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
Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
D-74321-Bietigheim-Bissingen
Tel.: +49 (0)7142-7776-0
Fax: +49 (0)7142-7776-211
E-Mail:
info@ropex.de
Internet:
www.ropex.de
Data subject to change

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  • Page 1 CIRUS UPT-6010 Operating instructions 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: www.ropex.de D-74321-Bietigheim-Bissingen Data subject to change...

  • Page 2: Table Of Contents

    Contents General information ....3 Device functions ....17 Intended use .

  • Page 3: General Information

    Line filter with any other heatsealing bands because they could be overheated and damaged beyond The use of an original ROPEX line filter is mandatory in repair. order to comply with the standards and provisions mentioned in section 1.6 "Standards / CE marking" on page 4.

  • Page 4: Standards / Ce Marking

    / or peripheral It must not be disposed of as residual components approved by ROPEX are used. If not, then wase! To guarantee proper disposal and / or the the equipment is operated on the user's own recover of reusable material, please take the device to responsibility.

  • Page 5: System Description

    = actual. observed. The system was put together and optimized A highly dynamic thermoelectric control loop is estab- by ROPEX GmbH in an intensive development pro- lished in this way because purely electrical variables cess. By observing our technical recommendations,...

  • Page 6: Booster

    To increase operational safety and interference immu- nity, all PROFINET signals are electrically isolated from the controller and the heating circuit. The compact design of the CIRUS UPT-6010 tempera- ture controller and the plug-in terminals make it very easy to mount and install.

  • Page 7: Mounting And Installation

    If a larger overcurrent Installation procedure protective device is fitted, you must match the cur- Proceed as follows to install the CIRUS UPT-6010 tem- rent carrying capacity of the other components perature controller: accordingly (e.g. cables, impulse transformer etc.).

  • Page 8: Power Supply

    Mounting and installation formers approved by ROPEX. Please note the Power supply power, duty cycle, and primary and secondary volt- ages ( Application Report). LINE Line L1 (L1) 400 VAC N (L2) GND/ 50/60 Hz Earth Over-current protection Double-pole circuit-breaker or fuses, ROPEX Application Report) Short-circuit protection only.

  • Page 9: Line Filter

    Mounting and installation ROPEX line filters are specially optimized for use in Line filter CIRUS control loops. Providing that they are installed and wired correctly, they guarantee compliance with To comply with EMC directives – corresponding to the EMC limit values.

  • Page 10: Wiring Diagram (Standard)

    Mounting and installation Wiring diagram (standard) Line filter LF-xx480 UPT-6010 LINE Ethernet PORT 1 (RJ45) Ethernet module prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Heat- Must be grounded sealing externally to element prevent twisted electrostatic...

  • Page 11: Wiring Diagram With Booster Connection

    Mounting and installation Wiring diagram with booster connection Line filter LF-xx480 UPT-6010 LINE Ethernet PORT 1 (RJ45) Booster twisted Ethernet Max. length 1m module prim. Shield Impulse Ethernet transformator PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Heat- Must be grounded sealing externally to...

  • Page 12: Startup And Operation

    (or several voltage and current ranges times) through the PEX-W2, PEX-W3, or PEX-W4 cur- The secondary voltage and current ranges are auto- rent transformer ( ROPEX Application Report). matically configured during the automatic calibration Page 12 of 49 UPT-6010...
  • Page 13 "Parameter data" on page 24). switches: If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization soft- Rotary coding Device name ware ( section 6.12 "USB interface for visualization...

  • Page 14: Heating Element

    ( section 6.12 "USB interface for visualiza- alarm / PC CONFIGURATION", you can select more tion software (ROPEXvisual®)" on page 34). alarm output configurations in the ROPEX visualization 5.3.2 Replacing the heating element Heating element The supply voltage (all poles) must be disconnected 5.3.1...
  • Page 15 ( section 5.2 "Device tion software ( section 6.12 "USB interface for configuration" on page 12, ROPEX Application visualization software (ROPEXvisual®)" Report). Repeat the calibration after correcting the page 34). In order to avoid malfunctions, please controller configuration.
  • Page 16 Startup and operation protocol) is a regular curve, in other words it must 12.Optimize the heating and control process either by not jump abruptly, fluctuate, or temporarily deviate in adjusting the correction factor Co in the parameter the wrong direction. This kind of behavior would data (GSDML file) or using the acyclic services indicate that the U measurement cable was laid...

  • Page 17: Device Functions

    PROCESS CONTROL EQUIPMENT 24V POWER Lit if external 24VDC power E464680 www.ROPEX.de (Green LED) supply is present. In addition to the functions shown above, the LEDs also indicate various controller operating states. These states are described in detail in the table below:...
  • Page 18 Device functions Blinks slowly (1 Hz) Blinks fast (4 Hz) Lit continuously AUTOCAL requested but "RS" bit set (reset) function blocked (e.g. AUTOCAL executing AUTOCAL START active) (yellow) LED blinks at a different frequency: Supply voltages incorrect (too low) START requested but function blocked (e.g.

  • Page 19: Profinet Communication

    If no line voltage is present however (e.g. if it is the configuring tool can be requested by e-mail switched off in order to open a door), error code 901 or (support@ropex.de) or downloaded from our website 201 (error group 7, no line voltage / sync signal) (www.ropex.de).

  • Page 20: Communication Protocol

    Device functions information and the control functions, to simplify Communication protocol decoding by the PROFINET controller. Bits 0…7 form the low byte and bits 8…15 the high byte The communication protocol consists of 2x16 bit input ("INTEL format"). words and 3x16 bit output words (from the point of view The 2 x 16-bit input data contains the set point in of the controller).
  • Page 21 Device functions bits are set to 0 (inactive). An active heatsealing pro- Reasons for blocked "AUTOCAL" function: cess is interrupted. 1. An AUTOCAL request cannot be accepted until 10 seconds after the controller is switched on. 6.5.1 Automatic zero calibration During this time the controller shows "AUTOCAL "AUTOCAL"...
  • Page 22 Device functions fully completed. This can take several hundred millisec- 6.5.3 Reset (RS) onds. This bit resets the controller if the controller shows a fault. 6.5.5 Master AUTOCAL (MA) No AUTOCAL or START requests are accepted as long as the "RS" bit is set. Until it is reset again, only Setting this control bit starts a calibration as described error codes 5 and 7 (201…203, 901, 913) are evalu- section 6.5.1...

  • Page 23: Output Data

    Device functions Δϑ function has finished. The channel currently being used side of the set temperature. The high ( ) and low high Δϑ by the controller is shown in the status information. ) limits of the tolerance band can be changed independently of one another in the parameter data section 6.7 "Parameter data"...

  • Page 24: Parameter Data

    Device functions a.) Temperature not OK 6.6.10 Actual value Actual value All 16 bits of the first word must be interpreted as a Set+ Δϑ high signed number (twos complement notation). The reso- lution is 1°C. During the calibration procedure or if a fault occurs, the actual value is 0.
  • Page 25 Device functions data can be addressed at slot 1, subslot 1, starting at index 4; it has the following structure: Index Function Value range Default value Temperature range / alloy 0, 1, 4, 5, 8, 10, 11 6.7.1) Low temperature OK threshold 10 K 3…99 K High temperature OK threshold...
  • Page 26 Device functions Index Function Value range Default value Correction factor, channel 2 100% 25…200 (25…200%) 34/35 Temperature coefficient, channel 2 1700 ppm/K 400…4000 ppm/K Calibration temperature, channel 3 20°C -1, 0…40°C Correction factor, channel 3 100% 25…200 (25…200%) 38/39 Temperature coefficient, channel 3 1700 ppm/K 400…4000 ppm/K Calibration temperature, channel 4...
  • Page 27 Device functions Index Function Default value Value range 0…99 Time: Milliseconds (not used) Time: Seconds 0…59 Time: Minutes 0…59 Time: Hours 0…23 8…11 Operating hours (in 0.1h) 0.0 h 0…99999999.9 h 12…15 Non-clearable total cycle counter 0…999999999 16…19 Clearable total cycle counter 0…999999999 20…23 Cycle counter, channel 0...
  • Page 28 Device functions Index Function Default value Value range 14/15 Calibration deviation, channel 7 -100%…100% 6.7.1 Temperature range and alloy 6.7.4 Variable calibration temperature This parameter determines both the temperature range The calibration temperature is set to 20°C by default. and the heatsealing band alloy. You can overwrite the You can change it to another value between 0°C and setting of the rotary coding switch ( section 5.2.2...
  • Page 29 (50%) or with the value recom- Setting: mended in the ROPEX Application Report minus 25%, It is advisable not to set this parameter until you have until the actual temperature at the end of the heating determined the optimum heatsealing parameters (tem- impulse corresponds to the set temperature.
  • Page 30 If this time is longer than the configured time, the plotted in the graphics window of the ROPEX visualiza- corresponding error code (304) appears and the alarm relay is switched ( section 6.19 "Error messages"...

  • Page 31: Integrated Web Server

    Internet connection in order to access the operating instructions. You can go direct to the official ROPEX website by ACTUAL clicking on the ROPEX logo in the top right-hand temperature corner.
  • Page 32 Device functions section 6.1 "LEDs and controls" on page 17) in the overall size of the protocol ("Total event entries") as right-hand column. well as the upload progress. All entries appear in the form of a table. A timestamp (generated by the built-in clock), the operating hours and cycle counters, and the channel selected at the time are shown for each entry.

  • Page 33: Undervoltage Detection

    Device functions "Clear" clears all data from the memory (disconnecting 6.10 Temperature meter(actual value the 24 VDC supply voltage has the same effect). output) The UPT-6010 supplies an analog 0…10 VDC signal, which is proportional to the real ACTUAL temperature, at terminals 17+18.

  • Page 34: Booster Connection

    ( section 10 "Accessories and modifications" on page 45). The meter not only facilitates SET-ACTUAL compari- The ROPEX visualization software is described in a sons but also enables other criteria such as the heating separate document. Page 34 of 49...

  • Page 35: Aux Interface

    The number of heatsealing cycles executed since the The built-in clock can be set and read out in the ROPEX controller was shipped is stored in the internal memory visualization software ( section 6.12 "USB interface...

  • Page 36: System Monitoring / Alarm Output

    Red "ALARM" LED on the controller the voltage value does not change any more. with three states: If a ROPEX temperature meter (e.g. an ATR-x) is con- 1. Blinking fast (4 Hz): nected to the controller’s analog output, the tempera- The "AUTOCAL"...
  • Page 37 Device functions visualization software ( section 6.12 "USB interface level controller, for instance – the tolerance visualization software (ROPEXvisual®)" window must be adjusted to prevent incorrect page 34) to facilitate troubleshooting). interpretations. Please note the tolerances of the actual value output ( section 8 "Technical data"...
  • Page 38 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 Cause already operated, HS...
  • Page 39 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 40: Fault Areas And Causes

    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 41: Factory Settings

    Factory settings The table below explains the possible fault causes. Fault area Explanation Possible causes Load circuit interrupted after U - Wire break, heatsealing band break - Contact to heatsealing band is defective pickoff point PEX-W2/-W3 current transformer measurement cable from current transformer interrupted signal interrupted - Wire break, triac in controller defective Primary circuit interrupted...
  • Page 42 Factory settings Slide switch Alarm relay energized at alarm alarm relay Temperature Temperature diagnosis: Off diagnosis Heatup Heatup timeout: Off timeout Page 42 of 49 UPT-6010...

  • Page 43: Technical Data

    Balanced TN or TT system, max. 415 VAC Power supply system Installation category III Operation in potential-free systems (e.g. an IT system) is only per- mitted after consultation with ROPEX. 47…63 Hz, automatic adjustment to frequencies in this range Line frequency = 5A (duty cycle = 100%)
  • Page 44 Technical data The temperature range and temperature coefficient settings can also be specified Heatsealing band in the ROPEX visualization software ( section 6.12 "USB interface for visualiza- type and temperature tion software (ROPEXvisual®)" on page 34) in addition to using the rotary coding...

  • Page 45: Dimensions

    A wide range of compatible accessories and peripheral 10.1 Accessories devices are available for the CIRUS UPT-6010 temper- ature controller. They allow it to be optimally adapted to The products described below are only a few of the your specific heatsealing application as well as to the wide range of accessories available for CIRUS temper- design and operating philosophy of your system.

  • Page 46: Modifications (Mods)

    MOD 01 Booster secondary voltages Owing to its universal design, the CIRUS UPT-6010 = 0.2…60 VAC). This modification is necessary, temperature controller is suitable for a very wide range for example, for very short or low-resistance heating of heatsealing applications.

  • Page 47: How To Order

    06: Continuous current 6 A, 480 VAC, Art. No. 885500 35: Continuous current 35 A, 480 VAC, Art. No. 885506 Impulse transformer See ROPEX Application Report for design and ordering information Temperature meter ATR - . 3: 300°C range, Art. No. 882130 5: 500°C range, Art.

  • Page 48: 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 Heatsealing band type "AL" bit Heatup timeout Alarm output Alarm relay Alloy Impulse transformer Altitude Input data Ambient conditions...
  • Page 49 Index ROPEXvisual Temperature range "RS" bit Time Timestamp "TO" bit Transformer Set point Type of construction Standby mode Start "START" bit Start temperature UL file Startup USB interface System diagnosis System monitoring View of the device Visualization software "TE" bit Temperature achieved Web server Temperature coefficient...

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