

S45

S43

Int

c1, c2, c3

Factory setting

c1=c2=c3=0

x=x1+c1·(x2-c2·x3+c3)

Adaptation

SA,SE

S49

III

wi1

S85

wi1

SES

2/3/(4/5)

0/1

Note: S52 = 4 is recommended for this controller

as of software --A5

S17, x3/wv

S16, x2

S15, x1

Int

00000000

0000

II/IV

fig.

3-27,

page

104

fig. 3-1,

page 49

Fig.

3-19,

page

tS tSH

Figure 3-10 Block diagram S1 = 2, DDC fixed setpoint controller

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

3.4.5 Controlled ratio controller (S1 = 3)

VEA

vis=

x1 - c5

PID

ya+c6 · z

0000

w=v · x2+c5

wvi

SES

v = vA to vE v=wv·(vE - vA)+vA

Int

∧CB

Figure 3-11 Control principle S1 = 3

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

w = v · x2 + c5

With xd = w - x1 the result is xd = v · x2 + c5 - x1

In the controlled state (xd = 0) the result is

x1 -- c5

, i.e. in the controlled state and at

c5 = 0

x1 x2

behaves according to the set ratio factor v.

A typical application are combustion rules where a fuel volume x1 belongs 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 the result is w = [wv (vE - vA) + vA] x2 + c5

In the ratio controller the standardized nominal ratio wv and the standardized actual ratio xv are displayed on the digital x/w-displays respectively in display levels I and II. A physical display is possible with dA, dE, dP. The controlled variable x1 and the evaluated commanding process variable w are displayed on the analog x - and w-displays respectively so that a direct control

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

difference monitoring is possible at all times. At S81 = 7, x1 and w can be displayed on the digital x/w-display in the levels III and IV. A physical display is possible with Pd, Ad, Ed.

At S81 = 2 or 3, the digital x/w-display can be switched to the external nominal ratio wv

(display level IV). The digital x/w-display indicates the actual ratio xy in display levels I and III. Switching between wvi and wv

takes place in the same way as in the slave controller

S1 = 1.

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

x1-c5

with v

ist

= xv (vE -- vA) + vA the result is for

xv =

-vA

vE-vA

xv =

vE-vA

x1-c5

-vA

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 linearization of the commanding process variable x2 or the following process variable x1 is possible (S21). 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.

With the Shift key (6) the digital x/w-display can be switched between the display levels I to IV depending on the position of S81.

In display level II the active nominal ratio wy can be displayed, in dispaly level I/III the actual ratio xy. The external setpoint wy

is displayed in display level IV. The displayed active or external nominal ratio can also be adjusted. The active setpoint- and actual value is displayed on the analog displays (see table 3-10).

Structure

switches

Posi-

tion

Function

S81 Switching the w/x-digital display

Display order

I II III IV

[0] x/xv w/wv -- --

1 x/xv w/wv x1/xv -2 x/xv w/wi1/wv -- wE/wvE/wi2 3 x/xv w/wi1/wv x1/xv wE/wvE/wi2

4 x/xv -- -- -5 -- w/wv -- -6 -- -- x1/xv -7 xv wv x1 w

Identification of the displayed variables by the w- or x-signal lamp: 1 = steady light, 0.5 = flashing light, 0 = off

Display order

I II III IV

1 0 0.5 (0 at S81=6) 0 x-signal lamp 0 1 0 0,5 w-signal lamp

Table 3-10 Display levels (S81)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

wvi

Adaptation

S85

xv =

S43

S45

S44

Int

Factory setting

vA=0, vE=1, c5=0

vA, vE, c5

IV II I/III

w=v · x2+c5

x1 - c5

v=vA to vE

v=wv (vE - vA)+vA

2,3

-vA vE-vA

S17,

x3/wv

S16, x2

S15, x1

as of software version --A52)as of software version –A9

SES

wvi

0/1/(4/5)

S85

0,1

2/3(4/5)

III

S81 = 7

A =H∨N∨Si

H=Hi∨He

0000 0000 00000000 0000

fig.

3-27,

page

104

fig. 3-1,

page 49

fig. 3-19,

page 89

Int

tS tSH

Figure 3-12 Block diagram S1 = 3 controlled ratio controller

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

The ratio controller behaves like the slave controller S1 = 1 with respect to switching of the setpoint ratio wv so that the information and tables there apply accordingly. The variables wi and w

must be replaced by wvi and wvE. This controller type can also be used as a ratio controller

with fixed ratio (manually adjustable) or with commanded ratio factor.

A fixed ratio factor is used for example in simple combustion rules, (see example) 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 command controller, the flow of alkali and acid the commanded process variable and the following (controlled) process variable of the ratio controller.

D Example of a ratio control

GAS

c

AIR

Figure 3-13 Control diagram ratio control

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

whichispresetintherange0to

12000 m

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

the gas flow Q

with a measuring range 0 to 3000 m3/hwhichisalsoavailableasa4to

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.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

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

1=QG

⋅ K

with the values from the example

100 %

3000 m

x2=Q

⋅ K

100 %

12,000 m

v= =

⋅

with



⋅ λ



⋅ λ

⋅

With the values from the example

⋅

1 4

100 % ⋅ h ⋅ 12,000 m

3,000 m3⋅ 100 % ⋅ h

⋅

the result is

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

that



corresponds to

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.

0.75

1.2

1.25

0.8

0.9

1.1

1.2

0.2 0.6

1.33

1.3

0.80.40

0.8

1.1

0.9

Figure 3-14 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 3-14 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.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

constant gas/air-ratio

gas/air-ratio with additional excess air

%mA

Gas m3/h

V=1,33 λ=0.75

0 2000 4000 6000 8000 10000 12000 m3/h air

V=1 λ=1

V=0.8

λ=1.25

V=1, c< 0

4 6 8 10 12 14 16 18 20 mA

0102030405060708090100 %

120

110

100

3500

3000

2500

2000

1500

1000

500

Figure 3-15 Display of gas-/air ratio in controlled s tatus

3.4.6 Control unit/process display (S1 = 4)

The following functions are possible in this configuration:

Process display and control unit. The configuration is identical for both applications. The input wiring for both is illustrated in figure 3-16, page 82.

D Process display, two-channel analog display with parallel,

switchable digital display (S85 = 0/1 and S42 = 1)

see figure 3-16, page 82

The process variables are assigned to the green analog display by w

and to the red ana-

log display by x2.

The display range of the analog display is 0 to 100 %. The four-digit digital x/w-display is connected in parallel to the analog displayd by the Shift key (6) to the positions I and II one after another.

The display range of the digital display is set for both display positions together with the parameters dA, dE, dP in the oFPA configuring mode. The linearizer (S21) which can be assigned to the analog input then acts on both the analog- and the digital display. If this is not desirable, the linearizer can also be assigned to x1 by S21 = 5 and connect the same analog

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

input (AI1 to AI4) by S15 (x1) and S16 (x2). In this case the unlinearized process variable is displayed in display order position II and the linearized process variable in position III.

Of course it is also possible to use the x1-display channel separately from the two analog displays as a third display channel.

Another display channel is available with the two-digit y-display via Y

D Process display, one-channel analog display with parallel,

digital display and displayed limit values

see fig. 3-16, page 82

The red analog display is fed via x2, a parallel physical digitual display is possible by assigning x1 via S15 to the same analog input if the linearizer is assigned to x1 by S21 = 5 and the display range is set by dA, dE to oFPA-mode.

Of course it is also possible to use the x1-display channel separately from the two analog displays as a second display channel.

A third display channel is available with the two-digit y-display via yR.

Via S80 = 5/6 the limit values A1, A2 or A1 to A4 can be displayed on the green analog display with a resultion of 3 %. When assigning the limit values to the displayed process variable in the red analog display, the position of the process variable to the limit values can be read. If a limit value responds, this is signaled by the corresponding alarm lamp (20) and the flashing alarm-LED on the green bargraph. The alarms can be labeled on the replaceable scale (21).

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

w-c5

S45

wES

SES

2/3

c4, c5

=c4 · w

+c5

SA,SE tS

+Δw

Δw

S55

oFF

Y1, Y2

Int

S44

0/1/(4/5)

S85

Factory setting

c4 = 1, c5 = 0

S54

=CB∧INT = CB∨Int

Int

-Δw

Δw

A1, A2

A1 ... A4

0 ... 4

S80

as of software --A5

--1

0000

III

00000000

IV II

fig. 3-27,

page 104

fig. 3-1,

page 49

fig. 3-19,

page 89

Figure 3-16 Block diagram control unit/process display (S1 = 4) setpoint generator S/K, manual control

station S/K

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

D Control units

The integrated control unit function always includes a setpoint generator and a manual control station in the following versions:

-- trackable K-setpoint generator

-- S-setpoint generator

-- trackable K-manual control station (S2 = 0)

-- S-two-position control unit with 2 outputs (heating/cooling) (S2 = 1)

-- S-three-position manual control unit internal feedback (S2 =2)

-- S-three-position manual control unit external feedback (S2 =3)

The ability to combine setpoint generator- and manual control station type depends on the application. Either the setpoint generator or the manual control station can use the K-output, the remaining function must have an S-output.

- Setpoint generator see figure 3-16, page 82

S- and K-setpoint generators are installed parallel. In the S-setpoint generator, the switching outputs ±Δw can be locked depending on the Internal key (16) and the control signal CB, the status message is output by the signal lamps Int and C, see table 3-7, page 71. The feedback of the setpoint adjusted incrementally by the switching outputs takes place via the w-display (input w

, the switching is blocked in position Ext, S42 =

1).

In the K-setpoint generator the tracking of the internal setpoint is controlled dependent on the Internal key (16) and the control signal CB, see table 3-7, page71. The tracking variable is fed in via w

. The active setpoint is output by assignment of w to the analog out-

put AO (S56 = 2/3).

With the Shift key (6) the digital x/w-display can be switched between the display levels I to IV depending on the position of S81. The controlled variable is displayed in the display level I. In display level II the active w can be displayed, in display level III the controlled variable x1. The inactive setpoint is displayed in the display level IV. The displayed active or external setpoint can also be adjusted (see table 3-11, page 84).

The active setpoint- and actual value is displayed on the analog displays.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Structure

switches

Posi-

tion

Function

S81 Switching the w/x-digital display

Display order

I II III IV

[0] x/xv w/wv -- --

1 x/xv w/wv x1/xv -2 x/xv w/wi1/wv -- wE/wvE/wi2 3 x/xv w/wi1/wv x1/xv wE/wvE/wi2

4 x/xv -- -- -5 -- w/wv -- -6 -- -- x1/xv -7 xv wv x1 w

Identification of the displayed variables by the w- or x-signal lamp: 1 = steady light, 0.5 = flashing light, 0 = off

Display order

I II III IV

1 0 0.5 (0 at S81=6) 0 x-signal lamp 0 1 0 0,5 w-signal lamp

Table 3-11 Display levels (S81)

Control signals Message signals

Digital

in-puts

Front Front Digital outputs

active w at

Eff

ect ofthe

±Δw-keys on

wiredor

Int∨CB

Inter-

nal

Inter-

nal

LED

RB RC

S44=0 S44=1 wi ±Δw/BA

0 0 0 1 0 1

we(n)

2) 3)

we(n)

no yes 0

1 0 0 0 0 1

we(n)

2) 3)

we(n)

no no 1

0 1 1 1 1 0

wi(n,↗)3)wi(n,↗) yes no 1

6) 3)

we(n)

2)6)

4)6)

The table is shown for static CB-switching without acknowledgement (S41 = 0).

Source for wEat S85 = 0, 1, (4, 5 as of software version -A5), is wEA, which is assigned by S17 or at S85 = 2, 3 wES, which is fed in via the SES.

Tracking only takes place at S45=0 and only wESand wi to the active setpoint. When feeding in via wEAthe feeding instrument must be tracked.

Only to be used as a flag pointer when no analog feedback is possible from the fed instrument.

RC = no K-setpoint generator operation, wi not adjustable.

Factory setting

wired-or-connection of Int = RB and CB supplies Int∨CB No S-setpoint optentiometer operation, Δw-keys not active

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

↗ adjustable

Table 3-12 Setpoint switching setpoint generator S/K, S1 = 4 process display/control unit

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

D Manual control station (S2 = 0, 1, 2, 3)

see figure 3-17, page 86 and figure 3-18, page 87

The controller output structures which can be configured by S2 are used for the manual control station function whereby automatic operation is replaced by the ”Hold manipulated variable” mode. All other operating modes are identical with the controller functions. The last manipulated variable before switching to this operating mode is transferred to this hold operation and the Δy-keys are inactive. If, in this operating mode, the manipulated variable output is to be tracked e.g. in 2-wait operation, the tracking operation must be activated by the control signal N and the input yN.

If only manual control function without switching is desired, the instrument must be blocked in manual mode with S51 = 2.

The following figures only show 2 examples. For the other variations, see the block diagrams of the controller-output structures (fig. 3-22, page 96, figure 3-23, page 97 and figure 3-25, page 100 to figure 3-28, page 105).

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

-Δy

Δy

2, 3

S54

S55

S51

Δy

-Δy

>50

+yBL

-yBL

Δy

S19

S57

S29 S30

GND

≤50

0 0 1 1 0 1 0

Block diagrams for S49 = 0 and manual control station S with ext. feedback (S2=3) see controller output structures figure 3-27, page 104

Figure 3-17 Block diagram control unit/process display (S1 = 4) manual control station S with internal

feedback S2 = 2

(manual operation has priority over tracking S49 = 1)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

S51

S54

S85

+yBL -yBL

oFF

2/3

0/1/(4/5)

S55

S52

tP, tM (S2 = 0)YAYE

S56

Δy

S57

S53

1/3

0/2

tM, tA

tP, tE

Δy

S57

1/3

0/2

S53

S18

S29

S30

S19

0/1

2/3/(4/5)

S85

as of software version --A52)as of software version --B2

HES

SES

12/13

10/11

0/1

S56

Block diagram for S49 = 0, see controller output structures figure 3-28, page 105

Figure 3-18 Block diagram control unit/process display (S1 = 4) manual control station with K-output

S2 = 0/two-position output S2 = 1 (manual operation has priority over tracking S49 = 1)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

Control signals

Message signals

Digital inputs Front Front Digital outputs

±yBL Si N Hi

LED

y-Ext.

LED

activeyatExplanations

0 0 0 0 0 0 0 0 0 ya(n) Hold operation

0 0 0 1 0 0,9

0 1 0 yH(n,↗) Manual mode

0 0 0 0 1 1 0 1 0 yH(n,↗) Manual mode

0 0 0 1 1 1 0 1 0 yH(n,↗) Manual mode

0 0 1 0 0 0 1 0 1 yE(n)

Tracking operation

0 0 1 1 0 0,5

1 1 1 yE(n) Tracking operation

0 0 1 0 1 0,5

1 1 1 yE(n) Tracking operation

0 0 1 1 1 0,5

1 1 1 yE(n) Tracking operation

1 0 0,5

5)6)

1 0 ±yBL

±Blocking operation

1 1

as above

0,5

5)6)

0 ±yBL

±Blocking operation

0 1

asabove

0,5

5)6)

above

0 y

Safety operation

Table 3-13 Output switching manual control station S/K (S1 = 4)

Tracking operation has priority over manual operation (S49 = 0)

Control signals Message signals

Digital inputs Front Front Digital outputs

±yBL Si N Hi

LED

y-Ext.

LED

activeyatExplanations

0 0 0 0 0 0 0 0 0 ya(n) Hold operation

0 0 0 1 0 0,9

0 1 0 yH(n,↗) Manual mode

0 0 0 0 1 1 0 1 0 yH(n,↗) Manual mode

0 0 0 1 1 1 0 1 0 yH(n,↗) Manual mode

0 0 1 0 0 0 1 0 1 yE(n)

Tracking operation

0 0 1 1 0 0,9

0,5 1 1 yH(n,↗) Manual mode

0 0 1 0 1 1 0,5

1 1 yH(n,↗) Manual mode

0 0 1 1 1 1 0,5 1 1 yH(n,↗) Manual mode

1 0 0,5

5)6)

1 0 ±yBL

±Blocking operation

1 1

as above

0,5

5)6)

0 ±yBL

±Blocking operation

0 1

asabove

0,5

5)6)

above

0 y

Safety operation

Source for yEat S85 = 0, 1, (4, 5 as of software version -A5), y isNas an absolute value assigned via S18. At S85 = 2, 3, y

via the SES. The external manipulated variable through which SES (yES) is fed in is tracked. When feeding in

via y

the feeding instrument must be tracked. At S-output with internal feedback, a yE-selection is not possible, here

the last y before switching is held.

Blocking operation acts direction-dependently, changes to the opposite direction are possible.

Function yEin S-controllers with internal feedback (S2 = 1) drive open- or closed otherwise parameterizable safety setting value.

0.9 flashing rhythm 0.1 off, 0.9 on

5) 0.5 = flashing rhythm 1:1

6) only if HiHe = 1

7) for S51

≠ 3,4

8) As of software version -A7 the signals He

and HeESwith S51 = 3, 4 have dynamic effect (0/1-edge). They then act

like the Hi-signal (see figure 3-3, page 53)

(n) tracking takes place to the value active before switching, therefore bumpless switching

↗ adjustable

Table 3-14 Output switching manual control station S/K (S1 = 4)

Manual operation has priority over tracking operation (S49 = 1)

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21 C73000-B7476-C143-08

3.4.7 Fixed setpoint controller with one setpoint (control system coupling)

(S1 = 5)

c1, c2, c3

S45

SA,SE

S43

Factory setting c1=c2=c3=0

x=x1+c1· (x2-c2 · x3+c3)

II, IV

Adaptation

wi1

n o

0/1

2...5

2/4 0/1/3

S51

as of software version --A5

SES

S85

Int∨

=H∨N∨Si

H=Hi∨He

0000

III

0000

Figure 3-29, Page 110

Figure 3-21, Page 92

Figure 3-1, Page 49

Figure 3-19 Block diagram S1 = 5, fixed setpoint controller with one setpoint for control system coupling

This fixed setpoint controller is designed specially for coupling to the control system. The control interventions by signals Int and CB are available for locking the control system operation via SES. With Int∨CB

the setpoint signal wiESis separated and manual intervention via HeESat

S51 = 3 is suppressed.

The other wiring of the input function is almost identical with the structure S1 = 0 (see chapter

3.4.2, page 59). (Due to the control system control possible at S1 = 5, only an internal setpoint can be implemented here)

S51 = 3 is expressly recommended for this connection.

3 Functional description of the structure switches

3.4 Controller types (S1, S42 to S45)

Manual

SIPART DR21

C73000-B7476-C143-08

3.4.8 Slave controller without Int/Ext -switching (control system coupling)

(S1 = 6)

tFI

c1, c3

SA,SE

Factory setting c1=c3=0

x=x1+c1· x2+c3

S15, x1

Adaptation

c4, c5

Factory setting c4=1, c5=0

=c4·wE+c5

as of software version --A5

S16, x2

II, IV

0000

S17 w

III

0000

Figure 3-29, Page 110

Figure 3-21, Page 92

Figure 3-1, Page 49

Figure 3-20 Block diagram S1 = 6, slave controller for control system coupling

This slave controller is designed specially for the control system coupling. It differs from the structure S1 = 1 (see chapter 3.4.3, page 62) in that the setpoint switching to via Int and CB is omitted and thus these control signals are available for locking the control system operation via the SES. With Int∨CB

manual intervention via HeESat S51 = 3 is suppressed.

The other functions are unchanged in relation to S1 = 1. S51 = 3 is expressly recommended for this connection.

3 Functional description of the structure switches

3.5 Control algorithm

Manual

SIPART DR21 C73000-B7476-C143-08

3.5 Control algorithm

D Control algorithm

The PID-control algorithm 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

ya xd

=  Kp

- PI-controller

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





⋅ Tn

- D-element connection (zD-part)

The D-element connection can be added optionally .

Tv vv

= Kp



⋅ Tv

1+j



⋅

The input variable E for the D element is xd, x, x1,-z, or +z depending on the setting of S47.

- z-connection

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

ya = c6 ⋅ zor

=  c6

D Controller direction of effect

The controller direction of effect is set with S46. It must always have the opposite behavior (negative follow-up) to the controlled system (including final control element and transmitter).

S46= 0, normally acting controller (+Kp, rising x causes falling y) for normally acting systems (rising y causes rising x)

S46=1, reversing controller (-Kp, rising x causes rising y) for reversing systems (rising y causes falling x).

3 Functional description of the structure switches

3.5 Control algorithm

Manual

SIPART DR21

C73000-B7476-C143-08

S20

S15

S47

Kp·c7

P (S27)

S46

AHItF

0/1/3

-1

c6 z

YA, YE

-(kp·c7·xd+c6·z)

Control structure

c7 in PI-operation = 1

c7 in P-operation 1 to 9.999 adjustable

-1

vv tv

Output structures S2

-p

Input signal processing figure 3-1, page 49 and controller types S1

Figure 3-21 Block diagram controller structure

3 Functional description of the structure switches

3.5 Control algorithm

Manual

SIPART DR21 C73000-B7476-C143-08

D Operating point yo for P-controllers

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

Automatic working point (Yo = Auto)

Whenever there is no automatic operation (manual-, tracking-, safety- or blocking operation) the operating point yo is tracked so that switching to automatic operation is bumpless. This gives an automatic setting of the operating point yo in manual mode:

yo = y

-(Kp·c7·(w-xH) + c6 · z)

If the actual value in manual mode (x

) is driven to the desired setpoint w by the appropriate

manual manipulated variable y

, the operating point yo is identical to the manual manipu-

lated variable y

yo = yH or yo = yH + c6 · z.

Fixed working point (Yo = 0 to 100 %)

The controller operates in all operating modes with the working point set as a permanent parameter.

D manipulated variable limit YA, YE

The manipulated variable limit with the parameters YA and YE is only active in automatic operation or in all operating modes depending on the switch position of S53. The limits of these parameters are at -10 and +110 %. However, it should be taken into account that the controller neither outputs negative actuating currents nor detects any negative position feedback signals.

If the manipulated variable y

reaches one of the limits Y A or YE in the limited operating mode, further integration is aborted to avoid integral saturation. This ensures that the manipulated variable can be changed immediately after reversing the polarity.

In manual-, tracking-(DDC) or safety operation, the manipulated variable y at S53 = 0 (limiting only in automatic operation) can be driven out of the limiting range. When switching to automatic operation the last manipulated variable is then transferred bumplessly but only changes in the manipulated variable in the direction of the YA to YE range are subsequently executed.

The manipulated variable limiting is possible at K-, two-position-and three-position-steppercontrollers with external position feedback (S2 = 0, 1, 3).

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21

C73000-B7476-C143-08

D Bumpless switching to automatic mode

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

D 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.

3.6 Controller output structures (S2, S49 to S55)

The controller structures follow four different controller output structures depending on structure switch S2.

S2=0 K-controller S2=1 Two-position controller with 2 S-outputs heating/cooling, optionally one K-output S2=2 S-controller with internal feedback S2=3 S-controller with external feedback

D S2=0: continuous (K) controller (figure 3-22, page 96 and figure 3-23, page 97)

To control proportional active actuators (e.g. pneumatic actuators or I/P-transformers) or as command controllers in cascades.

actuating time tP,tM (onPA)

The setting speed of the automatic manipulated variable is set with the parameters tP and tM. In the oFF position, no limiting takes place, in positions 1 to 1000 s the minimum actuating time for 0 to 100 % manipulated variable is preset. Whereby tP acts during increase and tM during decrease of the manipulated variable. The P-, I- and D-part as well as the disturbance variable z is limited in the rise speed. This setting speed limit is used:

- to avoid integral saturations in the actuating times of the following actuator>1 s

- to avoid hard output surges of the P-, D- and z-part.

In this case it must be taken into account that the control time is greater.

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21 C73000-B7476-C143-08

D S2 = 1: two-position controller, with 2 S-outputs heating/cooling;

optionally one K-output

This output structure is identical to the K-output structure in its switching options (see figure 3-22, page96 and figure 3-23, page97).

The controller can be operated exclusively as a two-position controller (both outputs as switching outputs) or as a controller with one K-output and one switching output.

The output variable can only adopt two states for every switching output + Δy, -Δy. Switching on or switching off. The relationship between switching on- and switching off is defined as

setting ratio =

switch-on duration

switch-on duration + switch-off duration

Switch on duration and switch off duration together give the period duration.

The setting range y from 0 to 100 % can be divided into two sub-ranges. The range Y1 with a falling characteristic for cooling, the range 100% Y2 with rising characteristic for heating. Two pulse stages are connected in series which transform the two sub manipulated variables into pulse-pause ratio. It is possible to use the manipulated variable limiting of y with the parameters yA and yE, the setting ratio 1 is then not reached. Since the minimum pulse duration or -pause can be set by tA or tE, further limiting is not normally necessary. A dead zone can bset between these two sub manipulated variables. By changing Y1 or Y2 (oFPA) the dead zone is preset and the slope adapted to the cooling- or heating aggregate.

Factory setting Y1 = Y2 = 50 % corresponds to dead zone = 0 %.

Every sub manipulated variable can be assigned a different period duration tP and tM (onPA). In every chapter the setting ratio 0 to 1 is run through, whereby the shortest switch on- or switch off duration is set with tE and tA (onPA). The period duration must be set so that the respective best compromise between the minimum permissible switch on duration of the actuator (e.g. contactor , solenoid valve, fan, cooling compressor), the switching frequency and the resulting curve of the controller variable is found.

With structure switch S56 one of the outputs Y1 and Y2 can be switched to the analog output (as of software version --B2).

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21

C73000-B7476-C143-08

DDC

tE, tP

tA, tM

S51

S54

S85

+yBL -yBL

oFF

2/3

0/1/(4/5

S55

S52

tP, tM (S2 = 0)YAYE

-Δy

S57

S53

Δy

S57

S53

S29

S30

S19

PID

0/(3/4)

S18

SES

0/1

2/3/4/5

S85

tP, tM

as of software version –A52)as of software version --B2

N/DDC

A=H∧N∧Si

H=Hi∨He

HES

S56

12/13

10/11

0/1

S56

Figure 3-22 Block diagram K-controller S2 = 0 or two-position output S2 = 1

Tracking (DDC) has priority over manual operation S49 = 0

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21 C73000-B7476-C143-08

DDC

S29

S51

S85

+yBL -yBL

2/3

/1/(4/5)

110

S52

tP, tM (S2 = 0)YAYE

S53

S30

0/(3/4)

SES

0/1

2/3/4/5

S85

tP, tM

S18

tE, tP

tA, tM

S54

oFF

S55

-Δy

S57

Δy

S57

S19

PID

A=H∧N∧Si

H=Hi∨He

S56

12/13

10/11

0/1

S56

as of software version –A52)as of software version --B2

Figure 3-23 Block diagram K-controller S2 = 0 or two-position output S2 = 1

Manual operation has priority over tracking operation S49 = 1

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21

C73000-B7476-C143-08

Y-display:

In switch position S54=2 the setting ranges heating/cooling are displayed with their setting ratio [%]. Switching of the output stages is visible as a point in the display (10) and indicates the setting range heating/cooling.

The ±Δy

-outputs can be assigned to the appropriate digital outputs with the structure switch

S57.

The analog output is assigned by the structure switch S56.

y=0toY1(cooling-Δy) period duration tM from 0 to 1000 s minimum pulse pause, -length: tA

y = Y2 to 100% (heating +Δy) period duration tP from 0 to 1000s minimum pulse pause, -length: tE

setting ratio

0,5

100 %

40%

Δy

―Δy

Heating

35%

Chapter y = Y1 to Y2

Dead zone no setting pulses

Off

tM tM

tP tP

Cooling, example with setting ratio = 50 %

Heating, example with setting ratio = 50 %

Cooling

y-display

Continuous contact

clocking

Dead zone, no output

Cooling

Heating

Figure 3-24 Setting ratio, actuating pulses of two-position controller

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

SIPART DR21 C73000-B7476-C143-08

D S2 = 2: Three-position step controller (S) with internal feedback

see figure 3-25, page 100 and figure 3-26, page 101

To control I-acting motorized actuating drives.

In S-controllers with internal feedback the K-controller is followed by an internal position controller. The positioning control circuit consists of a comparator with following three-position switch with hysteresis and an integrator in the feedback. The I-function of the actuator is simulated by the integrator with adjustable actuating time tY (parameterization mode onPA) which replaces the position feedback. T o ensure the internal integrator and the K-controller output do not drift apart or into saturation in time, both are set back rhythmically by the same amount (synchronized). The y-output is only a relative manipulated variable. It is therefore not possible to perform a manipulated variable limiting of Y

A and an absolute value preset of

E und YS. The safety manipulated variable YS is specified as a direction-dependent con-

tinuous contact. At Y

≤50 % (oFPA) -Δyswitches,atYS >50%,+Δy switches to continu- ous contact so that the end positions of the actuator represent the safety position. The position controller has an adjustable minimum pulse length (tE) and-pause (tA) with which the response threshold of the position controller is set indirectly:

- Switching on

Aee = 2

100 % ⋅ tE

- Switching off

Aea =

100 % ⋅ tE

- Hysteresis

Aee -- Aea =

100 % ⋅ tE

- Pause

Aa =

100 % ⋅ tA

- tY = tP, tM set actuating time (parameterization mode onPA)

Aee must be set up after a pulse pause at least as a deviation until an actuating pulse with length tE is output. Aea can remain as a constant control error of the position control circuit.

Aa can be set up after an actuating pulse as a deviation until an actuating pulse is output in the same or opposite direction. When time tA has expired, the position controller reacts accordingly to the set tE.

Setting criteria of tA and tE, see chapter 6.3, page 183.

The position feedback y

is only used to display the manipulated variable in S-controllers

with internal feedback. If it is not connected, S54 is set to 3, the y-display (9) is then dark.

3 Functional description of the structure switches

3.6 Controller output structures (S2, S49 to S55)

Manual

100

SIPART DR21

C73000-B7476-C143-08

2, 3

S54

S55

S51

Δy

-Δy

>50

+yBL -yBL

PID

tP, tM

tA, tE

internal position control circuit

ΔY

0/(3/4)*

S30S29

* as of software version –A5

0/(3/4)*

≤50

Δy

+Δy

S19

S57

GND

A=H

∧N∧Si

H=Hi∨He

1 00 00

Figure 3-25 Block diagram

S-controller with internal feedback S2 =2 Tracking (DDC) has priority over manual operation S49 = 0

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