SIPART DR21 Controllers

Description

The SIPART DR21 controller is a digital process controller featuring a comprehensive internal program memory with standard functions for process engineering applications. It is designed for users without programming knowledge, allowing simple selection and execution of functions. The controller offers high flexibility and can be quickly configured to meet specific application requirements, including a standard adaptation process.

Figure 5/1 SIPART DR21 controller: Depicts the front view of the SIPART DR21 controller unit.

Figure 5/2 SIPART DR21 controller - rear view, slots: Shows the rear view of the controller, highlighting the slots for additional modules.

Application

The SIPART DR21 controller can be utilized in various configurations:

Design

The SIPART DR21 process controller features a modular design, facilitating easy servicing and reconfiguration or retrofitting. The standard unit is fully functional and well-equipped. Additional modules can be inserted into the rear slots to expand its capabilities:

The standard unit comprises:

The backplane connects to the front module via a ribbon cable. The standard controller includes two fixed, non-isolated analog inputs for 0/4 to 20 mA current signals and two digital inputs. Available outputs for manipulated variables or status signals include:

The number of inputs and outputs can be increased by adding extra modules. Available input/output modules include:

Electrical supply for transmitters is provided by a short-circuit-proof L+ output. The tagging label and scale are replaceable.

Available versions:

Mode of Operation

The SIPART DR21 controller is built on a modern, highly integrated microcontroller using C-MOS technology. Its internal program memory contains numerous functions for process engineering applications. Users can select required functions by setting parameters and configuring switches. Configuration can be performed via the front panel or a PC using SIPROM DR21 or SIMATIC PDM software. The controller is factory-configured as a fixed setpoint controller, typically requiring only minor additional settings. Parameters are stored in non-volatile memory, ensuring data retention during power failures without needing a backup battery. The controller supports P, PD, PI, or PID control algorithms.

The SIPART DR21 utilizes a robust adaptation procedure that simplifies commissioning, even for critical control loops. It automatically calculates optimal control parameters without requiring prior user knowledge of the control loop's response. This procedure is suitable for loops with compensation, aperiodic transient response, and accounts for dead times.

Analog Input

The controller has a total of four analog inputs, with two included in the standard unit. Additional inputs can be configured. These inputs connect to function inputs (x1, x2, x3/we, yN, yR, z), which act as analog input channels depending on the controller's configuration. Function input 'z' is used for feedforward control, allowing dynamic or static superposition of a disturbance variable 'z' to the manipulated variable 'y'. Each analog input channel can optionally include a 1st-order filter for interference suppression and a square-root extractor. A linearizer with 13 vertices and kneepoint smoothing can be connected to one analog input.

Controller Manipulated Variables

K controller (continuous output)

In this configuration, the manipulated variable is output as a standardized current signal (0/4 to 20 mA), with the signal range determined during configuration.

S controller (switching output)

The manipulated variable is preferably output via floating relay contacts, equipped with protection circuits for contactor coils. Users must ensure the maximum switching voltage is not exceeded, and phase-shifting motors require intermediate switching devices. Relay contacts are mutually interlocked, but this can be disabled for universal digital output. Digital outputs can be used for high-speed manipulated variable output. When used as an S controller, the analog output can transmit an internal process quantity (x, w, or xd).

Twostep controller

The manipulated variable 'y' is output as a pulse duty factor with a variable period. For heating/cooling outputs, different periods can be assigned to each output, with each stage running through the pulse duty factor from 0 to 100%. A dead zone between heating/cooling stages can be parameterized. This controller type is primarily used for temperature control, switching heating/cooling power, or operating solenoid valves. One heating/cooling output can alternatively function as an analog signal (4 to 20 mA).

Digital Inputs and Outputs

The two digital inputs and outputs in the standard controller are configured for application-specific digital functions. They are non-isolated and operate in normal or inverted mode based on configuration. Digital outputs are active and provide a DC voltage signal. The number of digital I/Os can be increased with option modules. A coupling relay module (with 2 or 4 relays, each with 1 changeover contact for 250 V AC, 8 A) can be snapped onto the rear DIN rail, controlled by the digital outputs.

Functions connectable to digital inputs and outputs:

Display technology

The SIPART DR21 controller features easy-to-read displays conforming to NAMUR requirements. It includes:

The red digital indicators for actual and setpoint values are 4-digit and can be configured in engineering units or as a percentage. Some displays and controls may have different functions in the configuring levels.

Configurable functions

Application-specific circuits are prewired in the controller's EPROM and can be easily accessed. The configurable functions (controlled by switch S1) are presented as block diagrams.

Figure 5/3 Fixed setpoint controller with one or two independent setpoints as one, two or three-component controller: Describes the configuration for fixed setpoint control, allowing individual adjustment of setpoints wi1 and wi2.

Figure 5/4 Slave, synchro or SPC controller (Setpoint Control) with internal/external switchover: Details the configuration for slave, synchro, or SPC control, where remote setpoints can be entered via analog signal or serial interface, with options for synchronization.

Figure 5/5 DDC fixed setpoint controller as one, two or three-component controller: Explains the DDC mode where a process computer handles control functions, with a parallel compact controller safeguarding loop function during computer failure.

Figure 5/6 Fixed or controlled ratio controller with internal/external switchover: Describes ratio control where setpoint values are derived from the ratio between controlled and command variables, with options for external ratio control.

Figure 5/7 M/A control station/process variable indicator: Outlines the use as an M/A control station for parallel operation, a manual control unit, or a process variable indicator for multiple measured values, including limit value monitoring.

Other configurable functions

Controls and display functions

Parameter setting is organized into three levels: Process operation, Selection, and Configuring. This structure simplifies controller modification and prevents incorrect operation.

Process operation level

Figure 5/9 Controls and displays: This figure details the front panel elements. The layout and colors make operation intuitive.

Selection and configuring levels

The control panel switches from Process operation to Selection level by pressing and holding pushbutton (6) until 'PS' flashes on the digital indicator. 'PS' then displays constantly, and 'onPA' appears in the w/x digital indicator (3). In Selection level, parameter lists, configuring switch lists, or commissioning functions can be chosen using pushbuttons (14, 15).

In Configuring level, parameter and switch settings can be displayed and modified. Pressing the Enter button (11) when parameterization or configuring mode indicators appear allows switching to the relevant mode. Parameters/switches are selected with (7, 8) and modified with (14, 15). The Exit button (16) quits the current level.

Control mode remains active during online parameter setting, allowing immediate observation of system response. Output is blocked when setting configuring switches, offline parameters, or UNI module settings. A zebra pattern in the green analog indicator signifies offline mode. Configuring levels like 'AdAP' and 'CAE3' are displayed only if configured.

A lamp test can be initiated by pressing and holding pushbutton (6) for over 5 seconds, illuminating all LEDs.

The firmware status of the controller can also be displayed.

Function Diagram

Figure 5/10 SIPART DR21 controller, function diagram: This diagram illustrates the internal connections and signal flow. It shows analog inputs (AE1, AE2, AE3, AE4) and their potential configuration (I, U, R, UNI modules). Digital inputs (BE1, BE2) and outputs (BA1, BA2) are depicted, along with relay outputs. The diagram highlights the CPU, power supply connections (L+, M, LN, PE), and various configuring switches (S1-S92) that determine the controller's function, input/output assignments, control algorithm, and communication settings. It also shows connections for analog output (ly), switching output, and serial interface (SES) modules.

Configuring switch list

The controller's behavior is extensively defined by a series of configuring switches (S1-S92) and online/offline parameters.

Configuring SwitchFunctionOptions
S1Type of controller0: Fixed setpoint / three-component controller (1 or 2 independent setpoints)
1: Slave / synchronization / SPC controller
2: DDC controller
3: Ratio controller
4: Control station / Process variable indicator
5: Fixed setpoint controller for process control system (firmware A05+)
6: Slave controller for process control system (firmware A7+)
S2Output configuration0: K controller
1: Twostep controller for heating/cooling
2: S controller with internal feedback
3: S controller with external feedback
S3Mains frequency suppression0: 50 Hz
1: 60 Hz
S4 and S5Signal range of analog inputs AE1 and AE20 or 4 to 20 mA
S6 and S7Configuration of slots 1 (AE3) and 2 (AE4)Various options for input type and configuration
S8 to S10Measured variable, sensor type, engineering unit for slot 1 (AE3) with UNI moduleProgrammable
S11 to S14Extract square root of analog inputs AE1 to AE4Enable/Disable
S15 to S20Assignment of function inputs x1, x2, x3/we, yN, yR, z to analog inputs AE1 to AE4Various assignments
S21Assignment of lineariser to AE1 to AE4 or x1Various assignments
S22Slot 3 configurationVarious digital I/O assignments
S23 to S33Assignment of control signals CB, He, N, Si, P, ts, +yBL, -yBL, BLB, BLS, BLPS to digital inputs BE1 to BE7Various assignments
S34 to S40Logic of control signalsNormal/Inverted
S41Effect of control signal CB, static or dynamic (pulse)Static or Pulse
S42 to S45Setpoint switchoverInternal/External
S46Direction of action of controllerNormal/Reverse
S47Feedforward control of D elementEnable/Disable
S48Adaptation: type of adaptationVarious types
S49 to S53Manual/Automatic, switchover, priority N or H, disable ly, y limitingVarious configurations
S54 and S55Manipulated variable display: Selection of displayed variable and logicVarious selections
S56Assignment of internal controller signals to the analog outputVarious assignments
S57Assignment of the +/-Dy outputs to the digital outputs BA1/BA2 or relay outputs BA7/BA8Various assignments
S58 to S68Assignment of alarm signals RB, RC, H, Nw, A1, A2, A3, A4, MUF, +w, -w to digital outputs BA1/BA6 or relay outputs BA7/BA8Various assignments
S69 to S75Logic of alarm signalsNormal/Inverted
S76 and S77Assignment of limit monitors A1/A2 and A3/A4 to internal process variablesVarious assignments
S78 a. S79Function of limit monitors A1/A2 and A3/A4Max/Min, Max/Max, Min/Min
S80 and S81Selection of display values for the w/x digital indicatorVarious selections
S82 and S83Restart conditions following restoration of power supplyVarious configurations
S84 to S91Serial interface settings: station no., data transmission rate, parityConfigurable
S92Assignment of control signal tSH to digital inputs BE1 to BE7Various assignments
On-line parameterstF, Vv, KP, Tn, Tv, AH, Y0, YA, YE, tP, tM, tA, tE, t1 to t4, c1 to c7, drFilter time, gains, times, limits, constants, display refresh rate
Off-line parametersdP, dA, dE, A1 to A4, HA, SA, SE, SH, tS, vA, vE, YS, Y1, Y2, L1 to L11, Pd, Ad, EdDecimal point, scale limits, alarms, hysteresis, setpoint ramp, ratio factors, safety values, lineariser vertices

Technical data

General

Mounting position: Any

Climatic classes:

Protection acc. to EN 60529:

Controller design:

Certifications:

Weight of standard controller: Approx. 1.2 kg

Color:

Material:

Power supply connections:

Connections for process signals: Multipin screw-type terminal blocks, protected against reversed polarity for cables of 1.5 mm2 (AWG 14) diameter.

Protective earth connection: Earthing screw.

Mounting rail on rear of power supply unit: Included with the coupling relay module.

Figure 5/11 SIPART DR21 controller, dimensions in mm: Shows the physical dimensions of the controller unit, including width, height, and depth.

Figure 5/12 Panel cutouts, dimensions in mm: Details the required panel cutouts for mounting the controller, specifying dimensions for different numbers of devices.

Power supply

Parameter230 V AC / 115 V AC24 V AC/DC
Rated voltageSwitchable 230 V AC / 115 V AC24 V AC/DC
Operating voltage range195 to 264 V AC / 97 to 132 V AC20 to 28 V AC / 20 to 35 V DC 1)
Frequency range48 to 63 Hz-
Peak voltages to IEC 801-5 (Pulse: 1.2/50 ms)symmetric: 1 kV, asymmetric: 0.5 kVsymmetric: 1 kV, asymmetric: 0.5 kV
Total of all output currents (L+, BA, AA and SES)2 kV1 kV
Power consumption
Apparent power (capacitive)
Standard controller - no options, without IExt5 W / 9 VA4 W / 6 VA
- with options, without IExt11 W / 15 VA8.5 W / 12 VA
- with options, with IExt15 W / 19 VA12 W / 17 VA
Permitted voltage dips at 0.85 UN20 ms20 ms
Test voltages (1 min)
- Primary - secondary1.5 kV AC / 1.5 kV AC1.5 kV AC / 1.5 kV AC
- Primary - protective conductor700 V DC700 V DC
- Secondary - protective conductor500 V AC / 500 V AC500 V AC / 500 V AC

1) Includes harmonic content.

Analog inputs AE1, AE2

Transmitter supply L+

Digital inputs BE1 and BE2

Digital outputs BA1 and BA2 (with wired OR diodes)

Analog output ly

Relay output

CPU data

A/D conversion

Display technology

Ordering data

SIPART DR21 controller, Basic unit

Basic unit with 2 analog inputs, 2 digital inputs, 1 analog output, 2 relay outputs, 2 digital outputs.

DescriptionOrder No.
Power supply AC/DC 24 V6DR2100-4
Power supply AC 230 V, switchable to AC 115 V6DR2100-5

Input/output modules

Modules are described in Catalog Section 8.

Module TypeDescriptionOrder No.
Analog signalsFor current input 0/4 to 20 mA or 0/0.2 to 1 V or 0/2 to 10 V voltage input6DR2800-8J
For resistance-based sensor (R module)6DR2800-8R
For TC/RTD/R/mV signals, programmable (UNI module)6DR2800-8V
Reference junction terminal for TC, internal (with UNI module)6DR2805-8A
Measuring range connector for I = 20 mA and U = 10 V (with UNI module)6DR2805-8J
Switching signal moduleWith 2 relay outputs6DR2801-8D
With 4 digital outputs and a digital input6DR2801-8E
Coupling relay moduleWith 4 relays (AC 250 V)6DR2804-8A
With 2 relays (AC 250 V)6DR2804-8B
Interface modulesFor serial communications (SES) via RS232See Catalog Section 8
PROFIBUS DP module6DR2803-8P

Documentation

DescriptionOrder No.
Quick reference "Operating and configuring"German/English: C73000-B7474-C141
French/Spanish/Italian: C73000-B7450-C141
Assembly and installation instructionsGerman/English: C73000-M7474-C35
French/Spanish/Italian: C73000-M7450-C35
ManualGerman: C73000-B7400-C143
English: C73000-B7476-C143
Instructions "Serial SIPART DR21 V.28 bus interface"German: C73000-B7400-C145
English: C73000-B7476-C145

Scope of supply

The scope of supply for a SIPART DR21 controller includes:

Items marked with * are available ex-stores.

Input/output modules and accessories

Input/output modules are described in Section 8. Section 9 of the catalog details software for PC parameterization, system interfacing, and necessary accessories.

Training

Refer to the ITC catalog (German) for details on training courses for controllers listed in this catalog.

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