Siemens SIPART DR21 User Manual

SIPART DR21
C73000-B7476-C143-08

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SIPART DR21
6DR 210*--*

Edition 08/2010

Manual

SIPART DR21

C73000-B7476-C143-08

2

SIPART DR21
C73000-B7476-C143-08

3

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.

Copyright e Siemens AG 1999 All rights reserved

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

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Trademarks

SIMATICR,SIPARTR,SIRECR, SITRANSR registered trademarks of Siemens AG.

Third parties using for their own purposes any other names in this document which refer to trade­marks might infringe upon the rights of the trademark owners.

Controls and displays

1

2

3
4
5
6

7

8

9

10

11

13

12

14

15

16

17

18

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
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Block diagram

10

AI4A

S13

AI3A

t

S11

AI1A

S6

2

1

4

3

t

AI3

Slot 1

S7

Slot 2

I,U,R

I,U,R

AI4

Options

0%

Y

N

S18

DI1

DI2

24 V

5V

L+

GND

GND

N

L

M

+24 V

+5 V

U

REF

S14

t

S21

S57

DO7

DO8

24 V

5V

I

U

I

S56

15
14
13

8

7

S22

Z
S20

Y

R

S19

w

EA

/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

5V

DO2

DO1

+Δy

--Δy

AO/Jy

I

Options

Txd
Rxd

S3

=

1/4

1/3

1/2

1/1

2/4

2/3

2/2

2/1

5

6

12

11

9

PE

3/6

3/5
3/4
3/3

3/2

3/1

∽

AI1

--

+

AI2

UNI

S8 to S10

t

S12

AI2A

S4

S5

249

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

L

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Manual Contents

SIPART DR21
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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
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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

1

2

y

x

xd

w

-

+

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

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SIPART DR21

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- 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.

xd

t

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

o

.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

o

.

y

t

Kp · xd

y

O

Figure 1-3 Step-forced response of P controller

1 General Part -- Fundamental control technology termsManual

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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.

y

t

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.

y

t

Kp · xd

Tn

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.

y

t

Kp · xd

Tn

Tv
Vv

Figure 1-6 Step-forced response of PID controller

1 General Part -- Fundamental control technology terms Manual

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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

2

M

w

xd

5

3

4

L1

N

1

x

6

y

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

Tn

Kp · xd

y

Δy

t

t

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.

2

w

xd

3

1

x

y

-

4

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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SIPART DR21

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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

3

w

xd

1

y

2

x

z

t

t

x

y

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
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- 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

3

w

xd

1

y

2

x

z

t

t

y

On
Off

-

-

+

-

4

*)

T

w

Duty factor 0 %

Duty factor
100 %

2 ¢ 100 %

Kp

-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

16

SIPART DR21

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2 Technical Description

2.1 Safety notes and scope of delivery

Manual

SIPART DR21
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17

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

18

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
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19

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

20

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

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21

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

N

.

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.

tS

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

22

SIPART DR21

C73000-B7476-C143-08

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.

RB

Computer standby

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

RC

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
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23

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

24

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

25

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

2

1

10

9

7

8

Figure 2-2 Rear view

2 Technical Description

2.5 Function principle

Manual

26

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
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27

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

28

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
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29

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

30

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.