SIPART DR21 6DR 210*--* Edition 08/2010 Manual SIPART DR21 C73000-B7476-C143-08 1 2 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. Copyright e Siemens AG 1999 All rights reserved Disclaimer of Liability 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. 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. Siemens AG Bereich Automatisierungs-- und Antriebstechnik Geschaftsgebiet Prozessinstrumentierung-- und Analytik D--76181 Karlsruhe SIPART DR21 C73000-B7476-C143-08 e Siemens AG 1999 Technical data subject to change. 3 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. 4 SIPART DR21 C73000-B7476-C143-08 Controls and displays 18 17 16 1 2 19 20 15 14 12 13 11 3 4 5 6 7 10 9 8 Display of actual value and setpoint 1 2 3 4 5 6 Analog indication of actual value x Analog indication of setpoint w w/x digital display (other values can be displayed) Signalling lamp w -- lights up if w is displayed Signalling lamp x -- lights up if x is displayed Selector pushbutton for w/x digital display, acknowledgement pushbutton for flashing following return of power or pushbutton for entering selection mode Modification of manipulated variable 7 Pushbutton for adjustment of manipulated variable -closed (open) Pushbutton for adjustment of manipulated variable -open (closed) y digital display Signalling lamps of y digital outputs with S controller Switchover pushbutton Manual/Automatic or "Enter" pushbutton from selection mode of configuring mode Signalling lamp for manual mode Signalling lamp for y--external mode 8 9 10 11 12 13 Modification of setpoint Further messages . Note 14 15 16 17 18 Pushbutton for falling setpoint Pushbutton for rising setpoint Selector pushbutton for internal/external setpoint or ""Exit'" pushbutton from configuring and selection modes to process operation mode Signalling lamp for internal setpoint Signalling lamp for computer switched off (with wext) 19 20 Signalling lamp for adaptation procedure running Signalling lamp for "Limit triggered" Operation can be blocked using the digital signal bLb; exception: switching over o w/x digital display. SIPART DR21 C73000-B7476-C143-08 5 Block diagram S57 S11 AI1 + 2 1 -+ S4 t 249 S21 S5 4 AI2 3 -- x1 S15 AI1A AI2A t 249 S12 x2 S16 S6 1/4 S13 I,U,R 1/3 AI3 1/2 1/1 Options AI3A t UNI S8 to S10 YR S19 S7 2/4 2/3 AI4 YN S18 0% Slot 1 S14 I,U,R t Z S20 2/1 24 V DI2 6 L+ 9 GND 12 GND 11 Configuration of slot 3 S22 Setpoint tracking S42 to S45 Control algorithm S46 to S48 Analog output L I +5 V UREF AO/Jy 8 DO2 7 DO1 I 24 V S56 S22 3/6 S57 S81 4DO 24V 2DI 2DO Rel 3/5 3/4 3/3 3/2 5DI 3/1 Slot 3 Options S84 to S91 S82 to S83 4/2 5V 4/7 4/8 4/3 +24 V = 10 SES Slot 4 6 --y L 5V Serial interface S84 to S91 M N PE Restart conditions +y S54 to S55 x/w indicator S3 U Y switchover S49 to S53 Limit monitors S76 to S80 I S56 Digital inputs S23 to S41 Digital outputs S58 to S75 5V 15 14 13 S4 to S21 Switching output Slot 2 5 S1 to S3 Analog inputs Y indicator AI4A 2/2 DI1 wEA/x3 S17 DO7 DO8 Basic settings SIPART DR21 C73000-B7476-C143-08 Txd Rxd Manual Contents Contents page 1 General Part -- Fundamental control technology terms . . . . . . . . . . . . . . . . . . . . 9 2 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 4 4.1 4.2 Safety notes and scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Range of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 18 19 24 26 2.5.1 2.5.2 Standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 28 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.6.1 2.6.2 2.6.3 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 36 40 Functional description of the structure switches . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 General, recurrent functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed setpoint controller with 2 independent setpoints (S1 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slave controller, synchronized controller, SPC-controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DDC-Fixed setpoint controller (S1 = 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controlled ratio controller (S1 = 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit/process display (S1 = 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed setpoint controller with one setpoint (control system coupling) . . . . . . . . . . . . . . . . . . . . . . . Slave controller without Int/Ext -switching (control system coupling) . . . . . . . . . . . . . . . . . . . . . . . . Control algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller output structures (S2, S49 to S55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog output signal processing (S56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital output signal processing (S57 to S75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptation (S48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other functions of the standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 59 62 68 75 80 89 90 91 94 110 111 113 115 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6 Adaptive filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Response threshold AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit value alarm (S76 to S80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linearizer (S21, oFPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restart conditions (S82, S83) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial interface and PROFIBUS-DP (S84 to S91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 116 117 118 120 120 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog input signal processing (S3 to S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital input signal processing (S23 to S41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller types (S1, S42 to S45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 47 50 55 121 121 4.1.1 4.1.2 4.1.3 Work prior to installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the options modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 4.2.1 4.2.2 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.4 4.2.4.1 4.2.4.2 4.2.4.3 Warnings and block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection of the options modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modules for analog measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection examples for analog measuring inputs with the module 6DR2800-8J . . . . . . . . . . . . . Modules for expanding the digital inputs and digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection of the interface module 6DR2803-8C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS 232 point-to-point (END/END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS 485 bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROFIBUS-DP, 6DR2803-8P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 130 133 133 137 142 144 144 145 146 SIPART DR21 C73000-B7476-C143-08 121 124 125 7 Contents 5 5.1 5.2 5.3 5.4 5.5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 7.4 8 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.6.1 5.4.6.2 5.4.6.3 5.4.6.4 5.4.6.5 5.4.6.6 5.4.6.7 5.4.7 General, Online and Offline modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration mode online-parameters onPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration mode adaptation AdAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration level offline parameters oFPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration mode structure switch StrS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set UNI-module CAE3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring range for mV (S8 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring range for U, I (S8 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring range for thermocouple with internal reference point (S8 = 1) . . . . . . . . . . . . . . . . . . . . Measuring range for thermocouple with external reference point (S8 = 2) . . . . . . . . . . . . . . . . . . . . Measuring range for PT100 four-wire and three-wire connection (S8 = 3,4) . . . . . . . . . . . . . . . . . . Measuring range for PT100 two-wire connection (S8 = 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring range for resistance potentiometer (S8 = 6, 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APSt (All Preset) Reset to factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 149 150 152 154 154 155 156 163 165 173 175 175 175 176 176 177 177 178 CPU self-diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Application examples for configuring the controller . . . . . . . . . . . . . . . . . . . . . . . 193 Adapting the direction of control action to the controlled system . . . . . . . . . . . . . . . . . . . . . . . . . Setting of actuating time in K-controllers (S2 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptation of the S-controller to the actuating drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the filter and the response threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic setting of control parameters by the adaptation method . . . . . . . . . . . . . . . . . . . . . . . Manual setting of the control parameters without knowledge of the plant behavior . . . . . . . . . . Manual setting of the control parameters after the transient function . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working with different setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring tool, forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 183 183 185 186 189 191 193 195 199 216 8.1 8.2 8.3 8.4 8.5 General information and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED-test and software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 9 General explanation of abbreviations for SIPART DR . . . . . . . . . . . . . . . . . . . . . . 229 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 8 223 224 226 227 228 SIPART DR21 C73000-B7476-C143-08 Manual 1 HL1 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. z1 z2 z3 1 w Figure 1-1 x + xd y 2 w x xd y z Command variable Controlled variable System deviation Manipulated variable Disturbance variable 1 2 Controlled system Control equipment 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. SIPART DR21 C73000-B7476-C143-08 9 1 General Part -- Fundamental control technology terms Manual - 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 yo. 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 yo. y Kp * xd yO t Figure 1-3 10 Step-forced response of P controller SIPART DR21 C73000-B7476-C143-08 Manual 1 General Part -- Fundamental control technology terms 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 Kp * Vv * xd Tv Vv Figure 1-4 yO = 0 Kp * xd t 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 Kp * xd Tn Figure 1-5 t 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 Tv Vv Kp * xd Tn Figure 1-6 t Step-forced response of PID controller SIPART DR21 C73000-B7476-C143-08 11 1 General Part -- Fundamental control technology terms Manual 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. 1 0 to 20mA (4 to 20mA) 5 w 2 x 3 6 M xd y w x xd y Command variable Controlled variable System deviation Manipulated variable 1 2 3 4 Transmitter Stepoint adjuster Three-position switch Feedback with time response Control amplifier Actuator 5 6 4 L1 N 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. 12 SIPART DR21 C73000-B7476-C143-08 Manual 1 General Part -- Fundamental control technology terms y t Kp Tn xd y y y Proportional gain Integral action time System deviation Manipulated variable of controller Manipulated variable of motor Kp * xd t Tn 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. 1 0 to 20 mA (4 to 20 mA) w 2 Figure 1-9 x xd 3 4 0.2 to 1 bar y w x xd y Command variable Controlled variable System deviation Manipulated variable 1 2 3 4 Transmitter Stepoint adjuster Control amplifier Electropneumatic signal converter Pneumatic actuator 5 Function diagram of continuous controller This type of controller is preferentially used in the chemical industry. SIPART DR21 C73000-B7476-C143-08 13 1 General Part -- Fundamental control technology terms Manual 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. x w 3 x1 x2 1 xd y x 2 z 1 2 3 Controller Controlled system Setpoint adjuster Figure 1-10 a) Function diagram 14 t On Off w x y z y t Command variable Controlled variable Manipulated variable ON/OFF Disturbance variable b) Switching ouptupt and response of controlled variable SIPART DR21 C73000-B7476-C143-08 Manual - 1 General Part -- Fundamental control technology terms Two-position controller with feedback In modern two-position controllers with feedack -- such as the SIPART 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. Duty factor 0 % w 3 + 4 1 xd - 2 Duty factor 100 % y x t z 1 2 3 4 Period T System deviation xd Parameters Kp, Tn, Tv Control amplifier Controlled system Setpoint adjuster Pulse/pause converter 2 100 % Kp w y On Off t *) T w x y Z T Command variable Controlled variable Manipulated variable Disturbance variable Period *) Figure 1-11 a) Function diagram Duty factor (in % if period) 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. SIPART DR21 C73000-B7476-C143-08 15 1 General Part -- Fundamental control technology terms 16 Manual SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.1 Safety notes and scope of delivery 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 personnel must 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 1 2 2 1 Controller as ordered three-pin plug at 115/230 V AC or special plug at 24 V UC Clamps, pluggable Adhesive labels "Power supply 115 V" (for 115/230 V-version). CD ROM with documentation D Standard controllers The following variants of the SIPART DR21 are available: Order number: Output stage Power Supply 6DR2100-4 6DR2100-5 K/S-output K/S-output 24 V UC 115/230 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 SIPART DR21 C73000-B7476-C143-08 17 2 Technical Description 2.2 Range of Application Manual 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. 18 SIPART DR21 C73000-B7476-C143-08 Manual 2.3 2 Technical Description 2.3 Features 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, electrically isolated, permissible common mode voltage 50 V. U/Imodule AI3 (slot 1) AI4 (slot 2) 0/4 to 20 mA, 0/2 to 10 V, 0/0.2 V to 1 V 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. SIPART DR21 C73000-B7476-C143-08 19 2 Technical Description 2.3 Features ! Manual 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. - 24 V UC 20 SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.3 Features 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. SIPART DR21 C73000-B7476-C143-08 21 2 Technical Description 2.3 Features Manual 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. w Output of switching signals for setpoint adjustment This function is only active when the controller is structured as a control unit (S1=4). y 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 5 x DI Slot 3 4 binary outputs 24 V 2 binary inputs 24 V 5 binary inputs 24 V 2 x relays 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. 22 SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.3 Features D Others Further functions are also possible. Examples: Adaptationprocedure adaptive filter for xd Setpoint ramp Filter for all inputs Root extractor for all controller inputs Linearizer for an input variable Initialization of the display x/w Limits for the setpoint w Limits of the manipulated variable y x-Tracking Limit value alarms Transmitter monitoring Adaptation of the direction of action Restart conditions SIPART DR21 C73000-B7476-C143-08 Meaning see chapter Automatic determining of the controller parameters by means of a robust adaptation method which also considerably simplifies commissioning of even critical controlled systems. Filter which dampens amplitude-dependent interference, the value of the dampening is adapted automatically. Configuring level AdAP; 3.9 (page 113) and 5.4.3 (page 156) onPA-Parameter tF 3.10.1 (pg. 115) and 5.4.2 (page 155) oFPA-Parameter tS; 3.4.1 (pg. 55) and 5.4.4 (pg. 163) 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 . 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) 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) A linearizer with 13 (equidistant) support points and paraStructure switch bolic approximation can be assigned to one of the analog S21; 3.10.4 (pg. inputs AI1 to AI4 or to the controlled variable x1. 118) and 5.4.5 (pg. 165) The controlled variable x and the command variable w can oFPA-Parameter dA, be displayed in physical values. dE; 3.4.1 (pg. 55) and 5.4.4 (pg. 163) The setpoint can be limited anywhere within the selected oFPA-Parameter measuring range. SA, SE; 3.4.1 (pg. 55) and 5.4.4 (pg. 163) The manipulated variable y can be limited within the setting onPA-Parameter YA, range -10% and +110 %. YE; 3.5 (pg. 91) and (Not in S-controllers with internal feedback) 5.4.2 (pg. 155) The setpoint w is tracked to the controlled variable x in Structure switch manual-, tracking- and DDC-operation as well as at the S43; 3.4.1 (pg. 55) safety setpoint. and 5.4.5 (pg. 165) Any controller-internal variables or inputs can be monitored Structure switches for limit values. The output is by way of alarms A1 to A4. S76 and S77; 3.10.3 (pg. 117) and 5.4.5 (pg 165) All or specific analog inputs can be monitored for dropping Structure switches below- or- exceeding the range. In the event of a fault, the S4 to S7, S66; 3.2 four-digit digital display outputs a message selectively for (pg. 47) and 5.4.5 every input. A system fault can be output via the digital out(pg. 165) put MUF. SIPART DR21 operates with normal direction in the factory Structure switch setting. The direction of the controller can be changed for S46; 3.5 (pg 91) and reversing systems. 5.4.5 (pg. 165) After mains recovery the controller starts automatically with Structure switch the structured operating modes, setpoints and manipulated S82; 3.10.5 (pg.120) variables. and 5.4.5 (pg. 165) 23 2 Technical Description 2.4 Design 2.4 Manual 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 + y,- 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 24 SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.4 Design 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 2 10 1 2 3 4 5 9 7 8 6 7 8 9 3 4 5 6 Figure 2-2 10 Mains plug Power supply unit Slot 1 AI3 (I/U, R, P, T) Slot 2 AI4 (I/U, R, P, T) Slot 3 4DO,24 V or 2DO relay or 5DI Slot 4 SES/PROFIBUS-DP DIN rail (scope of delivery of the relay module) Terminal block 1 AI1 to AI2 (I) Terminal block 2 AO1 DI1 to DI2 DO1 to DO2 24 V L+; M Terminal block 3 Digital outputs y Rear view SIPART DR21 C73000-B7476-C143-08 25 2 Technical Description 2.5 Function principle Manual 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 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 designed 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 y 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 26 SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.5 Function principle 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 determined 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. SIPART DR21 C73000-B7476-C143-08 27 2 Technical Description 2.5 Function principle (AdAP) (CAE3) 2.5.2 Manual In the adaptation level the output conditions for automatic adaptation of the controller parameters to the process is preset and adaptation started. 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). Option module The following option modules are described in this chapter 6DR2800-8J 6DR2800-8R 6DR2800-8V 6DR2805-8A 6DR2805-8J 6DR2801-8D 6DR2801-8E 6DR2801-8C 6DR2803-8P 6DR2803-8C 6DR2804-8A 6DR2804-8B 6DR2800-8J I/U-module R-module UNI-module reference point measuring range plug module with 2 DO (relay) module with 2 DI and 4 DO module with 5 DI serial interface PROFIBUS-DP serial interface RS 232/RS 485 module with 4 DO relays module with 2 DO relays 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 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 to 1200 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. 28 SIPART DR21 C73000-B7476-C143-08 Manual 2 Technical Description 2.5 Function principle 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 k. 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 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. SIPART DR21 C73000-B7476-C143-08 29 2 Technical Description 2.5 Function principle 6DR2805-8J Manual 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 or 50 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 F) 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, S58 to S68). The digital outputs are short-circuit-proof and can drive commercially available relays or the interface relays 6DR2804-8A/8B directly. 30 SIPART DR21 C73000-B7476-C143-08 Manual 6DR2801-8C 2 Technical Description 2.5 Function principle 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. SIPART DR21 C73000-B7476-C143-08 31 2 Technical Description 2.5 Function principle 6DR2803-8C Manual 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 SIPART 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]. RS 485+150R 24 V 24 V 0V +7.5 V SIPART bus -7.5 V 0V +7.5V +7.5 V 8 +7.5V 3 Txd RS 232 2 +1 Txd RS 485 +7.5 V Txd Rxd/ Txd A Rxd/ Txd B Rxd 7 -7.5 V Rxd -1 -7.5V 3 8 Rxd Rxd/ Txd Other connections: NC Figure 2-3 32 Block diagram serial interface in RS 232/SIPART BUS 2, 7 NC Other connections: NC Figure 2-4 Block diagram serial interface at Interface RS 485 SIPART DR21 C73000-B7476-C143-08 Manual 6DR2804-8A 6DR2804-8B 2 Technical Description 2.5 Function principle module with 4 DO-relays 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. SIPART DR21 C73000-B7476-C143-08 33 2 Technical Description 2.6 Technical Data 2.6 Technical Data 2.6.1 General data Manual Installation position any Climate class to IEC 721 Part 3--1 Storage 1k2 Part 3--2 Transport 2k2 Part 3--3 Operation 3k3 --25 to +75 _C --25 to +75 _C 0 to +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 34 SIPART DR21 C73000-B7476-C143-08 Manual 2 Connection technique Power Supply 115/230 V AC 24 V UC Field signals Three-pin plug IEC320/V DIN 49457A Special 2-pin plug Plug-in terminals for 1.5 mm2 AWG 14 1) relay module 6DR2804-8A/B Figure 2-5 Installation depth necessary for changing the main board and modules Dimensions SIPART DR21, dimensions in mm Number of controllers 2) Figure 2-6 Technical Description 2.6 Technical Data Cut-out width b Under consideration of the permissible ambient temperature, tight installation one above the other is allowed Panel cut-outs, dimensions in mm SIPART DR21 C73000-B7476-C143-08 35 2 Technical Description 2.6 Technical Data 2.6.2 Manual Standard controller Power Supply Rated voltage g 230 V AC 115 V AC 24 V UC switchable Operating voltage range 195 to 264 V AC Frequency range External current Permissible voltage breaks based on 0.85 U N and max. load Time3) 20 to 28 V AC 48 to 63 Hz IExt2) Power consumption Standard controller without options without IExt active power/apparent power (capacitive) Standard controller with options without IExt active power/apparent power (capacitive) Standard controller with options with IExt active power/apparent power (capacitive) 1) 97 to 132 V AC 20 to 35 V DC1) -- -- -- 200 mA 5 W/9 VA 5 W/9 VA 4 W/6 VA 4W 11 W/15 VA 11 W/15 VA 8.5 W/12 VA 8.5 W 15 W/19 VA 15 W/19 VA 12 W/17 VA 12 W 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 2) 3) Table 2-1 Power supply standard controller Analog inputs AI1 to AI2 Current Rated signal range Modulation range Input resistance Difference (load) Filter time constant Zero error Full scale error Linearity error Temperature influence Static destruction limit Parameterizable transmitter fault message AI1/2 AI3/4 36 0/4 to 20 mA -0.1 to 22 mA 248 1 % 10 ms see AD-converter see AD-converter see AD-converter see AD-converter 40 mA 0 mA to 20 mA 4 mA to 20 mA 0/4 mA to 20 mA -0.5 %; -2.5 %; -2.5 %; 106.25 % 106.25 % 106.25 % SIPART DR21 C73000-B7476-C143-08 Manual 2 Digital inputs DI1, DI2 Signal status 0 Signal status 1 Input resistance Static destruction limit . Technical Description 2.6 Technical Data 4.5 V or open 13 V 27 k 35 V NOTE All error specifications refer to the rated signal range Analog outputs AO Rated signal range (0 to 100 %) Modulation range Load voltage No-load voltage Inductive load Time constant Residual ripple 900 Hz Resolution Load dependence Zero error Full scale error Linearity Temperature influence Zero point Full scale Static destruction limit S-output (relay 230 V) DO7 and DO8 - Contact material - Contact load capacity Switching voltage AC DC Switching current AC DC Rating AC DC 1) 0 to 20 mA or 4 to 20 mA 0 to 20.5 mA or 3.8 to 20.5 mA from --1 to 18 V 26 V 0.1 H 10 ms 0.2 % 0.1 % 0.1 % 0.3 % 1) 0.3 % 1) 0.05 % 0.1 %/10 K 0.1 %/10 K --1 to 35 V Ag / Ni 250 V 250 V Contacts locked 8A 8A Contacts unlocked 2.5 A 2.5 A 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 % SIPART DR21 C73000-B7476-C143-08 37 2 Technical Description 2.6 Technical Data Service life mechanical 230 V AC 8A electrical ohmic Spark quenching element Manual 2 107 switching cycles 105 switching cycles Series circuit 22 nF/220 parallel to it varistor 420 Vrms 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+ Rated voltage load current Short-circuit current Static destruction limit CPU data Cycle time Minimum integration speed A/D conversion except UNI module 6DR2800-8V Procedure Modulation range Resolution Zero error Full scale error Linearity error Temperature influence Zero point Full scale Setpoint- and manipulated variable adjustment Setting Speed Resolution wi y 38 +20 to 26 V 60 mA, short-circuit-proof 200 mA clocking --1 to +35 V 100 ms dy = dt kp xd tn = 0.1 0.1 % 104 s Successive approximation per input > 120 conversions and averaging within 20 or 16.67 ms -5 % to 105 % of the modulation range 11 bits 0.06 % of the modulation range 0.2 % of the modulation range 0.2 % of the modulation range 0.2 % of the modulation range 0.05 %/10 K of the modulation range 0.1 %/10 K of the modulation range With 2 keys (more - - less) progressive 1 digit 0.1 % of rated range 0 to 20 mA SIPART DR21 C73000-B7476-C143-08 Manual Parameters Setting Speed Resolution Linear parameters, % Linear parameters, physical Logarithmic parameters Accuracy Time parameters All others 2 Technical Description 2.6 Technical Data With two keys (more -- less) progressive 0.1 % 1 digit 128 values/octave 2 % Resolution accordingly, absolute Display technique -- x- and w-Digital display Color Digit height Display range Number range Overrun Decimal point Refresh rate Resolution Display error 4digit 7-segment LED red 7 mm Adjustable start and end --1999 to 9999 <--1999: --oFL >9999: oFL adjustable (fixed point) _.------ to -------Adjustable 0.1 to 9.9 s 1 digit but not better than AD-converter corresponding to AD-converter and analog inputs -- x- and w-Analog display Color x w Display range Overrun Refresh rate Resolution LED array vertical 30 LEDs red green 0 to 100 % flashing first or last LED cyclic 1.7 % by alternate glowing of 1 or 2 LEDs, the center of the illuminated field serves as a pointer -- y-display (digital) Color Digit height Display range Overrun Refresh rate Resolution 2digit 7-segment-LED red 7 mm 0 to 100 % -9 % to 109 %, display >99 % h0 to h9 Adjustable 0.1 s to 9.9 s 1% SIPART DR21 C73000-B7476-C143-08 39 2 Technical Description 2.6 Technical Data 2.6.3 Manual Option module 6DR2800-8J/R Analog inputs AI3 (slot 1), AI4 (slot 2) Signal converter for Current Voltage Order number: 6DR2800-8J 6DR2800-8J Range start 0 or 4 mA 1) 0 V or 2 V1) or 199.6 mV 1) Min. span (100 %) Max. zero point suppression Range full scale Dynamic range 20 mA --4 to 115 % Transmitter fault message MUF Input resistance Difference Common mode Permissible common mode voltage Supply current Line resistance Three-wire-circuit Filter time constant 20 % 10 V, 998 mV --4 to 115 % Resistance potentiometer 6DR2800-8R 0 R 0.3 R 3) RA 0.2 R 3) 1.1 R 3) --4 to 115 % --2,5 % MUF 106.25 % 49.9 0.1 % 500 k 0 to +10 V 200 k 200 k 0 to +10 V 5 mA 5% per < 10 50 ms 50 ms 50 ms 0.3 % 0.5 % 0.05 % 0.07 %/V 0.2 % 0.2 % 0.05 % 0.02 %/V 0.2 % 0.2 % 0.2 % -- 0.05 %/10 K 0.1 %/10 K 0.02 %/10 K 0.1 %/10 K 0.1 %/10 K 0.3 %/10 K 40 mA 35 V 500 V 35 V 35 V 500 V 35 V 35 V 500 V 2) Error Zero point Gain Linearity Common mode Influence of temperature 2) Zero point Gain Static destruction limit between the inp. referenced to M 1) 2) 3) Start of measuring by structuring Without errors of A/D-converter with R = RA +R + RE adjustable in three ranges: Table 2-2 40 R = 200 , R = 500 , R = 1000 Technical data for module 6DR2800-8J/R SIPART DR21 C73000-B7476-C143-08 Manual 2 6DR2800-8V UNI-module Analog input AI3 (slot 1) mV 1) Analog input AI3 Technical Description 2.6 Technical Data TC 2) Slot 1 Pt100 C R R R 600 R 2.8 k Start of scale MA -175 mV -175 mV -200 C 0 0 Full scale ME +175 mV +175 mV +850 C 600 2.8 k Span = ME -- MA parameterizable 0 to max Min. recommended span 5 mV Input current Supply current 5 mV 10 K 30 70 -2.5 % MUF 106.25 % 3) Transmitter fault message MUF 1 A 1 A -- -- -- -- -- 400 A 400 A 140 A Potential isolation Test voltage 500 V AC Perm. common mode voltage 50 V UC 50 V UC -- -- -- Line resistance 2L: RL1+RL4 1 k 300 50 -- -- 3L: (RL1) = RL2 = RL4 -- -- 50 -- -- 4L: RL1 to RL4 -- -- 100 -- -- without 500 to 550 Transmission 10 V 10 V 0.2 K 60 m 200 m Linearity 10 V 10 V 0.2 K 60 m 200 m 5 V 2 V 0.1 K 30 m 70 m 1 V/10 V 1 V/10 V -- -- -- -- 0.5 K -- -- -- Open loop signaling all terminals Open loop between Terminal 2--3 Error Resolution/noise Common mode Internal reference point Temperature error 0.05 %/10 K 3) Transmission Internal reference point Static destruction limit Cycle time Filter time constant adaptive 1) 2) 3) 4) 4) -- 0.1 K/10 K -- -- -- 35 V 35 V -- -- -- 100 ms 200 ms 300 ms 200 ms 200 ms <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 = ME -- MA In series with adaptive filter changeable by time constant t3 (onPA) Table 2-3 Technical data for UNI-module 6DR2800-8V SIPART DR21 C73000-B7476-C143-08 41 2 Technical Description 2.6 Technical Data 6DR2805-8J Measuring range plug 20 mA/10 V -- 20 mA conversion to 100 mV Load terminal 1--2 1--3 Stat. destruction limit -- 10 V divider to 100 mV Input resistance Statistical destruction limit 6DR2801-8D 2DO Relay 35 V -- Contact material -- Contact load capacity Switching voltage AC DC Switching current AC DC Rating AC DC -- Service life mechanical electrical 24 V/4 A ohmic 24 V/1 A inductive -- Spark quenching element Series circuit 42 Manual 0,3 % 50 250 40 mA 0,2 % 90 k 100 V Digital outputs DO3 and DO4 (slot 3) Ag / Ni 35 V 35 V 5A 5A 150 VA 100 W at 24 V 80 W at 35 V 2x107 switching cycles 2x106 switching cycles 2x105 switching cycles 1 F/22 parallel to it varistor 75 Vrms SIPART DR21 C73000-B7476-C143-08 Manual 6DR2801-8E 2 4DO 24 V, 2DI Technical Description 2.6 Technical Data Digital outputs DO3 to DO6 and DI3 to DI4 (slot 3) -- Digital outputs Signal status 0 Signal status 1 load current Short-circuit current Static destruction limit 1.5 V or open, residual current 50 A 19 to 26 V 30 mA 50 mA, clocking --1 V to +35 V -- Digital inputs Signal status 0 Signal status 1 Input resistance Static destruction limit 4.5 V or open 13 V 27 k 35 V 6DR2801-8C 5DI 24 V Digital inputs DI3 to DI7 (slot 3) Signal status 0 Signal status 1 Input resistance Statistical destruction limit 6DR2803-8P 4.5 V or open 13 V 27 k 35 V PROFIBUS-DP Transmittable signals Transmittable data Transmission procedure PROFIBUS-/ DP-protocol Data rate Station number Time monitoring of the data communication Electrical isolation between Rxd/Txd-P/-N and the controller Test voltage Repeater-control signal CNTR-P SIPART DR21 C73000-B7476-C143-08 RS 485, PROFIBUS-DP-protocol Operating state, process variables, parameters and structure switches According to DIN 19245, Part 1 and Part 3 (EN 50170) 9.6 kbit/s to 1.5 Mbit/s except 45.45 kBit/s 0 to 125 structurable on the controller in connection with DP-watchdog 50 V UC common mode voltage 500 V AC TTL-level with 1 TTL-load 43 2 Technical Description 2.6 Technical Data Manual Supply voltage VP (5 V) line lengths, per segment at 1.5 Mbit/s 6DR2803-8C 5 V -0.4 V/+0.2 V; short-circuit-proof 200 m, see ET 200-Manual 6ES5 9983ES12 for further details Serial interface Transmittable signals RS 232, RS 485 or SIPART BUS *) shuntable Operating state, process variables, parameters and structure switches According to DIN 66258 A or B 10 bits (start bit, ASCII-characters with 7 bits, parity bit and stop bit) 2 or 4 300 to 9600 bit/s Asynchronous, semiduplex 32 1 s to 25 s or without Transmittable data Transmission procedure Character format Hamming-distance h Data rate Transmission Addressable stations Time monitoring of the data communication 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 11) Input resistance 0 to +12 V 2) -3 to -12 V 2) 13 k UA > UB, +0.2 to +12 V UA < UB, -0.2 to -12 V 12 Send output Txd Signal level 0 Signal level 1 1) +5 to +10 V -5 to -10 V UA > UB, +1.5 to +6 V UA < UB, -1.5 to -6 V Load resistance 1.67 mA 54 1) 2) 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 p 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 *) 44 SIPART bus operation is no longer possible! The bus driver is no longer available! SIPART DR21 C73000-B7476-C143-08 Manual 6DR2804-8A/B 2 Technical Description 2.6 Technical Data Coupling relay 230 V 1 relay module 2 relay modules per relay module 6DR2804-8B 6DR2804-8A 2 relays with 1 switching contact each with spark quenching element - Silver-cadmium oxide - Contact material Switching voltage AC DC Switching current AC DC Rating AC DC Service life mechanical electrical AC 220 V, ohmic 250 V 250 V 8A 8A 1250 VA 30 W at 250 V 100 W at 24 V 2x107 switching cycles 2x106/I(A) switching cycles Series circuit 22 nF/220 parallel plus varistor 420 V rms - Spark quenching element - Exciter winding Voltage resistance +19 to +30 V 1.2 k 180 Electrical isolation between Exciter winding -- contacts Relay module - relay module (6DR2805-8A) Safe isolation 1) by reinforced isolation, airand creep lines for overvoltage class III 1) and degree of contamination 2 1) - contact -- contact of a relay module Safe isolation 1) by reinforced insulation, air- and creep lines for overvoltage class II 1) and degree of contamination 2 1) 1) - Type of protection Housing Connections (in plugged state) SIPART DR21 C73000-B7476-C143-08 according to DIN EN 61010 Part 1 IP50 according to DIN 40050 IP20 according to DIN 40050 45 2 Technical Description 2.6 Technical Data Manual - Housing material Polyamide 66 - Mounted on rail NS 35/7.5 NS 35/15 NS 32 - Dimensioned drawing see fig. 2-7 139 NS 35/15 136 NS 32 131.5 66 9 8 7 6 5 4 DIN EN 50022 DIN EN 50035 DIN EN 50035 NS 35/7.5 Center of the mounting rail 39 3 2 1 18 100 12 36 130 Figure 2-7 46 Dimensioned drawing coupling relay, dimensions in mm SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.1 General 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. SIPART DR21 C73000-B7476-C143-08 47 3 Functional description of the structure switches 3.2 Analog input signal processing (S3 to S21) Manual 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 119). 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). yN serves as a tracking input for the manipulated variable in K-controllers (S2=0) or S-controllers with external feedback (S2=3) and yR 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. 48 SIPART DR21 C73000-B7476-C143-08 AI2 +1/4 I --1/3 Figure 3-1 Analog input signal processing SIPART DR21 C73000-B7476-C143-08 I U Slot 2 S64 D or A U 0, 1 S6 S7 50 % 2, 3 4 to 20 mA 0, 1 S8, S9 2, 3 4 to 20 mA 4 MA ME to 7 1 60 Hz D D 2, 3 4 to 20 mA 0, 1 S5 2, 3 4 to 20 mA 0, 1 S4 0, 2 1,3 AI4 AI3 AI2 AI1 1,3 0,2 1,3 0,2 6,7 4,5 1,3 0,2 S4 S5 S6 --3 106 --3 106 --3 106 S7 --3 106 tF4 tF3 tF2 tF1 0 1 0 1 0 1 0 1 AI2A S21 AI3A S21 x/w display 4 AI4A S21 0/1/2/3/5 3 0/1/2/4/5 2 0/1/3/4/5 AI1A MUF Transmitter faultAI 1 2 3 4 signaling S14 S13 S12 S11 1 S21 0/2/3/4/5 0 3 S17 1 4 4 0 3 S16 1 1 2 3 S15 4 0 2 0% 2 0% 0 4 0 3 S20 1 3 S19 4 1 4 0 1 2 3 S18 0% 2 0% 2 0% 0% 5 S21 Z YR YN x3/wEA/ wvEA x2 x1 0/1/2/3/4 3 0 50 Hz S3 A A D A +I -- U Slot 1 S6< 4 D A +I -- U + AI4 I, U, R UNI AI3 I, U, R AI1 +1/2 I --1/1 Manual Functional description of the structure switches 3.2 Analog input signal processing (S3 to S21) 49 3 Functional description of the structure switches 3.3 Digital input signal processing (S23 to S41) 3.3 Manual 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)1) 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 CB ES (optionally time-monitored) or via CBDI (central Computer Fail line) . In addition the internal flip-flop can be activated at S85 = 2 to 5 parallel to pressing the keys via IntES. The CB-signal is formed at S85 = 2, (4)1) as an OR-function of CB ES via the serial interface and CB DI via a digital input so that operation can take place optionally with one signal. 1) 50 as of software version --A5 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.3 Digital input signal processing (S23 to S41) At S85 = 3, (5)1) 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 wES or wEA and for the tracking manipulated variable yES 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 = IntCB (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 = IntCB 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. Computer operation RC is also signalled negated as a message signal RC = IntCB . 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 = IntCB 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 HeES with RC = IntCB is released. 1) as of software version --A5 SIPART DR21 C73000-B7476-C143-08 51 Structureswitch setting 3 Functional description of the structure switches 3.3 Digital input signal processing (S23 to S41) S** 1 0 81) 0 Manual Assignment with structure switches S23 --1 1/5 1/6 S25 5V DI1 1 2 DI2 --1 S26 --1 Slot 3 S27 24 V 3/1 3/2 3/3 3/4 3/5 5V DI3 DI4 DI5 DI6 DI7 3 4 5 6 7 --1 S29 S30 --1 24 V 5V 3/1 3/6 DI3 DI4 4DO+2DI S22=1 3 4 S36 NDI 1 0 S37 SiDI 1 S38 PDI 1 0 S39 tSDI 1 S40 +yBLDI 1 0 S40 -yBLDI 1 S32 bLSDI S33 bLPSDI 0 S39 tSHDI 2) 1 only for CB (S23) and P (S27) as of software --B5 Figure 3-2 52 HeDI bLbDI --1 2) S35 S31 S92 1) 0 0 --1 CBDI 1 S28 5DI S22=2 Slot 3 0 0 --1 S34 1 S24 --1 24 V 0 Assignment and direction of action of the digital inputs S23 to S40 SIPART DR21 C73000-B7476-C143-08 Manual 3 0 1 Functional description of the structure switches 3.3 Digital input signal processing (S23 to S41) S51 0/2 (3/4)1) 1 ge 4 HeES 2/3/(4/5)1) 0,1,2,3 1 S85 S51 2 0/1 S51 & 3/4 0/1/2 S51 HeDI 2/3 (4/5)1) S85 3/4 S51 H 0,1(3/4)1) 0,1 0/1 0/1/2 SiES SiDI bLbDI bLSDI bLPSDI PDI NDI tSDI +yBLDI -yBLDI tSH 3) 2/3 (4/5)1) S85 & 0/1 Si bLb bLS bLPS P N tS PAU +yBL -yBL tSH 3) bLbES 2) tSHES 2/3 (4/5)1) S85 & 0/1 DI 0,1 SES S85 CBES 0/1 CBDI 2 & 2/3 (4/5)1) 3/51) 0/1/2/41) 1 0/1 IntES 2/3 (4/5)1) 1 0 S85 CB RC=IntCB not for S1 = 4 Control unit/processdisplay & 2 0 0 2 4) 0/1 S85 S41 S84 3 1 RB = Int S42 gn S 1 C gn 0,2 --1 1) as 2) as 3) as 4) as of software version --A5 of software version --B3 of software version --B5 of software version --C1 Figure 3-3 1 S41 Linking the digital inputs DI1 to DI7 with the control signals via the SES (S41, S42, S51, S85) SIPART DR21 C73000-B7476-C143-08 53 3 Functional description of the structure switches 3.3 Digital input signal processing (S23 to S41) Manual D Functional explanation of the control signals 54 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 N. 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. tS 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. SIPART DR21 C73000-B7476-C143-08 Manual 3 3.4 Controller types (S1, S42 to S45) 3.4.1 General, recurrent functions Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) D Manual setpoint preset wi or nominal ratio preset wvi on the control front panel. The internal setpoint can always be adjusted with the w-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 E may come from two different sources depending on the controller type. External setpoint as an absolute value via the analog inputs (wEA) external setpoint as an absolute value via the SES (wES) S85 =0, 1, (4, 5)1) or 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, wES at S45 = 1 and wEA, can be avoided. 1) as of software version -A5 SIPART DR21 C73000-B7476-C143-08 55 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual w tan = wE 100 % tS = w tw w tw = SH t tw external Setpoint Figure 3-4 w * tS 100 % safe Setpoint 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 (wES). The safety setpoint SH cannot be tracked. The external setpoint wEA 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 = HNSi 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. 56 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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. SIPART DR21 C73000-B7476-C143-08 57 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual 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 range adjustable with dP, dA, dE I... IV Display levels of the digital display 0000 x displayed variables x, w, xv or wv Display type 0000 digital display analog display 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. 58 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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) 0000 W 00 x yH INTCB wi1 y tS W wi2 + - x1 x2 P I D ya ya+c6 S z x x = x1+c1S (x2 -c2Sx3+c3) x3 z 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. SIPART DR21 C73000-B7476-C143-08 59 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Control commands Digital inputs Front Alarm signals Front LED Digital outputs HNSi CB internal internal 1) Manual C RB RC 0 0 0 0 1 0 1 0 0 0 1 1 0 0 1 1 0 1 0 1 0 0 1 1 0 1 1 1 1 1 1 1 1 0 1 0 0 0 1 1 0 0 1 1 0 1 0 1 0 0 1 1 0 1 1 1 Active w at S43= Explanations 0 1 2) wi1 wi2 wi2 wi2 wi1 (n)1) wi2 (n) wi2 (n) wi2 (n) switchover with CB, Int=0 switchover with Int,CB=1 2) wi1 wi2 wi2 wi2 x x x x switchover with CB,Int=0 switchover with Int,CB=1 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 = IntCB Factory setting 2) 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 Position S81 Function [0] 1 2 3 Switching the w/x-digital display Display order I II III IV x/xv w/wv --x/xv w/wv x1/xv -x/xv w/wi1/wv -wE/wvE/wi2 x/xv w/wi1/wv x1/xv wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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 Table 3-2 60 0 1 0.5 (0 at S81=6) 0 0 0,5 x-signal lamp w-signal lamp Display levels (S81) SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 1 IntCB S45 0 wi1 IntCB n o wi1/wi2 0/1 wi1ES IV 0000 IntCB S85 II w 0000 SA,SE A tS fig. w 3-27, page 104 w 2/3/(4/5)1) wi2 0/1 wi2ES SES n o S85 A=HNSi 2/3/(4/5)1) H = Hi He S43 0 S15 fig. 3-1, page 49 S16 S17 tS tSH A x1 x2 + -- 1 c1, c2, c3 x W x x=x1+c1 * (x2 - c2 * x3+c3) xd x fig. 3-19, page 89 x3 Factory setting c1=c2=c3=0 tF x1 III I 0000 0000 x Adaptation Note: S51=4 is recommended for this controller 1) as of software version --A5 Figure 3-6 Block diagram S1 = 0, fixed setpoint controller with 2 independent setpoints SIPART DR21 C73000-B7476-C143-08 61 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 3.4.3 Manual Slave controller, synchronized controller, SPC-controller with Int/Ext-swtiching (S1 = 1) 00 0000 W wi X wi yH SES wES y tS wE=c4 * we+c5 IntCB wE + X x3/wEA x1 W P I D ya+c6 * z ya x=x1+c1 * x2+c3 x2 X z Figure 3-7 Control principle S1 = 1 In this controller type you can switch between the internal setpoint wi and the external setpoint wE 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 wEA 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). 62 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) D SPC-controls Here a process computer takes over command of the setpoint during computer operation RC = IntCB = 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 = IntCB 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. SIPART DR21 C73000-B7476-C143-08 63 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual D Display of the external setpoint wE 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 wE 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 Position S81 Function [0] 1 2 3 Switching the w/x-digital display Display order I II III IV x/xv w/wv --x/xv w/wv x1/xv -x/xv w/wi1/wv -wE/wvE/wi2 x/xv w/wi1/wv x1/xv wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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, wE 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. 64 SIPART DR21 C73000-B7476-C143-08 Manual 3 Control signals Digital inputs Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Message signals active w at Digital outputs Front Front H N Si CB 1) Internal Internal LED C LED RB 0 1 0 0 0 0 4) E l Explanations ti RC 4) 0 S43=0 S44=0 S43=1 S44=0 S43=0 S44=1 S43=1 S44=1 wE(n)2) wE(n)2) Automatic mode, SPC-mode SH3) or wi(n,) Automatic mode, computer switched off, computer in SPC-standby 0 0 0 0 1 0 1 wi(n,) 0 1 1 1 0 1 1 wi(n,) 0 0 1 1 1 1 1 wi(n,) 1 1 0 0 0 0 0 wE (n)2) x wE (n)2) x 1 0 0 0 1 0 1 wi (n,) x SH3) or wi (n,) x 1 1 1 1 0 1 1 wi (n,) x wi (n,) x 1 0 1 1 1 1 1 wi (n,) x wi (n,) x Comput terfailure Automatic mode, computer on standby, controller not in SPC-standby 5) wi(n,) Automatic mode, computer switched off, computer in SPCstandby wi(n,) Manual-, tracking- or safety mode 5) 1) 2) The table is shown for static CB-switching without acknowledgement (S41 = 0). Source for wE at S85 = 0, 1, (4, 5 as of software version -A5) is wEA or at S85 = 2, 3 wES (SES). The external setpoint fed in through the SES (w ES) is tracked. Tracking is not possible when the external setpoint is fed in via wEA. 3) SH can only be reached after w , if Int = 0 and CB goes from 1 0 (computer failure). If CB = 0 and Int is switched E from 1 0, wi is still active. Since SH is not tracked, switching over to SH can take place with the setpoint ramp tS. 4) 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. 5) 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 SIPART DR21 C73000-B7476-C143-08 65 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Control signals Digital inputs Manual Message signals Front active w at Digital outputs Front E l Explanations ti H N Si CB 1) Internal Internal LED C LED RB 0 1 0 0 0 0 0 wE2) wE2) 0 0 0 0 1 0 1 wi() SH3) or wi() 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 4) RC 4) S43=0 S44=0 wE2) S43=1 S44=0 S43=0 S44=1 S43=1 S44=1 Automatic mode 5) x wE2) x x 1 0 0 0 1 0 1 wi() x SH3) or wi() 1 1 1 1 0 1 1 wi() x wi() x 1 0 1 1 1 1 1 wi() x wi() x Manual-, tracking- or safety mode 5) 1) 2) The table is shown for static computer switching without acknowledgement (S41 = 0). Source for wE at S85 = 1, 2, (4, 5 as of software version -A5) is wEA or at S85 = 3, 4 wES. Switching between the setpoints can take place with the setpoint ramp tS. 3) SH can only be reached after w , if Int = 0 and CB goes from 1 0 (computer failure). If CB = 0 and Int is switched E from 1 0, wi is still active. Since SH is not tracked, switching over to SH can take place with the setpoint ramp tS. 4) 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. 5) Factory setting adjustable Factory setting Table 3-5 66 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 SIPART DR21 C73000-B7476-C143-08 Figure 3-8 SIPART DR21 C73000-B7476-C143-08 x1 x2 S15, S16, wi1ES 0/1 Adaptation Factory setting c1=c3=0 tFI 1) as of software version -A5 S85 S44 c4, c5 1 0 S45 Factory setting c4 = 1, c5 = 0 wE=c4*wE+c5 SH 0/1/(4/5)1) wE 2/3 wES w-c3 c4 x=x1+c1 * x2+c3 c1, c3 wES S85 1) 0 wE CB CB wi Int Int 0 wE 1 S43 A A SA, SE x1 0000 III II x I X w tS 0000 0000 A = HNSi H = HiHe 0000 IV tSH tS W W X -- + x Figure 3-19, page 89 xd Figure 3-27, page 104 w 3 Note: S51 = 4 is recommended for this controller x3/wEA S17, Figure 3-1, page 49 SES 2/3/(4/5)1) n o wi1 1 Manual Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Block diagram S1 = 1 slave controller, synchronized controller, SPC-controller 67 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 3.4.4 Manual 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 = IntCB = 1 00 0000 W wi X x - TRACKING yH tS W + x1 x2 x3 Y P I D ya ya+c6 * z IntCB X yN x=x1+c1 * (x2 - c2 * x3+c3) yES z yN Figure 3-9 68 SES Control principle S1 = 2 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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 computer failure. The setpoint is always displayed which would become active after the computer failure. With S50 a choice is made between x-tracking and wi, with 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 N, 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. SIPART DR21 C73000-B7476-C143-08 69 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual Footnote explanation, see page 72 Table 3-6 70 DDC controller, S1 = 2, manual operation has priority over DDC operation S49 = 1 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Footnote explanation, see page 72 Table 3-7 DDC controller, S1 = 2, manual operation has priority over DDC operation S49 = 1 SIPART DR21 C73000-B7476-C143-08 71 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual Notes to table 3-9 and table 3-7 1) Manual operation can be achieved by: Control signals Digital input He Front Hi 0 1 0 1 Table 3-8 Message signals Front Manual LED Digital output H 0 0 1 1 0 0,9 6) 1 1 0 1 1 1 Generation of the control signal H = HiHe 2) In DDC-operation the setting current is switched off at S52 = 1. Source for yE at S85 = 0, 1,(4, 5 as of software version --A05), y isN. At S85 = 2, 3, y actsES (SES). The external manipulated variable fed in through the SES (y ES) is tracked. When feeding in via yN the feeding instrument must be tracked. 3) The table is shown for static computer switching without acknowledgement, S41 = 0. 4) 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. 5) 0.5 = Flashing rhythm 1 : 1 6) 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. 72 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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 Position S81 Function [0] 1 2 3 Switching the w/x-digital display Display order I II III IV x/xv w/wv --x/xv w/wv x1/xv -x/xv w/wi1/wv -wE/wvE/wi2 x/xv w/wi1/wv x1/xv wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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) SIPART DR21 C73000-B7476-C143-08 73 74 S15, x1 S16, x2 S17, x3/wvEA fig. 3-1, page 49 SES wi1ES c1, c2, c3 S85 1) wi 0 0 1 Adaptation Factory setting c1=c2=c3=0 tF x=x1+c1 * (x2 - c2 * x3+c3) 0/1 2/3/(4/5)1) n o wi1 SH 1 X S43 S44 1 0 1 0 H H H H H 1 0 S49 Si Si Si X X1 I 0000 Int Int 0000 III CB CB X SA,SE Note: S52 = 4 is recommended for this controller 1) as of software --A5 S43 S45 0000 tS II/IV tSH tS W W -- + x Fig. 3-19, page 89 xd fig. 3-27, page 104 w 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual Figure 3-10 Block diagram S1 = 2, DDC fixed setpoint controller SIPART DR21 C73000-B7476-C143-08 Manual 3 3.4.5 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Controlled ratio controller (S1 = 3) SES 00 0000 wvi wv wVES w x w wv yH tS w=v * x2+c5 x2 wVEA IntCB vis= x2 y v = vA to vE v = wv*(vE - vA)+vA xv W + - x1 - c5 x2 ya+c6 * z P I D X ya x1 x1 z 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 v = x1 -- c5 , i.e. in the controlled state and at x2 c5 = 0 x1 behaves according to the set ratio factor v. x2 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 wvE) 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 SIPART DR21 C73000-B7476-C143-08 75 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual 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 wvE (display level IV). The digital x/w-display indicates the actual ratio xy in display levels I and III. Switching between wvi and wvE 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: vis = x1-c5 x2 with vist = xv (vE -- vA) + vA the result is for xv = vis -vA vE-vA or xv = x1-c5 - vA x2 vE-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 wyE 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 Position S81 Function [0] 1 2 3 Switching the w/x-digital display Display order I II III IV x/xv w/wv --x/xv w/wv x1/xv -x/xv w/wi1/wv -wE/wvE/wi2 x/xv w/wi1/wv x1/xv wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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 76 Display levels (S81) SIPART DR21 C73000-B7476-C143-08 SIPART DR21 C73000-B7476-C143-08 S15, x1 tF 0,1 wVES 2/3(4/5)1) S85 1) 1 Adaptation wV E 0 1 S43 A A A = HNSi H = HiHe Int Int wV E of software version --A5 of software version -A9 CB CB wvi 1) as 2) as 0 S44 S85 0/1/(4/5)1) 2,3 wVES SH 1 S45 tS tS tSH w=v * x2+c5 vA, vE, c5 vis= x1 - c5 x2 xv = xv 0000 v=vA to vE v=wv (vE - vA)+vA Factory setting x2 vA=0, vE=1, c5=0 wV wv 0000 0000 I/III x Vis-vA vE-vA w x1 0000 w S81 = 7 III 2) -- + w 0000 IV 2) x fig. 3-19, page 89 xd fig. 3-27, page 104 w 3 S16, x2 fig. 3-1, page 49 S17, x3/wvEA SES wiES n o wvi 0 II IV Manual Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Figure 3-12 Block diagram S1 = 3 controlled ratio controller 77 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual 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 wE 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 c v x + w + x1 x2 KL + -- x d KG QG QL y GAS 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 QL which is preset in the range 0 to 12000 m3/h as a signal 4 to 20 mA. The controlled variable (following process variable) is the gas flow QG with a measuring range 0 to 3000 m3/h which is also available as a 4 to 20 mA signal. In an ideal combustion the air-/gas ratio is L ideal = QL = 4. QG QL =L QG 78 The air factor is then 1 and should be adjustable in the range from 0.75 to 1.25 on the controller. SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) The ratio factor v (at xd = 0) is determined partly by the transmission factors K of the transmitters (measuring ranges). 100 % x1 = QG KG with the values from the example KG = 3000 m 3/h x2 = QL KL KL = v= x1 K Q = G G x2 QL KL v= 1 KG L KL with QG = 1 QL L 100 % 12,000 m 3/h With the values from the example 1 100 % h 12,000 m 3 v= 1 4 3,000 m 3 100 % h the result is v = 1 1 KG KL = L that i.e. the choice of the transmitter ranges has been made so corresponds to The desired adjustment range of gives: vA = 1 1 = 1,25 E vE = = 0,8 1 1 = 0,75 A = 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 from 1.25 to 0.75. v 0.75 1.33 1.3 0.8 1.2 0.9 1.1 1 1 1.1 0.9 1.2 1.25 0.8 wv 0 0.2 0.4 0.6 0.8 1 Figure 3-14 Relationship ratio factor v and air factor 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 and c = 0 as well as at = 1 and c <0, i.e. with excess air. SIPART DR21 C73000-B7476-C143-08 79 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) X1 mA X1 % 120 22 20 18 16 12 10 100 6 4 V=1,33 80 =0.75 3500 V=1 =1 3000 90 V=0.8 2500 =1.25 1) V=1, c<0 2) 2000 60 50 1500 40 30 8 QG Gas m3/h 110 70 14 Manual 20 1000 500 10 0 0 0 2000 4000 6000 8000 10000 12000 m3/h air QL X2 1) 2) 0 10 4 6 20 30 8 40 10 50 60 12 14 70 80 16 90 100 18 20 % X2 mA constant gas/air-ratio gas/air-ratio with additional excess air Figure 3-15 Display of gas-/air ratio in controlled status 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 EA and to the red analog 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 80 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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 R. 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). SIPART DR21 C73000-B7476-C143-08 81 82 yR x1 x2 wEA fig. 3-1, page 49 Int CB 1 -w & 1 & & --1 & +w & & & wi SES -- + 0/1/(4/5)1) 2/3 wES w-c5 c4 S85 we c4, c5 SH 0 1 0 1 S45 1) S44 wi CB CB as of software --A5 Factory setting c4 = 1, c5 = 0 wE=c4 * wE+c5 RC = CBINT = CBInt wE Int Int wE II Y1, Y2 x x1 I 0000 X y 0000 x x1 SA,SE I 0000 III 0000 IV 2 1 tS Figure 3-16 Block diagram control unit/process display (S1 = 4) setpoint generator S/K, manual control station S/K SIPART DR21 C73000-B7476-C143-08 oFF 3 0 5 S54 W S80 0 ... 4 w 6 0 S55 1 x -- + xd y 00 x fig. 3-19, page 89 A1, A2 A1 ... A4 w fig. 3-27, page 104 -w +w RC 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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 w 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 EA, 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 EA. The active setpoint is output by assignment of w to the analog output 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. SIPART DR21 C73000-B7476-C143-08 83 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Structure switches Manual Position Function S81 [0] 1 2 3 Switching the w/x-digital display Display order I II III IV x/xv w/wv --x/xv w/wv x1/xv -x/xv w/wi1/wv -wE/wvE/wi2 x/xv w/wi1/wv x1/xv wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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 Table 3-11 CB1) 0 1 0.5 (0 at S81=6) 0 0 0,5 x-signal lamp w-signal lamp Display levels (S81) Control signals Digital in-puts 0 1 Message signals Front Front Digital outputs Internal Internal LED C LED RB 0 0 1 0 0 0 0 0 active w at Effect of the w-keys on wired or IntCB RC5) S44=0 S44=1 wi w/BA 1 3) we(n)2) 3) we(n)2) no yes 07) 1 3) we(n)2) 3) we(n)2) no no 1 3) wi(n,) yes no 1 SH4)6) no6) no6) 16) 0 1 1 1 1 0 3) wi(n,) 16) 16) 16) 06) 16) 16) 3) we(n)2)6) 1) 2) The table is shown for static CB-switching without acknowledgement (S41 = 0). Source for wE at 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. 3) Tracking only takes place at S45=0 and only w ES and wi to the active setpoint. When feeding in via wEA the feeding instrument must be tracked. 4) Only to be used as a flag pointer when no analog feedback is possible from the fed instrument. 5) RC = no K-setpoint generator operation, wi not adjustable. 6) Factory setting 7) wired-or-connection of Int = RB and CB supplies IntCB No S-setpoint optentiometer operation, w-keys not active (n) tracked to the value active before switching, therefore bumpless switching adjustable Table 3-12 84 Setpoint switching setpoint generator S/K, S1 = 4 process display/control unit SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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 y-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). SIPART DR21 C73000-B7476-C143-08 85 Manual +yBL 2, 3 1 S54 0 0 1 0 0 S55 yAn 1 0 +yH 0 N N 0 0 +y -y H 1 H rt 00 -yH 2 1 0 yS50 2 0 S51 1 S51 Si 1 Si 0 yS>50 +yBL S29 0 -yBL -yBL S30 S19 yR S57 -y S57 +y GND E y 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 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) 86 SIPART DR21 C73000-B7476-C143-08 00 tP, tE S55 YAn -y S57 tM, tA 2) 1) +yBL -yBL S30 S29 < tM 2/3/(4/5)1) yHES yN yn S18 SES yES 0/1/(4/5)1) S85 N 1/3 S53 A 0/2 ya tP, tM (S2 = 0) YA YE yE 2/3 0 yES 0/1 H S85 0 yH > YS Si 2 S51 1 as of software version --A5 as of software version --B2 yR N S52 1 0 YA YE 2) 2 S19 3 oFF S54 1 0 S2 0/2 1/3 S53 0 1 Y1 Y2 1 0 12/13 S56 10/11 0/1 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) +y S57 3 y S56 Manual 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) SIPART DR21 C73000-B7476-C143-08 87 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Manual Control signals Message signals Digital inputs Front Front Explanations 0 ya(n) Hold operation 0 yH(n,) Manual mode 1 0 yH(n,) Manual mode 0 1 0 yH(n,) Manual mode 1 0 1 yE(n)1) Tracking operation 0,55) 1 1 1 yE (n) Tracking operation 1 0,55) 1 1 1 yE (n) Tracking operation 1 0,55) 1 1 1 yE (n) Tracking operation 0 0,55)6) 1 0 1 1 0,55)6) yBL2) 1 0 1 0,55)6) 1 Si N 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 H LED y-Ext. LED H Nw 0 0 0 0 0 0,94) 0 1 0 1 1 0 0 1 1 1 1 0 0 0 0 1 1 0 0 0 1 0 0 0 1 1 1 Hi8) as above Table 3-13 Digital inputs Safety operation Digital outputs ya(n) Hold operation 0 yH(n,) Manual mode 1 0 yH(n,) Manual mode 0 1 0 yH(n,) Manual mode 0 1 0 1 yE(n)1) Tracking operation 0 0,94) 0,5 1 1 yH(n,) Manual mode 0 1 1 0,55) 1 1 yH(n,) Manual mode 1 1 1 0,5 1 1 yH(n,) Manual mode 0 0,55)6) 1 0 Blocking operation 1 1 0,55)6) yBL2) 1 0 1 0,55)6) 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 H LED y-Ext. LED H Nw 0 0 0 0 0 0,94) 0 1 0 1 1 0 0 1 1 1 0 1 0 0 0 0 1 1 0 0 1 0 0 1 1 as above as above 0 0 yBL2) yS3) Blocking operation Safety operation Source for yE at S85 = 0, 1, (4, 5 as of software version -A5), y isN as an absolute value assigned via S18. At S85 = 2, 3, y ES via the SES. The external manipulated variable through which SES (y ES) is fed in is tracked. When feeding in via yN 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 yE in 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 0.5 = flashing rhythm 1:1 only if HiHe = 1 for S51 3,4 As of software version -A7 the signals HeDI and HeES with S51 = 3, 4 have dynamic effect (0/1-edge). They then act like the Hi-signal (see figure 3-3, page 53) tracking takes place to the value active before switching, therefore bumpless switching adjustable Table 3-14 88 Blocking operation 0 Hi8) yS3) Blocking operation Explanations Hi7) (n) 0 yBL2) active y at N 4) Front Front Si 5) 6) 7) 8) 0 Message signals yBL 2) 3) as above Output switching manual control station S/K (S1 = 4) Tracking operation has priority over manual operation (S49 = 0) Control signals 1) Digital outputs active y at yBL Hi7) Output switching manual control station S/K (S1 = 4) Manual operation has priority over tracking operation (S49 = 1) SIPART DR21 C73000-B7476-C143-08 Manual 3 3.4.7 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) Fixed setpoint controller with one setpoint (control system coupling) (S1 = 5) 1) 1 S45 0 wi1 II, IV n o 0000 A W SA,SE tS IntCB 2/4 w1ES S85 2...5 w Figure 3-29, Page 110 0/1/3 A S51 A=HNSi H = Hi He S43 0/1 0 + -- 1 X xd W SES Figure 3-21, Page 92 c1, c2, c3 Figure 3-1, Page 49 x1 x2 x x3 Factory setting c1=c2=c3=0 tF 1) as x x =x1+c1 * (x2-c2 * x3+c3) of software version --A5 x1 III I 0000 0000 x Adaptation 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 IntCB the setpoint signal wiES is separated and manual intervention via HeES at 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. SIPART DR21 C73000-B7476-C143-08 89 3 Functional description of the structure switches 3.4 Controller types (S1, S42 to S45) 3.4.8 Manual Slave controller without Int/Ext -switching (control system coupling) (S1 = 6) 1) II, IV Figure 3-1, Page 49 0000 W c4, c5 SA,SE S17 wEA we tS w Figure 3-29, Page 110 wE =c4*wE + c5 Factory setting c4=1, c5=0 x xd + -- W Figure 3-21, Page 92 c1, c3 S15, x1 S16, x2 x x =x1+c1 * x2+c3 Factory setting c1=c3=0 tFI Adaptation 1) as x1 x III I 0000 0000 x of software version --A5 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 IntCB manual intervention via HeES at S51 = 3 is suppressed. The other functions are unchanged in relation to S1 = 1. S51 = 3 is expressly recommended for this connection. 90 SIPART DR21 C73000-B7476-C143-08 Manual 3.5 3 Functional description of the structure switches 3.5 Control algorithm 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 - PI-controller ya = Kp (xd + - ya = Kp xd or 1 Tn t0 xd dt) +yo(t) or ya 1 = Kp (1 + xd j Tn ) D-element connection (zD-part) The D-element connection can be added optionally. ya j Tv = Kp Tv E 1 + j vv 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 z or ya = c6 z 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). SIPART DR21 C73000-B7476-C143-08 91 ya Manual Output structures S2 c7 in PI-operation = 1 c7 in P-operation 1 to 9.999 adjustable + + d 1 0 1 -1 -1 x x1 S15 z S20 xd -1 tF Control structure 1 2 3 4 0 S47 AHI -1 -1 0 S46 S46 c6 Kp 1) c6 z Kp*c7 1) vv tn + + tv P yo yo=yn-p yo=yn-(kp*c7*xd+c6*z) p p i + P (S27) YA, YE 2 0/1/3 S2 yn 3 Functional description of the structure switches 3.5 Control algorithm Input signal processing figure 3-1, page 49 and controller types S1 Figure 3-21 Block diagram controller structure 92 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.5 Control algorithm 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 = yH - (Kp * c7 * (w - xH) + c6 * z) If the actual value in manual mode (xH) is driven to the desired setpoint w by the appropriate manual manipulated variable yH, the operating point yo is identical to the manual manipulated variable yH. 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 ya reaches one of the limits YA 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). SIPART DR21 C73000-B7476-C143-08 93 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Manual 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 S2=1 S2=2 S2=3 K-controller Two-position controller with 2 S-outputs heating/cooling, optionally one K-output S-controller with internal feedback 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. 94 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) 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 + y, -y. 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). SIPART DR21 C73000-B7476-C143-08 95 96 yH yn < PID yH > S85 SES yHES yN N/DDC yH 2/3/4/51) tP, tM 0/1 A 1) S53 H 0/(3/4) A = HNSi H = HiHe 0 1 ya tP, tM (S2 = 0) YA YE S85 N S18 yES 2/3 yES 0/1/(4/51) 2 1 S51 1) 2) S30 1 0 S52 as of software version -A5 as of software version --B2 +yBL -yBL S29 YS Si YA YE 0 1 DDC N/ yR S2 S53 2 S54 oFF 3 S19 1 0 1 0 Y2 Y1 1 0 Y1 12/13 Y2 0/1 10/11 S55 2) yAn 00 tE, tP tA, tM S56 +y S57 -y S57 y S56 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Manual Figure 3-22 Block diagram K-controller S2 = 0 or two-position output S2 = 1 Tracking (DDC) has priority over manual operation S49 = 0 SIPART DR21 C73000-B7476-C143-08 SIPART DR21 C73000-B7476-C143-08 yn PID S18 yn A yES yES 0/1/(4/5)1) S85 1 S53 yE N/ DDC 0 ya tP, tM (S2 = 0) YA YE yH 2/3 0 < yH > yH H S85 0/(3/4)1) SES yHES Si YS 0/1 2/3/4/51) tP, tM 2 1 S51 A = HNSi H = HiHe S30 +yBL -yBL S29 1) 2) S52 0 1 N/ DDC yR S2 S53 as of software version -A5 as of software version --B2 1 0 YA YE 2 S54 oFF 3 S19 1 0 1 0 Y2 Y1 1 0 y1 2) yAn 00 tE, tP tA, tM S56 S55 y2 12/13 10/11 0/1 +y S57 -y S57 y S56 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Figure 3-23 Block diagram K-controller S2 = 0 or two-position output S2 = 1 Manual operation has priority over tracking operation S49 = 1 97 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Manual 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 y-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 = Y2 to 100% (heating +y) period duration tP from 0 to 1000s minimum pulse pause, -length: tE y = 0 to Y1 (cooling -y) period duration tM from 0 to 1000 s minimum pulse pause, -length: tA setting ratio 1 1 Cooling Heating y +y 0,5 0,5 Chapter y = Y1 to Y2 Dead zone no setting pulses Y2 35% Y1 0% y 40% 100 % tA On Off tM tM tE Cooling, example with setting ratio = 50 % On Off tP tP Heating, example with setting ratio = 50 % Cooling y-display Continuous contact to clocking Heating to Dead zone, no output Figure 3-24 Setting ratio, actuating pulses of two-position controller 98 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) 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. To 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 YA and an absolute value preset of YE und YS. The safety manipulated variable YS is specified as a direction-dependent continuous contact. At YS 50 % (oFPA) -y switches, at YS > 50 %, +y switches to continuous 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: 100 % tE tY - Switching on Aee = 2 - Switching off Aea = - Hysteresis - Pause - tY = tP, tM set actuating time (parameterization mode onPA) 100 % tE tY Aee -- Aea = Aa = 100 % tE tY 100 % tA tY 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 yR 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. SIPART DR21 C73000-B7476-C143-08 99 Manual S30 2, 3 S54 1 H 1 0 1 -yH 2 0 N 0 * as of software version -A5 0 yS50 1 +yBL S29 0 yS>50 Si 0 Si 0/(3/4)* 1 S51 N 2 YAn S55 1 0 00 A = HNSi H = HiHe - +yH H 0/(3/4)* 1 S51 tP, tM + yn PID ya + - internal position control circuit tA, tE +Ya -yBL S19 yR S57 -y S57 +y GND E y 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Figure 3-25 Block diagram S-controller with internal feedback S2 =2 Tracking (DDC) has priority over manual operation S49 = 0 100 SIPART DR21 C73000-B7476-C143-08 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) * as of software version -A5 1 -yH 1 H 2/3 1 0 0 S54 N A +yH H YAn S55 1 00 A = HNSi H = HiHe - + tP, tM 0 -Ya A 0 N +Ya tA, tE + PID yn ya internal position control circuit -yBL S29 0 1 0 yS50 2 S51 0/(3/4)* 0/(3/4)* 2 1 S51 1 Si Si 0 yS>50 +YBL +yBL -yBL 0 S30 S19 yR S57 -y S57 +y GND E y Manual Figure 3-26 Block diagram S-controller with internal feedback S2 =2 Manual operation has priority over tracking (DDC) S49 = 1 SIPART DR21 C73000-B7476-C143-08 101 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Manual D S2 = 3: Three-position step controller (S) with external feedback see figure 3-27, page 104 and figure 3-28, page 105 To control I-acting motorized actuating drives. In S-controllers with external feedback the "internal position control circuit" is replaced by a real position controller (with the K-controller output y as a setpoint and the position feedback y R as an actual value). As a result a manipulated variable limiting of ya and an absolute value preset of yE and ys are now possible. With the absolute value preset of y E it is also possible to preset the manual manipulated variable via the SES as an absolute value y ES in tracking operation. Here too the response threshold of the position controller is preset with the parameters tE (minimum turn-on duration) and tA (minimum turn-off duration) in connection with tP and tM (actuating time positive/negative direction) which are all set in the parameterization mode onPA: 100 % tE tY 100 % tE 3 tY 100 % tE Aea = tY 100 % tA tY - Switching on Aee = 4 - Switching off Aea = - Hysteresis Aee -- - Pause Aa = tY = tP, tM set actuating time (parameterization mode onPA) If a control deviation of xds Aee is set up, the three-position switch switches directiondependently to continuous contact. xds is reduced by the negative follow-up of the position control circuit until xds <Aea is reached. The continuous contact is now switched off. After the pause time tA pulses of length tE are output with subsequent pause time tA until xds Aee is reached. +y -Aea -Aee Aea Aee xdS -y These single pulses are also output if xds coming from zero does not reach Aee. These single pulses which are not fully transformed into the path change (rotational movement) additionally settle the control circuit, i.e. in theory (without lag) the single pulses would switch off at 0.25 or 0.5 Aee. The opposite direction can only occur at appropriate control deviation after the pause time tA. 102 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) The manual adjustment is made as an incremental adjustment by far overranging of the three-position switch so that manual adjustment is also possible when the position feedback is interrupted. (Only at S54=1 or 3) To simplify commissioning of the position control circuit, the manual manipulated variable is preset absolutely at S54=0 (manipulated variable of the K-controller) so that the setpoint of the position control circuit is changed continuously by the manual manipulated variable in this structure switch position to enable optimization (see chapter 6.2, page 183 ). It should be taken into account here that the manual manipulated variable which is also displayed is changed faster by the actuating time tY than the active manipulated variable on the actuator and a lag therefore takes place. The controlling status can be monitored on the y-LEDs (9) in the y-display. After optimization, S54 should be set to 1 to display the active manipulated variable via the position feedback yR. SIPART DR21 C73000-B7476-C143-08 103 Manual S19 S29 * as of software version - A5 1 0 S53 0 2,3 1 -- + y S18 yH SES yH yN PID < yH S85 yHES 0,1 2,3,4,5 tP, tM yN yN S53 1 YA YE 0 ya yAN S55 0 yES 2/3 0/1 (4/5)* yES N/DDC 0/(3/4)* H 2 1 S51 yE S85 00 yS Si 1 y S54 YA YE +yBL --yBL S30 & tP, tM tA tE & external position control circuit yR S57 +y S57 --y GND E y 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Figure 3-27 Block diagram S-controller with external feedback S2 =3 Tracking (DDC) has priority over manual operation S49 = 0 104 SIPART DR21 C73000-B7476-C143-08 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) S19 S29 * as of software version - A5 S85 yAN S55 yHES S18 yN yES yH yH 0/1 yES 2,3 H S85 1 0/1/(4/5)* 2/3/4/5 tP, tM yS 00 yS Si 1 0 y 2 S51 0/(3/4)* N/DDC yE S53 0 yn PID SES 1 0 S54 S53 0 2,3 1 -- + y YA YE 1 ya * <> YA YE +yBL --yBL S30 & tP, tM tA tE & external position control circuit yR S57 +y S57 GND --y E y Manual Figure 3-28 Block diagram S-controller with external feedback S2 =3 Manual operation has priority over tracking (DDC) S49 = 1 SIPART DR21 C73000-B7476-C143-08 105 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Control signals Digital inputs Manual Message signals Front Digital outputs Front active y yBL Si N He7) Hi8) H LED y-Ext. LED H Nw 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 1 1 0 0,94) 1 1 0 0 0 0 0 1 1 1 0 0 0 0 ya (n) yH (n), () yH (n), () yH (n), () 0 0 0 0 0 0 0 0 1 1 1 1 0 1 0 1 0 0 1 1 0 0,55) 0,55) 0,55) 1 1 1 1 0 1 1 1 1 1 1 1 yE (n) 1) yE (n) yE (n) yE (n) 1 1 0 0 1 1 0,55)6) 0,55)6) 0,55)6) 1 1 1 as above 0 0 0 Table 3-15 as above yBL 2) yBL 2) yS 3) Explanation p Automatic mode Manual mode Manual mode Manual mode Tracking operation Tracking operation Tracking operation Tracking operation Blocking mode Blocking mode Safety operation Output switching of all controller types except DDC-fixed setpoint controller (S1 = 2) Tracking operation has priority over manual operation (S49 = 0) Control signals Digital inputs Message signals Front Digital outputs Front active y Hi8) H LED y-Ext. LED H Nw Explanation p yBL Si N He7) 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 1 1 0 0,94) 1 1 0 0 0 0 0 1 1 1 0 0 0 0 ya (n) yH (n), () yH (n), () yH (n), () Automatic mode Manual mode Manual mode Manual mode 0 0 0 0 0 0 0 0 1 1 1 1 0 1 0 1 0 0 1 1 0 0,94) 1 1 1 0,55) 0,55) 0,55) 0 1 1 1 1 0 0 0 yE (n) 1) yH (n), () yH (n), () yH (n), () Tracking operation Manual mode Manual mode Manual mode 1 1 0 0 1 1 0,55)6) 0,55)6) 0,55)6) 1 1 1 as above 0 0 0 Table 3-16 1) 2) 3) 4) 5) n 6) 7) 8) as above yBL 2) yBL 2) yS 3) Blocking mode Blocking mode Safety operation Output switching of all controller types except DDC-fixed setpoint controller (S1 = 2) Manual operation has priority over tracking operation (S49 = 1) Source for yE is at S85=0,1 (4, 5 as of software version -A5) yN, at S85=2, 3 yES via the SES. The external manipulated variable fed in through the SES (y ES) is tracked. When feeding in via yN the feeding instrument must be tracked. Blocking operation acts direction-dependently, changes to the opposite direction are possible. Function yS in 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 0.5 flashing rhythm 1:1 Tracked to the value active before switching, therefore bumpless switching adjustable only if Hi He for S51 3, 4 As of software version -A7 the signals HeDI and HeES with S52 = 3, 4 have dynamic effect (0/1-edge). They then act like the Hi-signal (see figure 3-3, page 53) 106 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) D Automatic mode (y = ya) The automatic mode is switched on with the Automatic/Manual key or in the case of dynamic switching (S51= 3,4) 1) via He (yellow manual LED (8) off). All other control signals He, N (DDC), Si and yBL must be 0. The automatic manipulated variable is connected through to the controller output. D Manual mode (y = yH) Manual operation is switched on by the Automatic/Manual key (yellow manual LED(12) on) or the control signal He as an OR function. The control signal He acts statically in the structure switch positions S51 = 0,1 static. At S51 = 3,4 it is dynamic, i.e. every positive edge causes a switching process. The control signals Si and yBL must be 0. If tracking operation has priority over manual operation (S49=0), the control signal N (DDC) must also be 0. Otherwise tracking operation or safety- or blocking operation become active, the manual-LED then flashes in 0.5 rhythm as an identification. The manual manipulated variable is switched through to the controller output. The manual manipulated variable is preset in K-controllers as an absolute value, in S-controllers as a positioning increment. D Tracking-(DDC)-operation (y = yE) The tracking operation is switched on by the control signal N (in DDC-mode by the control signal CB and the Internal/External, see chapter 3.4.4, page 68). The control signals Si and yBL must be 0. If manual mode has priority over tracking mode (S49 = 1) the control signal H = HiHe must be 0. The external manipulated variable yE is connected through to the controller output. The source for yE at S85 = 0, 1,(4, 5 as of software version --A05), is preset as an absolute value y N. With S85 = 2, 3 the absolute value becomes active as an external manipulated variable via the SES (yES). In S-controllers with internal feedback (S2 = 2), absolute value presets of the manipulated variable and thus the tracking operation are not possible. D Safety operation (y = YS) The safety operation is switched on by the control signal Si. The control signal yBL must be 0. The safety manipulated variable YS is through connected which can be set as a parameter in the structuring mode oFPA in the range from -10 to 110 %. In S-controllers with internal feedback (S2 = 2) absolute value preset of the manipulated variable is not possible. When safety operation is active, at YS50 % -y continuous contact and at YS > 50 % +y continous contact is output so that the actuator drives to the end positions. 1) as of software version - A05 SIPART DR21 C73000-B7476-C143-08 107 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) Manual D Direction-dependent blocking operation Blocking operation is controlled by the control signals yBL. All other control signals have no function. If a control signal is applied the manipulated variable output is blocked directiondependently, i.e. only changes in the opposite direction are allowed. If both control signals are applied simultaneously, the output is blocked absolutely. The direction-dependent blocking is necessary especially in S-controllers with internal feedback and actuators with limit stop switches to avoid integral saturation. If the control circuit is opened on reaching the end position of the actuator, further integration of the controller must be prevented in order to be able to react immediately in the event of control difference reversal. As described above, the control signals yBL have priority over Si and H or N. Priority of H or N can be selected via S49. All these operating modes have priority over automatic operation. Signaling of the switching states is made by the LEDs Manual (12) and y-external (13). When manual mode is active or preselected (if the priority opeating modes are active), the manual LED lights up. He = 1 is signaled by a flashing rhythm of 0.9 (control signal) if Hi = 0 (i.e. is in automatic mode by the manual/automatic switching). When switching the control signal He from 1 ! 0 the automatic mode becomes active. Tracking-(DDC), safety-and blocking operation is signaled by the y-External LED. Flashing rhythm 0.5 indicates that in "manual operation priority over tracking operation", manual operation is active but tracking operation is prepared and after switching to automatic operation also becomes active. D Blocking of the manual/automatic switching (S51) With S51 the manual/automatic switching can be blocked in the operating mode Automatic mode only or Manual mode only. The other operating modes are still possible. Then, tracking mode is only possible if tracking has priority over manual mode (see figure 3-22, page 96). D Manual mode in the case of a transmitter fault (S50) With S50 manual mode can be switched to when the transmitter group fault message occurs (see chapter 3.2, page 47). Manual operation starts at S50=1 with the last y or at S50 = 2 with the parameterized YS. In both cases the manual manipulated variable can be adjusted with the y keys after switching. D Source and direction of effect of the y-display (S54, S55) With S54 the y-display is switched to the different display sources or switched off. The absolute manipulated variable y or the split range-manipulated variables y1 and y2 in two-position controllers heating/cooling or the position feedback-signal yR in three-position-S-controllers can be displayed. With S55 the display direction rising/falling can be selected (see chapter 6.1), page 181. 108 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.6 Controller output structures (S2, S49 to S55) D Control system coupling via the serial interface As of software version A5 in addition to the DDC controller (S1 = 2) the SPC controller (S1 = 1) a parallel process operation is possible in all controller types via the serial interface. The control signals Int and Hi (via HeES at S51 = 3/4, see chapter 3.3, page 50) and the process variables wi and y H can be written at S85 2 via the serial interface so that switching from internal to external setpoint and Automatic/Manual switching is possible in all controller types. If the internal setpoint wi or the manual manipulated variable yH is active it can also be changed by the SES or the adjusting keys on the front panel. Since the SES can only adjust absolutely and not incrementally, it is advisable to use the setpoint ramp (tS) or the dynamic manipulated variable with tP and tM to avoid steps. This parallel operation using the serial interface can be locked at S51 = 3 by RC = IntCB (see figure 3-3, page 53). This locking facility for the operation via SES on the controller front is only useful in the controller types fixed setpoint controller with a setpoint (S1 = 5) and follow-up controller without Internal/External switching (S1 = 6) because in all other controller types both the Internal key and the control signal CB have other additional functions. At S51 = 4 this locking facility is omitted and operation is always parallel to the front keys. To avoid simultaneous actuation by the controller front and the SES the last switching action can be read on the process control system. For this, a status bit is set when writing IntES and HeES which is only reset when the front keys Int or Hi are actuated. By requesting the status bit, the process control system can issue a warning when the last operation took place via the front. If the last operation took place via the SES the warning SES flashes for 3 s in the x/w display when the Internal key or the Manual key is pressed. This initial pressing of the keys does not activate a switching function, only when the keys are pressed again is the desired switching function triggered. At S84 = 1 writing of status signals SiES... to ...tSHES is locked by /RC. If the last operation took place via the serial interface the warning SES flashes for 3 s in the x/w display when the internal key or the manual key is pressed. This initial pressing of the keys does not activate a switching function, only when the keys are pressed again is the desired switching function triggered. At S84 = 2 writing of status signals SiES... to ...tSHES is locked by CB. At S84 = 3*) the status signals SiES... to ...tSHES are always available via the serial interface (siehe figure 3-3, page 53). *) as of software version C1 SIPART DR21 C73000-B7476-C143-08 109 3 Functional description of the structure switches 3.7 Analog output signal processing (S56) 3.7 Manual Analog output signal processing (S56) The controller-internal variables are assigned to the analog output AO/Iy by structure switch S56, whereby every controller variable can be structured to 0 or 4 to 20 mA. The bipolar process variable xd is output with an offset of 50 % (10 mA or 12 mA). Analog output Iy assignment and current range S56 = 0 ... 20 y 4 ... 20 0 ... 20 w 4 ... 20 0 ... 20 x 4 ... 20 0 ... 20 x1 4 ... 20 0 ... 20 xd 50 % + 1 4 ... 20 + 0 ... 20 y1 4 ... 20 0 ... 20 y2 4 ... 20 0 ... 20 y1 -- 100 % + y2 -- 100 % + 1 4 ... 20 0 ... 20 1 4 ... 20 0 1 2 3 4 5 6 D U A 10 AO/ly I 7 8 9 10 as of software version -B2 11 12 13 14 15 16 17 Figure 3-29 110 SIPART DR21 C73000-B7476-C143-08 Manual 3.8 3 Functional description of the structure switches 3.8 Digital output signal processing (S57 to S75) Digital output signal processing (S57 to S75) The message signals RB, RC ... MUF, +w and -w are assigned to the digital outputs DO1 to DO8 by the structure switches S58 to S68 and can be negated optionally with the structure switches S69 to S75 (except +w and -w) (see figure 3-30, page 112). The digital outputs DO1, DO2 and DO7, DO8 of the standard controller can be extended with the options modules 4DO 24 V +2DI (6DR2801-8E) or 2DO-relay 35 V (6DR2801-8A) in slot 3 to a maximum 6 or 8 digital outputs respectively. When using 4DO 24 V +2DI in slot 3 by DO3 to DO6, when using 2DO-relay 35 V in slot 3 by DO3 and DO4. When using options modules in slot 3, structure switch S22 must be set according to the assignment, otherwise there will be error messages (see chapter 5.5, page 179 ). The control signals y (positioning increments of the S-controllers) are not negatable but they can be assigned to one of the binary outputs DO1, DO2, DO7 or DO8. The setting of S57 has priority over assignments with S58 to S68. The assigned digital outputs for y are not stored in "ST5" and "BABE" (refresh-time approx. 20 ms). Decription of ST5 and BABE: see operating instructions "Serial SIPART 6DR190x Bus Interface". On assigning different control signals to the same digital output an OR-function of the control signals is produced (exception at y). Unassigned digital outputs (switch position 0) are low and can be set by SES at S85 = 2. All digital outputs have wired-or-diodes. D Functional explanation of the digital message signals. RB No computer standby of the controller This signal indicates that the controller is in internal operation, i.e. not in computer standby. RC Computer operation This signal indicates the negated computer operation RC = IntCB and controls the setpoint switching or DDC-operation. H Manual mode The controller is in manual mode, triggered either by manual/automatic-switching on the front of the controller (Hi) or by the digital input signal He if the control signals Si, yBL and N (with tracking over manual operation priority) are Low. Nw Tracking operation The controller is in tracking mode when the control signals Si, yBL and H (in manual over tracking operation priority) are Low and the conmtrol signal N is High. A1/A2 Alarm 1 and 2 indicate response of the limit value alarms A1 and A2. A3/A4 Alarm 3 and 4 indicates response of the limit value alarms A3 and A4. MUF 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. y positioning increments for the y-adjustment in S-controllers w positioning increments for the w-adjustment, only for control unit/process display (S1 = 4) SIPART DR21 C73000-B7476-C143-08 111 3 Functional description of the structure switches 3.8 Digital output signal processing (S57 to S75) S** Structureswitch 0 1 0 S69 S58 --1 1 0 S70 S59 1 0 S71 S60 RC = IntCB --1 H +y 3) Assignment with --1 RB = Int Manual 5V 1 0/2 --1 4) 1 0 S72 S61 S62 --1 1 0 S73 S63 1 0 S74 S64 --1 A3 --1 A4 --1 1 0 S74 S65 1 0 S75 S66 S67 -w S68 DO1 1/7 DO2 1/8 0 S57 1/2/3 Slot 3 5V I 3 4 5 6 DO3 DO4 DO5 DO6 7 0/2 1/3 0 S57 0/3 1/2 DO7 S57 1/2/3 3/3 3/4 3/5 DO8 1/2/3 0 1/15 S2 1/14 1/13 S2 When using 2DO-relay 35 V, 6DR2801-8A (S22 = 3), only DO3 and DO4 are available. At S**=0 there is no assignment, the digital outputs are then 0 and can be set at S85 = 2 by the SES. Assignment of different control signals to one digital output causes an OR-function. Message signal active tracking mode see page 111. Figure 3-30 Assignment of digital outputs (S57 to S75) 112 3/2 4DO+2DI S22=11) 8 +w I 1/2/3 S2 24 V 1 0 S73 A2 MUF 1/2 --1 A1 0/3 24 V 0 1/3 S57 - y 1) 2) 3) 4) No assignment DO's = 0 2) No assignment DOs = 02) 2 Nw Structure switch position SIPART DR21 C73000-B7476-C143-08 Manual 3.9 3 Functional description of the structure switches 3.9 Adaptation (S48) Adaptation (S48) The adaptation procedure represents a reliable and easy to operate commissioning tool. The adaptation procedure is far superior to manual optimization especially in slow controlled systems and in PID controller types. It is activated by the operator and can be aborted at any time in the event of danger. The parameters determined by the adaptation can be changed and accepted specifically by the user. In the parameterization mode AdAP which is only accessible at S48 0, the following presettings are made for the adaptation procedure: tU Pv dY Monitoring time Direction of step command Amplitude of step command With the structure switch S48 the choice of the control behavior (with or without overshoot) is made. The adaptation principle is divided into system identification and controller design. D System identification The controller is driven to the desired operating point manually. By pressing the Enter key the set manual manipulated variable is changed by a step adjustable in the direction (dPv) and amplitude (dY). The y-step is output at the end of 10 % of the set monitoring time (tU) if there was a fixed state of the controlled variable during this time. Otherwise there is an error message with abortion of the identification (see table 5-3, page 162 ). The step response of the controlled system is then accepted with a max. 84 value pairs (time and amplitude). The respective main controlled variable of the different control types is filtered adaptively -- (see figures 3-6, page 61 to figure 3-7, page 62) and provided for saving. The storage procedure operates with cyclic data reduction and subsequent refilling so that slow controlled systems can be entered. After the start ID has been run through (the controlled variable x must have left the start ID band within 50% of the set monitoring time tU), 95% of the full range must have been reached at the latest at 2/3 of tU. The set monitoring time (tU) must be 2 * T95 of the controlled system with safety reserve. The remaining time is required for the full scale identification. The end value identification can also take place immediately after the start identification, but 1/3 of the performed measurements are always required for the end value identification. Recording of the measured value pairs is ended on identifying the full scale. A comparison with the recorded transient function is now made based on the stored Ptn-models with n = 1 to 8 and equal time constants T by variation of n and T. The determined line gain ks is transfered to the line models. The comparison is made over the minimum error area F (n, T) Additionally a special entry of real dead times is made which then shifts the identified control line to higher orders. SIPART DR21 C73000-B7476-C143-08 113 3 Functional description of the structure switches 3.9 Adaptation (S48) Manual Controlled systems with compensation and periodic transients of 1st and 8th order with a transient time T 95 of 5 s to 12 h can be identified. Dead time parts are permissible. In S-controllers, the transient time T95 should be double the actuating time max. (tP/tM). The monitoring time tU serves to optimize the cancel criteria. It can always be started with tU = off (dynamic system knowledge is unnecessary). y y ymanual tU F(n,T)=min x xM x measuring process x = ksy Model curve xM -10 0 50 Start ID 67 % % tU 100 Full scale ID ID fixed state Start of adaptation Figure 3-31 Time curve of an adaptation without error messages in which tU = 2x T95 Error checks are made during system identification in order to be able to prematurely abort the identification. There are 12 control steps altogether which are displayed by flashing on the digital x- and w-displays when errors occur. As soon as an error message appears, the system identification is aborted and it must be restarted after correcting the presettings in the parameterization mode AdAP if necessary. Acknowledgement of error messages, see chapter 5.4.2, page 155 list of error messages, see table 5-3page 162. D Controller design The controller is designed according to the absolute value optimum method (S48=2). This setting method is very robust and also allows variation of the line amplification. However, it generates an overshoot of approx. 5 % in the event of changes in the command variables. If this is undesirable, operation can also take place with the controller design without overshoot (S48 = 1). Kp is reduced to 80% here. 114 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.10 Other functions of the standard controller The controller is designed for PI and PID-behavior, therefore Kp, tn and for PID tv are calculated, whereby the derivative gain is fixed at 5. A prerequisite is that the D-element is connected with xd/x/x1 (S47 = 0 or 2). In S-controllers the response threshold AH is calculated in addition to Kp, tn, tv. The parameters tA and tE and tP/tM must be set beforehand according to the actuating drives used (see chapter 6.3 page183 ). If the transient time T 95 is in the vicinity of 2 tP/tM (actuating time), overshoots may also occur in controller designs with D-part even at S48=1. In 1st order controlled systems a PI or PID controller design, in 2nd order systems a PID controller design cannot be implemented according to the absolute value optimum because in these cases Kp goes to 1. A controller design is made in which the ratio of system time constant to control circuit constant is 3 (S48 = 1) or 10 (S48 = 2). The new parameters for PI-controllers and for PID-controllers are offered when adaptation has been completed. In addition the determined system order 1 to 8 is displayed as a suffix to the PI- or PID-identification. The operating technique of the adaptation procedure is described in chapter 5.4.3, page 156, the commissioning explained in chapter 6.5, page 186. 3.10 Other functions of the standard controller 3.10.1 Adaptive filter The control difference xd is fed through an adaptive filter. By adjusting tF (onPA) from oFF to 1 s the filter is switched on. By further increases to tF* the filter can be adapted to a low-frequency disturbance frequency (seconds- to hours time-constant). Within a band in which changes occur repeatedly, changes are interpreted as a fault by the filter and filtered with the preset time constant tF, changes in a direction out of the band are passed unfiltered to the PI(D)-algorithm to enable a faster control. If the disturbance level changes in time, the filter is automatically adapted to the new level. SIPART DR21 C73000-B7476-C143-08 115 3 Functional description of the structure switches 3.10 Other functions of the standard controller Manual E t A t Figure 3-32 Effect of the adaptive non-linear filter The factory setting of tF is 1 s. In controllers with D-part -- it should be set as great as possible because of the input noise amplified by vv S kp and in the adaptation. 3.10.2 Response threshold AH The response threshold AH (dead zone element) is in the control difference connected after the adaptive filter. xd output -AH xd input AH Figure 3-33 Effect of the dead zone element The dead zone element lends the controller a progressive behavior, at small control differences the gain is low or even 0, at larger control differences the specified Kp is reached. It should be taken into account that the remaining control difference can adopt the value of the set response threshold AH. The factory setting of AH is 0 % and can be set up to 10 % in the parameterization mode onPA. In S-controllers the minimum necessary setting of AH is given by the minimum x=ks*y (see chapter 6.3, page 183) and can be increased for further settling of the controlled system. In K-controllers a small threshold value is advisable for settling the control circuit and reducing wear on the actuator. 116 SIPART DR21 C73000-B7476-C143-08 Manual 3 3.10.3 Functional description of the structure switches 3.10 Other functions of the standard controller Limit value alarm (S76 to S80) The limit value alarm pairs A1, A2 and A3, A4 are assigned to the controller-internal variables xd, x ... AI3A, AI4A, lxdl by the structure switches S76 and S77. Every limit value alarm pair can be set to the monitoring functions Max/Min, Min/Min or Max/Max by S78 (A1, A2) or S79 (A3, A4). The response thresholds A1 to A4 and the hysteresis HA are set in the structuring mode oFPA. According to the switch position of S80 only the display or the display and adjustment of A1 to A4 is possible in the process operation level. In this case the switching cycle of the Shift key (6) is extended by the response thresholds A1, A2 or A1 to A4: Example display order switching key (6): w - y - A1 - A2 - A3 - A4 - x . . . The respective limit value is displayed on the y-display (9), the value on the x/w-digital display (3) or the w-bar display (2) and set depending on the assignment physically according to the display format of the digital x/w-display or in %. S1 assigned to 0 # 5/17 Parameter range Display format digital x/w-display S80 > 0 Bar display S80 = 5, 6 x/w-display xd # wv/lxdl according to dA to dE -1999 to 9999 % -110 % to 110 % referenced to dE - dA = 100 % 6 # 16 y # AI4A % % - 110 % to 110 % 0 # 3/17 xd # w/lxdl 1/2/3*) x1/x/w according to Ad to Ed -1999 to 9999 % --110 % to +110 % referenced to Ad--Ed=100% 4 # 5 xv # wv according to dA to dE -1999 to 9999 % -110 % to 110 % referenced to dE--dA = 100 % 6 # 16 y # AI4A % % - 110 % to 110 % 0 1 2 4 5 6 3 S76, S76 S77 Table 3-17 % according to**) Ad to Ed -1999 to 9999 - 110,0 % to 110,0 % % --110 % to +110 %**) referenced to Ad--Ed=100% Display format of the limit values A1 to A4 *) as of software version --A9 **) as of software version --C1 SIPART DR21 C73000-B7476-C143-08 117 3 Functional description of the structure switches 3.10 Other functions of the standard controller Manual A2 cannot be set greater than A1 and A4 not greater than A3. The hysteresis HA is set in % in the range from 0.1 to 10 % and applies for all 4 limit values. The function of the limit values (Min oder Max) always relates to the display, i.e. in the case of a falling characteristic (dE< dA) the direction of effect is reversed. The set Min-function for example becomes a Max-function related to the field signal. S** xd 0 x1 1 x 2 w 3 xv 4 wv 5 y 6 y1 7 y2 8 AI1 9 AI2 10 AI3 11 AI4 12 AI1A 13 AI2A 14 AI3A 15 AI4A 16 lxdl 17 Assignment with A1 A1A2 A2 S76 A3 A3A4 A4 S77 + -+ -- Min. + -+ -- Min. + -+ -- Min. + -+ -- Min. Max Max Max Max 0 HA S78 1 A1 2 0 S78 0 HA 1 A2 2 0 0 HA S79 1 A3 2 0 S79 0 HA 1 A4 2 0 Figure 3-34 Assignment and function of the limit value alarms (S76 to S79) 3.10.4 Linearizer (S21, oFPA) The linearizer is freely assignable to an input AI1 to AI4 or the main controlled variable x1. If the main controlled variable is linearized, the range dA to dE is decisive, otherwise there is a percentage reference to the measuring range. The curve is rounded at the support points. Example:Thermocouple 300 to 1000 C with transmitter without linearizer Set start of scale and full scale dA and dE and the decimal point dP in the structuring mode oFPA for the display. Divide measuring range UA to UE including 10 % overflow in 10 % sections and determine partial voltages. L -1 to L11 are equidistant support points with 10 %-steps. UA = 4.31 mV UE = 48.33 mV 118 Un = UE -UA 10 n + UA with n = --1 to 11 SIPART DR21 C73000-B7476-C143-08 Manual 3 Functional description of the structure switches 3.10 Other functions of the standard controller Determine the respective physical value from the appropriate function tables for every Un or graphically from the corresponding curve (interpolate if necessary) and enter the value for the respective vertex value (L-1 to L11 ) in physical variables in the structuring mode oFPA. [mV] UE 60 % n UE 110 50 UE=48.33 mV 100 90 80 11 52.732 ! L11 1048 10 48,33 ! L10 1000 9 43.928 ! L9 951 8 39.526 ! L8 900 7 35.124 ! L7 846 6 30.722 ! L6 790 5 26.32 ! L5 729 4 21.918 ! L4 664 3 17.516 ! L3 593 2 13.114 ! L2 514 1 8.712 ! L1 420 0 4.31 ! L0 300 ! L-1 0 40 70 60 30 50 40 20 30 20 10 10 UA=4.31 mV 0 -10 Un [mV] vertex- t [C] value 0 tA 0 100 200 300 dA -1 -0.092 tE 400 500 600 700 800 900 1000 1200 t [C] dE Figure 3-35 Example of linearization of a thermocouple type B Pt30Rh/Pt6, measuring range dA to dE from 300 to 1000 C SIPART DR21 C73000-B7476-C143-08 119 3 Functional description of the structure switches 3.10 Other functions of the standard controller 3.10.5 Manual Restart conditions (S82, S83) The restart conditions after mains recovery are determined with S82. With S82 = 0 the controller starts after mains recovery and after a watch-dog-reset with the operating mode and with the y which was active before the power failure. This variation must be used when temporary mains failures are to be expected in slow control circuits. With S82 = 1 starting after mains recovery takes place in manual- and in internal operation with ys in the K-controller (S2 = 0) and two-position controller (S2 = 1) or with the last y in the threeposition controller (S2 = 2, 3). If only external operating mode or only automatic operation was selected by S42 = 1 or S51 = 1 respectively, the restart takes place in these operating modes. With S83 the optical signaling of mains voltage recovery and reset is determined by flashing of the digital x-display. The flashing is acknowledged by pressing the Shift key (6) or by an alarm request via SES. 3.10.6 Serial interface and PROFIBUS-DP (S84 to S91) The structure switch determines whether operation is with SES (S84 = 1/2/3*)) or without SES (S84 = 0) (see also "Control system coupling via the serial interface", page 109). With S85 the depth of the SES-interventions is preset. Generally all available set data are read. In position 0 no transmission and reception of data to the controller is possible. In position 1 only parameters and structures can be transmitted. In positions 2 to 5 the process variables wES (external setpoint via the SES), wiES (internal setpoint via the SES), yES (external manipulated variable via the SES), yHES (manual manipulated variable via the SES) and all control signals can be sent additionally via the SES. At the same time, S85 switches over the sources for the external setpoint wES or wEA and for the tracking manipulated variable y ES or yN. This makes it possible to preset the process variables and the control signals only via the SES or the process variables analogly and only the control signals via the SES. With S84 = 1/2 writing of status signal SiES to tSHES can be locked via /RC or CB. The structure switches S86 to S91 determine the transmission procedure through the serial interface. See the user guide "Serial SIPART DR21 Bus Interface" for explanations; Internet address: www.fielddevices.com [Edition 05.2000]. Settings for PROFIBUS-DP see table 5-5, page 172 (structure switch list). *) as of software version C1 120 SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.1 Mechanical Installation 4 Installation 4.1 Mechanical Installation D Selecting the Installation Site Maintain an ambient temperature of 0 to 50 _C. Don't forget to allow for other heat sources in the vicinity. Remember that if instruments are stacked on top of each other with little or no gap between them, additional heat will be generated. The front and rear of the controller should have good accessibility. 4.1.1 Work prior to installation The controller type 6DR2100-5 is set to 230 V AC mains voltage in the as-delivered state. The switching contacts are locked. The backplane module must be removed to change the mains voltage setting or to unlock the relay contacts. D Removing the backplane module ! CAUTION The backplane module may only be removed when the mains plug and the 3-pin y-plug have been removed! Loosen the fastening screw (6) and pull the module out from the back. (1) (2) (3) (4) (5) (6) (7) Figure 4-1 1 Rating plate (example with two labels 115 V~) (as-delivered state 230 V~) 2 Plug y-outputs 3 Mains plug 4 Fastening screw for DIN rail 5 DIN rail 35 mm (DIN EN 50022) for mounting the coupling relay-modules 6DR2804-8A and 6DR2804-8B 6 Fastening screw for backplane module 7 PE conductor connecting screw Rear of controller SIPART DR21 C73000-B7476-C143-08 121 4 Installation 4.1 Mechanical Installation Manual D Switching mains 230 V to 115 V Fastening screw Plug-in jumpers (in the as-delivered state 230 V) Figure 4-2 Setting the mains voltage Re-plug jumpers as shown in the diagram in figure 4-2. Stick the two labels provided (115 V power supply) to the rating plate in the field 230 V AC and on the housing to the right of the mains plug vertically to the rear of the housing (see figure4-1). Re-install the backplane accordingly. D Unlock the relay contacts Re-plug the plug-in jumper (figure 4-4, page 123) to unlock. Labeling according to DIN 45100 Labeling on the terminal block 3-pin +/--y-plug Relay contacts 15 47 14 49 13 48 DO7 (+y) DO8 (--y) locked (as-delivered state) unlocked Figure 4-3 122 Circuit SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.1 Mechanical Installation (1) (2) (1) as-delivered state (locked) (2) Spark quenching element Adapt resistance to connected contacts or servo motors if necessary. Figure 4-4 Relay contact locking Re-install the backplane accordingly. D Changing the tag plate and scales (Please observe the "correct procedure"!) The tag plate and scales can be labeled individually on the back with a smear-proof pen. Figure 4-5 Tag plate SIPART DR21 C73000-B7476-C143-08 123 4 Installation 4.1 Mechanical Installation Manual Procedure / removing the front module - Remove the mains module and any modules which may be plugged in. - Turn the controller so that you are looking at the operating- and display front module from the front. - Carefully lever out the tag plate cover with a screwdriver at the cutout at the top and snap the cover out of the bottom hinge points by bending slightly. Loosen the screw (captive) Tilt the top of the front module at the head of the screw and pull it out angled slightly forwards. - The scales can now be removed from the narrow side of the operating- and display front module with a pair of tweezers. 4.1.2 Installing the controller D Panel mounting The SIPART DR21 controllers are installed either in single panel cutouts or in open tiers (dimensions, see figure 2-6, page 35). Procedure: - If necessary: Push the self-adhesive sealing ring for sealing the front frame/front panel over the tube and stick to the back of the tube collar. (to be ordered separately) - Insert the controller into the panel cut-out or open tier from the front and fit the two clamps provided to the controller unit from the rear so that they snap into the cut-outs in the housing. - Align the controller and do not tighten the locking screws too tight. The tightening range is 0 to 40 mm. Relay module * Figure 4-6 124 Installation depth necessary for changing the main circuit board and modules Dimensions SIPART DR21, dimensions in mm SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.1 Mechanical Installation 4.1.3 Installation of the options modules General Signal converter modules can be inserted in the slots provided in the SIPART DR21 controller from the rear. The slots are coded to avoid plugging the modules incorrectly. Jumper settings Jumpers may have to be set on the modules I/U, R, SES (figure 4-7) before they are plugged into the controller. (1) (2) (3) (4) (4) Figure 4-7 (3) (2) (1) Slot 1 Slot 2 Slot 3 Slot 4 AI3 (UNI, I/U, R) AI4 (UNI, I/U, R) 5DI; 2DI 4DO; 2DO rel. SES (serial interface, PROFIBUS) Rear of controller SIPART DR21 C73000-B7476-C143-08 125 4 Installation 4.2 Electrical Connection 4.2 Electrical Connection 4.2.1 Warnings and block diagram Manual The arrangement of the connecting elements can be seen in figure 4-7, page 125. ! WARNING The "Regulations for the installation of power systems with rated voltages under 1000 V" (VDE 0100) must be observed in the electrical installation! D PE conductor connection Connect the PE conductor to the ground screw (see figure 4-8, page 128) on the back of the controller. When connecting to 115 or 230 V AC-mains supply, the PE conductor can also be connected through the three-pin plug (see figure 4-9, page 129). The controller's groundconnection may also be connected with the PE conductor (grounded extra low voltages). ! WARNING Disconnection of the PE conductor while the controller is powered up can make the controller potentially dangerous. Disconnection of the PE conductor is prohibited. D Power supply connection The power supply is connected on 115 V AC or 230 V AC systems by a three-pin plug IEC 320/V DIN 49457 A, on 24 V UC systems by a special 2-pin plug (polarity irrelevant). The mains plugs are part of the scope of delivery. ! 126 WARNING Set the mains voltage plug-in jumpers (see figure 4-2), page 122 in the no-voltage state to the existing mains voltage. It is essential to observe the mains voltage specified on the rating plate or by the mains voltage jumpers (115/230 V AC) or on the voltage plate (24 V UC)! Lay the power cable through a fuse; limit the rating (fire protection EN 61010-1) to 150 VA. Limit the mains voltage alternatively to 30 V at 24 V UC. SIPART DR21 C73000-B7476-C143-08 Manual D 4 Installation 4.2 Electrical Connection Connection of measuring- and signal lines The process signals are connected via plug-in terminal blocks that can accommodate cables of up to 1.5 mm2 (AWG 14) cross-section. Standard controller Terminal block 1, 2, 3 3-pin 4-pin 8-pin S-outputs AI1, AI2 AO, DI, DO, L+, GND Options modules Slot 1 and 2 Slot 3 Slot 4 4-pin 6-pin 9-pin for analog input modules for digital I-O-modules for interface module The coupling relay module should be snapped onto the DIN rail (figure 4-7, page 125) and wired to the digital outputs. Slots 1 to 4 must be identified in the circuit diagrams. Makes sure that the module-terminal blocks are not switched. Measuring lines should be laid separately from power cables to avoid the risk of interference couplings. If this is not possible, or -- due to the type of installation -- the controller may not function properly as a result of interference on the measuring lines, the measuring lines must be shielded. The shield must be connected to the PE conductor of the controller or one of the ground-connections, depending on the fault source's reference point. The shield should always only be connected to one side of the controller when it is connected to the PE conductor to prevent creation of a ground loop. The SIPART DR21 is designed with a high electromagnetic compatibility (EMC) and has a high resistance to HF-interference. In order to maintain this high operational reliability we automatically assume that all inductances (e.g. relays, contactors, motors) installed in the vicinity of or connected to the controllers are assembled with suitable suppressors (e.g. RC-combinations)! To dissipate interference, the controller must be connected at the PEterminal of the cast body (figure 4-8, page 128 item 5) with good HF-conductance. SIPART DR21 C73000-B7476-C143-08 127 4 Installation 4.2 Electrical Connection Manual (1) (2) (12) (11) (9) (10) (1) (2) (3) (4) (5) (6) (7) (8) (9) (8) (7) (10) (11) (12) (6) Figure 4-8 . (5) (4) Mains plug Power supply module Slot 1 AI3 (UNI, I/U, R) Slot 2 AI4 (UNI, I/U, R) Slot 3 5DI; 2DI 4DO; 2DO rel. Slot 4 SES (serial interface-, PROFIBUS) Ground screw of the backplane module Fastening screw DIN rail, not included in the scope of delivery (accessories coupling relay module) Terminal block 1 AI1 to AI2 (I/U) Terminal block 2 AO; DI1 to DI2; DO1 to DO2 24 V; L+; M Terminal block 3digital outputs y (3) Controller backplane with terminal assignment of the standard controller NOTE The screw-type terminal blocks for connecting the process signals to the controller are of the plug-in type. D Zero-Volt-system The SIPART DR21 controllers only have a 0V-conductor (ground, GND) on the process side which is output double at terminals 11 and 12 of the standard controller. If these GNDconnections are not sufficient, additional proprietary terminals can be snapped onto the DIN rail on the power pack. The controller uses a common GND-conductor for both inputs- and outputs, all process signals are referred to this point. The GND-connection is also connected to vacant terminal modules. These may only be used if practically no input current flows through this connection (see e.g. figure 4-17, page 133). The power supply connection is electrically isolated from the process signals. In systems with unmeshed control circuits, the SIPART DR21s need not be interconnected. In meshed control circuits the GND-connections of all controllers must be fed singly to a common termination or the continuous GND-rail with a large cross-section. This common termination may be connected with the system's PE conductor only at one point. The signal current is tapped at the analog signal inputs by a four-pole measurement on the input measuring resistor. Voltage dips on the supply lines therefore have no effect. In the case of digital signals, the signal-to-noise ratio is so great that voltage dips on the GND-rail can be ignored. 128 SIPART DR21 C73000-B7476-C143-08 Figure 4-9 SIPART DR21 C73000-B7476-C143-08 1/1 1/2 1/3 1/4 3 4 1 2 6 9 12 11 DI2 L+ GND GND PE N L 5 2/1 2/2 2/3 2/4 Options -- -+ + DI1 AI4 AI3 AI2 AI1 5V 24 V Slot 2 I,U,R S7 Slot 1 = I S5 S3 S8 to S10 UNI I,U,R S6 249 249 S4 t t t t GND S14 S13 0% S12 S11 +5 V UREF +24 V AI4A AI3A AI2A AI1A x2 S16 Z S20 YR S19 YN S18 wIO/x3 S17 S21 x1 S15 S22 S4 to S21 S1 to S3 S57 S82 to S83 S81 Serial interface S84 to S91 Restart conditions x/w display Limit value alarms S76 to S80 Digital outputs S58 to S75 Switching output S56 S54 to S55 S49 to S53 Analog output Y-display Y-switching Control algorithm S46 to S48 Setpoint command S42 to S45 Digital inputs S23 to S41 Assignment Slot 3 Analog inputs Standardsettings U I I Block diagram SIPART DR21 129 SES Slot 4 5V S84 to S91 Slot 3 5DI 2DO rel. 4/3 4/8 4/7 4/2 Options 3/1 3/2 3/4 3/3 3/5 3/6 7 8 10 15 DO8 14 13 DO7 4DO 24V 2DI S22 24 V 5V S56 S57 Txd Rxd DO1 DO2 AO/ly 6DR2100/ 6DR2104 K-controller 6DR2100/ 6DR2101 --y S-controller L +y Manual 4 Installation 4.2 Electrical Connection 4 Installation 4.2 Electrical Connection 4.2.2 Manual Connection standard controller D Power supply connection CAUTION ! - Pay attention to mains jumpering (see figure 4-2, page 122)! 6DR210x-5 (115/230 V AC) Fusing of the supply line to VDE 0411 part 1 EN61 010, part 1 max. 150 VA 0.63 A slow-blow at 115 V 0.315 A slow-blow at 230 V Three-pin plug IEC 320 IV DIN 49457A 230 V 115 V L per controller N +24 V +5 V UREF = PE DR21 6DR210x-5 Other loads on the same control loop 1) L N PE 115 or 230 V AC Figure 4-10 Connection 115/230 V AC power supply - 6DR210x-4 (24 V UC) 1.6A, slow-blow Fusing of the supply line to VDE 0411 part 1 EN61 010, part 1 max. 150 VA or UL30 V per controller Special 2-pin plug, any polarity L N +24 V +5 V UREF = UL = 24 V UC Other loads on the same control loop 1) DR21 6DR210x-4 Figure 4-11 Connection 24 V UC power supply 1) The connection between the PE conductor screw (figure4-8, item 5, page128) to ground must be established additionally for high electromagnetic compatibility (EMC) in 115/230 V-controllers. This connection must also be low resistive for high frequencies (Cu-band or Hf-strand). Alternatively at least 2.5 mm2 flexible should be used. 130 SIPART DR21 C73000-B7476-C143-08 Manual D 4 Installation 4.2 Electrical Connection Connection of measuring- and signal lines AI1 and AI2 I 4L UH + I 2L +UH + + AI+ AI-- - AI+ I AI-- I - 1) AI1 L+ L+ AI+ AI+ AI- AI- GND GND GND GND AI2 9 2 4 1 3 11/12 Set 0/4 to 20 mA with S4 to S5 1) The series circuiting of several inputs is not possible because AI1/2 is connected internally to GND. Figure 4-12 Wiring AI1 to AI2, current inputs D DI1 to DI2 L+ >13 V or 9 DI1 5 DI2 6 <4.5 V Set function with S23 to S33/S92 Set direction of effect with S34 to S40 11/12 GND Figure 4-13 Connection DI1 to DI2 D AO 10 11/12 AO 0/4 ... 20 mA 900 GND Function: 0/4 to 20 mA Set with S56 Figure 4-14 Connection AO SIPART DR21 C73000-B7476-C143-08 131 4 Installation 4.2 Electrical Connection Manual D DO1 to DO2 7 DO1 8 DO2 19 V 50 mA Set function with S58 to S68 Set direction of effect with S69 to S75 11/12 GND Figure 4-15 Connection DO1 to DO2 D L+ (auxiliary voltage output) 9 11 12 L+ GND GND 20 V 60 mA Figure 4-16 Connection L+ 132 SIPART DR21 C73000-B7476-C143-08 Manual 4.2.3 4 Installation 4.2 Electrical Connection Connection of the options modules 4.2.3.1 Modules for analog measuring inputs D 6DR2800-8J (U or I-input) Set AI3 in slot 1 with S6 AI4 in slot 2 with S7 U measuring range 0 to 1 V, 10 V, 20 mA or 0.2 V, 2 V, 4 mA to 1 V, 10 V, 20 mA +UH UH + + 4 311 U 3 392 2 312 I -- 1 GND + GND 4 311 -- 3 392 2 312 1) 0 to 500 12 x4 9 L+ I 4 311 1 12 1 V/10 V I 2L I 4L 3 392 GND 49,9 + -- 2 312 1 12 x5 x6 GND x7 x8 x9 1 V 10 V 2) 6DR2800-8J 0/2 ... 10 V 0/0.2 ... 1 V 0/4 ... 20 mA x5=x6/10 V (x8=x9) x4=x5/1 V (x7=x8) x4=x5/1 V (x7=x8) 1) 2) possible load resistances of other controllers x7, x8, x9 omitted from the circuit board C73451--A3000-L106 factory setting 1 V, x4=x5 (and x7=x8) Figure 4-17 Connection U/I-module 6DR2800-8J SIPART DR21 C73000-B7476-C143-08 133 4 Installation 4.2 Electrical Connection D 6DR2800-8R Manual (resistor input) Set AI3 slot 1; Set AI4 slot 2; S6 = 0 or 1 S7 = 0 or 1 R I 6DR2800-8R UREF for potentiometer with Is% 5 mA or R > 1 k 4 411 UH 3 + I 2 -G N D Is=5 mA 4 411 3 493 RE -RP R RA -- R 1 S1 = 20 mA 493 4 411 RE R RA -- R 3 -- 2 2 1 1 493 R200 R -- 200 + 5 mA Is IK max. R 200 500 1 k -49,9 243 332 0 S1 S1=200 Rp = +24 V S1 200 500 1 k 20mA 1k 500 200 factory setting S1 = 200 Figure 4-18 Connection R-module 6DR2800-8R - Calibration 1. Slide switch or plug-in jumper S1 according to measuring range 2. Set RA with "0A display or analog output (structured accordingly) to start value or 4 mA. 3. Set RE with 134 display or analog output to full scale value or 20 mA. SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection D 6DR2800-8V (universal module for analog input) The universal module can only be inserted in slot 1. It is assigned to AI3 with S6> 3 and structured with S8, S9, S10. The measuring ranges are set with the menu CAE3 (see chapter 5.4.6, page 173). - Connector pin assignment for mV-transmitter S8 = 0 Direct input Umax = 175 mV im mV +REF U + -- RL4 RL1 4 3 + 2 -- A D 1 Sensor RL1+RL41 k 6DR2800-8V Block diagram mV-module 6DR2800-8V Figure 4-19 Connection UNI-module AE3 S8=0 - Pin assignment measuring range plug 6DR2805-8J for U or I S8 = 0 10 V 20 mA 4L 20 mA 2L SMART im L+ + + UH + -- + --- 4 -SMART 20 mA 4 89k1 200R 2 1 -- perm. common mode voltage 50 V UC 3 50R +REF U 10 V 8k95 1) 1k 3 + 2 -- A D 1 -- Sensor GND Measuring range plug 6DR2805-8J 1) DR21: Jumper must be plugged 6DR2800-8V Block diagram mV-module 6DR2800-8V Figure 4-20 Connection UNI-module AE3 S8=0 with measuring range plug SIPART DR21 C73000-B7476-C143-08 135 4 Installation 4.2 Electrical Connection - Manual Pin assignment for thermocouple TC S8 = 1, 2 External reference point Internal reference point + + RL4 RL4 RL1 RL1 -- RL1 + RL4300 +REF U 4 T Tb -- im 3 + 2 -- A D 1 Internal reference point 6DR2805-8A Sensor 6DR2800-8V Block diagram mV-module 6DR2800-8V Figure 4-21 Connection UNI-module AI3 S8 = 1, 2 - Pin assignment for Pt100-sensor RTD S8 = 3, 4, 5 Pt100 4-conductor 3-conductor RL4 RL4 RL2 RL3 Pt100 RL2 im 2-conductor RL4 Pt100 +REF U 4 3 + 2 -- A D 1 RL1 RL per 100 RL1 RL1 = RL2 = RL4 50 RL1 RL1 + RL4 50 Sensor 6DR2800-8V Block diagram mV-module 6DR2800-8V Figure 4-22 Connection UNI-module AI3 S8 = 3, 4, 5 136 SIPART DR21 C73000-B7476-C143-08 Manual - 4 Installation 4.2 Electrical Connection Pin assignment for resistance potentiometer R S8 = 6, 7 3-Conductor terminal im 2-Conductor terminal +REF U RL4 Rp RL2 RL4 4 1) Rs 3 Rp 2 3 + 2 -- A D 1 1 RL1 RL1 RL450 RSRp RS + Rp 4 Sensor RL1 + RL450 6DR2800-8V 2,8 k, Rp > 5 K not recommended Block diagram of UNI-module 6DR2800-8V 1) Rs Shunt impedance only necessary if 2.8 k < R 5 k Figure 4-23 Connection UNI-module AI3 S8 = 6, 7 4.2.3.2 Connection examples for analog measuring inputs with the module 6DR2800-8J In current inputs the input load resistance is between AI+ and AI--. If the signal is still required during service work in which the terminal is disconnected, the input load resistance must be connected to the terminal between AI+ and AI--. The internal 49.9 resistance must then be disconnected in 6DR2800-8J by appropriate rewiring. 1 V/10 V 20 mA AI+ 20 mA AI+ 4 + 49.9 3 49.9 AI - AI optionally 2 1 -6DR2800-8J set 1 V jumper Figure 4-24 Current input via options modules, internal or external 49.9 resistance SIPART DR21 C73000-B7476-C143-08 137 4 Installation 4.2 Electrical Connection UH + Manual AI+ 0/4 to 20 mA 4 + 49.9 3 I 2 GND 1 AI-- -- -6DR2800-8J Figure 4-25 Connection of a 4-wire-transmitter 0/4 to 20 mA with potential isolation +UH 0/4 to 20 mA + AI+ 4 + 49.9 I 3 -- AI-- -- 2 1 6DR2800-8J GND Figure 4-26 Connection of a 0/4 to 20 mA 3-wire transmitter with negative polarity to ground AI+ -UH 4 + -- 0/4 to 20 mA 49.9 AI-3 I + 2 GND 1 -- 6DR2800-8J Figure 4-27 Connection of a 0/4 to 20 mA 3-wire transmitter with positive polarity to ground 138 SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection + L+ 4 to 20 mA I AI+ ~ ~ referenced to ground 4 -- 49.9 + 3 -- 2 1 6DR2800-8J GND Figure 4-28 Connection of a 4 to 20 mA 2-wire transmitter supplied from controller's L+ + L+ 4 to 20 mA I -- ~ ~ AI+ 4 + 49.9 AI-3 -- 2 Controller 1 GND 1 6DR2800-8J 4 + 49.9 3 GND 2 1 -- Controller 2 6DR2800-8J Figure 4-29 Connection of a 4 to 20 mA 2-wire-transmitter to two instruments in series supplied by L+ from one of the instruments Every input amplifier is supplied by a differential input voltage of 0.2 to 1 V. The input amplifier of controller 1 has an additional common mode voltage of 0.2 to 1 V which is suppressed. Several instruments with a total common-mode voltage of up to 10 V can be connected in series. The last controller referenced to ground may also have a ground referenced input load (e.g. AI1 or AI2 of SIPART DR21). The permissible load voltage of the transmitter must be observed in series circuiting of load resistors. SIPART DR21 C73000-B7476-C143-08 139 4 Installation 4.2 Electrical Connection Manual D Voltages 0/0.2 to 1 V or 0/2 to 10 V UH + AI+ 4 + 49.9 3 AI-- U -- 2 -- 1 6DR2800-8J GND Figure 4-30 Connection of a floating voltage supply +UH + 4 AI+ + 49.9 U -- 3 AI-- -- 2 1 6DR2800-8J GND Figure 4-31 Single-pin connection of a non-floating voltage supply with negative polarity to ground AI+ 4 - -UH -U + + 49.9 AI-- only permitted when connected for 1 V 3 2 1 -6DR2800-8J GND Figure 4-32 Single-pin connection of a non-floating voltage supply with positive polarity to ground Figure 4-31 and figure 4-32: The voltage dip on the ground-rail between the voltage source and the input amplifier appears as a measuring error. Only use when ground cables are short or choose a circuit configuration as shown in figure 4-33, page 141! 140 SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection +UH + 4 AI+ U 3 AI-- -- + -- 2 1 6DR2800-8J GND Figure 4-33 Double-pin wiring of a voltage source with negative polarity to ground L+ ~ ~ 4 AI+ U + -- + 49.9 AI-- 3 -- 2 GND 1 AI+ Controller 1 6DR2800-8J 4 + 49.9 AI-- 3 2 1 -- Controller 2 6DR2800-8J GND Figure 4-34 Parallel wiring of a non-floating voltage source to two instruments. The voltage source is supplied by L+ of one of the instruments and negative is referred to ground. Figure 4-33 and figure 4-34: The voltage dip on the ground-rail between the voltage source and the input amplifier appears as a common mode voltage and is suppressed. SIPART DR21 C73000-B7476-C143-08 141 4 Installation 4.2 Electrical Connection Manual 4.2.3.3 Modules for expanding the digital inputs and digital outputs D 6DR2801-8C (5DI) DI3 to 7 in slot 3 (S22 = 2) Set function with S23 to S33 Set direction of effect with S34 to S40 Terminals Labeling according to DIN 45140 or >13 V <4.5 V DI7 9 L+ 5 781 DI6 4 681 DI5 3 581 DI4 2 481 DI3 1 381 11 Standard controller Standard controller Figure 4-35 Wiring of 5DI module 6DR2801-8C D 6DR2801-8E (4DO 24 V +2 DI) DO3 to DO6 in slot 3 (S22 = 1) Function DO with S58 to S68 DI with S23 to S33 Direction of effect DO with S69 to S75 Set DI with S34 to S40 Terminals Labeling according to DIN 45140 or >13 V DI4 <4.5 V DO6 19 V DO5 30 mA DO4 DO3 DI3 9 L+ 6 481 5 685 4 585 3 485 2 385 1 381 11 Standard controller Standard controller Figure 4-36 Connection of 4DO (24 V)-module 6DR2801-8E 142 SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection D 6DR2801-8D 2DO relay 35 V ! WARNING The relay contacts are only permitted for switching voltages up to UC 35 C. DO3 and DO4 in slot 3 (S22 = 2) Set function with S58 to S68 Set direction of effect with S69 to S75 Terminals DO3 497 4 496 6 495 3 397 2 396 1 395 2x68 V AC DO4 5 .... 2x68 V AC Labeling according to DIN 45140 .... 1 ...... ...... 1 22 1 1 22 AC contact load capacity U 35 V I 5 A max. power 150 VA DC contact load capacity U 35 V I 5 A max. power 80 W at 35 V 100 W at 24 V Figure 4-37 Connection of 2DO (relay) -module 6DR2801-8D D 6DR2804-8A (coupling relay 230 V, 4 relay) 6DR2804-8B (coupling relay 230 V, 2 relay) Can be snapped onto DIN rail on the back of the controller. Wired externally to the desired digital outputs. These must then be structured with S57 to S68. e.g. connection for y outputs in the S-controller with coupling relay 230 V, 2 relays (6DR2804-8B) DO1 +y 7 6 1 22n 420 V 4 220 5 DO2 --y 8 2 GND 9 22n 420 V 7 220 GND 11/ 12 3 8 N L Figure 4-38 Connection of coupling relay 230 V 6DR2804-8B SIPART DR21 C73000-B7476-C143-08 143 4 Installation 4.2 Electrical Connection Manual Contacts in the connection are interlocked! ! CAUTION Observe the maximum switching voltage! (For excess resonance in phase shift motors, see "CAUTION" on page 33) The coupling relay 6DR2804-8B (figure 4-38, page 143) contains 2 relays. The coupling relay 6DR2804-8A contains 4 relays. The terminals 1 to 9 are therefore available double. AC 4.2.4 250 V 8A 1250 VA DC 250 V 8A 30 W at 250 V 100 W at 24 V Connection of the interface module 6DR2803-8C 4.2.4.1 RS 232 point-to-point (END/END) Can be inserted in slot 4, set structure switches S84 to S91 for transmission procedure. Remote system (PC) Controller SIPART BUS 4/3 Rxd Txd Reference RS 485 +150 R RS 485 RS 232 END/END 4/2 2 3 5 4/7 4/8 Figure 4-39 Setting on the SES-module 6DR2803-8C with RS 232 point-to-point connection 144 SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection 4.2.4.2 RS 485 bus SIPART BUS RS 485 +150 R RS 485 RS 232 END/END Can be inserted in slot 4, set structure switches S84 to S91 for transmission procedure. Figure 4-40 Jumper settings SES-module 6DR2803-8C in RS 485 bus SES 8 Rxd/Txd-A RS 485 bus 1200 m Rxd/Txd-A Controller 1 Rxd/Txd-B Jumper setting RS 485 SES 3 Rxd/Txd-B Remote system 8 Rxd/Txd-A Controller 2 . to SES 3 Rxd/Txd-B Note line termination: The RS 485-bus must be terminated with its characteristic impedance. To do this, the terminating resistor in the "last" bus user is switched by plugging the coding bridge appropriately. 8 Rxd/Txd-A Controller 32 3 Rxd/Txd-B Jumper setting RS 485 + 150R 9-pin bus-plug for round cable: C73451-A347-D39 Figure 4-41 RS 485-bus connection SIPART DR21 C73000-B7476-C143-08 145 4 Installation 4.2 Electrical Connection Manual 4.2.4.3 PROFIBUS-DP, 6DR2803-8P Technical Data Transmittable signals Transmittable data Transmission procedure PROFIBUS-/-DP-protocol. Transmission speed Station number Time monitoring of the data communication Electrical isolation between Rxd/Txd-P/-N and the controller Test voltage Repeater-control signal CNTR-P Supply voltage VP (5 V) Line lengths, per segment at 1.5 MBit/s 146 RS 485, PROFIBUS-DP-protocol Operating state, process variables, parameters and structure switches According to DIN 19245, Part 1 and Part 3 (EN 50 170) 9.6 kbit/s to 1.5 Mbit/s 0 to 125 (note software version) Can be structured on the controller in connection with DP watchdog 50 V UC common mode voltage 500 V AC TTL-level with 1 TTL load 5 V --0.4 V/+0.2 V; short-circuit-proof 200 m; for other data see manual "ET 200 Distributed I/O System", order no. 6ES5 998-3ES22. SIPART DR21 C73000-B7476-C143-08 Manual 4 Installation 4.2 Electrical Connection Connecting the interface PROFIBUS-DP, 6DR2803-8P D Connection Can be inserted in slot 4, set structure switches S84 to S91 for transmission procedure. PROFIBUS-plug PROFIBUSmodule RxD/TxD-P VP Controller 1 (Slave) DGND RxD/TxD-N 3 6 5 B ON 390R A 220R 390R 6ES7 972- A 8 B 3 B to RxD/TxD-P PROFIBUSmodule VP Controller n (Slave) DGND RxD/TxD-N Master n 6 390R 5 390R OFF 220R A 8 B A RxD/TxD-A 6ES7 972-- RxD/TxD-B Switch ON max. number of controllers, dependent on master, max. 122 Figure 4-42 Block diagram SIPART DR21 via PROFIBUS-DP and bus plug to master . NOTE line termination: The RS 485-bus must be terminated with a characteristic impedance. To do this, the switch in the bus connector must be switched "ON" in the "first" and "last" bus users. The switch may not be "ON" in any of the other bus users. A detailed description and notes on cable laying and bus cable laying can be found in the manual "ET 200 Distributed I/O System" order number 6ES5 998-3ES22. SIPART DR21 C73000-B7476-C143-08 147 4 Installation 4.2 Electrical Connection 148 Manual SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.1 General 5 Operation 5.1 General D Operating modes The SIPART DR21 is operated exclusively and fully with the operating keys on the front module. The function of the operating panel can be switched between three main levels: Process operation mode The process values x, w, y and the controller status are displayed, the process operation mode can be controlled by the operating keys. Selection level Here the list is selected which can be changed or activated in the configuration mode. These are the following lists: onPA (AdAP) oFPA StrS (CAE3) APSt Online parameters Start adaptation Offline parameters Structure switches Set UNI-module all preset The lists for onPA, oFPA, StrS and APST are always displayed in the selection mode. The lists for AdAP and CAE3 only appear in the display when they have been selected by structure switches. Configuration modes Settings are made in the selected list or functions are activated. Some of the keys and displays on the front module are assigned different control and display functions when the operating mode is changed. See the description of the respective main level for details. D Operating locks Operation of the controller or access to the selection or configuration modes can be locked by digital signals. The following blocking steps are possible: bLb Blocking, Operation The complete operation of the controller is blocked. Exception: Switching over the w/x digital display. "bLb" appears in the display on pressing the operating keys. bLS Blocking, Structuring Blocking the lists AdAP, oFPA, StrS, CAE3 and APSt. Only the list for onPA is accessible. "bLS" appears in the display when the blocked mode is called bLPS Blocking, Parameterization and Structuring The complete selection and configuration mode is blocked. The process operation mode is free. "bLPS" appears in the display when the blocked mode is called SIPART DR21 C73000-B7476-C143-08 149 5 Operation 5.2 Process operation mode Manual D Behavior of the controller in the factory setting SIPART DR21 operates as a fixed value controller in the factory setting. For safety reasons the online parameters, "proportional action factor Kp" and the "integral action time Tn" are preset to uncritical values. It is absolutely essential that these parameters be set to suit the requirements of your controlled system. 5.2 Process operation mode D Control elements See page 5 for the control and display elements. The operation of the SIPART DR21 in process mode requires no detailed explanation due to the design and color scheme of the operating panel, the control elements and the labeling. D Actual value The red vertical LED bargraph (1) and -- with the red x LED (5) -- of the four-digit digital display (3) lit steadily indicate the actual value. D Setpoint The green vertical LED bargraph (2) and -- with the green w LED (4) -- of the four-digit digital display (3) lit steadily indicate the setpoint. The green Internal/External key (16) switches between the internal and external setpoint. The internal setpoint is set with the green w adjusting keys (14), (15). The green internal LED (17) signals operation with the internal setpoint, C LED (18) also lights green when there is no CB control signal. However, a change in the setpoint setting is only possible when the green LEDs (4 and 17) signal that the four-digit display shows the setpoint and Internal operation is active. D Manipulated variable In the y display (9) the manipulated variable y or, according to the position of the structure switch S54, the position feedback y R or split range y1/y2 is always displayed independently of the variable output at the analog output AO. The yellow H/A-key (11) is used to switch between manual and automatic operation. The yellow manual LED (12) signals by lighting steadily or flashing that manual operation has been activated. Lighting up of the yellow y external LED (13) signals an external intervention in the manipulated variable, i.e. a tracking (DDC) , safety or blocking operation. The manipulated variable generally displayed in the y digital display (9) can be adjusted with the yellow y keys (7), (8) in manual operation. The y LEDs (10) indicate the output of the positioning increments in all operating modes of the S-controller. The alarm LEDs (20) and signal exceeding or dropping below the limit values. 150 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.2 Process operation mode The adaptation LED (19) signals the progress of the parameter optimization during the adaptation process by lighting steadily or flashing. D Adaptation The adaptation LED (19) signals the active adaptation procedure by flashing. D Lamp test If the button (6) is kept pressed for longer than 5 s, all LEDs on the front of the controller are driven independently of the respective display until the button is released again. The original display position is restored after checking the lamp function. D Display of the software version The software for the SIPART DR21 controller will be improved based on new knowledge if required. The respective version of the software is stored in the EPROM with identification and can be called as follows: " Run the lamp test with the button (6), " Then press the button (16) additionally. On the digital displays (3) and (9) the identification can now be read off for the controller software version. D Alarms The red alarm LEDs (20) signal exceeding or dropping below the limit values which can be set with the offline parameters A1 to A4. The assignment to the variables to be monitored is made with the structure switches S76, S77, their display with S80. SIPART DR21 C73000-B7476-C143-08 151 5 Operation 5.3 Selection mode 5.3 Manual Selection mode You enter the selection mode the various configuring menus by pressing the Shift key (6) for longer (approx. 5 s) until "PS" flashes in the y display. Condition: Digital signal "Blocking Operation" and "Blocking Parameterization, Structuring" are not active. bLb = 0 and bLPS = 0 The controller operates in online mode in the selection level, i.e. its last operating mode is retained, the current process variables can be traced on the analog displays (1), (2). The configuration menus can be selected with the w keys (14), (15). If none of these menus is called with the Enter key (11) within about 20 s ( enter the configuring mode), the controller automatically returns to the process operation mode. SIPART DR21 PV X SP W 100 17 16 C 18 ADAPT 19 Internal LED: current status Exit key : Return to processoperation mode Exit LED: flashes Adaptation LED: off A1 15 A2 SP-W Command variable w 50 2 14 A3 A4 12 11 Controlled variable x 1 13 6 0 Display of selected con- 3 figuring level PS (Parameterization/ Structuring) Selection onPA-(AdAP)-oFPAStrS-(CAE3)-APSt W X 4, 5 9 Manual LED: current status Enter key : Jump to selected Configuring mode Enter LED: flashes Shift key: Enter selection mode both LEDs off, no function OUT-Y SIEMENS SIPART DR21 7 8 no function Figure 5-1 152 Control and display elements in the selection mode SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.3 Selection mode Operating and Monitoring bLb = 0 At bLb = 1 no operation at all is possible. Process operation mode Exitkey (16) Shift key (6) up to approx. 5 s bLPS = 0 1) PS in the y display flashes bLb = 1 or bLPS = 1 bLb or bLPS in the w/x-display, PS in the y display flashes Release of the Shift key (6) Enter key (11) Online-parameters see chapter 5.4.2, page 155 onPA Exit key (16) w key (14, 15) Enter key (11) Adaptation see chapter 5.4.3, page 156 AdAP, only appears at S48 > 0 Exit key (16) Parameterization mode (online) w key (14, 15) BLS = 1 BLS = 0 Enter key (11) up to (approx. 3 s) oFPA Exit key (16) Offine parameters see chapter 5.4.4, page 163 w key (14, 15) Enter key (11) up to (approx. 3 s) StrS Structure switches see chapter 5.4.5, page 165 Exit key (16) w key (14, 15) CAE3, only appears at S6 > 3 Enter key (11) up to (approx. 3 s) CAE-menu see chapter 5.4.6, page 173 Exit key (16) w key (14, 15) Enter key (11) up to (approx. 3 s) APSt w key (14, 15) Selection mode 1) All Preset (sets controller to factory setting) see chapter 5.4.7, page 178 Exit key (16) Structuring modes (offline) automatic return if there is no Enter function to a parameterization- or structuring mode within 20 s. Figure 5-2 Overview selection mode SIPART DR21 C73000-B7476-C143-08 153 5 Operation 5.4 Configuration modes 5.4 Configuration modes 5.4.1 General, Online and Offline modes Manual The settings in the configuration modes onPA and AdAP and the selection in the selection mode (see fig. 5-2, page 153 takes place in online mode, i.e. the controller continues operating in its last mode. The onPA and AdAP modes are entered directly from the selection modes by pressing the Enter key (11). The analog x display (1) and w display (2) still display the process image so that the reaction of the controlled system to parameter changes can be read off directly. The Internal LED (17) and Manual LED (12) and the Alarm LEDs A1 to A4 indicate the current operating state. The Internal/External key (16) becomes the Exit key, the corresponding CLED (18) indicates ready to exit, i.e. every time the LED flashes, pressing the Exit key jumps from the selected mode to the next level up in the hierarchy. The Automatic /Manual key (11) becomes the Enter key, the corresponding y external LED (13) indicates ready to enter, i.e. whenever the LED flashes, pressing the Enter key jumps to the next level down in the hierarchy. Press the Enter key (11) for 3 s to go from the preselection mode to the offline mode with the oFPA, StrS, APSt and CAE3 menus The user stays offline when returning (from offline menu) to the preselection mode. When subsequently jumping to another off line mode the three-second time condition is irrelevant. The three-second time condition for entering an offline menu is only valid again after exiting the offline mode by selecting an online mode with the onPA and Adap menus or exiting the preselection mode. The controller switches into the absolute manual mode (offline mode), i.e. the last manipulated variable of the online mode is retained (in K-controllers the last manipulated variable, in S-controllers no positioning increments are output). A change in the manipulated variable using the y-keys (7), (8) is not possible, the control signals N (DDC), Si and yBL are not effective. The analog output, the digital outputs and the alarm LEDs A1 to A4 are held at the last value or status. To identify the offline mode, the analog w display shows a striped pattern and the manual LED (12) lights up. The absolute manual mode is retained when returning to the parameterization preselection mode (online mode) or the process operation mode from the structuring preselection mode with the Exit key (16). This also applies if only automatic operation has been preselected with S51 = 1. The controller must also be reactivated in the process operation mode for safety reasons by switching to automatic operation. The analog x display (1) continues to display the controlled variable x during offline mode, the Internal LED (17) the current status. The control elements keys (11), (16) and the LEDs (12), (13), (17), (18) have the same function as in the online configuration modes. If the control signal bLPS = 1, parameterization and structuring is blocked, no PS (w/x and y displays) appears when you press the Shift key. If the control signal bLS = 1, structuring is blocked. Only onPA and AdAP appear in the selection mode. . NOTE Please note that changed parameters and structure switch settings are only transferred to the failsafe EEPROM after returning to the process operation mode. 154 SIPART DR21 C73000-B7476-C143-08 Manual 5.4.2 5 Operation 5.4 Configuration modes Configuration mode online-parameters onPA The parameters for which the effect on the process when they are adjusted must be observed directly are arranged in the parameterization mode onPA. The other parameters are arranged in the structuring mode oFPA. After pressing the Enter key (11) in the onPA configuration mode, the first parameter of table 5-1 Filter time constant tF in the y display (9) appears with its current value in the w/x display (3) the first time the mains is switched on. Otherwise the parameter selected last the last time the onPA mode was exited appears. With the y keys (7), (8) the parameters are selected, with keys w (14), (15) the value is set. The parameters with a large number range can be adjusted in fast mode. First select the adjustment direction with one w key and then switch on the rapid action by simultaneously pressing the other w key. onPA Online Parameter list parameters y Num. Parameter name Filter time constant for filter xd (adaptive) Derivative-action gain Vv Proportional gain factor Kp Integral-action time Tn Derivative-action time Tv Response threshold Operating point Output start (YAYE) Output end y actuating time open/period heating y actuating time closed/period cooling Actuating pulse pause Actuating pulse length Filter time AI1 Filter time AI2 Filter time AI3 Filter time AI4 Constant c1 Constant c2 Constant c3 Constant c4 Constant c5 Constant c6 Constant c7 Display refresh rate 1) 2) In two-position controller In two-position controllers: Table 5-1 w/x display Min. Max. Unit Factory setting tF off/1.000 1000 1.000 s uu cP tn tv AH Y0 YA YE tP tM tA 2) tE 2) t1 t2 t3 t4 c1 c2 c3 c4 c5 c6 c7 dr 0.100 0.100 1.000 off/1.000 0.0 Auto/0.0 -10.0 -10.0 off/0.100 off/0.100 20 20 off/0.100 off/0.100 off/0.100 off/0.100 -1.999 -1.999 -1.999 -1.999 -1.999 -9.99 +1.000 0.100 10.00 100.0 9984 2992 10.0 100.0 110.0 110.0 1000 1000 1) 600 1) 600 1000 1000 1000 1000 9.999 9.999 9.999 9.999 9.999 9.99 9.999 9.900 5.000 0.100 9984 off 0.0 Auto -5.0 105.0 1.000 1.000 200 200 1.000 1.000 1.000 1.000 0.000 0.000 0.000 1.000 0.000 0.00 1.000 1.000 1 1 s s % % % % s s ms ms s s s s s S2 = 1 up to 9980 ms tA = shortest turn-on pulse and shortest pulse pause in the cooling branch tE = shortest turn-on pulse and shortest pulse duration in the heating branch Online selection list SIPART DR21 C73000-B7476-C143-08 155 5 Operation 5.4 Configuration modes Manual SIPART DR21 PV X SP W 100 17 16 C 18 ADAPT 19 Internal LED: current status Exit key : Return to selectionmode after onPA Exit LED: flashes Adaptation LED: off A1 15 A2 SP-W Setpoint w 50 2 14 Adjustment of parameter value with rapid action A3 A4 12 11 Setpoint x 1 13 0 Parameter value Parameter name tF, vv... c1...c7 6 W 3 X Manual LED: current status Enter key : no function Enter LED: Shift key: off no function 4, 5 9 OUT-Y SIEMENS SIPART DR21 7 8 no function Figure 5-3 5.4.3 Control and display elements in the configuration mode onPA Configuration mode adaptation AdAP This mode only appears in the selection mode S48 > 0 (with adaptation). The Enter function to the AdAP configuration mode is only possible when the controller is in manual mode. For this the structure switch S51 must be 1 (see structure switch list, table 5-5, page 172). In the parameterization mode AdAP, the controller influences the process online (but in manual operation). A distinction is made between 4 different states in the AdAP configuration mode - Pre adaptation, During adaptation, Aborted adaptation, Post adaptation In pre- and post-adaptation the digital displays and the keys are used for the parameter display and setting as is the case in the parameterization mode and structuring mode onPA or oFPA. The complete process image as described in chapter 5.2, page 150 is displayed during adaptation. In the case of aborted adaptation the error message flashes in the digital w/xdisplay (3). The error messages are acknowledged with the Enter key (11) (see figure 5-5, page 160). 156 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes D Conditions for adaptation - - The controller must be in a stationary condition, i.e. the controlled variable x must be constant. The system to be adapted must be a system with compensation, i.e. the manipulated variable step in the adaptation must lead to a constant controlled variable x. No adaptation can be performed in stepper controllers with S2 = 2 and firmware version A04 or earlier. Adaptation here is only possible in connection with the external feedback (jumper setting via S19 to yR). As of firmware A05 or higher the change in the manipulated variable required for adaptation is determined from the drive runtime. Accurate setting of the parameters tP and tM is presumed. It is recommended to start the adaptation from the y value (operating point) usual for this type of control circuit. D Pre adaptation The controller must be switched to manual (key (11)) before entering the selection mode. The "AdAP" menu can only be selected at S48 > 0. It is called with the Enter key (11). The adaption LED (19) is off and indicates readiness for adaptation. First the parameters for the presettings (tU, dPv, dY) are displayed. They must be set according to the desired step command. Then the old online parameters appear on the displays (see table 5-1, page 155) with their respective value. This can only be preset in the onPA mode. NOTICE Make sure the set step command causes no damage to the process control system. The control loop is not closed during the adaptation. The adaptation procedure is unsuitable for systems without compensation (systems with integral behaviour). The selection of the parameters is made with the keys (7), (8), the setting of the values with the keys (14), (15). The LED (13) flashes when "Strt" appears in the w/x display (3). Adaptation can now be started with Enter (11). D During adaptation The adaptation LED (19) flashes indicating that the adaptation is in progress. The process can be monitored over the whole process display. Keys (7), (8), (14) and (15) have no function. The w/x display (3) can be switched over with the key (6) depending on the position of S81. The adaptation can be aborted manually with the key (16). D Aborted adaptation The current adaptation can be aborted manually or automatically by the error monitor. The adaptation LED (19) is off indicating readiness for adaptation after error acknowledgement. The Enter LED (13) flashes as a request for error acknowledgement. Manual abortion can be activated in the event of danger by pressing the Exit key (16). The program then jumps to the selection mode after AdAP. From there you can return to the process operation level by pressing the Exit key (16) again. The controller is in manual operation and the manual manipulated variable can be adjusted. SIPART DR21 C73000-B7476-C143-08 157 5 Operation 5.4 Configuration modes Manual Automatic abortion is effected by the error monitors (see table 5-3, page 162). The error messages are displayed on the digital w/xdisplay. The error message is acknowledged by pressing the Enter key (11), the configuration mode AdAP is retained, tU is displayed, the presettings can be corrected if necessary. The adaptation is aborted by the signals N (DDC), Si and yBL. Abortion by the SES control signals N ES (DDC), SiES,yBLES can be prevented by Internal operation. 158 SIPART DR21 C73000-B7476-C143-08 Figure 5-4 SIPART DR21 C73000-B7476-C143-08 Switch controller to automatic mode, new parameters are effective Old parameters are overwritten by new parameters Shift key press for about 5 s Switch controller to manual mode, set desired operating point and wait for stationary condition. BLB = 0, BLPS = 0 Process operation mode Exit (16) (6) AdAP keys (14, (15) w- onPA Selection mode Exit (16) Enter (11) Enter (11) Error message acknowledge old parametervalues remain retained by errors in the adaptation method see table 5-3, page 162 Exit AdAP for error correction new parameter values can be changed with w keys (14), (15) Pi..x Pid.x2) 2) Parameter set selectable with w keys (14), (15) Parameter selectable with y keys (7), (8) vv cP tn tv AH values are provided for transfer new parameter manually by Exit key Post adaptation Adaptation LED (19) on Adaptation LED (19) flashing Complete process display During adaptation Aborted adaptation Adaptation LED (19) off Error message Start of adaptation Enter key (11) xx = manipulated variable Strt Old values can only be set in onPA configuration level 0FF,0.1 to 24 h nEG, PoS 0,5 to 90 % Strt Adaptation repeat 1) tU dPv dY xx1) w cP tn tv AH xx1) Pre-adaptation Pre-settings Adaptation LED (19) off Configuration level AdAP Manual 5 Operation 5.4 Configuration modes Overview configuration level AdAP 159 5 Operation 5.4 Configuration modes Manual D Post adaptation The adaptation LED (19) is on indicating the end of adaptation. PI .x appears in the w/x display. You can switch over to PID.x with the keys (14), (15). These are the two controller designs which have been determined for the new online parameters. The digit x stands for the calculated system order. With the keys (7), (8) the new parameters belonging respectively to the PI or PID controller can be displayed and their values changed with the keys (14), (15). After pressing the Exit key (16) twice you go to the process operation mode. The previously selected parameter set PI or PID is only entered now and becomes effective in the control process after switching over to automatic operation with key (11). The respective other parameter set is not saved. SIPART DR21 Setpoint w 2 PV X SP W 100 C 17 Internal LED: current status 16 Exit key : manually aborted adaptation Return to selection mode after AdAP 18 ADAPT 19 Exit LED: flashes Adaptation LED: A1 Controlled variable x 1 15 A2 SP-W 50 Parameter name tU, Pv, dy, vv, cP, tn, tv, AH Pre adaptation: Setting of values for adaptation default Post adaptation: Adjust parameter value 14 A3 A4 Pre adaptation: Adaptation defaults, old parameter values Post adaptation PI or PID, new parameter values 3 after abortion: Error messages Pre adaptation: off (adaptation standby) Post adaptation: on (adaptation ended) During adaptation flashes 12 11 13 0 W 6 X Manual LED: on (manual mode) current status Enter key : pre-adaptation : Start of adaptation Post adaptation: no function after abortion : error acknowledgement Enter LED: Pre adaptation: only flashes when "Strt" in w/x display (3) Post adaptation: off, after abortion: flashes Shift key: no function 9 4, 5 OUT-Y SIEMENS SIPART DR21 7 both LEDs: no function 1) During adaptation: Display of the process variables 8 no function Figure 5-5 160 Control and display elements in the configuration mode AdAP SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes List of start parameters Parameters Monitoring time Recommendation: "off" (automatic) Direction of y step Amplitude of y step, y display Parameter names tU Min. off / 0,1 Pv dY nEG 0,5 w/x display Factory Max. setting 24 off PoS 90 Unit h PoS 0,5 -% Recommendation Choose step width so that x rises/falls by about 10%. Start position for adaptation Pre adaptation controller parameter Start position for adaptation 1) y value uu cP tn tv AH y value vv value Kp value Tn value Tv value AH value Strt -- values not changeable 1) 1 1 s s % Strt -- Value range see online parameters Table 5-2 Parameter list AdAP SIPART DR21 C73000-B7476-C143-08 161 5 Operation 5.4 Configuration modes Manual Error messages of the adaptation procedure D Error messages Explanation digital x/w display StAt not stable at 10 % tU after Start of adaptation wait and restart adaptation x, y y -10 0 100 % tU nody after expiry of the step command the y step in the S- controller is not yet executed correctly Check position feedback and drive of the final control element y.OFL y outside the manipulated variable limits YA, YE (see online parameters) step response in wrong direction within 30 % tU Change controller direction of effect (S46) control loop undershoot (all pass loop), all-pass loops not defined among loop models yManual y too big or too small PASS SMAL x after 50 % tU still within starting band x, y y -10 0 y tU selected too small y step too small at 67 % tU full scale value not reached yet 100 x, y -10 0 n.End % tU 30 x, y tU selected too small loop cannot reach full scale value, e.g. integrally active line transient recovery time t95 > 12 h P.oFL x outside the measuring span 0 to 100 % FASt because of too small a line time constant no adaptation of sufficient quality is possible ovEr Shot > 10 % overshoot of the transient function 67 % tU (transient recovery time t95 < 5 s) y x, y adaptation of sufficient quality is possible -10 0 67 tracking or DCC mode by control signals Si safety operation via the control signals yBL direction-dependent blocking mode via the control signals 162 100 yManual y too big or too small n.ddc Table 5-3 % tU y -10 0 100 50 100 % tU cancel mode of operation Adaptation error messages SIPART DR21 C73000-B7476-C143-08 Manual 5.4.4 5 Operation 5.4 Configuration modes Configuration level offline parameters oFPA The offline parameters determine basic functions such as display ranges, limit values, safety values and transmission function of the input variables. After pressing the Enter key (11) in the ofPA configuration mode (approx. 3 s), the first parameter of table 5-4, page 164 dP in the y display (9) appears with its current value in the w/x display (3) the first time the mains is switched on. Otherwise the parameter selected last the last time the ofPA mode was exited appears. With the y keys (7), (8) the parameters are selected, with keys w keys (14), (15) the value is set. The parameters with a large number range can be adjusted in fast mode. First select the adjustment direction with one w key and then switch on the rapid action by simultaneously pressing the other w key. The ofPA display reappears after pressing the Exit key (16) once. From this state you can change to any other offline configuration mode without the 3 s wait necessary for a new entry by tapping the Enter key (11). This applies accordingly for all offline configuration modes. SIPART DR21 PV X SP W 100 17 16 C 18 ADAPT 19 Internal LED: current status Exit key : Return to selectionmode after oFPA Exit LED: flashes Adaptation LED: off A1 15 A2 SP-W Striped pattern Identification Offline 50 2 14 A3 A4 12 11 1 Controlled variable x 13 6 0 W 3 Parameter value X Parameter name dP . . . L11 flashing Adjustment of parameter value with rapid action 4, 5 9 Manual LED: on (manual operation) Enter key : no function Enter LED: off Shift key: no function both LEDs: no function OUT-Y SIEMENS SIPART DR21 7 8 no function Figure 5-6 Control and display elements in the parameterization mode oFPA SIPART DR21 C73000-B7476-C143-08 163 5 Operation 5.4 Configuration modes oFPA Offline parameter list Parameter Decimal point w/x num. Start of scale Full scale y display Paramnames dP dA dE w / x display Min. _.-------1999 --1999 Max. -------9999 9999 Unit -- A1 A2 A3 A4 Hysteresis alarms HA Setpoint start Setpoint end Safety setpoint SA SE SH Setpoint ramp time tS oFF/0.100 9984 oFF Ratio factor start Ratio factor end vA vE 0.000 0.000 9.999 9.999 0.000 1.000 1 1 Safety output variable Split range left (Y1Y2) Split range right YS Y1 Y2 --10.0 0.0 0.0 110.0 100.0 100.0 0.0 50.0 50.0 % % % L--1 L0 L1 L2 --10.0 --10.0 --10.0 --10.0 110.0 110.0 110.0 110.0 --10.0 0.0 10.0 20.0 % (1) % (1) % (1) % (1) L3 L4 L5 L6 --10.0 --10.0 --10.0 --10.0 110.0 110.0 110.0 110.0 30.0 40.0 50.0 60.0 % (1) % (1) % (1) % (1) L7 L8 L9 L10 L11 --10.0 --10.0 --10.0 --10.0 --10.0 110.0 110.0 110.0 110.0 110.0 70.0 80.0 90.0 100.0 110.0 % (1) % (1) % (1) % (1) % (1) Pd Ad Ed _.-------1999 --1999 ____ 9999 9999 _ _ _.-0.0 100.0 -- (1) Note At S21 S21=5, 5 values standardized to dA to dE. Decimal point 1) Start value 1) Full scale value 1) --110% to 110% from dA, dE at S76 / S77 = 0 to 5 and 17 Factory setting _ _ _.-0.0 100.0 Alarm 1 Alarm 2 (A2A1) Alarm 3 Alarm 4 (A4A3) Output O t t values l off th the lilinearizer i L--1 (--10%) to L11 (110%) are equidistant input vertex points 1) Manual 0.1 5.0 --5.0 5.0 --5.0 10.0 --10% to 110% from dA, dE 1.0 % --5.0 105.0 0.0 min as of software version -A9, only in ratio controller (S1 = 3) Display range of controlled variable x1 and the weighted commanding process variable w (S81 = 7) Table 5-4 164 Offline parameter list SIPART DR21 C73000-B7476-C143-08 Manual 5.4.5 5 Operation 5.4 Configuration modes Configuration mode structure switch StrS The structure switches are software switches which determine the function and structure of the controller. They are set in the offline mode. After pressing the Enter key (11) in the StrS configuration mode (approx. 3 s), the structure switch S1 in the y display (9) appears with its current setting in the w/x- display the first time the mains is switched on. Otherwise structure switch selected last the last time the StrS- mode was exited appears. The switch number is changed with the y keys (7), (8). If the adjustment direction is selected with a y key, tens steps of the counter can be generated by simultaneously pressing the other y key. With the w keys (14), (15) the respective switch is set (see table 5-5, page 172). SIPART DR21 PV X SP W 100 17 16 C 18 ADAPT 19 Internal LED: current status Exit key : Return to selectionmode after StrS Exit LED: flashes Adaptation LED: off A1 15 A2 SP-W Striped pattern Identification Offline 50 2 14 A3 A4 12 11 1 Controlled variable x 13 6 0 Display Structureswitch setting Structure switchesnumber 1 to 92 flashing Adjustment of structure switch position W 3 X 4, 5 9 Manual LED: on (manual operation) Enter key : no function Enter LED: off Shift key: no function both LEDs: no function OUT-Y SIEMENS SIPART DR21 7 8 no function Figure 5-7 Control and display elements in the configuration mode StrS SIPART DR21 C73000-B7476-C143-08 165 5 Operation 5.4 Configuration modes Manual StrS -- structure switch list Structure switch switch position Function [0] 1 2 3 4 5 6 Controller type Fixed value/three-component controller/controller with 2 internal setpoints Slave / synchronization / SPC controller DDC controller Ratio controller Control unit / process display Fixed value controller with 1 setpoint for control system coupling (as of software version-A7) Slave controller without internal/external switching for control system coupling (as of software version -A7) B sic s Basi settin ngs S1 S2 [0] 1 2 3 Output structure K--output S--output two-position controller with 2 outputs heating/cooling *) S--output: three-position step controller for motorized drives, internal feedback *) S--output: three-position step controller for motorized drives, external feedback *) [0] 1 Mains frequency suppression 50 Hz 60 Hz [0] 1 2 3 Input signal AI1 and transmitter fault message 0...20 mA without MUF 0...20 mA with MUF 4...20 mA without MUF 4...20 mA with MUF [0] 1 2 3 Input signal AI2 and transmitter fault message 0...20 mA without MUF 0...20 mA with MUF 4...20 mA without MUF 4...20 mA with MUF [0] 1 2 3 Input signal AI3 (slot 1) and transmitter fault message 0...20 mA or U,R,P,T without MUF 0...20 mA or U,R,P,T with MUF 4...20 mA or U without MUF 4...20 mA or U with MUF 4 5 6 7 UNI module Min UNI module Max UNI module Min UNI module Max [0] 1 2 3 Input signal AI4 (slot 2) and transmitter fault message 0...20 mA or U,R,P,T without MUF 0...20 mA or U,R,P,T with MUF 4...20 mA or U without MUF 4...20 mA or U with MUF S3 S4 S5 A alog Analo g inpu puts S6 S7 at sensor break at sensor break at sensor break at sensor break without MUF without MUF with MUF with MUF S8 Input signal AI3 (slot 1) with UNI--module (only active at S6=4/5/6/7) [0] mV (linear), with measuring range plug U or I (no active sensor break monitoring) 1 Thermocouple with internal reference point 2 Thermocouple with external reference point 3 PT100 4--wire connection incl. supply lines 4 PT100 3--wire connection incl. supply lines 5 PT100 2--wire connection incl. supply lines 6 Resistance potentiometer with R < 600 7 Resistance potentiometer with 600 R < 2.8 k *) see chapter 6.3 "Adaptation of the S-controller to the actuating drive", page 183 166 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes Structure switch switch position S9 Thermocouple type AI3 (slot 1) with UNI--module (only active at S8=1/2) [0] 1 2 3 4 5 6 7 8 9 10 S10 [0] 1 2 Analo log in inpu puts s Function Type L Type J Type K Type S Type B Type R Type E Type N Type T Type U any type (without linearization) Temperature unit AI3 (slot 1) with UNI--module (only active at S8=1/2/3/4/5) Degrees Celsius Degrees Fahrenheit Kelvin Root extraction AI1 to AI4 no yes AI1 AI2 AI3 AI4 S11 S12 S13 S14 [0] [0] [0] [0] 1 1 1 1 Assignment of x1, x2, x3, yN, yR, z from AI1A to AI4A 0% AI1A AI2A AI3A AI4A S15 S16 S17 x1 x2 x3/we 0 0 0 [1] 1 1 2 [2] 2 3 3 [3] 4 4 4 S18 S19 S20 yN yR z 0 [0] [0] 1 1 1 2 2 2 3 3 3 [4] 4 4 A alog in Ana inpu uts S21 [0] 1 2 Assignment of the linearizer (see ofPA) open none AI1 AI2 3 4 5 AI3 AI4 x1 S22 Slot 3 Sl [0] 1 2 3 SIPART DR21 C73000-B7476-C143-08 Assignment slot 3 not used 4 DO / 2 DI (DO3 -- DO6 / DI3, DI4) 4 DO / 1 DI (DO3 -- DO6 / DI3, DI4=0) 5 DI (DI3 -- DI7) 2 relays (DO3, DO4) 167 5 Operation 5.4 Configuration modes Structure switch Manual switch position Function Digi gital inputs Assignment of the control signals to digital inputs Stand. contr. Slot 3 Low DI1 DI2 DI3 DI4 DI5 DI6 DI7 S23 S24 S25 S26 CB He N Si 0 [0] 0 0 1 1 [1] 1 2 2 2 [2] 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 [8] ---- S27 S28 S29 S30 P tS +yBL --yBL [0] [0] [0] [0] 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 ---- S31 S32 S33 bLb bLS bLPS [0] [0] [0] 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 ---- S92 tSH [0] 1 2 3 4 5 6 7 *) * as of software version -B5 Direction of effect of the DIs on assigned control signals 24 V = High 0 V = High S34 S35 S36 CB He N [0] [0] [0] 1 1 1 S37 S38 S39 S40 Si P tS/tSH +/--yBL [0] [0] [0] [0] 1 1 1 1 S41 [0] 1 2 Control signal CB static without acknowledgement static with acknowledgement dynamic as pulse (flip- flop effect) [0] 1 2 Blocking of internal/external setpoint switching internal only external only no blocking [0] 1 x tracking at H or N (DDC) or Si no yes [0] 1 setpoint at CB failure last wi safety setpoint SH [0] 1 Tracking wi to the active setpoint w or tracking of wvi to the active nominal ratio wv yes no [0] 1 Direction of control action to xd ( w - x) normal (Kp > 0) reversed (Kp < 0) [0] 1 2 3 4 D-element connection xd x x1 z direction of control action against x z direction of control action with x S42 set etpoi oint s switc tchin ing S43 S44 S45 C ntrol Cont ol alg gorith thm m S46 168 High S47 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes C ntrol Cont algo a orithm hm Structure switch switch position S48 Adaptation selection [0] no adaptation 1 control behavior without overshoot 2 control behavior with transient recovery after the absolute value optimum [0] 1 Priority N (DDC) or H N (DDC) H [0] 1 2 Manual mode with transmitter fault no switching (display only) manual operation starting with last y manual operation starting with ys S49 S50 S51 switching manual / automatic via output switching Manual key Hi [0] 1 2 3 4 S52 yes no Locking HeES yes / static yes / static no switching manual operation yes yes / dynamic yes yes / dynamic with with with without Iy switch--off in DDC or tracking mode (only K-controllers) without with [0] 1 Output variable limit YA / YE only active in automatic operation active in all operating modes [0] 1 2 3 Output variable display controller output y position feedback yR Split range y1/y2 no display [0] 1 Direction of control action of the output variable display yAn normal: yAn = y reversed: yAn = 100% -- y S54 y dis ispla lay Control signal He [0] 1 S53 S55 S56 Sw tchin Switc ing an analo alog o outp tput ut Function Assignment of controller variables to the analog output [0] 1 2 3 4 5 6 7 8 9 y y w w x x x1 x1 xd + 50% xd + 50% 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 10 11 12 13 14 15 16 17 y1 y1 y2 y2 1--y1 1--y1 1--y2 1--y2 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA 0 to 20 mA 4 to 20 mA SIPART DR21 C73000-B7476-C143-08 as of version --B2 as of version --B2 as of version --B2 as of version --B2 as of version --B2 as of version --B2 as of version --B2 as of version --B2 169 5 Operation 5.4 Configuration modes Structure switch Manual switch position S57 Function Assignment +/--y [0] 1 2 3 DO1 DO2 DO7 (relay) DO8 (relay) -+y -+y ---y --y -- +y -+y -- --y ----y Note: S57 has priority over S58 to S68 Assignment of message signals to digital outputs Digital outputs Stand. contr. Slot 3 none DO1 DO2 DO3 DO4 DO5 DO6 Standard controller DO7 DO8 (relay) (relay) S58 S59 S60 S61 RB RC H Nw [0] [0] [0] [0] 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 S62 S63 S64 S65 A1 A2 A3 A4 0 0 [0] [0] [1] 1 1 1 2 [2] 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 S66 S67 S68 MUF +w --w [0] [0] [0] 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 Notes: If DO1/2 or DO7/8 are occupied by S57 with +/--y, no double assignment is possible! S67 and S68 only active at S1=4 (control unit/process display). Direction of control action of the DOs on assigned message signals S69 S70 S71 RB RC H S72 S73 S74 S75 Nw A1/A2 A3/A4 MUF 24 V = High [0] [0] [0] 0 V = High 1 1 1 [0] [0] [0] [0] 1 1 1 1 Limit v Li value alarms Assignment of A1/A2 and A3/A4 to process variables 170 A1/ A2 A3/ A4 S76 S77 xd x1 x w xv wv y y1 y2 AI 1 AI 2 AI 3 AI AI AI AI AI 4 1A 2A 3A 4A |xd| [0] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17*) [0] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17*) *) as of software version -B5 S78 [0] 1 2 Function of the limit value alarms A1/A2 A1 max /A2 min A1 min /A2 min A1 max /A2 max SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes Structure switch switch position S79 [0] 1 2 S80 Function Function of the limit value alarms A3/A4 A3 max /A4 min A3 min /A4 min A3 max /A4 max Display and setting of the limit values A1 to A4 in the process operation mode Limit value alarms Limit value display w/x-digital display w bargraph display 1) [0] 1 2 no A1 / A2 A1 / A2 / A3 / A4 no no no no no no 3 4 5 6 A1 / A2 A1 / A2 / A3 / A4 A1 / A2 A1 / A2 / A3 / A4 no no A1 / A2 A1 / A2 A3 / A4 A1 / A2 A1 / A2 / A3 / A4 A1 / A2 A1 / A2 A3 / A4 1) S81 w/x display adjustable At S80 = 5/6 the limit values are displayed continuously, w is no longer displayed, a responding limit value flashes (recommended at S1 = 4). w/x digital display switching I II III IV [0] 1 2 3 x/xv x/xv x/xv x/xv w/wv w/wv w/wi1/wv w/wi1/wv -x1/xv x1/xv --wE/wvE/wi2 wE/wvE/wi2 4 5 6 7 x/xv --xv -w/wv -wv --x1/xv 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 S82 Re art Restar co ondititions [0] 1 S83 [0] 1 SIPART DR21 C73000-B7476-C143-08 I II III IV 1 0 0 1 0.5 (0 at S81 = 6) 0 0 0,5 x signal lamp w signal lamp Restart after mains recovery last operating mode, last w, last y manual and internal operation, last w, in K-and two--position controllers Ys, in three--position controllers last y optical signaling after mains recovery without flashing of the w/x digital display with flashing of the w/x digital display 171 5 Operation 5.4 Configuration modes Structure switch switch position S84 0 [1] 21) 31) S85 nothing only Configuring CBDI Configuring CBDICBES Process var. CBDICBES Status register CBDICBES CBDICBES [0} 1 2 Data transfer rate 9600 bps 4800 bps 2400 bps Seri rial iinte erface ce 3 4 5 1200 bps 600 bps 300 bps [0] 1 Cross parity even odd [0] 1 2 Longitudinal parity position without after ETX before ETX [0] 1 Longitudinal parity normal inverted [0] to 125 Station number 0 to 125 [0] 1 to 25 Time monitoring CB (ES) without time monitoring 1 s to 25 s S88 S89 S90 S91 172 Serial interface (slot 4) without with serial interface, with lock via RC with serial interface, with lock via CB with serial interface, without lock 1) as of software version --C1 0 [1] 2 3 4 5 S87 Table 5-5 Function Data transfer Reception Control signal by DR21 CBDI/CBES S86 S92 Manual Source for wE yN wEA yN wES yES wEA yN see structure switch S33 following Structure switches SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes The serial interface in the DR21 must be set as follows for operation on the PROFIBUS-DP. Structure switch S84 S85 S86 S87 S88 S89 S90 S91 5.4.6 Setting 1 2 0 0 0 0 3 to 125 0 to 9 Set UNI-module CAE3 The CAE3 menu is only offered in the selection mode if the structure switch S6 is set = 4 to 7 (input signal for AI3 is generated by the UNI-module) With this menu the measuring range can be determined for the various signal transmitters (selection with S8 and S9) and fine adjustment can be made. S6 [0] 1 2 3 Input signal AI3 (slot 1) and transmitter fault message 0...20 mA or U,R,P,T without MUF 0...20 mA or U,R,P,T with MUF 4...20 mA or U without MUF 4...20 mA or U with MUF 4 5 6 7 UNI module UNI module UNI module UNI module [0] 1 2 3 4 5 6 7 Input signal AI3 (slot 1) with UNI--module (only active at S6=4/5/6/7) mV (linear), with measuring range plug U or I Thermocouple with internal reference point Thermocouple with external reference point PT100 4--wire connection PT100 3--wire connection PT100 2--wire connection Resistance potentiometer with R < 600 Resistance potentiometer with 600 R < 2.8 k S8 S9 Min Max Min Max at sensor break at sensor break at sensor break at sensor break without MUF without MUF with MUF with MUF Thermocouple type AI3 (slot 1) with UNI--module (only active at S8=1/2) [0] 1 2 3 4 5 6 7 8 9 10 S10 [0] 1 2 Table 5-6 Type L Type J Type K Type S Type B Type R Type E Type N Type T Type U any type (without linearization) Temperature unit AI3 (slot 1) with UNI--module (only active at S8=1/2/3/4/5) Degrees Celsius Degrees Fahrenheit Kelvin Excerpt from the structure switch table SIPART DR21 C73000-B7476-C143-08 173 5 Operation 5.4 Configuration modes Manual D Calling, setting and leaving the CAE3 menu - Press the shift key (6) for about 5 s until "PS" flashes in the y display (9). Select the CAE3 menu with the w keys (14), (15) To enter the CAE3 menu, press the Enter key (11) for about 3 s. Select the CAE3 parameters with the y keys (7), (8) Set the CAE3 parameters with the w keys (14), (15) You return to the process operation mode by pressing the Exit key (16) twice. D The following parameters are available in the CAE3 menu for setting the measuring range and adjustment y display parameter name w/x display setting range Factory setting Display unit Meaning/function of parameter Display and function only at: tb 1) 0 to 400.0 50 _C, _F, K Reference temperature external reference point S8 = 2 Mr 0.00 to 99.99 10 Measuring of RLn. (Pt100-2L) Difference value to Mr Calibr. of RLn. (Pt100-2L) Cr MP _.------ to ____ MA 2) --19999 to 9999 0.0 2) --19999 to 9999 100.0 ME CA CE PC 5) Table 5-7 act. measured value A 3) act. measured value E 3) no, YES, no C no C S8 = 5 Decimal point measuring range physical Dimension depending on the measuring variable Measuring range full scale 4) Calibr. Meas. range full scale -- Preset Calibration Measuring range start S8 = 0 to 7 Calibr. Meas. range Start S8 = 0 to 5 CAE3-menu parameter list 1) If no specified thermocouple type is selected with S9 = 10, the parameter tb has no effect. 2) The set measuring range is transferred as a standardized number range from 0 to 1 to the controller. If the measured value mode is to be displayed physically, the offline parameters dP, dA and dE must be set accordingly. 3) For S8 = 0 to 5 : A, E do not appear as own parameters. The correction values for calibrating the start or full scale of the measuring range are arbitrary. 4) For S8 = 6, 7 the unit of the CA/CE display is in %. 5) For S8 = 0 to 5 : With A = E = 0, PC = no C is displayed, it is not possible to switch over with the w--keys (7), (8) to PC = YES. By adjusting CA/CE, PC = no is displayed, switching to PC = YES is possible. If PC = YES is displayed A = E = 0 can be set with the Enter key (press for approx. 3 s), whereupon PC = no C is displayed. The corresponding settings of the CAE3 menu for the different signal transmitters are described below. The range and thus the current measured value can be corrected with the parameters CA/CE to compensate tolerances of the transmitters or adjustments with other display instruments (for S 8 = 0 to 5). To avoid measuring errors, the assembly instructions in chapter 4.2.2, page 130 and especially the maximum permissible line resistances (see table 2-3, page 41) must be observed in the determination of the measuring range. 174 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes 5.4.6.1 Measuring range for mV (S8 = 0) D MA/ME - set measuring range Call parameters MA, ME, set range start and full scale: Measuring range limits -175 mV MA ME +175 mV D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 5.4.6.2 Measuring range for U, I (S8 = 0) only with measuring range plug 6DR2805-8J D MA/ME - set measuring range Call parameters MA, ME, set range start and full scale: Measuring range limits -175 mV MA ME +175 mV Initialization in the measuring range plug 0 to 10V or 0 to 20mA signal corresponds to MA = 0mV 2 to 10V or 4 to 20mA signal corresponds to MA = 20mV ME = 100mV ME = 100mV D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 5.4.6.3 Measuring range for thermocouple with internal reference point (S8 = 1) D MA/ME - set measuring range Call parameters MA, ME, set the start of scale and full scale according to the thermocouple type (S9) and the temperature unit (S10). SIPART DR21 C73000-B7476-C143-08 175 5 Operation 5.4 Configuration modes Manual D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 5.4.6.4 Measuring range for thermocouple with external reference point (S8 = 2) D tb - external reference points-temperature Set the external reference point temperature with tb. Specify temperature unit with S10. Attention: tb has no effect at S9 = 10! D MA/ME - set measuring range Call parameters MA, ME, set the start of scale and full scale according to the thermocouple type (S9) and the temperature unit. D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 5.4.6.5 Measuring range for PT100 four-wire and three-wire connection (S8 = 3,4) D MA/ME - set measuring range Call parameters MA, ME, set range start and full scale: Measuring range limits -200 _C MA ME +850 _C Specify temperature unit with S10. D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 176 SIPART DR21 C73000-B7476-C143-08 Manual 5 Operation 5.4 Configuration modes 5.4.6.6 Measuring range for PT100 two-wire connection (S8 = 5) D MR/CR adjustment of the feed line resistance Path 1: The feed line resistance is known. - Path 2: Enter the known resistance with parameter MR.-CR is ignored. The feed line resistance is not known. - Short circuit PT100-sensor at the measuring point. Call parameter CR and press the Enter key (11) until 0.00 is displayed. MR displays the measured resistance value D MA/ME - set measuring range Call parameters MA, ME, set range start and full scale: Measuring range limits -200 _C MA ME +850 _C Specify temperature unit with S10. D CA/CE - fine adjustment (only if necessary) Call parameter CA, Set signal to start of scale Correct the display with CA if necessary Call parameter CE, Set signal to full scale, Correct the display with CE if necessary 5.4.6.7 Measuring range for resistance potentiometer (S8 = 6, 7) Path 1 : - The start and end values of the R- potentiometer are known. Call parameter MA, ME, set start of scale and full scale: 0 MA ME 600 / 2.8 k Parameters CA/CE display at R=MA 0%, at R=ME 100 %. The following applies for a 3-wire connection: R = Rp+ RL4 The following applies for a 4-wire connection: R = Rp+ RL1 + RL4 Path 2 : The start and end values of the R- potentiometer are not known. - Call parameter CA , Move output to position 0 %, press the Enter key (11) until 0.0 % is displayed. Call parameter CE, Move output to position 100 %, press the Enter key until 100.0 % is displayed. Parameters MA/ME show the appropriate resistance values. MP must be set so that there is no 'exceeding of the range' (display (3): oFL) SIPART DR21 C73000-B7476-C143-08 177 5 Operation 5.4 Configuration modes 5.4.7 Manual APSt (All Preset) Reset to factory setting APSt serves to reset all controller functions (parameters and structures) to the factory setting. We recommend you to run the APSt function first if major changes are to be made to the configuration. The controller is in offline operation in the structuring mode. NOTICE The APSt function cannot be canceled. SIPART DR21 PV X SP W 100 17 16 C 18 ADAPT 19 Internal LED: current status Exit key : Return to selection mode after APSt Exit LED: flashes Adaptation LED: off A1 15 A2 SP-W Striped pattern ID offline 50 2 14 A3 A4 12 11 Controlled variable x 1 Display no or YES 3 13 6 0 W X PS (Parameterization/structuring) Adjustment no or YES, set YES 4, 5 9 Manual LED: ON (manual operation) Enter key : until configuration mode StrS appears Enter LED: flashes if YES Shift key: no function both LEDs: no function OUT-Y SIEMENS SIPART DR21 7 8 no function Figure 5-8 Control and display elements in the structuring mode APSt No appears after jumping to the structuring mode APSt with the Enter key (11). Set YES with +w key (14, 15) and press the Enter key (11) until the configuration mode StrS appears. The Preset function is run. Select structuring mode Strs by pressing the Enter key and re-structure the controller. The offline and online parameters must also be reset. 178 SIPART DR21 C73000-B7476-C143-08 Manual 5.5 5 Operation 5.5 CPU self-diagnostics CPU self-diagnostics The CPU runs safety diagnostics routines which run after only one reset or cyclically. The CPU is familiar with two different types of reset: Power On--Reset always take place when the 5 V supply drops below 4.45 V, i.e. the power supply is interrupted for longer than specified in the technical data. All parameters and structures are reloaded from the user program memory into the RAM. The current process variables and the controller status are reloaded from the EEPROM for these data. At S83 = 1 the digital w/x- display flashes as an indication after a Power-On-Reset, acknowledgement is by the Shift key (6) for w/x digital display. With S83 = 0, the flashing is suppressed. Watch_dog Reset The processor has an integrated watchdog which monitors the cyclic program runs independently. When a watch-dog reset occurs the parameters and structures from the user program memory are loaded into the RAM. The current process variables and the controller status are read out of the RAM for further processing. There are no flashing signals on the front module. tESt appears for a maximum 5 s in the digital w/x display after every reset. Every detected error of the self--monitoring leads to a flashing error message on the digital w/x display with defined states of the analog and digital outputs. The reactions listed in the table are only possible of course (since this is a self-test) if the errors occur in such a way that the appropriate outputs or the front module are still controlled properly or the outputs themselves are still functioning. Error message w/x display Monitoring of Monitoring time during monitoring tESt in the case of an error CPU EEPROM, RAM, EPROM after every reset MEM OP.1.* 1) EEPROM when storing Data communication slot 1: UNI-module cyclic Option not plugged, defective or S6 does not correspond to plugged option / plug or change option or correct S6. OP.*.3 1) Data communication slot 3 4DO + 2DI or 5 DI option cyclic Option not plugged, defective or S22 does not correspond to plugged option / plug or change option or correct S22 2) 1) 2) Primary cause of the error/remedy monitored components of the CPU or EEPROM defective/change front module also double error display OP.1.3 possible. * means digit dark If 2DO relay is selected with S 22 = 3, no monitoring takes place. At DI3 to DI7, S22 = 2 the effect of the digital inputs (after inversion) are set to 0 in the event of an error. Table 5-8 Error message of the CPU SIPART DR21 C73000-B7476-C143-08 179 5 Operation 5.5 CPU self-diagnostics 180 Manual SIPART DR21 C73000-B7476-C143-08 Manual 6 Commissioning 6.1 Adapting the direction of control action to the controlled system 6 Commissioning 6.1 Adapting the direction of control action to the controlled system D Definitions Normal control action system Rising y causes rising x; e.g. an increasing energy supply or mass flow causes a rising temperature. Normal effecting actuator (valve): Increasing current or positioning command +y cause the actuating element (increasing y) to open, e.g. more energy or greater mass flow. ydispl. is the displayed manipulated variable. The direction of control action is referred to the controlled variable x1. The following statements apply for transmitters with normal control action (increasing physical variable causes increasing transmitter current), increasing process display (dE > dA) and no falling characteristic in the linearizers. D Direction of control action of system and final control element known K-controller The following is prescribed: Direction of control action of the system normall revers reversi ing Direction of control action of the actuator Direction of control action of the system and the actuator normal normal reversing reversing normal reversing reversi ing normal Select the desired control action here: 20 mA on pressing the right key causes in manual operation This gives the settings of S46 and S55 and the mode of operation of the controller actuating current ly valve Actual value/ controlled variable S46 Kp (cP) S55 ydispl. = 100 % rises opens rises 0 pos. 0 y 0% falls opens rises 1 neg. 1 100 % -y 0% falls closes rises 1 neg. 1 100 % -y 100 % rises opens falls 1 neg. 0 y 100 % rises closes rises 0 pos. 0 y 0% falls opens falls 0 pos. 1 100 % -y Two more lines could be added to the table which are useless in practice: normal action system in which the actual values falls with a rising change in the manipulated variable. Table 6-1 Direction of control action and y-display direction of control action of the system- and final control element direction of control action in K-controllers SIPART DR21 C73000-B7476-C143-08 181 6 Commissioning 6.1 Adapting the direction of control action to the controlled system Manual S-controller The following is prescribed: Direction of control action of the system Direction of control action of the actuator Direction of control action of the system and actuator normal +y opens reversi ing +y y opens Select the desired control action here: pressing the right key causes in manual operation: This g gives the settings g of S46 and d S55 and d th the mode d off operation of the controller Actual value/ con controlled variable rises S46 Kp (cP) S55 ydispl. = active switching output is valve normal +y opens rises 0 pos. 0 yR reversi ing -y closes rises 1 neg. 1 100 % - yR +y opens falls 1 neg. 0 yR If the actuator is connected reversing as an exception (+y closes), the position feedback must also be reversed and the controller direction of control action (Kp) negated. Table 6-2 D Controller direction of control action and y-display direction of control action of the systemand final control element direction of control action in S-controllers Direction of control action of system and final control element unknown Put controller in manual mode, leave structure switches S46 and S55 in factory setting (0). - Determine direction of control action of the final control element Press the right manipulated variable adjustment key with the process switched off if possible or close to its safety position and observe whether the final control element opens or closes. If the final control element opens this means it has normal action. If closing is determined in S-controllers, the connections + y and - y should be switched. The final control element can be observed as follows (if the direction of control action of the system is known): - - normal control action system: rising x means normal control action actuator reversing system: falling x means normal control action actuator in S-controllers and already correctly connected position feedback rising y-display means normal control action actuator The final control element can be monitored additionally at the installation location. Determine the direction of control action of the system Press the right output adjustment key and observe on the actual value display whether the controlled variable (actual value) rises or falls. Rising means normal control action system with normal action actuator, reversing control action system with reversing actuator. Falling means reversing control action system with normal control action actuator, normal control action system with reversing actuator. With the direction of control action of actuator and system determined in this way, the controller can be set according to table 6-1 and 6-2. 182 SIPART DR21 C73000-B7476-C143-08 Manual 6.2 6 Commissioning 6.2 Setting of actuating time in K-controllers (S2 = 0) Setting of actuating time in K-controllers (S2 = 0) D Actuating time tP, tM Set the actuating time tP (open) or tM (closed) to the actuating time of the following actuator. If the control circuit is to be settled additionally, e.g. to avoid hard impact on the actuating drive, tP, tM can be further increased in Automatic operation. The value of tP is usually set identical to the value of tM. 6.3 D Adaptation of the S-controller to the actuating drive Output Two-position controller for heating/cooling (S2 = 1) The setting range y can be divided into two sections. The offline-parameters Y1 and Y2 and the online-parameters YA and YE determine tehse sections(see fig. 3-24, page 98.) The period duration and the shortest turn-on- and turn-off duration are determined in the cooling branch (section [YA, Y1]) by the online-parameters tM and tA and in the heating branch (section [Y2, YE]) by the online parameters tP and tE. The period durations tP and tM should be chosen as great as possible, whereby the following should be observed: - Great values of tP and tM result in low wear of the internal and external switchgear. - Large values cause a periodic fluctuation of the controlled variable x which is greater the faster the controlled system is. D S-controller with internal feedback (S2 = 2) Set the actuating time of the actuating drive (e.g. 60 s) with the online-parameters tP, tM (0.1 to 1000 s). NOTICE The factory setting is 1 s! The online-parameter tE (minimum turn-on duration) should be selected at least great enough that the actuating drive starts moving reliably under consideration of the power switches connected before it. The greater the value of tE, the more resistant to wear and more gently the switching and drive elements connected after the controller operate. Large values of tE require a greater dead band AH in which the controller cannot control defined because the resolution of the controlled variable diminishes with increasing turn-on duration. The factory setting for tE is 200 ms. This corresponds to a y-resolution in a 60-s-actuating drive of: y = 100 % * tE tP (or tM) SIPART DR21 C73000-B7476-C143-08 = 100 % * 200 ms 60 s = 0.33 % 183 6 Commissioning 6.3 Adaptation of the S-controller to the actuating drive Manual The minimum possible resolution is transferred with the system gain Ks to the controlled variable x = Ks * y The parameter tA (minimum turn-off duration) should be chosen at least great enough that the actuating drive is safely disconnected under consideration of the power switches connected before it before a new pulse appears (especially in the opposite direction). The greater the value of tA, the more resistant to wear the switching- and drive elements connected after the controller operate and the greater the dead time of the controller under some circumstances. The value of tA is usually set identical to the value of tE. tA = tE = 120 to 240 ms are recommended for 60 s actuating drives. The more restless the controlled system, the greater the two parameters should be selected if this is reasonably justified by the controller result. The response threshold AH must be set corresponding to the set tE and the resulting y or x. The following condition must be satisfied: AH > x 2 or AH > KstE100 % 2tP (or tM) Otherwise the controller outputs positioning increments although the control deviation has reached the smallest possible value due to the finite resolution. For setting AH, see chapter 5.4, page 154. D S-controller with external feedback (S2 = 3) The position control circuit is optimized with the online-parameters tP/tM. The same relationships apply as in the S-controller with internal position feedback whereby the dynamic of the position control circuit (non-linearities, follow-up) is added to the criteria of the processability of the positioning increments by the final control element. It will usually be necessary to select tP/tM and the resulting response threshold smaller than in the S-controller with internal position feedback for the above mentioned reasons. The position control circuit is optimized in manual mode. To do this, S54 is set to 0 for the optimizing phase so that the manual manipulated variable is preset as an absolute value. It must be noted that the active manipulated variable trails the manipulated variable display due to the actuating time of the actuator. In the case of non-linearity in the position control circuit, the optimization must take place in the range of greatest slope. Procedure for optimization of the position control circuit: - Set S54 to 0 (position controller also active in manual mode) - Set tA and tE so that the actuating drive can just process the positioning increments (see S-controller with internal feedback). - Set 1st order filter of the y R -input (t1, 2, 3 or 4) to 0.01 TP/TM (real actuating time of the drive). - Increase tP/tM until the position control circuit overshoots due to small manual changes in the manipulated variable (observe opposite pulse on the y-LEDs (10) in the y-display). 184 SIPART DR21 C73000-B7476-C143-08 Manual 6 Commissioning 6.4 Setting the filter and the response threshold - Reduce tP/tM slightly again until the position control circuit settles. - Reset S54 to 1 (position controller no longer active in manual mode) 6.4 Setting the filter and the response threshold Set the structure switch S3 to the mains frequency 50 or 60 Hz existing in the system (factory setting 50 Hz) to suppress faults due to the mains frequency. D Filter of first order of analog inputs The filter time constants (t1 to t4) for the input filters are set in the onPA-parameterization mode and to the greatest possible value permitted by the control circuit without affecting the controllability (t1 to t4 < Tg). When using the adaptation method the appropriate input filters must be optimized. D Adaptive, non-linear filters of the control difference Since the dead zone sets itself automatically and its size is therefore unknown, the time tF (onPA) can only be selected so great that the control circuit cannot oscillate in the case of a large dead zone (tF less than Tg). When using the D-part (PD, PID) the use of the adaptive, non-linear filter is strongly recommended because the input noise amplified by Kp*vv can be suppressed. If filters are required, they must be set before using the adaptation method. D Optimization of the response threshold AH If the output of the controller is to additionally settled or the load on the actuator reduced, the necessary response threshold AH can be increased. The response threshold AH is given in three-position controllers (S2 = 2, 3) by the setting of tE (see chapter 6.3, page 183) and must automatically be greater than zero. In K-controllers and two-position controllers (S2 = 0, 1) a response threshold of approx. 0.5 % is recommendable. It must be taken into account that the remaining control error can assume the value of the set response threshold. SIPART DR21 C73000-B7476-C143-08 185 6 Commissioning 6.5 Automatic setting of control parameters by the adaptation method 6.5 Manual Automatic setting of control parameters by the adaptation method see chapter 3.9 "Adaptation (S48)", page 113 The adaptation method should always be preferred to manual settings because the control results with the parameters gained from adaptation are better especially in slow controlled systems and this saves optimization time. D Presetting - S48 selecting the control behavior (structuring mode StrS) No adaptation is possible when S48 = 0. In position 1 a control behavior without overshoot is offered. In position 2 changes in the command variables can be expected with a maximum 5 % overshoot. - tU: Monitoring time (parameterization mode AdAP) tU is only necessary for the error messages and has no influence on the quality of identification It can always be started with tU = oFF. Otherwise tU must be set at least twice as great as the transient time T 95 of the controlled system. After successful adaptation tU is automatically set to 2T95. At tU < 0.1 h (6 min), tU = oFF is displayed. - Pv: Direction of the step command (parameterization mode AdAP) The direction of the controlled variable change from the set operating point is selected with this configuring switch: xmanual x = ks (ymanual y). In controlled systems with batches it is recommendable to perform one adaptation with rising x and one with falling x. The averaged or dynamically more uncritical parameters can then be used for the control. - dy: Amplitude of the step command (parameterization mode AdAP) The step command must be selected so great that the controlled variable changes by at least 4 % and the controlled variable change must be 5 times the average noise level. The greater the controlled variable change, the better the identification quality. Controlled variable changes of approx. 10 % are recommended. D Notes on the adaptation results - D-part In S-controllers and K-controllers on 1st order controlled systems, the D part brings no noticeable advantages due to the finite actuating time Ty or for reasons founded in the control theory. The disadvantages in the form of wear on the positioning side dominate. - Range limits If one of the determined parameters reaches its range limits, the other parameter should be adjusted slightly in the opposite direction of action. If 8th order systems are identified, the determined kp must be reduced for safety reasons. The determined Kp must be increased again if the control circuit is too slow (uncritical). 186 SIPART DR21 C73000-B7476-C143-08 Manual - 6 Commissioning 6.5 Automatic setting of control parameters by the adaptation method Kp variation In the special cases 1st order controlled system in connection with PI and PID controllers and 2nd order controlled systems in connection with PID-controllers, the Kp can be varied freely. In controller design according to the absolute value optimum, Kp can be increased up to 30 % as a rule without the control behavior becoming critical. SIPART DR21 C73000-B7476-C143-08 187 188 Figure 6-1 onPA wkeys (14), (15) AdAP + Switch controller to automatic mode, new parameters are effective Exit (16) (6) Selectionlevel - Old parameters are overwritten by new parameters Shift key press for about 5 s Switch controller to manual mode, set desired operating point and wait for stationary condition. bLb = 0, bLPS = 0 Process operation-level Exit (16) Enter (11) Old values can only be set in onPA configuration level xx1) w cP Enter (11) by errors in the adaptation method see table 5-3, page 162 Exit AdAP for error correction Error message new parameter values can be changed with w-keys (14), (15) Pi..x Pid.x2) 2) Parameter set selectable with w-keys (14), (15) Parameter selectable with y-keys (7), (8) vv cP tn tv AH values are provided for transfer new parameter- manually by Exit key Post adaptation Adaptation LED (19) on Adaptation LED (19) flashing Complete process display During adaptation Aborted adaptation Adaptation LED (19) off old para-metervalues are retained Start of adaptation Enter key (11) Error message acknowledge = manipulated variable Adaptation repeat 1) xx AH xx1) Strt Strt dPv dY tn tv 0FF,0.1 to 24 h nEG, PoS 0,5 to 90 % tU Pre-adaptation Pre-settings Adaptation LED (19) off Configuration level AdAP 6 Commissioning 6.5 Automatic setting of control parameters by the adaptation method Manual Overview configuration level AdAP SIPART DR21 C73000-B7476-C143-08 Manual 6.6 6 Commissioning 6.6 Manual setting of the control parameters Manual setting of the control parameters without knowledge of the plant behavior The control parameters for optimum control of the system are not yet known in this case. To keep the control circuit stable in all cases, the following factory settings must be made: Proportional action factor Integral action time Derivative action time D Kp Tn Tv = = = 0.1 9984 s oFF P-controller (control signal P = high) - Set the desired setpoint and set the control difference to zero in manual operation. - The operating point necessary for the control difference is set automatically in manual operation at Yo=AUto (factory setting). The operating point can also be set manually by setting the online-parameter yo to the desired operating point. - Switch to automatic operation. - Increase Kp slowly until the control loop tends to oscillate due to slight setpoint changes. - Reduce Kp slightly until the oscillations disappear. D PD-controller (control signal P = high) - Set the desired setpoint and set the control difference to zero in manual operation. - The operating point necessary for the control difference is set automatically in manual operation at Yo = AUto (factory setting). The operating point can also be set manually by setting the online-parameter y o to the desired operating point. - Switch to automatic operation. - Increase Kp slowly until the control loop tends to oscillate due to slight setpoint changes. - Switch Tv from oFF to 1 s. - Increase Tv until the oscillations disappear. - Increase Kp slowly until oscillations reappear. - Repeat the setting according to the two previous steps until the oscillations can no longer be eliminated. - Reduce Tv and Kp slightly until the oscillations are eliminated. SIPART DR21 C73000-B7476-C143-08 189 6 Commissioning 6.6 Manual setting of the control parameters Manual D PI-controller (control signal P = Low) - Set the desired setpoint and set the control difference to zero in manual operation. - Switch to automatic operation. - Increase Kp slowly until the control loop tends to oscillate due to slight setpoint changes. - Reduce Kp slightly until the oscillations disappear. - Reduce Tn until the control loop tends to oscillate again. - Increase Tn slightly until the tendency to oscillate disappears. D PID-controller (control signal P = Low) - Set the desired setpoint and set the control difference to zero in manual operation. - Switch to automatic operation. - Increase Kp slowly until the control loop tends to oscillate due to slight setpoint changes. - Switch Tv from oFF to 1 s. - Increase Tv until the oscillations disappear. - Increase Kp slowly again until the oscillations reappear. - Repeat the setting according to the previous two steps until the oscillations cannot be eliminated again. - Reduce Tv and Kp slightly until the oscillations stop. - Reduce Tn until the control loop tends to oscillate again. - Increase Tn slightly until the tendency to oscillate disappears 190 SIPART DR21 C73000-B7476-C143-08 Manual 6 Commissioning 6.7 Manual setting of the control parameters 6.7 Manual setting of the control parameters after the transient function If the transient function of the controlled system is active or can be determined, the control parameters can be set according to the setting guidelines specified in the literature. The transient function can be recorded in the Manual operation" position of the controller by a sudden change in the manipulated variable and the course of the controlled variable registered with a recorder. This will roughly give a transient function corresponding to the one shown in figure 6-2. Good average values from the setting data of several authors give the following rules of thumb: P-controller: Proportional gain factor Kp Tg Tu * Ks PI-controller: Proportional gain factor Integral action time Tg Tu * Ks Kp 0.8 * Tn 3 * Tu PID-controller: Proportional gain factor Kp 1.2 * Tg Tu * Ks Integral action time Tn Tu Derivative action time Tv 0.4 Tu y y t Tg x x manipulated variable measured variable time delay time compensation time transmission factor of the controlled system Ks = x y t Tu Figure 6-2 y x t Tu Tg Ks Transient function of a controlled system with compensation SIPART DR21 C73000-B7476-C143-08 191 6 Commissioning 6.7 Manual setting of the control parameters 192 Manual SIPART DR21 C73000-B7476-C143-08 Manual 7 Application examples for configuring the controller 7.1 General 7 Application examples for configuring the controller 7.1 General Frequent applications/connections of the SIPART DR21 controllers in the form of configuration examples are listed below. The circuits are sorted according to their application S-controller, K-controller, control unit/process display or two-position controller. All input and output connections and the order numbers of the respective required controllers or accessory modules are stated. A principle circuit diagram of the control circuit and a short description make comprehension easier We have purposely described the simple applications in very great detail to help the technician above all who only needs to design these circuits very occasionally. Mains voltage As shown, the power supply must be fused and the PE conductor connected. The permissible power supply range must be stated respectively with the type number of the controller. Fuses and connecting leads are not supplied with the controllers. Input circuits A wide variety of input circuits are shown. Please note that the supply voltage remaining for the transmitter may only be 15 V DC in the worst case when a two-wire transmitter is fed by the SIPART DR21 and the analog inputs AI1/AI2 are used at the same time. Output circuits The outputs are represented uniformly. In S-controllers, the switching outputs are output via relays which may be loaded with a max. 250 V AC. If the position outputs of the S-controller are desired with digital signals, the digital outputs DO1 and DO2 must be used. If inductances (e.g. positioning motors, contactors, etc.) are switched with the planned relay outputs, an adequate interference suppression must be provided for on the system side by wiring with RC-combinations or other suitable means in order to achieve EMC protection aims. SIPART DR21 C73000-B7476-C143-08 193 7 Application examples for configuring the controller 7.1 General Manual D Configuring Structure switches S All controllers are supplied with the specified factory settings and must be structured to suit the application during commissioning. The switch positions for the respective application which deviate from the factory setting are listed in the examples. In addition other settings may be necessary due to system-specific criteria. The following configuration examples have exclusively parallel circuits. Therefore the structure switches which relate to the serial interface are not specified. Parameters onPA and oFPA The controllers must be adapted in every case using the system data. The factory setting of the control parameters must be selected so that the control loop does not tend to oscillate even under worst case conditions (Kp = 0, 1, Tn = 9984 s). Kp and Tn or y0 and if necessary Tv and AH must be set. Control algorithm All configuration examples (except Z1) are shown for PI or PID behavior. Switching to P or PD behavior is possible with a digital input signal (structure switch S27). In the SIPART DR21 as an S-controller, a P-or PD-controller operation is only possible with external position feedback (S2=3). 194 SIPART DR21 C73000-B7476-C143-08 Manual 7.2 7 Application examples for configuring the controller 7.2 Working with different setpoints Working with different setpoints Function diagrams are shown on the following pages which illustrate on the time axis how setpoints change when - the Internal/External key (16) on the front is pressed - the structured functions of the digital input DI are triggered with logic 1 or logic 0. The structure switches named next to the examples must be put in the specified positions for the illustrated functions. Structure switches not listed are in the factory setting. Example 1 two-setpoint operation as a fixed setpoint controller (see chapter 3.4.2, page 59) At S81 = 2/3 both setpoints can be called with the key (6) in the four-digit display (3) and then adjusted with the keys (14), (15) on the front of the instrument. Switching from w1 to w2 takes place with the Internal/External switch (16) (at CB = 1). The active setpoint is always shown on the analog bargraph display (2). At S81 = 0/1/5 only the active setpoint can be shown on the digital display. w1 = wi1 (can be set on the front) w2 = wi2 (can be set on the front) tS = setpoint ramp w (%) 100 wi2 S1 = 0 S23= 8 S45 = 1 S42 = 2 S81 = 2 wi1 tS tS 0 Int Hi t Lo CB = 1 = High Figure 7-1 Hi Lo Setpoint curve according to example 1 SIPART DR21 C73000-B7476-C143-08 195 7 Application examples for configuring the controller 7.2 Working with different setpoints Example 2 wE SH wi Manual Three-setpoint operation with a slave controller (see chapter 3.4.3, page 62) is an external variable setpoint safety setpoint fixed by parameterization in oFPA is an internal setpoint which can be adjusted on the front The switching between wE and SH takes place with the digital signal CB (Internal/External key (16) must be set to "External"). The External/Internal key (16) switches between wE/SH and wi. Figure 7-2 shows the setpoint curve with and without setpoint ramp tS. w (%) 100 CB on DI1 S 1=1 S 23 = 1 wE on AI2 S S S S S S 25 = 0 (1) 42 = 2 43 = 0 44 = 1 45 = 1 17 = 2 wE wE SH 0 wi t Int/Ext key Attention! SH (safety setpoint) can only be selected based on wE (external setpoint). Int Int CB CB Figure 7-2 196 Setpoint curve according to example 2 SIPART DR21 C73000-B7476-C143-08 Manual 7 Example 3 Application examples for configuring the controller 7.2 Working with different setpoints Four-setpoint operation with one slave controller with Internal/ External switching and CB signal through the digital input The analog input AI2/wE is overcontrolled to 0 or 100%: wi wE SH wE setpoint which can be adjusted on the front setpoint limit fixed by parameterization oFPA (setpoint limit start SA), wE over controlled to 0 %. safety setpoint set by parameterization. setpoint limit fixed by parameterization oFPA (setpoint limit end SE) wE overcontrolled to 100 %. Switchings take place: wi= wE= SH= wE= key (16) to Internal key (16) to External (INT), CB signal High (CB). AI2 overcontrolled to 0% (SA) key (16) to External, CB from High to Low (CB) key (16) to External (INT), CB signal High (CB). AI2 overcontrolled to 100% (SE) Restriction of this circuit wi and SH must be within the limits SA to SE. Also only the active setpoint can be displayed at S81 = 2/3. SH can only be reached by the transition INTCB to INTCB. w (%) 100 wE on AI2 CB on DI1 wE (SE) S1 = 1 S17 = 2 S23 = 1 S42 = 2 S43 = 0 S44 = 1 S45 = 1 SH wi 0 Int/Ext key wE (SA) t Int Int DI1 Attention! SH (safety setpoint) can only be selected based on wE (external setpoint). Figure 7-3 CB CB 100 % AI2 0% Setpoint curve according to example 3 SIPART DR21 C73000-B7476-C143-08 197 7 Application examples for configuring the controller 7.2 Working with different setpoints Example 4 Manual Fixed setpoint controller with setpoint ramp (ts > 0) Operation with an adjustable setpoint wi, with x tracking by Si (safety manipulated variable yS). Due to x tracking the active setpoint follows the controlled variable x without a delay at Si=1 (DI for safety manipulated variable). If Si becomes 0 the setpoint returns to the setpoint wiset earlier with the setpoint ramp set as a time parameter. The setpoint ramp is not effective in x tracking. w1 = wi (can be set on the front) w2 = x (x tracking) w (%) 100 Si on DI2 x tracking ts wi wi S1 = 0 S26 = 2 S37 = 0 S43 = 1 S45 = 1 ts > 0 w= x 0 DI2(Si) t Hi Lo t x (%) 100 0 t y (%) Attention! SH (safety setpoint) can only be selected based on wE (external setpoint). 50 0 Figure 7-4 198 t Setpoint curve according to example 4 SIPART DR21 C73000-B7476-C143-08 Manual 7.3 7 Application examples for configuring the controller 7.3 Configuration examples Configuration examples Configuration example K1 w The controlled variable x from the transmitter goes to the analog input AI1 of the controller. The input signal range is 0 to 20 mA. The manipulated variable is also 0 to 20 mA. y x Drive I Fixed setpoint controller as a K-controller Controlled variable by a four-wire transmitter Transmitter with UH = 24 V: The transmitter can also be fed from the controller (+ at terminal 9 and - at terminal 11). Please read the foreword to chapter 7.1, page 193 Setting the structure switches: S1 = 0 S2 = 0 S4 = 0, 1 S56 = 0 Slot 3 Limit value Slot 2 AI4 not used Option module 6DR2801-8D M1 A1 R1 1 2 3 A2 R2 4 5 Slot 1 AI3 PE N L UC 24 C PE N L AC 115 V AC 230 V SIPART DR21 standard controller 6DR2100-5 6DR2100-4 not used (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 M2 6 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L 13 -y +y 14 x Transmitter feed UH SIPART DR21 C73000-B7476-C143-08 + -- -- + I -- + I 199 15 7 Application examples for configuring the controller 7.3 Configuration examples Configuration example K2 Two common mode controllers as K-controllers; external setpoint from a two-wire transmitter with external feeding; Controlled variables from two-wire transmitters, feeding from the SIPART DR21 controller The external setpoint is looped serially through both controllers. Since the analog inputs AI1, AI2 of the controller are referenced to ground, the options module must be used for the current input in one of the controllers because this can process the appropriate common mode voltage. The setpopint wE is evaluated differently in the two controllers in this example. As a result the controlled variables x1, x2 have a constant relationship with each other. The external common setpoint can be evaluated with the online parameters c4, c5. wE = c4*wE + c5 If the factory setting is left in controller 1 c4 = 1, c5 = 0, the values for c4, c5 of controller 2 in the controlled state gives the relationship between the controlled variables x1, x2. x2 -- c5 x1 = c4 wE y1 y2 y2 y1 wE Drive x1 Drive x2 Manual Please read the foreword to chapter 7.1, page 193 Controller 1 Setting the structure switches controller 1: S1 = 1 S2 = 0 S15 = 1 S17 = 3 Slot 3 Limit value not used 1 2 3 4 5 1 Slot 2 AI4 Slot 1 AI3 not used Option module 6DR2800-8J 2 3 4 -- R + 1 2 3 4 Uexternal -- + UC 24 C PE N L AC 115 V AC 230 V SIPART-DR21 standard controller GND + PE N L wE I 6DR2100-5 6DR2100-4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 -- 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 wE x1 -- + I + L 13 G N D -y +y 14 15 (c) -I wE +18 V < U_ < +28 V 200 SIPART DR21 C73000-B7476-C143-08 Manual 7 Configuration example K2 Application examples for configuring the controller 7.3 Configuration examples continued Controller 2 Setting the structure switches controller 2: S1 = 1 S2 = 0 S15 = 1 S16 = 0 S17 = 2 PE N L UC 24 C PE N L AC 115 V AC 230 V Set online parameters c4, c5 Slot 3 Limit value Slot 2 AI4 Slot 1 AI3 Option module 6DR2801-8D not used not used M1 A1 R1 1 2 3 A2 R2 4 5 SIPART DR21 standard controller 6DR2100-5 6DR2100-4 AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 M2 6 (AC230 V/115 V) (UC 24 C) 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 -y +y L 13 14 (c) x2 -- + I I SIPART DR21 C73000-B7476-C143-08 201 15 7 Application examples for configuring the controller 7.3 Configuration examples Configuration example K3 w Drive I Fixed setpoint controller as a K-controller Controlled variable by a two-wire transmitter The controlled variable x from the transmitter goes to the analog input AI1 of the controller. The transmitter is fed by the same lines. The input signal range and the output manipulated variable of the controller are 4 to 20 mA. y x Manual Please read the foreword to chapter 7.1, page 193 Setting the structure switches: S1 = 0 S2 = 0 S4 = 2, 3 S56 = 1 Slot 3 Limit value Slot 2 AI4 Slot 1 AI3 Option module 6DR2801-8D not used not used M1 A1 R1 1 2 3 A2 R2 4 5 M2 PE N L UC 24 C PE N L AC 115 V AC 230 V SIPART DR21 standard controller 6DR2100-5 6DR2100-4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 6 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L 13 -y +y 14 x -When using AI1 the feed voltage at the transmitter may be only 15 V under worst case conditions. 202 + I -- + I SIPART DR21 C73000-B7476-C143-08 15 Manual 7 Configuration example S1 Slave control, three-position step controller with internal feedback; Controlled variable by a two-wire transmitter, externally fed position feedback via an ESR; External setpoint potentiometer The controlled variable of the transmitter goes to the analog input AI1, the position feedback of ESR to the analog input AI2 of the controller. A signal range of 0 to 20 mA is programmed for both inputs. Transmitter and ESR are externally fed. A cascade is disconnected preferably by switching the master controller to manual mode. The slave controller is still in automatic mode, its setpoint is still the output signal of the master controller, i.e. now its manual manipulated variable. The slave controller therefore becomes the fixed setpoint controller. Switching back the master controller to automatic mode and thus the interconnection of the cascade takes place bumplessly but not without drift if the setpoint of the slave controller but not that of the master controller was adjusted during switching. The drifting after switching back can be prevented if the master controller is programmed with structure switch S43 = 1 to x tracking. Then the setpoint of the master controller is tracked to the actual value which changes with the delay time of the system as long as the cascade is disconnected. wext y x Application examples for configuring the controller 7.3 Configuration examples Drive yR Please read the foreword in chapter 7.1, page 193 and the warnings in chapter 2.1 (from page 17) Setting the structure switches: S1 = 1 S19 = 2 S2 = 2 S42 = 1 S17 = 4 S54 = 1 Slot 2 AI4 Slot 3 Limit value Option module 6DR2801-8D M1 A1 R1 1 2 3 A2 R2 4 5 Slot 1 AI3 M2 GND M/A 6 1 2 S E 3 4 6DR2100-5 6DR2100-4 2 3 PE N L AC 115 V AC 230 V Spark quenching internal (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 UC 24 C SIPART DR21 standard controller not used Option module 6DR2800-8R PE N L 4 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L --y +y 13 14 15 x WE + S R = RA + R + RE RA R RE U external -External setpoint potentiometer +18 V < U < +28 V + I -- x + UH SIPART DR21 C73000-B7476-C143-08 C yR -ESR R L N Perform spark quenching according to EMC requirements! 203 7 Application examples for configuring the controller 7.3 Configuration examples S2 Configuration example Command Command controller K controller S Manual cascade control, K-controller and S-controller (internal feedback); The controlled variables of the master controller and the slave controller come directly from the resistance thermometers Pt100. The master controller is a SIPART DR21 with K-output, the slave controller has one three-position step output. The controlled variables of both the master controller and slave controller come directly from the resistance thermometers Pt100 and are connected at the analog input AI3 in both controllers. The position feedback of the step switching slave controller comes from a potentiometer, connected at the analog input AI4. The output signal of the master controller is the setpoint for the slave controller and is fed to its analog input AI1. y Drive Please read the foreword in chapter 7.1, page 193 and the warnings in chapter 2.1 (from page 17) Master controller Setting the structure switches of the master controller: S8 = 4 S1 = 0 S15 = 3 S2 = 0 S17 = 0 S6 = 4 to 7 Slot 2 AI4 Slot 3 Limit value not used Option module 6DR2801-8D M1 A1 R1 1 2 3 A2 R2 4 5 Slot 1 AI3 Option module 2 3 PE N L AC 115 V AC 230 V (AC230 V/115 V) (UC 24 C) 6DR2800-8V AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 UC 24 C SIPART DR21 standard controller 6DR2100-5 6DR2100-4 M2 6 PE N L 1 4 RL1 2 3 RL2 1 4 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L 13 -y +y 14 RL4 (c) RL1 = RL2 = RL4 50 Pt100 204 SIPART DR21 C73000-B7476-C143-08 15 Manual 7 S2 Configuration example Application examples for configuring the controller 7.3 Configuration examples continued Slave controller Setting the structure switches of the follow-up controller: S1 = 1 S8 = 4 S42 = 1, S2 = 3 S15 = 3 S54 = 1 S6 = 4 to 7 S17 = 1 S7 = 0, 1 S19 = 4 Slot 3 Limit value Slot 2 AI4 Slot 1 AI3 Option module 6DR2801-8D Option module Option module M1 A1 R1 1 2 3 A2 R2 4 5 6 GN M/A D 1 yR 2 S E 3 4 6DR2100-5 6DR2100-4 RL1 2 3 RL2 PE N L AC 115 V AC 230 V Spark quenching internal (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 UC 24 C SIPART DR21 standard controller 6DR2800-8V 6DR2800-8R M2 PE N L 1 4 2 3 4 5 6 7 RL4 8 C R L+ AO GND GND 9 10 C y 11 12 L --y +y 13 14 R 15 L (c) S N RE RA Perform spark quenching according to EMC requirements! Pt100 SIPART DR21 C73000-B7476-C143-08 205 7 Application examples for configuring the controller 7.3 Configuration examples S3 Configuration example Ratio control, S-controller (internal feedback) Commanded process variable and commanding variable directly from two-wire transmitters w The commanded process variable x1 from the transmitter goes to the analog input AI1, the commanding process variable is connected to the analog input AI2. The input signal ranges are 4 to 20 mA. The feedback of the final control element position comes from a resistance potentiometer to the analog input AI4. y Drive x2 x1 Manual The setting of the ratio factor range is described in chapter 3.4.5, page 75. yR Please read the foreword in chapter 7.1, pg. 193 and the warnings in chapter 2.1 (from page 17) Setting the structure switches: S1 = 3 S7 = 0, 1 S2 = 2 S19 = 4 S4 = 2, 3 S54 = 1 S5 = 2, 3 Slot 3 Limit value Slot 2 AI4 Option module 6DR2801-8D Option module M1 A1 R1 1 2 3 A2 R2 4 5 Slot 1 AI3 6 GND M/A 1 2 S E 3 4 6DR2100-5 6DR2100-4 2 3 4 1 + I R = RA + R + RE S RE PE N L AC 115 V AC 230 V Spark quenching internal (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 UC 24 C SIPART DR21 standard controller not used 6DR2800-8R M2 PE N L 2 3 -- 4 -I 5 + 6 7 8 C R L+ AO GND GND 9 10 C 11 12 L --y +y 13 14 R 15 L N x1 x2 Perform spark quenching according to EMC requirements! RA When using the analog inputs AI1 and AI2 the feed voltage at the transmitter may be only 15 V under worst case conditions. 206 SIPART DR21 C73000-B7476-C143-08 Manual 7 Z1 Configuration example w Application examples for configuring the controller 7.3 Configuration examples Fixed setpoint control with PD two-position controller The controlled variable comes from a thermocouple with internal reference point. The controlled variable of the thermocouple is fed directly to the analog input AI3. The type of thermocouple is selected with S9. The measuring range must be set in the CAE menu (see chapter5.4.5, page 165). +y / --y System adaptation with the parameters Y1 and Y2. Two-position controller structure see chapter 3.6, page 94 Please note the possibilities of setting the operating point in the P-controller (page 93) and the foreword in chapter 7.1, page 193 PE UC 24 C N Setting the structure switches: L S2 = 1 S15 = 3 S6 = 4 to 7 PE S27 = 8 AC 115 V S8 = 1 N S54 = 3 AC 230 V L Slot 2 AI4 Slot 3 Limit value not used Option module 6DR2801-8D M1 A1 R1 1 2 3 A2 R2 4 5 Slot 1 AI3 Option module 6DR2801-8V M2 6 1 2 3 SIPART DR21 standard controller 6DR2100-5 6DR2100-4 4 -- I 1 2 + 3 4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L 13 --y +y 14 15 Rcomp RL L N RL 300 -- + Cooling SIPART DR21 C73000-B7476-C143-08 Heating 207 7 Application examples for configuring the controller 7.3 Configuration examples Configuration example L1 Process display Structured as a process display, the SIPART DR21 controller can display and monitor the process variables. If the manipulated variable y and yR is structured, it can be monitored to the y display and can be adjusted with the keys (7) and (8) with the appropriate wiring. The controlled variable x can be shown in the red analog display (1) with structuring as x2. If the limit value A1 to A4 if referred to x with S76, S77, S80 and shown in the green bar display (2), the relation of the variable to be monitored to the limit values can be seen at a glance. With the parameters dA, dE (oFPA) the variables w, x, A1 to A4 can be displayed in their right physical variable in the w/x display (3). The y display is made in 0 to 100%. See also fig. 3-16, page 82 to the controller w wi w from the controller y Drive x Manual to the controller Please read the foreword to chapter 7.1, page 193 Setting the structure switches of the process display: S1 = 4, process display S42 = 2, w: int $ ext S2 = 2, S-controller internal S54 = 1, yR display feedback S56 = 2, w ! AO S15 = 0, x1 = 0 S57 = 1, y ! DO1/2 S16 = 3, x2 ! AI3 S76 = 2, A1/A2 referred S17 = 1, we ! AI1 S77 = 2, A3/A4 to x S19 = 2, yR ! AI2 S80 = 6, Alarms A1 to A4 in the process operation mode can be displayed and adjusted Slot 3 Limit value Slot 2 AI4 not used not used 1 2 3 Slot 1 AI3 4 5 1 2 3 UC 24 C PE N L AC 115 V AC 230 V SIPART DR21 standard controller 6DR2100-5 6DR2100-4 Option module 6DR2800-8J 4 PE N L GND -- R + 1 2 3 4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 x2 wE 2 3 4 5 yR 6 7 8 L+ AO GND GND 9 10 11 12 L 13 --y +y 14 15 w +y --y 1) + + -I -- 1) for further processing e.g. in another SIPART DR controller 208 SIPART DR21 C73000-B7476-C143-08 Manual 7 Configuration example Application examples for configuring the controller 7.3 Configuration examples L1 process display (continued) SIPART DR21 17 16 PV X SP W 100 C 18 ADAPT A3 19 Internal LED: current status Shift key setpoint int $ ext Display CB signal Adaptation LED: off A1 Limit value A1 exceeded ! flashes A1 SP-W 50 Analog display Limit values A1 to A4 Controlled variable x w/x display values A1 to A4 15 A2 2 14 Adjustment of setpoint with rapid action 20 Signal lamps for "limit value A1 to A4 activated" A3 A4 12 11 A2 1 13 6 A4 W 3 yR display or time value A1 to A4 Manual LED: current status Shift key Manual/Tracking Manual Ext/Tracking-LED Shift key: w/x display X 9 OUT-Y SIEMENS SIPART DR21 7 8 Adjusting keys y Process operation mode -- control and display elements in the setting as a process display SIPART DR21 C73000-B7476-C143-08 209 7 Application examples for configuring the controller 7.3 Configuration examples Configuration example Display/ manual control unit yN L2 Manual control unit (HS) The "Manual control unit" operating mode is implemented in the setting S1 = 4 (control unit/process display). The output of a K-controller (e.g. another SIPART DR21) can be remote controlled with the HS. Controller yN yN The manual control unit has priority over the controller. In the HS manual operation has priority over tracking, in the controller tracking over manual operation. The HS is tracked if it is not in manual operation itself, i.e. if LED (13) H external lights and LED (12) Manual is dark. The controller is always tracked when the HS is in manual operation, i.e. if the LED (12) on the HS is alight. If LED (12) H flashes on the controller, this means that manual operation is not possible from the controller because tracking from the HS has priority. LEDd (13) on the controller lights up. wi x2 Manual x1 y Drive Please read the foreword to chapter 7.1, page 193 Manual control unit Setting the structure switches of the manual control unit: S1 = 4, control unit S18 = 2, yN $ AI2 S2 = 0, K-controller S23 = 0, CB = 0 S15 = 0, x1 = 0 S49 = 1 S16 = 1, x2 ! AI1 S60 = 1, H ! DO1 Slot 2 AI4 Slot 3 Limit value Slot 1 AI3 not used not used 1 2 3 4 5 6 1 2 3 6DR2100-5 6DR2100-4 6DR2800-8J 4 1 2 PE N L AC 115 V AC 230 V (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO L+ AO GND GND 1 2 -+ -+ R + 3 UC 24 C SIPART DR21 standard controller Option module GND -- PE N L 1 4 2 3 x2 4 5 yN 6 7 8 9 10 11 12 L --y +y 13 14 15 ly (c) + -- -I + | 210 SIPART DR21 C73000-B7476-C143-08 Manual 7 Application examples for configuring the controller 7.3 Configuration examples L2 Manual control unit (HS) (continued) Configuration example The process variables controlled variable and manipulated variable can be displayed online on the HS. The setpoint can only be simulated as a flag, i.e. it must be transmitted manually by the controller. For this, CB must be = 0 (S23 = 0) on the HS. See also chapter 3.4.6, page 80 and figure 3-18, page 87. K-controller Setting the structure switches of the K-controller: S1 = 0, fixed setpoint controller S2 = 0, K-controller S15 = 4, X1 ! AI4 S18 = 1, yN ! AI1 S61 = 1, Nw ! DO1 S72 = 1 Slot 3 Limit value Slot 2 AI4 Slot 1 AI3 not used Option module not used 6DR2800-8J GND -- 1 2 3 4 5 6 1 2 6DR2100-5 6DR2100-4 1 x1 2 3 PE N L AC 115 V AC 230 V (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 4 UC 24 C SIPART DR21 standard controller R + 3 PE N L 4 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L --y +y 13 14 15 ly yN (c) | + I SIPART DR21 C73000-B7476-C143-08 211 7 Application examples for configuring the controller 7.3 Configuration examples Manual L3 control unit (LG) with slave controller (FR) Configuration example LG operates as a setpoint transmitter and manual control unit with S-output. Control unit w With the LG the setpoint and the S-output of the slave controller can be remote controlled. The FR has priority with respect to setpoint and manual operation. The setpoint of the FR can only be set with the LG when the LED (17) internal, LED (18)c and LED (4) w display are alight. It is recommended to switch off the setpoint ramp on the FR. Before switching over to setpoint presetting from the FR, you have to wait for the setpoint set on the LG (max. 6 s). Parallel to the FR, the process variables setpoint, controller variable and position feedback can be displayed on the LG. x2 must be structured with S16 on the LG for the analog x value display. F-controller w w w y y x Drive Please read the foreword to chapter 7.1, page 193 Control unit (LG) Setting the structure switches of the control unit: S1 = 4, control unit S30 = 2, --yBL ! DI2 S2 = 0, S-controller i.Rf. S42 = 2, wi: int $ ext S15 = 0, x1 = 0 S49 = 1 S17 = 1, we ! AI1 S54 = 1, yR display S19 = 3, yR ! AI3 S56 = 2, w ! AO S22 = 1, Opt. Position 3 S57=1,y ! DO1/2 S23 = 1, CB ! DI1 S58 = 3, RB ! DO3 S25 = 0, N = 0 S60 = 4, H ! DO4 S26 = 0, Si = 0 S62 = 5, A1 ! DO5 S29 = 2, +yBL ! DI2 S63 = 6, A2 ! DO6 Slot 3 Slot 2 AI4 Slot 1 AI3 not used Option module 6DR2801-8E 6DR2800-8J 1 2 3 4 5 6 GND -- 1 2 3 4 1 2 R + 3 UC 24 C PE N L AC 115 V AC 230 V SIPART DR21 standard controller Option module DI3 DO DO DO DO DI4 3 4 5 6 PE N L 4 6DR2100-5 6DR2100-4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L --y +y 13 14 15 (c) A1 A2 | 212 SIPART DR21 C73000-B7476-C143-08 Manual 7 Configuration example Application examples for configuring the controller 7.3 Configuration examples L3 Control unit (LG) with slave controller (FR) (continued) Tracking of the internal setpoint wi to the active setpoint (S45 = 0) and the latter wi as a setpoint at CB failure (S44 = 0) must be set otherwise setpoint steps occur when switching between LG and FR. Manual control of the manipulated variable from the LG is only possible if the LED (12) Manual on the LG lights up and the LED (13) H ext. is dark. Lighting of the LED (13) indicates manual operation of the FR. If the LED (12) of the FR is alight, manual operation is possible from there in any case. See also chapter 3.4.6, page 80 and figure 3-18, page 87. Slave controller (FR) Setting the structure switches of the follow-up controller: S1 = 1, follow-up controller S49 = 1 S2 = 2, S-controller i.Rf. S54 = 1, yR display S15 = 3, x1 ! AI3 S56 = 2, w ! AO S16 = 0, x2 ! 0 S57 = 1, y ! DO1/2 S17 = 1, we ! AI1 S58 = 3, RB ! DO3 S19 = 2, yR ! AI2 S60 = 4, H ! DO4 S22 = 1, Opt. Position 3 S62 = 5, A1 ! DO5 S23 = 2, CB ! DI2 S63 = 6, A2 ! DO6 S26 = 0, Si ! 0 S42 = 2, wi int $ ext Slot 3 Slot 2 AI4 Slot 1 AI3 not used Option module 6DR2801-8E 1 2 3 4 5 6 1 2 3 6DR2100-5 6DR2100-4 6DR2800-8J GND -- 4 1 2 PE N L AC 115 V AC 230 V (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 R + 3 UC 24 C SIPART DR21 standard controller Option module DI DO DO DO DO DI4 3 3 4 5 6 PE N L 4 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L --y +y 13 14 15 x (c) A2 A1 | + -- 1 + 2 9 I 3 Coupling relay 6DR2804-8B 8 7 6 5 4 -yR + -- + ESR -- SIPART DR21 C73000-B7476-C143-08 I N L 213 7 Application examples for configuring the controller 7.3 Configuration examples Configuration example Manual L4 control unit (LG) with slave controller (FR) The control unit (SIPART DR21) operates as a setpoint transmitter and manual control unit, the slave controller (FR) SIPART DR22 as a K-controller Control unit yR F-controller yR y wi wi wE If the controller following the control unit is to operate as a K-controller, a SIPART DR22 must be used. In the SIPART DR22 an additional analog output is available for output of the setpoint and switching inputs for tracking the manipulated variable. In this example the control unit is structured as a K-setpoint transmitter and as an S-manual control unit. The controller has priority with respect to manual operation and internal setpoint presetting. The setpoint can only be preset by the LG and accepted by the FR if both LEDs Int/Ext (17) and C (18) light up. In all other cases the value preset by the FR is only displayed in the LG. Manual operation of the LG is only possible when the Manual LED (12) lights steadily. y y x Drive Please read the foreword to chapter 7.1, page 193 SIPART DR21 control unit Setting the structure switches of the SIPART DR21 control unit: S1 = 4, control unit S25 = 0, N !DI2 S2 = 2, S-controller i.Rf. S26 = 0, Si !0 S15 = 0, x1 ! 0 S42 = 2, wi int $ ext S17 = 1, we ! AI1 S54 = 1, yR display S19 = 3, yR ! AI3 S56 = 2, w ! AO S22 = 1, Opt. Position 3 S57 = 1, y ! DO1/2 S23 = 21, CB ! DI1 S58 = 4, RB ! DO4 S60 = 3, H ! DO3 Slot 3 Slot 2 AI4 Slot 1 AI3 not used Option module 6DR2801-8E 6DR2800-8J 2 3 4 5 6 GND -- 1 2 3 4 1 2 R + 3 PE N L UC 24 C PE N L AC 115 V AC 230 V SIPART DR21 standard controller Option module DI DO DO DO DO DI4 3 3 4 5 6 1 Control unit (LG) 4 6DR2100-5 6DR2100-4 (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 2 3 4 5 6 7 8 L+ AO GND GND 9 10 11 12 L --y +y 13 14 15 (c) | 214 SIPART DR21 C73000-B7476-C143-08 Manual 7 Configuration example L4 Application examples for configuring the controller 7.3 Configuration examples continued If the FR is switched to manual in this state, lighting of the LED (13) indicates tracking mode, flashing of LED (12) the ineffectiveness of the positioning keys (7) and (8). Tracking has priority over manual operation. Lighting of the LED (13) on the FR indicates tracking i.e. manual control from the control unit (LG). If the FR is now switched to manual, LED (13) flashes and the Manual LED lights steadily because manual operation has priority over tracking on the FR. The manipulated variable of the FR is controlled incrementally by the LG. Therefore the actuating time ty (onPA) must be set to a finite value (ty > 20 s) otherwise the final value will be reached immediately when the positioning keys (7) or (8) are pressed briefly. See also chapter 3.4.6, page 80 and figure 3-17, page 86. Slave controller SIPART DR22 Setting the structure switches of the SIPART DR22 slave controller: S1 = 3, slave controller S61 = 1, H > N S16 = 0, FE2 !0 S62 = 1, yN !yN S24 = 4, CB !DI4 S74 = 18, w !AO2 S25 = 0, He !0 S78 = 4, H !DO4 S35 = 1, +y !DI1 S85 = 8, Int !DO8 S36 = 2, --y !DI2 S89 = 1, N !N S49 = 2, wi int $ ext PE N L UC 24 C PE N L AC 115 V AC 230 V ty > 20 s SIPART DR22 standard controller 6DR2210-5 (AC230 V/115 V) 6DR2210-4 (UC 24 C) GND GND L+ 1 2 3 DO DO DO DO DO DO DO DO AI1 AI1 AI2 AI2 AI3 AI3 AA1 AA2 AA3 DI1 DI2 DI3 DI4 -+ -+ 1 2 3 4 5 6 7 8 -+ 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 (c) | + -- SIPART DR21 C73000-B7476-C143-08 -- + I + Transmitter -I Drive 215 7 Application examples for configuring the controller 7.4 Configuring tool, forms 7.4 Manual Configuring tool, forms We recommend the following procedure for solving your controller problems: - Determining the assembly of the controller If necessary: Determining the position of bridges and switches on the backplane module and signal transformers Drawing the wiring diagram Enter settings further down in the onPA, ofPA and Stru list (structuring, parameterizing) The SIMATIC PDM program is available for PC-supported configurations. For notes 216 SIPART DR21 C73000-B7476-C143-08 Manual 7 Circuit design K/S-controller 6DR2100-4/-5 Slot 3 Limit value Slot 2 AI4 Slot 1 AI3 Option module 6DR2801-8D not used not used M1 A1 R1 1 2 3 A2 R2 4 5 6DR2100-5 6DR2100-4 SIPART DR21 C73000-B7476-C143-08 2 3 4 1 2 3 UC 24 C PE N L AC 115 V AC 230 V Spark quenching internal (AC230 V/115 V) (UC 24 C) AI1 AI1 AI2 AI2 DI1 DI2 DO DO -+ -+ 1 2 1 PE N L SIPART DR21 standard controller M2 6 Application examples for configuring the controller 7.4 Configuring tool, forms 4 1 2 3 4 5 6 7 8 C R L+ AO GND GND 9 10 11 12 -y +y L 13 14 217 15 7 Application examples for configuring the controller 7.4 Configuring tool, forms Manual Settings SIPART DR21, controller number / measuring point . . . . . . . . . . . . . . . . . . Parameter onPA Parameter meaning Filter time constant xd (adaptive) ( p ) Derivative action gain g Proportional p gain g factor Integral-action g time Derivative-action time Response p threshold Operating point Output p variable limiting g start Output p variable limit end (YA ( YE)) y actuating g time open/period p p heating g y actuating time open/period cooling min. actuating g pulse p pause p min. actuating pulse length Filter time constant AI1 Filter time constant AI2 Filter time constant AI3 Filter time constant AI4 Multiplicative p constant Multiplicative p constant Additive constant Multiplicative p constant Additive constant Multiplicative p constant Multiplicative constant Display refresh rate 218 Digital indication on display 3 (w/x) for preset 9 (y) tF vv cP tn tv AH YO YA YE tP tM tA tE t1 t2 t3 t4 c1 c2 c3 c4 c5 c6 c7 dr Fact tory setting Dimension i 1.000 5.000 0.100 9984 oFF 0.0 Auto --5.0 105.0 1.000 1.000 200 200 1.000 1.000 1.000 1.000 0.000 0.000 0.000 1.000 0.000 0.0 1.000 1.000 s 1 1 s s % % % % s s ms ms s s s s 1 1 100 % 1 100 % 1 1 s SIPART DR21 C73000-B7476-C143-08 Manual 7 Application examples for configuring the controller 7.4 Configuring tool, forms Settings SIPART DR21, controller number / measuring point . . . . . . . . . . . . . . . . . . Parameter oFPA Parameter meaning Decimal point p w/x display p y Start of scale Full scale Alarm 1 Alarm 2 (A2 ( A1)) Alarm 3 Alarm 4 (A4 ( A3)) Hysteresis alarms Setpoint p limit start Setpoint p limit end Safety setpoint Setpoint ramp time Ratio factor start Ratio factor end Safety y output p variable Split p range g left y1 y (y1 (y yy2)) Split range right y2 Vertex value at --10 % V Vertex value l at 0% Vertex value at 10 % Vertex value at 20 % Vertex value at 30 % Vertex value at 40 % Vertex value at 50 % Vertex value at 60 % Vertex value at 70 % Vertex value at 80 % Vertex value at 90 % Vertex value at 100 % Vertex value at 110 % Digital indication on display 3 (w/x) for preset 9 (y) dP dA dE A1 A2 A3 A4 HA SA SE SH tS vA vE YS Y1 Y2 L--1 L0 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 Decimal point p Start of scale Full scale (only at S1 = 3) Pd Ad Ed SIPART DR21 C73000-B7476-C143-08 Fact tory setting Dimension i 0.0 100.0 5,0 , --5,0 , 5,0 , --5,0 , 1 --5,0 , 105,0 , 0,0 oFF 0,000 , 1,000 0,0 , 50,0 , 50,0 --10 0 10 20 30 40 50 60 70 80 90 100 110 -------% ---min 1 1 % % % % % % % % % % % % % % % % 0,0 , 100,0 ---- 219 7 Application examples for configuring the controller 7.4 Configuring tool, forms Manual Settings SIPART DR21, controller number / measuring point . . . . . . . . . . . . . . . . . . . Parameter CAE3 Parameter meaning Digital indication on displays 16 (x) Sensor type SEnS Temperature unit unit Thermocouple type tc Temperature reference point tb Line resistance Mr Decimal point measuring range MP Range start MA Range full scale ME 220 19 (w) SIPART DR21 C73000-B7476-C143-08 Manual 7 Application examples for configuring the controller 7.4 Configuring tool, forms Settings SIPART DR21, controller number / measuring point . . . . . . . . . . . . . . . . . . Structure switches Stru Switch number b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 SIPART DR21 C73000-B7476-C143-08 Preset Factory setting i 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 0 0 0 0 8 0 1 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Switch number 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 1) as 2) as Preset Factory set. 0 0 0 0 0 0 0 0 0 0 1 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0/1 1) 0/1 1) 0 0 0 0 0 0 0 2) of software version --A5 of software version --B5 221 7 Application examples for configuring the controller 7.4 Configuring tool, forms 222 Manual SIPART DR21 C73000-B7476-C143-08 Manual 8 Maintenance 8.1 General information and handling 8 Maintenance 8.1 General information and handling The controller is maintenance-free. White spirit or industrial alcohol is recommended for cleaning the front foil and the plastic housing if necessary. be changed freely without readjustment with power supplied. The other modules may also be replaced without readjustment (procedure as described in chapter 8.2). CAUTION All modules contain components which are vulnerable to static. Observe the safety precautions! S-actuators on S-controllers remain in their last position. ! WARNING ! WARNING The backplane module may only be changed after the power supply has been safely disconnected. Modules may only be repaired in an authorized workshop. This applies particularly to the backplane module because of the safety functions (safe disconnection and safety extra low voltages). SIPART DR21 C73000-B7476-C143-08 223 8 Maintenance 8.2 Exchanging components 8.2 D Manual Exchanging components Replacing the front module - Pull out the mains plug - Remove the backplane module and any options modules which may be plugged in. - Carefully lever out the label cover with a screwdriver at the cutout at the top and snap the cover out of the bottom hinge points by bending slightly. - Loosen the fastening screw (captive) (see (2) fig. 8-1). - Tilt the top of the front module at the head of the screw and pull it out angled slightly forwards. - Install in reverse order. Make sure the sealing ring is positioned perfectly! (3) (2) (1) (1) Front module (2) Fastening screw (shaft screw M3) for the front module (3) Tag plate cover Figure 8-1 224 Front module with removed tag plate cover SIPART DR21 C73000-B7476-C143-08 Manual 8 Maintenance 8.2 Exchanging components Replacing the options modules D - Pull off the plug terminals. - Release the lock and remove the options module (see (6) figure 8-2). - Push in the new module to the stop and lock it (the modules are slot coded). Please make sure the right modules are plugged into the slots provided for the different options (see chapter 2.4, page 24). - Plug in the terminal (pay attention to slot labeling!), (1) (10) (2) (9) (8) (7) (1) (2) (3) (4) (5) (6) (7) (6) Figure 8-2 (5) (4) (3) (8) (9) (10) Front module Plastic housing Module locked Dummy cover Terminals Module unlocked Fastening screw for the backplane-module Terminal 4-pole Terminal 8-pole Terminal 3-pole Controller rear view D Replacement of the backplane module (power supply unit + basic circuit board) - Pull out the mains plug! - Pull off the plug terminals. - Disconnect the PE conductor - Loosen the fastening screw of the backplane module (see (2) fig. 8-2) and pull out the module. - Install in reverse order. SIPART DR21 C73000-B7476-C143-08 225 8 Maintenance 8.3 LED-test and software version D Manual Disconnect the power supply unit from the basic circuit board (Components of the backplane module) - Pull out the backplane module (see replacement of the backplane module) - Pull out the ribbon cable plug (see (5) figue 8-3) - Loosen the fastening screw of the basic circuit board (see (7) figure 8-3). - Separate the basic circuit board and the power supply unit. - Re-assemble in reverse order. (Pay attention to correct plugging of jumpers (see (3) figure 8-3)) (7) (6) (1) Connecting plug (2) Fastening screw for the backplane module (3) Plug--in jumpers (5) (4) Power supply unit (5) Plug ribbon cable (1) (6) Basic circuit board (7) Fastening screws for the Basic circuit board (4) Figure 8-3 8.3 (3) (2) Backplane module LED-test and software version If the Shift key (6) is pressed for about 10 s ("PS" flashes on the manipulated variable display after about 5 s), this leads to the LED-test. All LEDs light up, the displays show "8.8.8.8." or "88." and a light marker covering 2 LEDs runs from 0 to 100% on both bargraphs (on reaching 100% it starts again at 0%). If the Internal-/External key (16) is additionally pressed permanently during the lamp test, "dr21" appears on the digital x/w-display and the controller software version on the digital y-display. During the LED-test and display of the software version the controller continues to operate online in its last operating mode. 226 SIPART DR21 C73000-B7476-C143-08 Manual 8 Maintenance 8.4 Spare parts list 8.4 Spare parts list Item Figure Description 1 1.1 1.2 1.3 1.4 (1) Figure 8-1 (2) Figure 8-1 (3) Figure 8-1 -- Front module Front module complete Shaft screw (M3) Tag plate cover 10 Tag plate labels 2 2.1 2.2 2.3 2.4 (2) Figure 8-2 (4) Figure 8-2 --- 3 3.1 3.2 3.3 3.4 3.5 3.6 (4) Figure 8-3 " (6) Figure 8-3 (8) Figure 8-2 (9) Figure 8-2 (10) Figure 8-2 3.7 -- 3.8 -- 4 -- 4.1 4.2 4.3 4.4 ----- Comments C73451-A3004-B112 D7964-L9010-S3 C73451-A3001-C5 C73451-A3001-C16 Housing Plastic housing Dummy covers for unoccupied slots Clamps 10 self--adhesive sealing rings (Front frame/panel) Backplane module Power supply unit -- 24 V UC -- 115/230 V AC Basic circuit board: S-/K-controller Terminal: -- 4-pole -- 8-pole -- 3-pole Mains plug: -3-pin plug for 115/230 V AC IEC--230/V, DIN 49457A -Special 2-pin plug for 24 V UC Options Terminals: -4-pin for 6DR2800-8J/8R -4-pin for 6DR2800-8V -5-pin for 6DR2801-8C -6-pin for 6DR2801-8D/8E Order number C73451-A3004-C3 C73451-A3000-C11 C73451-A3000-B20 C73451-A3000-C41 without mains plug C73451-A3004-B8 C73451-A3004-B5 C73451-A3004-L105 W73078-B1003-A904 W73078-B1017-A908 W73078-B1018-A903 C73334-Z343-C3 C73334-Z343-C6 see chapter 8.5, Ordering data W73078-B1001-A904 W73078-B1003-A904 W73078-B1001-A705 W73078-B1001-A906 D Ordering information The order must contain: - Quantity - Order number - Description We recommend you to specify the controller order number to be on the safe side. D Ordering example 2 units W73078-B1003-A904 Terminal 4-pin backplane module DR21 SIPART DR21 C73000-B7476-C143-08 227 8 Maintenance 8.5 Ordering data 8.5 Manual Ordering data SIPART DR21 process controller 72 x 144 S-/K-controller for -Power supply UC 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2100-4 -Power supply AC 230 V, can be switched to AC 115 V . . . . . . . . . . . . . . . . . . . . 6DR2100-5 Options/accessories Signal converter/analog signals -for current input 0/4 to 20 mA or 0/0.2 to 1 V or 0/2 to 10 V (U/I-module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2800-8J -for resistance potentiometer (R-module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2800-8R -for TC/RTD/R/MV-signals, programmable (UNI-module) . . . . . . . . . . . . . . . . . 6DR2800-8V -Reference point terminal for TC, internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2805-8A -Measuring range plug for I = 20 mA and U = 10 V . . . . . . . . . . . . . . . . . . . . . . . 6DR2805-8J Signal converter/switching signals -with 5 digital inputs (5DI-module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2801-8C -with 2 relay outputs (35 V) (2 DO-relay-module) . . . . . . . . . . . . . . . . . . . . . . . . 6DR2801-8D -with 4 digital outputs and 2 digital inputs (2DI 4DO-module) . . . . . . . . . . . . . 6DR2801-8E Interface for serial communication RS 232/RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2803-8C Interface for PROFIBUS DP RS 232/RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2803-8P Coupling relay module for mounting on a DIN rail on the back of the controller -with 4 relays (AC 250 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2804-8A -with 2 relays (AC 250 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DR2804-8B Assembly- and installation guide -German/English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-M7474-C35 -French/Spanish/Italian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-M7450-C35 Quick Reference -German/English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-B7474-C141 -French/Spanish/Italian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-B7450-C141 Manual -German . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-B7400-C143 -English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C73000-B7476-C143 SIPART DR21 Serial SIPART DR210x bus interface / Operating Manual can be downloaded from the INTERNET. Internet address: www.fielddevices.com (version 05/2000) 228 SIPART DR21 C73000-B7476-C143-08 Manual 9 9 General explanation of abbreviations for SIPART DR General explanation of abbreviations for SIPART DR A . . . . . . . . . . . . . . . . . control signal no automatic mode A* . . . . . . . . . . . . . . . . Parameter Alarms (limit values) Ad . . . . . . . . . . . . . . . . . AdAP . . . . . . . . . . . . . Parameterization mode Adaptation AdAPT . . . . . . . . . . . . LED, adaptation mode AH* . . . . . . . . . . . . . . Response threshold (dead zone) AI* . . . . . . . . . . . . . . . Analog inputs AI*A . . . . . . . . . . . . . . Outputs of the analog inputs AO . . . . . . . . . . . . . . . Analog output APSt . . . . . . . . . . . . . Structuring mode All Preset (whole controller to factory setting) AUto . . . . . . . . . . . . . . automatic Ar* . . . . . . . . . . . . . . . Function block, Arithmetic bLb . . . . . . . . . . . . . . . bLPS . . . . . . . . . . . . . bLPSDI . . . . . . . . . . . . bLPSES . . . . . . . . . . . bLS . . . . . . . . . . . . . . bLSDI . . . . . . . . . . . . . bLSES . . . . . . . . . . . . Control signal, Blocking, Operating Control signal, Blocking, Parameterization/Structuring Control signal, Blocking, Parameterization/Structuring via digital input Control signal, Blocking, Parameterization/Structuring via SES Control signal, Blocking, Structuring Control signal, Blocking, Structuring via digital input Control signal, Blocking, Structuring via SES c* . . . . . . . . . . . . . . . . C................. CA . . . . . . . . . . . . . . . CAE3 . . . . . . . . . . . . . CB . . . . . . . . . . . . . . . CBDI . . . . . . . . . . . . . . CBES . . . . . . . . . . . . . cP . . . . . . . . . . . . . . . . CPU . . . . . . . . . . . . . . Cr . . . . . . . . . . . . . . . . Parameter, Constants LED, no computer standby Calibration, start of range Parameterization mode, UNI-module Control signal, Computer operation Control signal, Computer operation via digital inputs Control signal, Computer operation via SES (Kp) Proportional action factor central processing unit Calibration, adjustment of line resistances (RL) dA . . . . . . . . . . . . . . . . DDC . . . . . . . . . . . . . . dE . . . . . . . . . . . . . . . . DI** . . . . . . . . . . . . . . DO** . . . . . . . . . . . . . dP . . . . . . . . . . . . . . . . dPv . . . . . . . . . . . . . . . dr . . . . . . . . . . . . . . . . dY . . . . . . . . . . . . . . . . Parameter, display range, start direct digital control Parameter, display range, end Digital inputs Digital outputs Parameter, display decimal point Parameter direction of step command Parameter, display refresh rate Parameter amplitude of the step command Ed . . . . . . . . . . . . . . . . . End . . . . . . . . . . . . . . Error message end SIPART DR21 C73000-B7476-C143-08 229 9 General explanation of abbreviations for SIPART DR Manual Err . . . . . . . . . . . . . . . Error FAST . . . . . . . . . . . . . Error message for adaptation, system too fast HA . . . . . . . . . . . . . . . H................. Hi . . . . . . . . . . . . . . . . HeDI . . . . . . . . . . . . . . HeES . . . . . . . . . . . . . HE . . . . . . . . . . . . . . . HOLD . . . . . . . . . . . . Parameter, hysteresis alarms Control signal manual mode Control signal manual internal Control signal manual external via digital input Control signal manual external via SES Error message manual external Programm controller, comparison with end of interval with hold function Int . . . . . . . . . . . . . . . . Control signal internal Iy . . . . . . . . . . . . . . . . Analog output, current manipulated variable Kp . . . . . . . . . . . . . . . . Proportional gain factor LED . . . . . . . . . . . . . . light emitting diode L1 to L11 . . . . . . . . . . Parameter vertex points linearizer MA* . . . . . . . . . . . . . . ME* . . . . . . . . . . . . . . MEM . . . . . . . . . . . . . ModE . . . . . . . . . . . . . MP* . . . . . . . . . . . . . . Mr* . . . . . . . . . . . . . . . MUF . . . . . . . . . . . . . . Start of measuring range Range full scale Memory Operating mode Parameter measuring decimal point Parameter measuring of (RL) line resistances Signal transmitter fault message n.ddc . . . . . . . . . . . . . n.End . . . . . . . . . . . . . no . . . . . . . . . . . . . . . . no C . . . . . . . . . . . . . . no.dY . . . . . . . . . . . . . not . . . . . . . . . . . . . . . nPoS . . . . . . . . . . . . . N................. NDI . . . . . . . . . . . . . . . NES . . . . . . . . . . . . . . Nw . . . . . . . . . . . . . . . Error message tracking or DDC Error message full scale value not reached no Parameter setting (PC) nor calibrated Error message, y-Step not correct none not positioned Control signal tracking Control signal tracking via digital input Control signal tracking via SES Control signal tracking effective oFL . . . . . . . . . . . . . . . -oFL . . . . . . . . . . . . . . onPA . . . . . . . . . . . . . oFPA . . . . . . . . . . . . . OP** . . . . . . . . . . . . . . OUT . . . . . . . . . . . . . . ovEr Shot . . . . . . . . . overflow, positive overflow -overflow, negative overflow Parameterization mode, on-line-parameterization Structuring mode, offline-parameterization Error message option (slot) Output, output variable y Error message overshoot 230 SIPART DR21 C73000-B7476-C143-08 Manual P ................. PDI . . . . . . . . . . . . . . . . . . . PES . . . . . . . . . . . . . . . . . . . PASS . . . . . . . . . . . . . PAU . . . . . . . . . . . . . . PAUDI . . . . . . . . . . . . PAUES . . . . . . . . . . . . PC . . . . . . . . . . . . . . . P.oFL . . . . . . . . . . . . . PV . . . . . . . . . . . . . . . 9 General explanation of abbreviations for SIPART DR Control signal-P-operation Control signal P-operation via digital input Control signal P-operation via SES Error message step response in wrong direction Control signal parameter switching Control signal parameter switching via digital input Control signal parameter switching via SES Parameter Preset Calibration Error message x above the span Process variable RB . . . . . . . . . . . . . . . Control signal, no computer standby RC . . . . . . . . . . . . . . . Control signal, no computer operation S ................. SA . . . . . . . . . . . . . . . Sb . . . . . . . . . . . . . . . . SE . . . . . . . . . . . . . . . SES . . . . . . . . . . . . . . SG . . . . . . . . . . . . . . . SH . . . . . . . . . . . . . . . Si . . . . . . . . . . . . . . . . SiDI . . . . . . . . . . . . . . . SiES . . . . . . . . . . . . . . SMAL . . . . . . . . . . . . . SP . . . . . . . . . . . . . . . SPC . . . . . . . . . . . . . . StAt . . . . . . . . . . . . . . StrS . . . . . . . . . . . . . . StrU . . . . . . . . . . . . . . Structure switch Parameter setpoint limiting start Parameter limiting setpoint Parameter setpoint limiting end Serial interface Parameter controlling variable Parameter safety setpoint Control signal safety operation, error message safety operation Control signal safety operation via digital input Control signal safety operation via SES Error message small Setpoint Setpoint control, setpoint via external system Error message, stationary, static Structuring mode, structure switch Parameterization preselection level select structuring t* . . . . . . . . . . . . . . . . . tA . . . . . . . . . . . . . . . . tb . . . . . . . . . . . . . . . . tE . . . . . . . . . . . . . . . . tESt . . . . . . . . . . . . . . tF* . . . . . . . . . . . . . . . tM . . . . . . . . . . . . . . . . tn . . . . . . . . . . . . . . . . tp . . . . . . . . . . . . . . . . tS . . . . . . . . . . . . . . . . tSH . . . . . . . . . . . . . . . to . . . . . . . . . . . . . . . . tU . . . . . . . . . . . . . . . . tv . . . . . . . . . . . . . . . . tY . . . . . . . . . . . . . . . . Filter time AI* Parameter minimum turn-off duration Parameter reference temperature Parameter minimum turn-on duration Self-test Parameter filter time constant Parameter y-actuating time closed/cooling time Parameter integral action time Parameter y-actuating time open/heating Parameter setpoint ramp Parameter setpoint ramp "HALT" to Monitoring time Parameter derivative action time Parameter actuating time SIPART DR21 C73000-B7476-C143-08 231 9 General explanation of abbreviations for SIPART DR Manual v ................. vact . . . . . . . . . . . . . . . vA . . . . . . . . . . . . . . . . vE . . . . . . . . . . . . . . . . vv . . . . . . . . . . . . . . . . vvc . . . . . . . . . . . . . . . Setpoint ratio factor Actual ratio factor Parameter ratio factor range start Parameter ratio factor range end Derivative action gain Derivative action gain uncontrolled w................. wE . . . . . . . . . . . . . . . . wEA . . . . . . . . . . . . . . wES . . . . . . . . . . . . . . wE . . . . . . . . . . . . . . wi . . . . . . . . . . . . . . . . wv . . . . . . . . . . . . . . . . Setpoint w External setpoint External setpoint via analog input External setpoint via SES External setpoint incremental Internal setpoint Standardized nominal ratio factor x ................. x* . . . . . . . . . . . . . . . . xd* . . . . . . . . . . . . . . . xds . . . . . . . . . . . . . . . xv . . . . . . . . . . . . . . . . xw . . . . . . . . . . . . . . . . Controlled variable x (actual value) Auxiliary controlled variables, partial controlled variables Control difference Control difference, position controller Standardized actual ratio factor Control error (--xd) y ................. y1 . . . . . . . . . . . . . . . . y2 . . . . . . . . . . . . . . . . Y1 . . . . . . . . . . . . . . . . Y2 . . . . . . . . . . . . . . . . YA . . . . . . . . . . . . . . . YE . . . . . . . . . . . . . . . yE . . . . . . . . . . . . . . . . YES . . . . . . . . . . . . . . yES . . . . . . . . . . . . . . . yE . . . . . . . . . . . . . . . yH . . . . . . . . . . . . . . . . yN . . . . . . . . . . . . . . . . yS . . . . . . . . . . . . . . . . YS . . . . . . . . . . . . . . . Yo . . . . . . . . . . . . . . . . YBL . . . . . . . . . . . . . . y.oFL . . . . . . . . . . . . . Output variable Partial output variables in split range Partial output variables in split range Parameter output variable range 1 in split range Parameter output variable range 2 in split range Parameter output variable limit start Parameter output variable limit end External output variable Reset parameter setting (PC) Calibration External output variable via SES External output variable incremental Manual output variable External output variable (tracking output variable) Safety output variable Parameter safety output variable Parameter operating point Error message blocking mode Error message y outside the setpoint limits yBL . . . . . . . . . . . . . Control signal direction--dependent y-Blocking yBLDI . . . . . . . . . . . Control signal direction--dependent y-Blocking via digital inputs yBLES . . . . . . . . . . Control signal direction--dependent y-Blocking via SES w . . . . . . . . . . . . . Control signal incremental w-Adjustment wDI . . . . . . . . . . . . Control signal incremental w-Adjustment by digital inputs 232 SIPART DR21 C73000-B7476-C143-08 Manual 9 wES . . . . . . . . . . . y . . . . . . . . . . . . . . yDI . . . . . . . . . . . . yES . . . . . . . . . . . . z ................. General explanation of abbreviations for SIPART DR Control signal incremental w-Adjustment by SES Control signal incremental y-Adjustment Control signal incremental y-Adjustment by digital inputs Control signal incremental y-Adjustment by SES Disturbance variable -1.1 to 11.1 . . . . . . . . Parameter vertex points linearizer FE1 -1.3 to 11.3 . . . . . . . . Parameter vertex points linearizer FE3 . . . . . . . . . Controller . . . . . . . . . Internal . . . . . . . . . Manual (internal manipulated variable preset) . . . . . . . . . External (tracking) . . . . . . . . . Exit . . . . . . . . . Enter . . . . . . . . . Fault AI** . . . . . . . . . Error message Fault analog inputs . . . . . . . . . Identification decimal point . . . . . . . . . . . . . . . . adjustable **.o . . . . . . . . . . . . . . . old parameters **.n . . . . . . . . . . . . . . . new parameters * . . . . . . . . . . . . . . . . . stands for counter number or parameter name SIPART DR21 C73000-B7476-C143-08 233 9 General explanation of abbreviations for SIPART DR 234 Manual SIPART DR21 C73000-B7476-C143-08 Manual Index Numbers 6DR210x--4, Connection, 130 6DR210x--5, Connection, 130 6DR2800--8J Connection, 133 Connection example, 137 Function principle of the option module, 28 Technical Data, 40 6DR2800--8R Connection, 134 Function principle of the option modules, 28 Technical Data, 40 6DR2800--8V Connection, 135 Function principle of the option modules, 29 Technical Data, 41 6DR2801--8C, 142 Function principle of the option modules, 31 Technical Data, 43 6DR2801--8D, 143 Function principle of the option modules, 30 Technical Data, 42 6DR2801--8E, 142 Function principle of the option modules, 30 Technical Data, 43 6DR2803--8C, 144 Function principle of the option modules, 32 Technical Data, 44 6DR2803--8P, 146 Connection, 147 Function principle of the option modules, 31 Technical Data, 43 6DR2804--8A, 143 6DR2804--8A/B, Technical Data, 45 6DR2804--8B, 143 6DR2805--8A, Function principle of the option modules, 29 6DR2805--8J, 135 Function principle of the option modules, 30 Technical Data, 42 SIPART DR21 C73000-B7476-C143-07 A A/D converter, Technical Data, 38 A1 to A4, Digital outputs, Features, 22 Actual value, 150 Actual value display, Functional explanation, 58 Actuating time tp and tM, 94 AdAP, 186 Configuration mode, 156 Parameter list, 161 Adaptation, 113 Aborted, 157 Condition, 157 Error messages, 162 Adaptive filter, 115, 185 Alarm LED, 151 Amplitude of the step command, 186 Analog input, Universal module, 135 Analog inputs Features, 19 Functional principle of the standard controller, 26 Technical Data, 36 Analog output signal processing (S56), 110 Analog outputs, Technical Data, 37 AO, Connection, 131 Application examples, 193 APSt, 178 Configuring, 27 Automatic mode, Controller output structure, 107 B Backplane module Removal, 121 Replacing, 225 Backplane module with power supply unit, Design, 24 bLb Digital outputs, Features, 21 Functional explanation, 54 Operating locks, 149 235 Manual Block diagram, 129 bLPS Digital outputs, Features, 21 Functional explanation, 54 Operating locks, 149 bLS Digital outputs, Features, 21 Functional explanation, 54 bLS, Operating locks, 149 C CAE3, Set UNI--module, 173 Cascade controls, 63 CB Digital outputs, Features, 21 Functional explanation, 54 Changing the scales, 123 Changing the tag plate, 123 Commissioning, 181 Configuration examples, 199 Configuration mode, 149, 154 AdAP (adaptation), 156 oFPA (offline parameters), 163 onPA (online parameters), 155 StrS (structure switch), 165 Configuring, Functional principle of the standard controller, 27 Configuring the controller, Application examples, 193 Configuring tool, 216 for structuring, 221 to oFPA, 219 to onPA, 218 Connecting elements, Arrangement, 126 Connection 6DR210x--4, 130 6DR210x--5, 130 6DR2800--8J, 133 6DR2800--8R, 134 6DR2800--8V, 135 AO, 131 Options modules, 133 DI1 to DI2, 131 DO1 to DO2, 132 Electrical, 126 Examples, 137 236 Ground, 128 Interface module, 144 Measuring lines, 127, 130 PE conductor, 126 Power Supply, 126, 130 PROFIBUS--DP, 147 RS 232, 144 Signal lines, 127, 130 Standard controller, 130 Connection technique, Design, 25 Constants c1 to c7, Functional explanation, 57 Control algorithm, 91 Control parameters automatic setting, 186 Setting by the adaptation method, 189 Control signals for setpoint switching, 63 Functional explanation, 54, 57 Display range, Functional explanation, 58 Control system coupling, 89, 90 via serial interface, 109 Control unit, 80, 83 DDC fixed setpoint controller, 69 Controlled ratio controller, 75 Controlled system with compensation, Transient function, 191 Controlled variable processing, 64 Controller, installing, 124 Controller design, Adaptation, 114 Controller direction of control action, Adaptation to controlled system, 181 Controller direction of effect, 91 Controller output structure S2=0, 94 S2=1, 95 S2=2, 99 S2=3, 102 Controller output structures, 94 Controller types, 55 Controls SPC, 63 Cascade, 63 Synchronized, 63 Coupling relay, Technical Data, 45 SIPART DR21 C73000-B7476-C143-07 Manual CPU Direction--dependent blocking operation, 108 Functional principle of the standard control- Display, software version, 151 ler, 26 Display levels, 73 self--diagnostics, 179 Display technique, Technical Data, 39 DO1 to DO2, Connection, 132 D dy -- amplitude of the step command, PresetDDC fixed setpoint controller, 68 ting, 186 Control unit, 69 Design, 24 E DI1 to DI2, Connection, 131 Error messages, Adaptation, 162 Digital inputs Explanation of abbreviations, 229 Assignment and direction of effect, 50 external setpoint wE, 64 Features, 21, 22 Functional principle of the standard controller, 26 F Linking with the control signals, 50 Factory setting, 178 Technical Data, 37 Behavior of the controller, 150 Digital output signal processing (S57 to S75), Features, 19 111 Filter, Setting, 185 Digital outputs Fixed setpoint controller Features DDC, 68 A1 to A4, 22 with 2 independent setpoints, 59 bLb, 21 with one setpoint (control system coupling), bLPS, 21 89 bLS, 21 CB, 21 Front module H, 22 Design, 24 He, 21 Replacing, 224 MUF, 22 Function principle, 26 N, 21 Functional description Nw, 22 Controller types, 55 P, 21 RB, 22 Structure switches, 47 RC, 22 Functional explanation, of the digital message Si, 21 signals, 111 tS, 21 Fundamental control technology terms, 9 tSH, 21 Actuators, 9 w, 22 Controller output signal, 12 y, 22 Continuous controller, 13 yBL, 21 Control loop, 9 Functional principle of the standard controller, 26 control response, 10 Technical Data, 38 Three--position step controller with internal feedback, 12 Direction of control action, 181 Final control elements, 9 of actuator, 181 P controller, 10 of system, 181 PD controller, 11 Direction of effect PI controller, 11 actuator, 182 PID controller, 11 system, 182 SIPART DR21 C73000-B7476-C143-07 237 Manual Sensor, 9 Step function, 10 transmitter, 9 Two--position controller, 14 H H, Digital outputs, Features, 22 He Digital outputs, Features, 21 Functional explanation, 54 I I/U module, Function principle of the option modules, 28 Installation, 121 Selecting the Installation Site, 121 Internet address:, 31 K K controller Direction of effect, 181 Setting the floating time, 183 Kp, 187 Pt100, 176 Resistance potentiometer, 177 Thermocouples, 175 U, 175 Measuring range plug Function principle of the option modules, 30 Pin assignment, 135 Technical Data, 42 Measuring transmitter feed, Technical Data, 38 Mechanical Installation, 121 Modules for analog measuring inputs, 133 for expanding the digital inputs, 142 for expanding the digital outputs, 142 Monitoring time tU, Presetting, 186 MUF, Digital outputs, Features, 22 mV transmitter, Pin assignment, 135 N N Digital outputs, Features, 21 Functional explanation, 54 Tracking N, Functional explanation, 56 Nw, Digital outputs, Features, 22 L O Lamp test, 151 Limit value alarms, 117 Line capacitance, Technical Data, 44 Linearizer, 118 Offline mode, 154 Parameter list, 164 oFPA Configuration mode, 163 Configuring, 27 Configuring tool, 219 Online mode, 154 Parameter list, 155 onPA Configuration mode, 155 Configuring, 27 Configuring tool, 218 Operating locks, 149 bLb, 149 bLPS, 149 bLS, 149 Operating point automatic, 93 fixed, 93 M Maintenance, 223 Manipulated variable, 150 Manipulated variable adjustment, Technical Data, 38 Manipulated variable limit, 93 Manual control station, 85 Manual mode, 107 absolute ~, 154 Measuring inputs, Modules, 133 Measuring range I, 175 mV, 175 238 SIPART DR21 C73000-B7476-C143-07 Manual y0 in P--controller, 93 Operation, 149 Operation mode Configuration mode, 149 Process operation mode, 149 Selection level, 149 Operation with 2 or 3 setpoints, 64 Option module, Function principle, 28 Options modules Connection, 133 Installation, 125 Replacing, 225 Ordering data, 228 Output signal processing analog, 110 digital, 111 Output structure, Features, 19 Outputs for the manipulated variable Y, Functional principle of the standard controller, 26 P P Digital outputs, Features, 21 Functional explanation, 54 P--controller, 91 Setting, 189 Parameter list AdAP, 161 oFPA (offline parameters), 164 onPA (online parameters), 155 parameters, Technical Data, 39 PD--controller, Setting, 189 PI--controller, 91 PI--controller, Setting, 190 PID controller, Setting, 190 Pin assignment Measuring range plug, 135 mV transmitter, 135 Pt100 sensor, 136 Resistance potentiometer, 137 Thermocouples, 136 Power Supply, Standard controller, 36 Power supply unit Features, 20 SIPART DR21 C73000-B7476-C143-07 Functional principle of the standard controller, 27 Presetting Amplitude of the step command dy, 186 Direction of step command Pv, 186 Monitoring time tU, 186 Process display, 80 Process operation mode, 149, 150 PROFIBUS DP, 120 Technical Data, 43 PROFIBUS--DP, 146 Connection, 147 Structure switches, 173 PT100, Measuring range, 176 Pt100 sensor, Pin assignment, 136 Pv -- Direction of step command, Presetting, 186 R R, 137 R module, Function principle of the option modules, 28 Range of Application, 18 Ratio controller controlled, 75 Example, 78 RB, Digital outputs, Features, 22 RC, Digital outputs, Features, 22 Rear of controller, 121 reference point, Function principle of the option modules, 29 Relay contacts, unlock, 122 Replacing Backplane module, 225 Front module, 224 Options modules, 225 Resistance potentiometer Measuring range, 177 Pin assignment, 137 Resistor input, 134 Response threshold, Setting, 185 Response threshold AH, 116 Restart conditions, 120 239 Manual RS 485, 145 RTD, 136 the control parameters manually, 189, 191 Si Digital outputs, Features, 21 Functional explanation, 54 S Slave controller, 62 S controller without Int/Ext switching, 90 Adaptation to the actuating drive, 183 software version, Display, 151 Direction of effect, 182 Spare parts list, 227 S--output, Technical Data, 37 SPC controls, 63 S2=0, Controller output structure, 94 SPC--controller, 62 S2=1, Controller output structure, 95 Standard controller S2=2, Controller output structure, 99 Connection, 130 S2=3, Controller output structure, 102 Design, 24 SA, Functional explanation, 56 Function principle, 26 Safety notes, 17 Other functions, 115 Power Supply, 36 Safety operation, 107 Start parameters, 161 Scope of delivery, 17 Step command, Presetting, 186 SE, Functional explanation, 56 StrS Selecting the control behavior, 186 Configuration mode, 165 Selection level, 149 Configuring, 27 Selection mode, 152 Structure switches, 166 Serial interface, 120 Stru, Configuring tool, 221 Control system coupling, 109 Structure switch list, 166 Features, 22 Structure switches PROFIBUS--DP, Function principle of the Analog input signal processing, 47 option modules, 31 Configuring tool, 221 RS 232/RS 485, Function principle of the Digital input signal processing, 50 option modules, 32 Functional description, 47 Technical Data, 44 Switching Setpoint, 150 P--PI, 94 Setpoint change tSH, Functional explanation, to automatic mode, 94 54 Switching over to manual operation, 47, 108 Setpoint display, Functional explanation, 58 Setpoint limits SA and SE, Functional explana- Synchronized controller, 62 tion, 56 Synchronized controls, 63 Setpoint potentiometer, 83 System identification, Adaptation, 113 Setpoint ramp tS Functional description, 55 T Functional explanation, 54 TC, 136 Setpoints, 195 Technical Data, 34 Setting Technical Description, 17 P--controller, 189 Thermocouples PD--controller, 189 Measuring range, 175 PI--controller, 190 Pin assignment, 136 PID controller, 190 the control parameters automatically, 186 Tracking operation, 107 240 SIPART DR21 C73000-B7476-C143-07 Manual Transient function, of a controlled system with compensation, 191 Transmitter fault, Switching over to manual operation, 47, 108 tS Digital outputs, Features, 21 Functional description, 55 Functional explanation, 54 tSH Digital outputs, Features, 21 Functional explanation, 54 tU (monitoring time), Presetting, 186 wE, 64 wi Functional description, 55 Manual setpoint setting, 55 Work prior to installation, 121 Working with different setpoints, 195 wvi, Nominal ratio setting, 55 X x--tracking (S43), Functional explanation, 56 Y U y, Digital outputs, Features, 22 UNI module: y display, 59, 98 Function principle of the option modules, 29 Source and direction of effect, 108 Technical Data, 41 yBL Universal module for analog input, 135 Digital outputs, Features, 21 Functional explanation, 54 V Voltage output, Features, 20 Z W zD, 91 zy, 91 w, Digital outputs, Features, 22 SIPART DR21 C73000-B7476-C143-07 241 Manual 242 SIPART DR21 C73000-B7476-C143-07