Ropex CIRUS UPT-6010 Operating Instructions Manual Download Page 2 | Manualshive

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UPT-6010

Version 2

Contents

Revision list

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General information

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Copyright . . . . . . . . . . . . . . . . . . . . . . . 3

Intended use . . . . . . . . . . . . . . . . . . . . 3

Heating element . . . . . . . . . . . . . . . . . 4

Impulse transformer . . . . . . . . . . . . . . 4

Current transformer PEX-W4/-W5 . . . . 4

Line filter . . . . . . . . . . . . . . . . . . . . . . . 4

Standards / CE marking . . . . . . . . . . . 4

Maintenance . . . . . . . . . . . . . . . . . . . . 5

Transportation . . . . . . . . . . . . . . . . . . . 5

2.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5

Application

. . . . . . . . . . . . . . . . . . . . . . . . . . 6

System description

. . . . . . . . . . . . . . . . . . . 7

Functional principle . . . . . . . . . . . . . . . 7

Device features

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Mounting and installation

. . . . . . . . . . . . . . 9

Installation notes . . . . . . . . . . . . . . . . . 9

Installation procedure . . . . . . . . . . . . . 9

Power supply . . . . . . . . . . . . . . . . . . . 11

Line filter . . . . . . . . . . . . . . . . . . . . . . 12

Current transformer PEX-W4/-W5 . . . 12

Wiring diagram (standard) . . . . . . . . . 14

Wiring diagram with booster connection
15

Startup and operation

. . . . . . . . . . . . . . . . 16

View of the device . . . . . . . . . . . . . . . 16

Device configuration . . . . . . . . . . . . . 16

Heating element . . . . . . . . . . . . . . . . 18

Commissioning rules . . . . . . . . . . . . . 19

Device functions

. . . . . . . . . . . . . . . . . . . . 21

LEDs and controls . . . . . . . . . . . . . . . 21

PROFINET communication . . . . . . . . 22

Device master file (GSDML) . . . . . . . 22

Communication protocol . . . . . . . . . . 23

Input data . . . . . . . . . . . . . . . . . . . . . . 24

Output data . . . . . . . . . . . . . . . . . . . . 26

Parameter data . . . . . . . . . . . . . . . . . 29

Integrated web server . . . . . . . . . . . . 37

Undervoltage detection . . . . . . . . . . . 41

8.10 Temperature meter (actual value output)

8.11 Booster connection . . . . . . . . . . . . . . 43
8.12 USB interface for visualization software

® . . . . . . . . . . . . . . . . . . . . . . . 43

8.13 AUX interface  . . . . . . . . . . . . . . . . . .  44
8.14 Total cycle counter  . . . . . . . . . . . . . . 44
8.15 Operating hours counter  . . . . . . . . . .  44
8.16 Data memory for error messages and

AUTOCAL . . . . . . . . . . . . . . . . . . . . . 44

8.17 Built-in clock (date and time) . . . . . . .  44
8.18 System monitoring / alarm output  . . .  45
8.19 Error messages . . . . . . . . . . . . . . . . .  46
8.20 Fault areas and causes . . . . . . . . . . . 50

Factory settings

. . . . . . . . . . . . . . . . . . . . . 51

Technical data

. . . . . . . . . . . . . . . . . . . . . . 52

. . . . . . . . . . . . . . . . . . . . . . . . 54

Modifications (MODs)

. . . . . . . . . . . . . . . . 54

How to order

. . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Summary of Contents for CIRUS UPT-6010

Page 1: ...ement 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 temp...

Page 2: ...the device 16 7 2 Device configuration 16 7 3 Heating element 18 7 4 Commissioning rules 19 8 Device functions 21 8 1 LEDs and controls 21 8 2 PROFINET communication 22 8 3 Device master file GSDML 22 8 4 Communication protocol 23 8 5 Input data 24 8 6 Output data 26 8 7 Parameter data 29 8 8 Integrated web server 37 8 9 Undervoltage detection 41 8 10 Temperature meter actual value output 42 8 11 ...

Page 3: ...cular texts photographs and graphics are protected by copyright All rights including to rep lication publication editing and translation are reserved 2 2 Intended use CIRUS temperature controllers may only be used for heating and temperature control of heatsealing elements which are expressly approved for them and providing the regulations notes and warnings contained in these instructions are obs...

Page 4: ... may cause the equipment to malfunction The current transformer may only be operated if it is correctly connected to the CIRUS temperature controller see section Startup and operation The relevant safety instructions contained in section Power supply must be observed External monitoring modules can be used in order to additionally increase operating safety They are not included in the scope of sup...

Page 5: ...and dirt from liquids result in a loss of function Accordingly installation in a switch cabinet or terminal cabined with IP54 is recommended 2 9 Transportation Store and transport the device in its original carton After transport perform a visual inspection for possible damage 2 10 Disposal This device is subject to Directive 2012 19 EU concerning the reduction of the increasing amount of waste el...

Page 6: ...00 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 The most common application areas are vertical and horizontal form fill seal machines VFFS and HFFS bagging filling and sealing machines bag production machines foil welding devices foil splicer etc ...

Page 7: ...ns 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 4 1 Functional principle The controller determines the resistance of the heating element...

Page 8: ...rnal system heating element wiring etc and the internal electronics A differentiated error message is output through the PROFINET interface in case of malfunction To increase operational security and immunity to interference all PROFINET signals from the controller and heating circuit are electrically isolated Adjustment for different heating element alloys and setting of the temperature range to ...

Page 9: ...urement cable see How to order on page 55 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 6 2 Installation procedure Proceed as follows to install the CIRUS temperature controller UPT 60...

Page 10: ...e device is fitted you must match the current carrying capacity of the other components accordingly e g cables impulse transformer etc 5 A disconnecting device must be provided when the system is installed it must be marked as belonging to the system and fitted in a readily accessible position If a miniature circuit breaker is used it can also perform the function of this device 6 Connect the CIRU...

Page 11: ...res load side CIRUS temperature controller Relay Kb Load break all pole e g in combination with the alarm output of the temp controller ROPEX recommendation When using a series resistor RV 1 the relay Kb shall be installed Impulse Transformer Designed according to EN 61558 isolating transformer with reinforced insulation Connect core to ground Use transformers with a one section bobbin The power d...

Page 12: ...on Report calculated for your particular heatsealing application For more technical information Line filter documentation It is permissible to supply several CIRUS control loops with a single line filter providing the total current does not exceed the maximum current of the filter The wiring instructions contained in section 6 3 Power supply on page 11 must be observed Example drawing for LF 06480...

Page 13: ...sion 2 UPT 6010 Seite 13 6 5 1 PEX W4 6 5 2 PEX W5 Mounting on DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 Snap on for DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 terminal block terminal wires 14 60 24 75 14 23 28 26 39 12 ...

Page 14: ...er Heating element LINE sec U2 prim U1 Line filter 8 7 5 4 6 3 2 1 Termination RX RX TX Ethernet PORT 1 RJ45 TX Ethernet PORT 2 RJ45 for assignment see PORT 1 Shield ALARM OUTPUT max 30 V 0 2 A Ground Must be grounded externally to prevent electrostatic charging C ATR _ ANALOG OUTPUT 0 10 VDC BOOSTER OUTPUT Current transformer V V 24 VDC POWER SUPPLY twisted UPT 6010 ...

Page 15: ...OUT 1 3 Line filter NC NC 14 13 12 7 5 Ethernet module 18 17 6 8 7 5 4 6 3 2 1 Termination RX RX TX Ethernet PORT 1 RJ45 TX Ethernet PORT 2 RJ45 for assignment see PORT 1 Shield ALARM OUTPUT max 30 V 0 2 A Ground Must be grounded externally to prevent electrostatic charging C ATR _ ANALOG OUTPUT 0 10 VDC Heating element sec U2 prim U1 twisted Max length 1m 2 4 V V 24 VDC POWER SUPPLY UPT 6010 ...

Page 16: ...unction AUTOCAL The voltage is configured in the range from 0 4 VAC to 120 VAC and the current in the range from 30 A to 500 A If the voltage and or current are outside of the permissible range a detailed error message appears on the controller section 8 19 Error messages on page 46 If the secondary current I2 is less than 30 A the secondary high current wire must be laid twice or several times th...

Page 17: ...evice name can be erased by means of the rotary coding switches To do this make sure the controller is de energized then set the switches to 0xFF and switch the controller on again It is sufficient to supply the controller with 24 VDC No connection is required to the PROFINET network After the device name has been successfully erased the red DATA EXCHANGE LED blinks at approx 4 Hz The power supply...

Page 18: ...oo complex to be discussed at length here We shall therefore only refer to a few of the most important physical and electrical properties The measuring principle used for this system requires a heating element alloy with a suitable temperature coeffi cient TCR i e one whose resistance increases as the temperature rises Too low a TCR leads to oscillation or uncontrolled heating If a heating element...

Page 19: ...onds to indi cate that the controller is being powered up correctly The red BUS FAILURE LED lights up as long as no PROFINET communication is active It does not go out again until it detects an active communication If the red ALARM LED lights up for 0 3 1 5 s when the voltage is switched on in addition to the yellow AUTOCAL LED the configuration of this controller has been changed in the visualiza...

Page 20: ...he controller is functioning correctly if the temperature which corresponds to the signal change at the analog output or the actual value in the PROFINET protocol is a regular curve in other words it must not jump abruptly fluctuate or temporarily deviate in the wrong direction This kind of behaviour would indicate that the UR measurement cable was laid incorrectly If an error code is displayed pr...

Page 21: ...ED red green LED µC POWER DATA EXCH green LED green LED 24 V POWER Lit green while data exchange with PROFINET controller Lit or blinking if no connection exists to PROFINET Lit if external 24 VDC power supply is present Lit if internal power supply for PROFINET interface is OK AUTOCAL yellow LED yellow LED HEAT red LED green LED ALARM OUTPUT Lit during heating phase Lit or blinking to indicate fa...

Page 22: ...ster file GSDML The configuring tools for the PROFINET controller interpret the content of the device master files GSDML and use this information to create a parameter set for the 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 ...

Page 23: ...nt and the actual value of the UPT 6010 from the status infor mation and the control functions to simplify decoding by the PROFINET controller Bits 0 7 form the low byte and bits 8 15 the high byte INTEL format The 2 x 16 bit input data contains the set point in word and the control functions in word The 3 x 16 bit output data contains the actual value in word the status information in word and th...

Page 24: ...nput data when the AUTOCAL function is activated AC bit 1 This specified value must not be changed until the AUTOCAL function has finished If the specified temperature is too high greater than 40 C or if the specified value fluctuates an error message appears error codes 115 and 116 section 8 19 Error messages on page 46 The AUTOCAL request AC bit 1 is executed by the controller provided the AUTOC...

Page 25: ...utput by the error diagnosis function The power unit is not activated in this state and no measuring impulses are generated As a result of this the actual value is no longer updated The reset request is not accepted until the RS bit is reset PROFINET Communications are not interrupted by a con troller reset The controller actual value output changes to 0 3 C i e approximately 0 VDC and the SA bit ...

Page 26: ...nstance in applications where frequent changes of format are necessary The tools can then be changed as required in order to handle the different formats A channel containing the relevant cali bration data record is assigned to each tool Once all tools have been calibrated with a unique channel assign ment they can be changed at any time simply by selecting the appropriate channel If the applicati...

Page 27: ...following set tings are possible 1 Off The TO bit is always reset 2 Active when Tact Tset factory setting The TO bit is set if the actual value is inside the specified temperature tolerance band If the actual temperature is outside of the tolerance band the TO bit is reset see graph below Unlike the Temperature achieved status bit TE bit the actual temperature is evaluated independently of the con...

Page 28: ... heating impulse This would then be an indication of excessive temperature which can result in a bad sealing seam As soon as a measurement is performed again the MU bit goes back to 0 8 6 11 Actual value All 16 bits of the first word must be interpreted as a signed number twos complement notation The resolution is 1 C During the calibration procedure or if a fault occurs the actual value is 0 8 6 ...

Page 29: ...ransferred from the PROFINET controller to the UPT 6010 each time the system is started up The parameters can also be queried by the PROFINET controller or transmitted by it to the UPT 6011 controller at any time using asynchronous read write services They are not stored in the UPT 6010 The parameter data can be addressed at slot 1 subslot 1 starting at index 4 It has the following structure Index...

Page 30: ...ent channel 3 1700 ppm K 400 4000 ppm K 40 Calibration temperature channel 4 20 C 1 0 40 C 41 Correction factor channel 4 100 25 200 25 200 42 43 Temperature coefficient channel 4 1700 ppm K 400 4000 ppm K 44 Calibration temperature channel 5 20 C 1 0 40 C 45 Correction factor channel 5 100 25 200 25 200 46 47 Temperature coefficient channel 5 1700 ppm K 400 4000 ppm K 48 Calibration temperature c...

Page 31: ...at slot 1 subslot 4 section 8 5 5 Master AUTOCAL MA on page 26 They are read only values which cannot be changed The absolute calibration Index Function Default value Value range 0 Date Day 1 31 1 Date Month 1 12 2 3 Date Year 2000 2099 4 Time Milliseconds not used 1 1 Milliseconds are not supported by the internal real time clock Read accesses always return 0 A value in the range 0 99 must be tra...

Page 32: ... 15 Calibration deviation channel 7 in 0 01 0 100 00 100 00 16 Passes through current transformer 1 1 9 17 18 Calibration resistance channel 0 in 0 1 mΩ 0 0 6553 5 mΩ 19 20 Calibration resistance channel 1 in 0 1 mΩ 0 0 6553 5 mΩ 21 22 Calibration resistance channel 2 in 0 1 mΩ 0 0 6553 5 mΩ 23 24 Calibration resistance channel 3 in 0 1 mΩ 0 0 6553 5 mΩ 25 26 Calibration resistance channel 4 in 0 ...

Page 33: ...e cannot be adapted to the actual ambient conditions in the machines The calibration temperature can thus be enabled for setting by means of the input data by specifying the value 1 in the parameter data The calibration temperature can then be specified via the Set point AC temperature input data section 8 5 1 Automatic zero calibration AUTOCAL AC on page 24 After a change of the calibration tempe...

Page 34: ...ttle Endian Intel or Big Endian Motorola in the cyclic data this setting applies to both input and output data section 8 4 Communication protocol on page 23 We recommend selecting Big Endian Motorola for Siemens PLCs 8 7 9 Correction factor Co The correction factor Co allows you to adapt the controller to the actual conditions in the machine type of UPT heating element impulse transformer specific...

Page 35: ...l you have determined the optimum heatsealing parameters temper ature and cooling time for production The start temperature should be set to approximately 50 of the heat sealing temperature for the trial run to enable the optimum working parameters to be established correctly 8 7 11 Temperature diagnosis An additional temperature diagnosis can be activated in the parameter data GSDML file The UPT ...

Page 36: ...red time the corresponding error code 304 appears and the alarm relay is switched section 8 19 Error messages on page 46 The Heatup timeout function must be enabled for use in the parameter data section 8 7 Parameter data on page 29 default setting heatup timeout off 8 7 13 Hold mode The ACTUAL temperature output via the PROFINET protocol can be configured in the parameter data GSDML file as follo...

Page 37: ...ion of the operating instructions can be downloaded from the ROPEX website by clicking on the picture of the device on any page To make sure this latest version is always available in any selectable language the instructions are not stored in the device you must therefore have an Internet connection in order to access the operating instructions You can go direct to the official ROPEX website by cl...

Page 38: ...his page provides an overview of the current controller status Online indicates whether a connection has been set up to the PLC The inputs section 8 5 Input data on page 24 are shown in the left hand column the outputs section 8 6 Output data on page 26 in the middle column and the current status of all device LEDs section 8 1 LEDs and controls on page 21 in the right hand column 8 8 3 Parameters ...

Page 39: ...are shown for each entry In addition to errors the protocol also contains entries of general interest such as Clock set or the AUTOCAL function An error code provides information on the cause of all events in the protocol The error codes are described in detail in section 8 19 Error messages on page 46 Each error code is explained in a tooltip when you hover over it briefly The data can also be ex...

Page 40: ...upply voltage has the same effect The vertical lines mark the beginning of a new heatsealing impulse ST bit set A negative set point indicates the start of a new impulse in the exported data Cooling processes are not normally visible because they take place when the ST bit is reset 8 8 6 Calibration page This page is first available as from firmware version 303 The temperature controller stores th...

Page 41: ...nd imprecision due to toler ances in production to application dimensioning to quality of cabling to fluctuations in the power supply etc 8 9 Undervoltage detection Trouble free operation of the temperature controller is guaranteed within the line voltage and 24 VDC supply voltage tolerances specified in section 10 Technical data on page 52 If the 24 VDC supply voltage drops below the permitted lo...

Page 42: ...pending on the device configuration The relationship between the change in the output voltage and the ACTUAL temperature is linear UPT 6010 Actual value output 0 10 VDC 18 17 0 V Temperature meter e g ATR 3 0 10 VDC Max 5mA 0 300 C range 2 3 4 5 6 7 8 9 10 300 Temperatu re T C VDC Voltage U 60 90 120 150 180 210 240 270 1 20 ºC ZERO 0 66 V 0 500 C range 2 3 4 5 6 7 8 9 10 500 100 150 200 250 300 3...

Page 43: ...og output is used to display a selective error message section 8 19 Error mes sages on page 46 8 11 Booster connection The UPT 6010 controller has a connection for an external switching amplifier booster as standard This connec tion at terminals 15 16 is necessary for high primary currents continuous current 5 A pulsed current 25 A The booster should be connected as described in section 6 7 Wiring...

Page 44: ... for error messages and AUTOCAL To simplify error diagnoses during operation the UPT 6010 controller has a data memory for error messages section 8 19 Error messages on page 46 and executed AUTOCAL functions section 8 5 1 Automatic zero calibration AUTOCAL AC on page 24 The 400 most recent messages are stored They can be read out and displayed in the ROPEX visualization soft ware section 8 12 USB ...

Page 45: ...ver this has no effect on the temperature control functions 8 18 System monitoring alarm output To increase operational safety and avoid faulty heatsealing this controller incorporates special hardware and soft ware features to facilitate selective error detection and diagnosis Both the external wiring and the internal system are monitored These features significantly assist the operator in identi...

Page 46: ...messages may appear when the controller is switched off owing to the undefined operating state This must be taken into account when they are evaluated by the higher level controller e g a PLC in order to avoid false alarms 8 19 Error messages In addition to the error codes diagnosed in the event protocol you can also access the PROFINET diagnosis func tion extended device diagnosis The error codes...

Page 47: ...ea Fault areas 107 2 66 Temperature step down Fault areas loose contact Fault areas loose contact 108 Temperature step up 307 Temperature too high low section 8 7 11 308 309 310 201 3 33 No line frequency line fre quency fluctuates Check power supply Check power supply 202 Line frequency too high fluctuates 203 Line frequency too low fluctuates 304 4 00 Heatup time too long section 8 7 12 Perform ...

Page 48: ...ine started for first time Action if machine already operated heating element not changed 104 5 33 10 Current signal incorrect incorrect impulse transformer specification Perform AUTOCAL check transformer specifi cation fault areas Fault areas loose contact 105 Voltage signal incorrect incorrect impulse transformer specification 106 Current and voltage signals incorrect incorrect impulse transform...

Page 49: ...no calibration possible Fault area check configuration Fault areas loose contact 112 7 33 10 Voltage signal incorrect no calibration possible Fault area check configuration Fault areas loose contact 113 8 00 10 Current voltage signals incor rect no calibration possible Fault area check configuration Fault areas loose contact 114 8 66 10 Temperature fluctuates no calibration possible Perform AUTOCA...

Page 50: ... of impulse transformer interrupted No UR signal Measurement cable interrupted Partial short circuit delta R Heating element partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heating element break Contact to heating element is defective Total short circuit Heating element incorrectly installed no insulation at heat sealing bar ends or ...

Page 51: ...ture range Heatsealing element alloy 1700 ppm K Temperature range 300 C Rotary coding switch 0 position Slide switch for alarm relay Alarm relay energized at alarm Temperature diagnosis Temperature diagnosis Off Heatup timeout Heatup timeout Off Fault area Explanation Possible causes 0 5 1 2 3 4 6 7 8 9 AUX CONFIGURATION ALARM OUTPUT ENERGIZED AT ALARM DE ENERGIZED SWITCH POS 4 0 9 TEMP RANGE 500 ...

Page 52: ...V supplied from max 300 VAC Cat II Measuring range Secondary voltage UR 0 4 120 VAC Secondary current IR 30 500 A with PEX W4 W5 current transformer ROPEX Application Report PROFINET interface Conformance Class C IO RT and IRT acc to IEC 61784 2 2 Ethernet switch ports RJ45 Wiring IEC 61784 5 3 Data transfer rate 100 MHz Data transport layer Ethernet II IEEE 802 3 Topology discovery LLDP SNMP V1 M...

Page 53: ...m all round e g from other devices and wiring must be allowed when installing the device The moving clip required for fastening must be facing down for mounting on a horizontal top hat rail End holders to mechanically fix the controller must be fitted at both ends for mounting on a vertical top hat rail Weight Approx 0 5 kg incl connector plug in parts Housing material Plastic polycarbonate UL 94 ...

Page 54: ...wide range of heatsealing applications One modification MOD is available for the CIRUS temperature controller UPT 6010 for implementing special applications The modifications must be ordered separately MOD 01 Booster for low secondary voltages UR 0 2 60 VAC This modification is necessary for example for very short or low resistance heating elements 75 0 90 0 113 0 135 0 ...

Page 55: ...ansformer PEX W5 Art no 885107 Monitoring current transformer MSW 2 Art no 885212 Network filter LF 06480 Continuous current 6 A 480 VAC art no 885500 with UL certification 10520 Continuous curr 10 A 520 VAC art no 885504 with UL and CSA certification 35480 Continuous curr 35 A 480 VAC art no 885506 50520 Continuous curr 50 A 520 VAC art no 885509 with UL and CSA certification Impulse transformer ...

Page 56: ...er Seite 56 UPT 6010 Version 2 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 ...

Page 57: ...r file GSDML 22 Dimensions 54 Disposal 5 E Error code format 35 Error diagnosis 8 Error messages 46 External module channel errors 34 External switching amplifier 15 F Factory settings 51 Fault 27 Fault areas 50 Fuse 11 H Heating element 4 18 Heating element type 52 Heatup timeout 36 I Impulse transformer 4 11 55 Input data 24 Installation 9 53 Installation procedure 9 Installation regulations 10 ...

Page 58: ... 43 System monitoring 45 T TCR 18 TE bit 27 Temperature achieved 27 Temperature coefficient 18 Temperature diagnosis 35 36 Temperature meter 43 55 Temperature OK 27 Temperature range 17 52 Thermal impulse process 6 Time 44 Timestamp 44 TO bit 27 Transformer 4 11 55 Transportation 5 Type of construction 52 U UL file 53 USB interface 43 V View of the device 16 Visualization software 43 W Web server ...

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