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:
- Fixed setpoint controller for one, two, or three-component control, with an option for two setpoint values.
- DDC (Direct Digital Control) fixed setpoint controller for one, two, or three-component control.
- Slave, synchro, or SPC (Setpoint Control) controller, with internal/external switchover options.
- Fixed or controlled ratio controller with internal/external switchover.
- M/A (Manual/Automatic) control station, process variable indicator, or setpoint transmitter. In these modes, the control algorithm is disabled.
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:
- Slot 1: Analog input 3 (AE3)
- Slot 2: Analog input 4 (AE4)
- Slot 3: Digital inputs/outputs (BE/BA)
- Slot 4: Interface modules
The standard unit comprises:
- Front module (controls, displays, motherboard, CPU)
- Backplane (contains power supply unit and connectors)
- Plastic molded housing with fittings for installation in control panels, consoles, or machines.
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:
- Analog output: 0/4 to 20 mA
- Relay outputs: 2
- Digital outputs: 2
The number of inputs and outputs can be increased by adding extra modules. Available input/output modules include:
- Current or voltage input (U/I)
- UNI module for TC/RTD/R/mV (also mA and V with adapter), galvanically isolated
- Resistance input (potentiometer) (R)
- Digital inputs and outputs (BE/BA)
- Relay outputs (Rel)
- Serial interface (SES)
- PROFIBUS DP module
Electrical supply for transmitters is provided by a short-circuit-proof L+ output. The tagging label and scale are replaceable.
Available versions:
- 6DR21004: for power supply 24 V AC/DC
- 6DR21005: for power supply 230 V AC, switchable to 115 V AC.
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:
- Digital inputs: CB (Computer ready), He (Manual mode, external), N (Tracking), Si (Safety mode), P (Controller P mode), tS (Disable setpoint ramp time), yBL (Direction-dependent blocking of manipulated variable), BLB (Blocking of command level), BLS (Blocking of configuring), BLPS (Blocking of parameterization and configuring), tSH (Stopping of setpoint range).
- Digital outputs: RB (Computer relay), RC (Computer mode), H (Manual mode), Nw (Setpoint tracking mode), A1,2,3,4 (Alarm monitor A1, A2, A3, A4), MUF (Transmitter fault), Dw (Incremental w adjustment).
Display technology
The SIPART DR21 controller features easy-to-read displays conforming to NAMUR requirements. It includes:
- An analog indicator for actual value (x) and setpoint value (w) using vertical LED bargraphs, facilitating easy setpoint/actual comparison.
- A digital indicator switchable between actual value (x) and setpoint value (w).
- A digital indicator for the manipulated variable (y).
- Alarm and status indicators (11 LEDs on the front).
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
- Transmitter monitoring: Outputs messages for measurements outside defined limits (< -3% or > +103%). A group fault message can be output on a digital output. Automatic switchover to manual mode is selectable.
- Setpoint limitation: The effective setpoint value is always limited.
- Setpoint ramp: The 'ts' parameter specifies the rate of change for the setpoint value.
- x tracking: In manual, tracking, and DDC modes, the setpoint 'w' tracks the controlled variable 'x'.
- Filter and response threshold of control difference: An adaptive filter (tF) smooths the control difference, and a response threshold can be set for stabilization.
- Varying the direction of control: Allows inversion of the control action for reverse-action control loops.
- Special features of the control algorithm: P(D) and PI(D) algorithms are non-interacting parallel structures. Switchover between PI(D) and P(D) is signal-controlled. Bumpless switchover between automatic and manual modes is standard.
- Limiting the manipulated variable: Parameters YA and YE limit the manipulated variable for K output and S output with external feedback. Direction-dependent limiting is also available via control signals +yBL and -yBL.
- Limit monitor: Alarm functions A1/A2 and A3/A4 can monitor internal process variables for maximum/minimum values. Violations are indicated on LEDs and can trigger digital outputs. Hysteresis is parameterizable.
- Restart conditions: The power supply unit buffers short voltage dips. Parameters and data are retained in non-volatile memory during longer power failures. The controller automatically restarts with the last configured settings. An optical signal can indicate power restoration.
- Self-diagnosis: Comprehensive monitoring routines check internal data traffic. Error messages indicating the cause and remedy are output on the digital indicator.
- Communication with higher-level systems: Interface modules (optional) enable transmission/reception of status flags, process variables, parameters, and configuration settings. Available modules include PROFIBUS DP (up to 1.5 Mbits/s) and SES module (RS232/RS485, up to 9.6 kbits/s). Advantages include straightforward adaptation, operational safety during system shutdowns, flexibility, and distributed system structure.
- Input/output modules (option modules): Hardware configuration can be extended using modules inserted into rear slots, which are coded to prevent incorrect insertion.
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.
- The four-digit digital indicator (3) shows actual value (x), setpoint (w), or limit values (A1-A4), toggled by pushbutton (6).
- LEDs (4, 5) and digital indicator (9) show which variable is displayed.
- Green LED bargraph (2) shows setpoint or enabled alarms; red LED (1) shows actual value.
- Internal setpoint is adjusted using pushbuttons (14, 15).
- Setpoint switchover between internal and external is managed by pushbutton (16); LED (17) indicates internal mode.
- Manual/Automatic mode toggle is via yellow pushbutton (11); yellow LED (12) indicates active mode.
- Yellow LED (13) signals external modification of the manipulated variable (e.g., tracking mode).
- Manipulated variable in manual mode is set using yellow pushbuttons (7, 8) and displayed on the two-digit digital indicator (9).
- Red LEDs (10) indicate +/-D increment for S and two-step controllers.
- Alarm LEDs (20) signal limit value violations.
- LED (19) indicates adaptation progress (steady or flashing).
- Tagging label (21) and scale (22) are visible.
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 Switch | Function | Options |
---|---|---|
S1 | Type of controller | 0: 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+) |
S2 | Output configuration | 0: K controller 1: Twostep controller for heating/cooling 2: S controller with internal feedback 3: S controller with external feedback |
S3 | Mains frequency suppression | 0: 50 Hz 1: 60 Hz |
S4 and S5 | Signal range of analog inputs AE1 and AE2 | 0 or 4 to 20 mA |
S6 and S7 | Configuration of slots 1 (AE3) and 2 (AE4) | Various options for input type and configuration |
S8 to S10 | Measured variable, sensor type, engineering unit for slot 1 (AE3) with UNI module | Programmable |
S11 to S14 | Extract square root of analog inputs AE1 to AE4 | Enable/Disable |
S15 to S20 | Assignment of function inputs x1, x2, x3/we, yN, yR, z to analog inputs AE1 to AE4 | Various assignments |
S21 | Assignment of lineariser to AE1 to AE4 or x1 | Various assignments |
S22 | Slot 3 configuration | Various digital I/O assignments |
S23 to S33 | Assignment of control signals CB, He, N, Si, P, ts, +yBL, -yBL, BLB, BLS, BLPS to digital inputs BE1 to BE7 | Various assignments |
S34 to S40 | Logic of control signals | Normal/Inverted |
S41 | Effect of control signal CB, static or dynamic (pulse) | Static or Pulse |
S42 to S45 | Setpoint switchover | Internal/External |
S46 | Direction of action of controller | Normal/Reverse |
S47 | Feedforward control of D element | Enable/Disable |
S48 | Adaptation: type of adaptation | Various types |
S49 to S53 | Manual/Automatic, switchover, priority N or H, disable ly, y limiting | Various configurations |
S54 and S55 | Manipulated variable display: Selection of displayed variable and logic | Various selections |
S56 | Assignment of internal controller signals to the analog output | Various assignments |
S57 | Assignment of the +/-Dy outputs to the digital outputs BA1/BA2 or relay outputs BA7/BA8 | Various assignments |
S58 to S68 | Assignment of alarm signals RB, RC, H, Nw, A1, A2, A3, A4, MUF, +w, -w to digital outputs BA1/BA6 or relay outputs BA7/BA8 | Various assignments |
S69 to S75 | Logic of alarm signals | Normal/Inverted |
S76 and S77 | Assignment of limit monitors A1/A2 and A3/A4 to internal process variables | Various assignments |
S78 a. S79 | Function of limit monitors A1/A2 and A3/A4 | Max/Min, Max/Max, Min/Min |
S80 and S81 | Selection of display values for the w/x digital indicator | Various selections |
S82 and S83 | Restart conditions following restoration of power supply | Various configurations |
S84 to S91 | Serial interface settings: station no., data transmission rate, parity | Configurable |
S92 | Assignment of control signal tSH to digital inputs BE1 to BE7 | Various assignments |
On-line parameters | tF, Vv, KP, Tn, Tv, AH, Y0, YA, YE, tP, tM, tA, tE, t1 to t4, c1 to c7, dr | Filter time, gains, times, limits, constants, display refresh rate |
Off-line parameters | dP, dA, dE, A1 to A4, HA, SA, SE, SH, tS, vA, vE, YS, Y1, Y2, L1 to L11, Pd, Ad, Ed | Decimal point, scale limits, alarms, hysteresis, setpoint ramp, ratio factors, safety values, lineariser vertices |
Technical data
General
Mounting position: Any
Climatic classes:
- Storage: 1K2 according to DIN IEC 721 Part 3-1 (-25 to +75 C)
- Transport: 2K2 according to DIN IEC 721 Part 3-2 (-25 to +75 C)
- Operation: 3K3 according to DIN IEC 721 Part 3-3 (0 to +50 C)
Protection acc. to EN 60529:
- Front: IP 64
- Housing: IP 30
- Terminals: IP 20
Controller design:
- Meets DIN EN 61 010 Part 1 (IEC 1010-1+A1).
- Protection class I according to IEC 536.
- Outputs are functional extra-low voltages, safely isolated to DIN/VDE 0100 Part 410.
- Power supply isolated from field signals according to DIN/VDE 106 (DIN/VDE 0551, T1).
- Ventilation and creepage paths for surge class III and pollution level 2 according to DIN/VDE 0110 Part 1.
Certifications:
- CE mark (EU Certificate of Conformance no. DR211/1995)
- Emitted interference: DIN EN 50 081-1 (TV certified)
- Immunity to interference: DIN EN 50 082-2 (TV certified)
- NAMUR, NE 21 (TV certified)
- NS Guidelines 73/23 EWG: EN 61 010 Part 1, EN 60 529
- Certification of Germanischer Lloyd
- DIN test and inspection mark as temperature controller (test basis DIN 3440)
- TV certificate for water level controller (VdTV water level 100 and 100/1)
Weight of standard controller: Approx. 1.2 kg
Color:
- Fascia frame: RAL 7037
- Fascia: RAL 7035
Material:
- Housing and fascia frame: Polycarbonate, glass fiber reinforced
- Front foil: Polyester
Power supply connections:
- 115/230 V AC: 3-pin earthed plug IEC 320/V
- 24 V AC/DC: DIN 49 457A Special 2-pin plug
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
Parameter | 230 V AC / 115 V AC | 24 V AC/DC |
---|---|---|
Rated voltage | Switchable 230 V AC / 115 V AC | 24 V AC/DC |
Operating voltage range | 195 to 264 V AC / 97 to 132 V AC | 20 to 28 V AC / 20 to 35 V DC 1) |
Frequency range | 48 to 63 Hz | - |
Peak voltages to IEC 801-5 (Pulse: 1.2/50 ms) | symmetric: 1 kV, asymmetric: 0.5 kV | symmetric: 1 kV, asymmetric: 0.5 kV |
Total of all output currents (L+, BA, AA and SES) | 2 kV | 1 kV |
Power consumption | ||
Apparent power (capacitive) | ||
Standard controller - no options, without IExt | 5 W / 9 VA | 4 W / 6 VA |
- with options, without IExt | 11 W / 15 VA | 8.5 W / 12 VA |
- with options, with IExt | 15 W / 19 VA | 12 W / 17 VA |
Permitted voltage dips at 0.85 UN | 20 ms | 20 ms |
Test voltages (1 min) | ||
- Primary - secondary | 1.5 kV AC / 1.5 kV AC | 1.5 kV AC / 1.5 kV AC |
- Primary - protective conductor | 700 V DC | 700 V DC |
- Secondary - protective conductor | 500 V AC / 500 V AC | 500 V AC / 500 V AC |
1) Includes harmonic content.
Analog inputs AE1, AE2
- Current: 0/4 to 20 mA
- Input impedance: 248 W
- Output range: -0.1 to +22 mA
- Filter time constant: 10 ms
Transmitter supply L+
- Rated voltage: 20 to 26 V
- Onload current: v 60 mA, short-circuit proof
- Short-circuit current: v 200 mA, pulsed
Digital inputs BE1 and BE2
- Signal status '0': v 4.5 V or open
- Signal status '1': w 13 V
- Input impedance: 27 kW
Digital outputs BA1 and BA2 (with wired OR diodes)
- Signal status '0': v 1.5 V
- Signal status '1': +19 to 26 V
- Onload current: v 30 mA
- Short-circuit current: v 50 mA, pulsed
Analog output ly
- Rated signal range: 0 to 20 mA or 4 to 20 mA
- Output range: 0 to 20.5 mA or 3.8 to 20.5 mA
- Load voltage: -1 to +18 V
- Max. permitted inductive load: 0.1 H
Relay output
- Contact material: AgNi
- Contact rating: 250 V AC / 8 A, 250 V DC / 8 A
- Max. switching voltage: 250 V AC
- Max. switching current: 8 A
- Max. switching capacity: 1250 VA (230 V AC, W loading), 100 W at 24 V, 30 W at 250 V
- Service life: Mechanical: 2 x 107 switching operations, Electrical: 2 x 106 switching operations
- Spark suppressor: 22 nF and 220 W connected in series with a 420 V varistor wired in parallel
CPU data
- Cycle time: 100 ms
A/D conversion
- Method: Successive approximation with > 120 measurements per input and averaging within 20 or 16.67 ms
- Resolution: 11 bit
- Zero error: 0.06 %
- Gain error: v 0.2 % of measuring span
- Linearity deviation: v 0.2 % of measuring span
Display technology
- Digital x/w indicator: 4-digit, red, 7-segment LED display, 7 mm character height. Adjustable start and full scale. -1999 to +9999 numerical range. Decimal point adjustable. Refresh rate: 0.1 to 9.9 s, variable.
- Analog x indicator: Vertical row of 30 LEDs (red). Display range 0 to 100 %. Resolution 1.7 %.
- Analog w indicator: Vertical row of 30 LEDs (green). Display range 0 to 100 %. Resolution 1.7 %.
- Digital y indicator: 2-digit, red, 7-segment LED display, 7 mm character height. Display range 0 to 100 %. Resolution 1%. Refresh rate: 0.1 to 9.9 s, variable.
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.
Description | Order No. |
---|---|
Power supply AC/DC 24 V | 6DR2100-4 |
Power supply AC 230 V, switchable to AC 115 V | 6DR2100-5 |
Input/output modules
Modules are described in Catalog Section 8.
Module Type | Description | Order No. |
---|---|---|
Analog signals | For current input 0/4 to 20 mA or 0/0.2 to 1 V or 0/2 to 10 V voltage input | 6DR2800-8J |
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 module | With 2 relay outputs | 6DR2801-8D |
With 4 digital outputs and a digital input | 6DR2801-8E | |
Coupling relay module | With 4 relays (AC 250 V) | 6DR2804-8A |
With 2 relays (AC 250 V) | 6DR2804-8B | |
Interface modules | For serial communications (SES) via RS232 | See Catalog Section 8 |
PROFIBUS DP module | 6DR2803-8P |
Documentation
Description | Order No. |
---|---|
Quick reference "Operating and configuring" | German/English: C73000-B7474-C141 French/Spanish/Italian: C73000-B7450-C141 |
Assembly and installation instructions | German/English: C73000-M7474-C35 French/Spanish/Italian: C73000-M7450-C35 |
Manual | German: 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:
- 1 controller as ordered
- 1 power supply connector (115/230 V AC or special connector for 24 V AC/DC)
- 2 clamping elements, pluggable
- 1 Quick Reference (English/German)
- 1 Assembly and Installation Instructions (English/German)
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.