Ropex CIRUS UPT-6010 Operating Instructions Manual
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Ropex CIRUS UPT-6010 Operating Instructions Manual

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CIRUS
UPT-6010
Operating
instructions
®
The CIRUS
temperature controller UPT-6010 is a key component in an ULTRA-PULSE system,
because it is responsible for all heat management functions, i.e. controlling the temperature of
the heating element.
Important features
•
Complete control via PROFINET interface („Conformance Class C", IO/RT and IRT acc. to IEC
61784-2) (2 x RJ-45)
•
Automatic zeroing (AUTOCAL)
•
Automatic configuration of the secondary voltage and current range (AUTORANGE)
•
Automatic frequency adaptation
•
Booster output standard
•
Analogue output 0...10 VDC for ACTUAL temperature
•
Alarm function with error diagnosis
•
Heating element alloy and temperature range can be selected
•
Cooling system monitored
•
Wide voltage range for the use of 110...415 V
•
Eight channels for administration of various calibration values
•
Micro-USB interface for ROPEXvisual
•
cULus approval
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)
®
Tel.: +49 (0)7142-7776-0
Fax: +49 (0)7142-7776-211
E-Mail:
info@ropex.de
Internet:
https://ropex.de
Technische Änderungen vorbehalten

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Summary of Contents for Ropex CIRUS UPT-6010

  • Page 1 Wide voltage range for the use of 110…415 V • Eight channels for administration of various calibration values ® • Micro-USB interface for ROPEXvisual • cULus approval ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: info@ropex.de Adolf-Heim-Str. 4 Fax: +49 (0)7142-7776-211 Internet: https://ropex.de 74321 Bietigheim-Bissingen (Germany) Technische Änderungen vorbehalten...

  • Page 2: Table Of Contents

    Contents Revision list ......3 Device functions ....21 LEDs and controls .

  • Page 3: Revision List

    Version Change • Creation of documentation • Change to one column layout • ROPEX logo changed • Covering page with important features • Additions in general information  section 2 "General information" on page 3 • Addition in Communication protocol: Status bit measurement interruption ...

  • Page 4: Heating Element

    The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions mentioned in section 2.7 "Standards / CE marking" on page 4. This device must be installed and connected according to the instructions contained in section "Power supply"...

  • Page 5: Maintenance

    Compliance with these standards and provisions is only guaranteed if original accessories and / or peripheral components approved by ROPEX are used. If not, then the equipment is operated on the user's own responsibility. The CE marking on the controller confirms that the device itself complies with the above-mentioned standards.

  • Page 6: Application

    Application This device must not be disposed of as residual waste! Application ® This CIRUS temperature controller is an integral part of the "series 6000". Its sole purpose is to control the tem- perature of CIRUS/UPT heating elements.The main application area is sealing or cutting of thermoplastics using the thermal impulse process.

  • Page 7: System Description

    Exact compliance with the installation and wiring instructions is essential. The system has been evolved and optimized by ROPEX GmbH in an intensive development process. Users who follow our technical recommendations will profit from the unique functionality of this technology, which reduces the customer's effort for installation, commissioning and maintenance to a minimum.

  • Page 8: Device Features

    Device features A highly dynamic thermoelectric control loop is established in this way because purely electrical variables are measured in rapid succession and the heating layer of the UPT heating element has a small mass. Temperature impulse Current impulses Time Thanks to the microprocessor based technology, the controller has an optimized control algorithm as well as numerous functions tailored to specific tasks such as AUTOCAL, ALARM with error diagnosis etc.

  • Page 9: Mounting And Installation

    5. Ensure an adequate cable cross-section for the primary and secondary circuits (Ä Application Report). 6. Use only ROPEX impulse transformers or transformers approved by ROPEX. Please note the power, duty cycle, and primary and secondary voltages (Ä Application Report).
  • Page 10 If one such device is not adequate for the heatsealing application, two separate overcurrent protective devices should be provided – one for the controller and one for the application ( ROPEX Application Report). The overcurrent protective device must be located directly adjacent to the controller.

  • Page 11: Power Supply

    Connect core to ground. Use transformers with a one section bobbin. The power, duty cycle and voltage values must be deter- mined individually according to the application ( ROPEX SEC. Application Report and "Accessories" leaflet for impulse transformers).

  • Page 12: Line Filter

    ROPEX line filters are specially optimized for use in CIRUS control loops. Providing that they are installed and wired correctly, they guarantee compliance with the EMC limit values. You can find the exact specification of the line filter in the ROPEX Application Report calculated for your particular heatsealing application.
  • Page 13 Mounting and installation 6.5.1 PEX-W4 terminal wires terminal block Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022) 6.5.2 PEX-W5 Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022). Version 2 UPT-6010 Seite 13...

  • Page 14: Wiring Diagram (Standard)

    Mounting and installation Wiring diagram (standard) Line filter UPT-6010 LINE Ethernet PORT 1 (RJ45) BOOSTER OUTPUT Ethernet module prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Must be grounded Heating externally to element prevent twisted electrostatic...

  • Page 15: Wiring Diagram With Booster Connection

    Mounting and installation Wiring diagram with booster connection Line filter UPT-6010 LINE Ethernet PORT 1 (RJ45) Booster twisted Ethernet Max. length 1m module prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Must be grounded Heating externally to element...

  • Page 16: Startup And Operation

    ( section 8.19 "Error messages" on page 46). If the secondary current I is less than 30 A, the secondary high-current wire must be laid twice (or several times) through the PEX-W4 or PEX-W5 current transformer ( ROPEX Application Report). Seite 16 UPT-6010...
  • Page 17 The setting of the rotary coding switch for the temperature range and alloy can be overwritten with the parameter data ( section 8.7 "Parameter data" on page 29). If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization software ®...

  • Page 18: Heating Element

    (factory setting) If the switch is set to "Alarm relay de-energized at alarm / PC CONFIGURATION", you can select more alarm output configurations in the ROPEX visualization software ( section 8.12 "USB interface for visualization soft- ® ware ROPEXvisual "...

  • Page 19: Commissioning Rules

    Startup and operation Each time the heating element is replaced, you must run the "AUTOCAL" function ( section 8.5.1 "Automatic zero calibration AUTOCAL (AC)" on page 24) and set the correction factor Co ( section 8.7.9 "Correction factor Co" on page 34). Any production-related resistance tolerances of the heating element are compensated in this way.
  • Page 20 (1 Hz). In this case the controller configuration is incorrect ( section 7.2 "Device configuration" on page 16, ROPEX Application Report). Repeat the calibration after correcting the controller configuration. 10.After the zero point has been successfully calibrated, specify a defined temperature by means of the PROFINET protocol (set point) and set the ST bit.

  • Page 21: Device Functions

    E QUI P M E NT 24 V POWER Lit if external 24 VDC power E 464680 www. ROPEX (green LED) supply is present. Made in Germany In addition to the functions shown above, the LEDs also indicate various controller operating states. These states...

  • Page 22: Profinet Communication

    PROFINET controller which controls user data traffic. The GSDML-V2.35-ROPEX-0150-UPT-6010-20190520.XML file of the UPT-6010 contains all essential controller information for the configuration, e.g. the I/O data description, parameter descriptions, error messages etc. The...

  • Page 23: Communication Protocol

    (.BMP) for visualization in the configuring tool can be requested by e-mail (support@ropex.de) or downloaded from our website (https://ropex.de). If the controller already has an IP address, the device master file can also be downloaded from the integrated web server.

  • Page 24: Input Data

    Device functions If the optional "Temperatures" submodule has been configured, the controller returns another 16 bit output word with the start temperature:  Start temperature (signed) Name: Bit no.: Input data The term "input data" refers to the data that is transferred from the PROFINET controller to the UPT-6010. It con- tains the set point as well as the control functions such as START or AUTOCAL for the UPT-6010.
  • Page 25 Device functions controller is switched on ( section 8.19 "Error messages" on page 46). It also cannot be activated if error codes 201…203 or 9xx appear and the controller has operated correctly at least once since being switched on. If the AUTOCAL function is blocked (AG bit = 1), an AUTOCAL request (AC bit = 1) causes the "AUTOCAL" LED to blink fast (4 Hz).

  • Page 26: Output Data

    Device functions 8.5.5 Master AUTOCAL (MA) Setting this control bit starts a calibration as described in section 8.5.1 "Automatic zero calibration AUTOCAL (AC)" on page 24. However, if the AUTOCAL function is successful, the heating element resistance which is deter- mined by the controller is also used as a reference value, e.g.
  • Page 27 Device functions 8.6.3 Alarm active (AL) If the AL bit is set, an alarm has been triggered but not yet reset. The error code provides information on the exact cause ( section 8.19 "Error messages" on page 46). 8.6.4 Warning active (WA) This bit can be set in addition to the AL bit.
  • Page 28 Device functions a.) Temperature not ok b.) Temperature ok Actual value Actual value Set+ Δϑ Set+ Δϑ high high Setpoint Setpoint Set+ Δϑ Set+ Δϑ Time Time ST bit ST bit Time Time TO bit TO bit Time Time ± The limits of the tolerance band are adjustable up to a maximum of 99 K.

  • Page 29: Parameter Data

    Device functions 8.6.13 Error codes If a fault is signalled (AL bit = 1), you can determine the exact cause with the help of the error code. The error code is contained in the third word at bit positions 0…9 ( section 8.19 "Error messages" on page 46). In addition to the error codes, the PROFINET diagnosis function also sends error messages to the PROFINET controller.
  • Page 30 Device functions Index Function Value range Default value 24/25 Heatup timeout (10 ms steps) 0…999 (0…9.99 s) Temperature OK bit Off (0), Active when Tact=Tset active when Tact=Tset (1), active when Tact=Tset with latch (2) Hold mode Off (0), on (1), 2 s (2) Calibration temperature, channel 1 20 °C -1, 0…40 °C...
  • Page 31 Device functions The date, time, operating hours counter, and counters for the individual calibration channels can be read out at slot 1, subslot 2. Apart from the operating hours counter (index 4…7) and the non-clearable total cycle counter (index 8…11), these counters can also be reset by means of a write access. A plausibility check which takes account of leap years is performed after writing the date or time.
  • Page 32 Device functions resistances are available from index 17. At index 16 the value of the passes through the current transformer is available. This value can also be written and will be stored remanently in the controllers memory with every change. The correct calculation of the absolute calibration resistances is only possible if the real count of wire passes through the current transformer is given in this parameter.
  • Page 33 Device functions 8.7.1 Temperature range and alloy This parameter determines both the temperature range and the heating element alloy. You can overwrite the set- ting of the rotary coding switch ( section 7.2.2 "Configuration of the rotary coding switch for the temperature range and alloy"...
  • Page 34 Slowly increase the correction factor, starting either with the lowest value (50%) or with the value recommended in the ROPEX Application Report minus 25%, until the actual temperature at the end of the heating impulse cor- responds to the set temperature.
  • Page 35 Device functions 8.7.10 Maximum start temperature You can set the required maximum start temperature in the parameter data. This temperature is the maximum allowable actual value at the start time. The value is determined by the controller at the start of each impulse and compared with the set value.
  • Page 36 The high and low tolerance limits cannot be set in the ROPEX visualization software. The same limits apply as with the TO bit. They can only be set in the parameter data ( section 8.7 "Parameter data" on page 29).

  • Page 37: Integrated Web Server

    You can go direct to the official ROPEX website by clicking on the ROPEX logo in the top right-hand corner. The web server uses JavaScript and has been successfully tested with Internet Explorer 9, 10, and 11 as well as with Microsoft Edge.
  • Page 38 Device functions 8.8.1 Home page This page contains general product information under "Device Information", for instance the product name, serial number, firmware version, MAC address, and real-time Ethernet protocol. You can also download the correct device description file for your product here ( section 8.3 "Device master file (GSDML)" on page 22). No Internet connection is necessary to do this because the file is already stored in the device’s internal memory.
  • Page 39 Device functions Under "Counters" you see a list of all cycle and operating hours counters, which are useful for statistical purposes. 8.8.4 Protocol page You can download and display the device protocol for the temperature controller on this page. You see the overall size of the protocol ("Total event entries") as well as the upload progress.
  • Page 40 Device functions If any new events occur while this page is displayed, you do not see them until you refresh the list by clicking on the "Protocol" menu again. 8.8.5 Graphic page The temperature controller has an internal memory which can store temperature curves over a period of up to 5 seconds.

  • Page 41: Undervoltage Detection

    Device functions These initial calibration resistances are the basis for the calculation of the calibration deviation. Each execution of the AUTOCAL function will calculate both, the absolute calibration resistance and likewise the percentual calibra- tion deviation towards the initial calibration resistance. These values are displayed on the Calibration page.

  • Page 42: Temperature Meter (Actual Value Output)

    Device functions 8.10 Temperature meter (actual value output) The UPT-6010 supplies an analog 0…10 VDC signal, which is proportional to the real ACTUAL temperature, at terminals 17+18. UPT-6010 Max. 5mA Actual value output 0…10 VDC 0…10 VDC Temperature meter e.g. ATR-3 Voltage values: 0 VDC 0 °C...

  • Page 43: Booster Connection

    An indicating instrument can be connected to this output in order to visualize the temperature of the heating ele- ment. The ROPEX ATR-x temperature meter is optimally adapted to this application in every respect (size, scale, dynamic behaviour) and can be used for this, if needed ( section 13 "How to order" on page 55).

  • Page 44: Aux Interface

    The number of heatsealing cycles executed since the controller was shipped is stored in the internal memory (ST bit = 1). This is a read-only counter which cannot be reset. It can be displayed in the ROPEX visualization soft- ®...

  • Page 45: System Monitoring / Alarm Output

    Device functions The built-in clock can be set and read out in the ROPEX visualization software ( section 8.12 "USB interface for ® visualization software ROPEXvisual " on page 43) or using the acyclic services of the PROFINETinterface. The date and time can be read out but not set via the integrated server.

  • Page 46: Error Messages

    If a ROPEX temperature meter (e.g. an ATR-x) is connected to the controller’s analog output, the temperature indication can be directly assigned to the error codes if an alarm is signalled.
  • Page 47 Device functions Part 1 of 3: Error messages (faults) NOTE: The error messages shown here are output as faults (constant error voltage at actual value output, alarm LED lit continuously, alarm relay energized). Act. val. Action if machine Error output Action if machine already operated, Cause...
  • Page 48 Device functions Part 2 of 3: Error messages (warnings) NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values, alarm LED blinks, alarm relay de-energized). When the START signal is activated, the warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm LED lit continuously, alarm relay energized).
  • Page 49 Device functions Part 3 of 3: Error messages (warnings) NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values, alarm LED blinks, alarm relay de-energized). When the START signal is activated, the warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm LED lit continuously, alarm relay energized).

  • Page 50: Fault Areas And Causes

    Device functions 8.20 Fault areas and causes Temperature controller HARDWARE The table below explains the possible fault causes. Fault area Explanation Possible causes Load circuit interrupted after U - Wire break, heating element break - Contact to heating element is defective pickoff point ...

  • Page 51: Factory Settings

    Factory settings Fault area Explanation Possible causes - Hardware fault (replace controller) Internal device fault / no line - Jumper for alarm relay not connected or incorrectly con-  voltage nected - No line voltage Factory settings ® The CIRUS UPT-6010 temperature controller is configured at the factory as follows: Rotary coding switch Heatsealing element alloy: 1700 ppm/K...

  • Page 52: Technical Data

    FSU (Fast-Startup) support: Yes, but startup time approx. 2.5s. Heating element type The temperature range and temperature coefficient settings can also be specified and temperature in the ROPEX visualization software ( section 8.12 "USB interface for visualiza- ® range tion software ROPEXvisual "...
  • Page 53 Technical data Analog output 0…10 VDC, I = 5 mA (actual value) Equivalent to 0…300 °C or 0…500 °C Terminals 17+18 Accuracy: ±1% plus 50 mV Alarm relay = 30 V (DC/AC), I = 0.2 A, changeover contact, potential-free Terminals 12, 13, 14 Power loss Max.

  • Page 54: Dimensions

    Dimensions Dimensions 75.0 90.0 Modifications (MODs) ® Owing to its universal design, the CIRUS temperature controller UPT-6010 is suitable for a very wide range of heatsealing applications. ® One modification (MOD) is available for the CIRUS temperature controller UPT-6010 for implementing special applications.

  • Page 55: How To Order

    50520: Continuous curr. 50 A, 520 VAC, art. no. 885509 (with UL and CSA certification) Impulse transformer For design and order specifications, see ROPEX applica- tion report Design in accordance with EN 61558 Available with UL certifications and thermal switch, if nec- essary.
  • Page 56 Booster B- . . . 075415: Impulse loaded 75 A, 415 VAC, art. no. 885302 100400: Impulse loaded 100 A, 400 VAC, art. no. 885304 Lines For design and order specifications, see ROPEX applica- tion report Seite 56 UPT-6010 Version 2...

  • Page 57: Index

    Index Index Numbers 24 VDC supply voltage Factory settings Fault Fault areas Fuse AA bit AC bit Actual value Actual value output Heating element AG bit Heating element type AL bit Heatup timeout Alarm output Alarm relay Alloy Impulse transformer Altitude Input data Ambient conditions...
  • Page 58 Index Temperature meter Temperature OK RA bit Temperature range Relative humidity Thermal impulse process Replacing the heating element Time Reset Timestamp ROPEXvisual TO bit RS bit Transformer Transportation Type of construction Set point ST bit Standby mode UL file Start USB interface Start temperature Startup...

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