Ropex CIRUS UPT-640 Operating Instructions Manual Download Page 17

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Startup and operation

UPT-640 (as of SW 100)

Startup and operation

8.1

Front view of the controller

8.2

Rear view of the controller

Nameplate

Terminals
Wiring diagram
Diagnostic interface
(on rear of controller)

Operator keys

Clips

Display

10 11

19 20 21 22 23 24 25 26

50V / 0,2A

ROPEX

19 20 21 22 23 24 25 26

16 17 18

4 5 6 7 8 9 10 11

PRIM.

24V

. O

.IN

0 -

START
24VDC

NTAC

BOOSTER

ALARM

GND

FILTER

N (L1)

(PE)

L1 (L2)

y w

ith

lter

)

2 3

SEC.

AUTO

RANGE

0,4 - 120V

30 - 500A

E6014431

DIAG

Printed wiring diagram

Terminals

Diagnostic interface

Terminals

Summary of Contents for CIRUS UPT-640

Page 1: ...rs multilingual Alternatively VF display blue 4 lines 20 characters multilingual Automatic zero calibration AUTOCAL Automatic configuration of the secondary voltage and current ranges AUTORANGE Booster connection as standard Heatsealing band alloy and temperature range selectable Time control heatsealing time and cooling time settable Externally or internally generated release impulse with program...

Page 2: ... 21 9 Controller functions 23 9 1 Indicators and controls 23 9 2 Display 23 9 3 Navigation in the menus 25 9 4 Menu structure 27 9 5 Two digit numbering system up to software revision 022 29 9 6 Temperature setting set point selection 30 9 7 Temperature indication actual value output 31 9 8 Automatic zero calibration AUTOCAL 32 9 9 START signal HEAT 33 9 10 RESET signal 34 9 11 Correction factor C...

Page 3: ...ond repair 1 3 Impulse transformer A suitable impulse transformer is necessary to ensure that the control loop functions perfectly This transformer must be designed according to VDE 0570 EN 61558 isolating transformer with reinforced insulation and have a one section bobbin When the impulse transformer is installed suitable shock protection must be provided in accordance with the national installa...

Page 4: ... electrical overloading natural wear incorrect or negligent handling chemical influences or mechanical overloading as well as devices that have been modified relabeled or otherwise altered by the customer for example in an attempt to repair them or install additional components are excluded from the warranty Warranty claims must be examined in the factory and approved by ROPEX 2 Application This C...

Page 5: ... 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 commis sioning and maintenance to a minimum 3 1 Temperature controller The controller calculates the resistance of the heating element by measuring the current and voltage at a high sampling ...

Page 6: ... SW 100 controller is designed for installation in a front panel cutout but can also be accommodated in the electrical cabinet using an adapter for top hat rail mounting Adapter for top hat rail mounting HS Adapter 01 on page 8 3 2 Current transformer PEX W2 W3 The PEX W2 current transformer supplied with the CIRUS UPT 640 as of SW 100 controller is an integral part of the control system Only this...

Page 7: ...cur in impulse mode Digital temperature meter DTR x For front panel mounting or mounting on a top hat rail DIN TS35 Digital indication of the ACTUAL temperature of the heatsealing band in C with HOLD function Line filter LF xx480 Essential in order to ensure CE conformity Optimized for the CIRUS temperature controller Impulse transformer ITR x Designed according to VDE 0570 EN 61558 with a one sec...

Page 8: ...ndard PEX W2 W3 current transformer Transparent front cover TFA 1 For increasing the degree of protection on the front of the controller to IP65 Also facilitates applications in the food technology sector GMP Adapter for top hat rail mounting HS Adapter 01 For mounting the CIRUS temperature controller UPT 640 as of SW 100 on a top hat rail DIN TS35 Allows the controller to be installed in the elec...

Page 9: ...0 300 C or 0 500 C Analog output actual value Terminals 20 24 0 10VDC Imax 5mA Equivalent to 0 300 C or 0 500 C Electrically isolated Accuracy 1 add 50mV Digital logic levels Terminals 3 4 22 25 26 LOW 0V 0 2VDC HIGH 24VDC 12 30VDC max current input 6mA Electrically isolated reverse polarity protected START and RELEASE CH1 with contact Terminals 2 7 and 2 19 Switching threshold 3 5VDC Umax 5VDC Im...

Page 10: ...38 0 2 x 68 0 2 mm Fastened with clips Weight Approx 1 0kg incl connector plug in parts Housing material Black plastic type Noryl SE1 GFN2 Connecting cable Type cross sections Rigid or flexible 0 2 2 5mm AWG 24 12 Plug in connectors If ferrules are used they must be crimped in accordance with DIN 46228 and IEC EN 60947 1 This is essential for proper electrical contact in the terminals ...

Page 11: ... Dimensions front panel cutout 29 132 9 136 66 144 72 front panel terminal blocks terminal wires rubber seal mounting clamp terminal blocks terminal wires outline dimensions front frame panel cutout 138 x 68 0 2 0 2 DIP switch to select U I 2 2 front frame ...

Page 12: ...sformers or transfor mers approved by ROPEX Please note the power the duty cycle and the primary and secondary voltages Application Report 7 2 Installation procedure Proceed as follows to install the CIRUS temperature controller UPT 640 as of SW 100 1 Switch off the line voltage and verify the safe isola tion from the supply 2 The supply voltage specified on the nameplate of the CIRUS temperature ...

Page 13: ... 6xx Series 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 VDE 0570 EN 61558 isolating transformer with reinforced insulation Connect core to ground Use transformers with a one section bobbin The power duty cycle and voltage ...

Page 14: ...ling application For more technical information Line filter docu mentation It is permissible to supply several CIRUS control loops with a single line filter provi ding the total current does not exceed the maximum current of the filter The wiring instructions contained in section 7 3 Power supply on page 13 must be observed 7 5 Current transformer PEX W3 The PEX W3 current transformer supplied wit...

Page 15: ...tact closed or opened by ALARM see configuration Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Internal ground Terminal 2 Impuls transformer Remark Only principal diagram Heating sensor elements impulse transformer and wiring must be determined individually according to the application see ROPEX Application Report R IR UR Current transformer PEX W2 W3 LI...

Page 16: ...00VDC 1 5A 240VAC 1 5A GND GND Contact closed or opened by ALARM see configuration Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Internal ground Terminal 2 LINE Booster NC NC 2 4 IN OUT 1 3 Line filter LF xx480 Impuls transformer Remark Only principal diagram Heating sensor elements impulse transformer and wiring must be determined individually according...

Page 17: ... 3 4 5 6 7 8 9 10 11 19 20 21 22 23 24 25 26 18 17 16 50V 0 2A ROPEX 19 20 21 22 23 24 25 26 1 16 17 18 K1 U1 4 5 6 7 8 9 10 11 12 13 14 15 PRIM CH1 24VDC TEMP OK AUTOCAL RESET GND TEMP IN 0 10VDC TEMP OUT 0 10VDC START 24VDC START CONTACT CH1 CONTACT BOOSTER ALARM GND FILTER N L1 PE L1 L2 only with filter 2 3 R U R I R U2 SEC 0V AUTO RANGE R U 2 I 0 4 120V 30 500A E6014431 DIAG Printed wiring dia...

Page 18: ...nguage setting step 201 in the Configura tion menu remains unchanged Please refer to section 10 Factory settings on page 51 for more information about the factory settings If the controller settings are unknown when it is started up for the first time the factory set tings must be restored in order to prevent malfunc tions 8 3 4 Configuration of the alloy Temperature coefficient The heatsealing ba...

Page 19: ...active They are described in section 9 23 6 Relay K1 with time control on page 41 8 3 8 Output 1 Temperature OK signal without time control On controllers up to software revision 022 the switching output at terminals 20 21 was called Temperature OK The more general name Output 1 is used as of software revision 100 because this output now also supports other func tions The Output 1 signal is availa...

Page 20: ...heatsealing cycle is in progress it is immediately interrupted If the temperature diagnosis is not activated by the time the START signal is deactivated i e if the ACTUAL temperature does not exceed the upper or lower tole rance band limit the corresponding error code 309 310 is indicated and the fault relay is switched If the temperature diagnosis function is activated an additional delay time of...

Page 21: ...eating element will be compensated 8 5 Startup procedure Please also refer to Kap 1 Safety and warning notes auf Seite 3 and Kap 2 Application auf Seite 4 Installation and startup may only be per formed by technically trained skilled per sons who are familiar with the associated risks and warranty provisions 8 5 1 Initial startup Prerequisites The controller must be correctly installed and connect...

Page 22: ...Settings menu or apply a 0 10VDC voltage to the analog input terminals 20 23 and activate the START signal HEAT Alternatively a heatsealing process can be started by pressing the HAND key display in home position The indication of the ACTUAL tem perature on the display digital value and dynamic bar permits the heating and control process to be monitored The controller is functioning correctly if t...

Page 23: ...AND RESET Ultra Pulse UPT 640 ROPEX CIRUS Heater System MENU key for advancing to next menu step or switching menu 1 sec Press Next menu step 1 2 sec Press Return to previous position 2 sec Press Hold Return to home position ENTER key ENTER function HAND function RESET function Save values Manual mode Reset after alarm UP and DOWN keys for setting values Press 2 sec Slow change Hold 2 sec Fast cha...

Page 24: ...p 9 4 Menu structure auf Seite 27 9 2 4 Error messages The fault diagnosis function of the controller is always active If a fault is detected it is indicated on the display immediately in the form of an error message Kap 9 25 System monitoring alarm output auf Seite 46 Icon indicates that NO contact of additional Specified heatsealing temperature SET temperature relay K1 is closed Measured ACTUAL ...

Page 25: ...he menu structure providing a con troller alarm is not active In this case the Alarm menu is opened instead If the display is in the home position or an alarm is indi cated and you press the MENU key for longer than 2s you are taken directly to the configuration level starting at step 201 In addition you always return to the home position if you do not press any keys for a period of 30s There is n...

Page 26: ...riefly pressing the MENU key 2s You can then activate the AUTOCAL function by pressing the ENTER key section 9 8 Automatic zero cali bration AUTOCAL on page 32 If you press the MENU key for longer than 2s in the Alarm menu you are taken directly to the configuration level starting at step 201 You can return from the Configuration menu to the Alarm menu either by pres sing the MENU key for longer t...

Page 27: ...ion 213 Lock HAND key 207 Set point reached 205 Temperature range Settings Configuration 1 Time control ON 2 Time control OFF 3 TCR variable 4 TCR not variable 5 Cooling mode abso lute relative time 6 Cooling mode none 211 Start of sealing time Fault 215 Alarm relay 204 Temp coefficient 214 Cycles 107 Autocal 102 Preheating temp Autocal 3 4 209 Time control 1 2 216 Analog output 1 2 217 Temp diagn...

Page 28: ...ller functions 28 UPT 640 as of SW 100 221 Autocomp 220 Meas imp length 219 Heatup timeout Configuration 222 Output 1 Continued from previous page Back to home position 225 Temperature unit 224 Starting temp ...

Page 29: ... 4 Menu structure on page 27 respectively Menu Menu steps Numbering up to software revision 022 Numbering as of software revision 100 Settings menu Heatsealing temperature 2 101 Starting delay 3 103 Heatsealing time 3 104 Cooling value 4 105 Hold mode 5 106 AUTOCAL 1 107 Correction factor Co 6 110 Release temperature 10 115 Release delay 11 116 Release duration 12 117 Configuration menu Language 3...

Page 30: ... band type temperature range set with step 205 The set point that is selected for the heatsealing tempe rature must be greater than 40 C If not the heatse aling band will not be heated up when the START signal is activated or the HAND key is pressed The set heatsealing temperature is displayed in the main menu once it has been entered If the heatsealing temperature is specified via the analog inpu...

Page 31: ...s linear Only the two temperature ranges 300 C and 500 C appear at this actual value output If a temperature range of 200 C is set for the controller with step 205 in the Configuration menu it appears at this output in the 0 300 C range A 400 C temperature range is indi cated as 0 500 C An indicating instrument can be connected to this output in order to visualize the temperature of the heat seali...

Page 32: ...tion AUTOCAL Owing to the automatic zero calibration AUTOCAL function there is no need to adjust the zero point manu ally on the controller The AUTOCAL function mat ches the controller to the current and voltage signals that are present in the system This function can be activated in two ways By means of a 24VDC signal at terminals 20 25 By selecting step 107 in the Settings menu and pressing the ...

Page 33: ...very 100 000 sealing cyles for preventing measurement failures of the ACTUAL temperature 9 9 START signal HEAT The heating process is activated by means of the START signal in different ways depending on the time control status timer function Configuration menu step 209 1 Time control off deactivated When the START signal is activated the con troller internal set actual comparison is enabled immed...

Page 34: ...cutes an internal initializa tion for approximately 500ms after the RESET signal is deactivated The next heatse aling process cannot be started until it has fini shed If a contactor Kb is used to deactivate the control loop Kap 7 3 Power supply auf Seite 13 it must be energized again 50ms at the latest after the RESET signal is deactivated If it is energized too late an error message will be outpu...

Page 35: ...un to enable the optimum working parameters to be established correctly 9 13 Cycle counter Each activation of the START signal during operation is detected by a cycle counter integrated in the con troller Actuations of the HAND key are not counted The counter reading can be displayed with step 214 in the Configuration menu The cycle counter is reset to 0 if the ENTER key is pressed or if the maxim...

Page 36: ...ing process The heatsealing band is heated as long as the HAND key remains pressed 2 Lock ON The HAND key is locked when the display is in the home position in other words it has no function 9 17 Temperature unit Celsius Fahrenheit as of software revision 103 As of software revision 103 the unit for the temperature indication and value selection can be switched between C Celsius and F Fahrenheit 1...

Page 37: ...been canceled In the factory setting the Configuration menu is not disabled 9 19 Setting the display brightness VF display only If the display is in the home position the brightness of the VF display blue can be set in 4 steps 25 50 75 100 with the UP and DOWN keys The factory setting is 75 The life of the VF display can be prolonged by reducing the brightness 9 20 Undervoltage detection Trouble f...

Page 38: ...ns An incorrectly parameterized timer function may cause disruptions to operation and damage to the machine The timer function is activated with step 209 26 in the Configuration menu There are two possible settings in this menu 1 OFF Factory setting Time control timer function deactivated 2 ON Time control timer function activated The internal timeout is started by activating the START signal The ...

Page 39: ...rnal timeout The current condition of relay K1 is indicated by means of a separate icon If the icon is visible the normally open contact of the relay is closed Separate settings can be entered for the individual timeouts These settings are possible with steps 103 104 and 105 in the Settings menu and with steps 210 and 212 in the Configuration menu The options available with these advanced settings...

Page 40: ... Configuration menu of the UPT 640 as of SW 100 controller The possible set tings are as follows 1 Absolute Factory setting The cooling phase ends when the ACTUAL tempe rature of the heatsealing band falls below a speci fied temperature value This cooling temperature can be set with step 105 in the Settings menu 2 Relative The cooling phase ends when the ACTUAL tempe rature falls to a value corres...

Page 41: ...tting with menu step 210 Time The cooling phase ends when the specified time elapses This time can be set between 0 and 9 99s The factory setting is 1 00s 9 23 6 Relay K1 with time control The function of relay K1 when time control is active is also specified with step 212 in the Configuration menu section 8 3 7 Relay K1 without time control on page 19 The settings described here are only pos sibl...

Page 42: ...perature leaves the tolerance band once during the heatsealing phase relay K1 is opened The relay is not closed again until the next START signal is activated The switching state of relay K1 can thus also be interrogated by the higher level PLC after a heatsealing process latch func tion see graph below ACTUAL temperature START signal 24VDC T t t 0 0 95 of set point When start signal present t 0 R...

Page 43: ...21 as a digital control signal If time control timer function is active the switching output at terminals 20 21 Output 1 can be parame terized in the same way as relay K1 The options for Output 1 are specified with step 222 in the Configura tion menu as followed 1 Off 2 When start signal present 3 When temperature reached 4 While cooling 5 End of cycle impulse 6 Active if Tact Tset 7 Active if Tac...

Page 44: ...to be applied at exactly the right instant in the heatsealing sequence The temperature and dura tion of this impulse can be set individually The sealing impulse is applied with the sealing bar and the jaw bars closed The sealing bar begins to open after the tool has cooled down A release impulse is applied when the film is clamped as the sealing bar is with drawn The film is released and the jaw b...

Page 45: ...is signal can be activated in two ways By means of a 24VDC signal at terminals 22 4 By means of a control contact at terminals 2 19 The following functions are possible depending on the time control setting in step 37 section 9 23 Time control timer function on page 38 1 If time control is OFF The delay and the impulse duration cannot be spe cified internally by the controller The start and dura t...

Page 46: ...figuration is incorrect error codes 104 106 111 113 or 211 the actual value output jumps back and forth at 1Hz between the voltage value that corresponds to this error and the end of the scale 10VDC i e 300 C or 500 C If the START signal is activated in one of these states the voltage value does not change any more Selective fault detection and indication can thus be implemented simply and inexpen...

Page 47: ...er Replace controller Cause I R signal missing U R signal missing U R and I R signals missing Temperature step down Temperature step up Temperature too low high section 8 3 9 Frequency fluctuation inadmissible line frequency Heatup time too long section 8 3 10 Starting temperature too high section 9 12 Int faut contr defective Triac defective Int faut contr defective Int faut contr defective Int f...

Page 48: ...mer Fault area Run AUTOCAL and or fault area loose contact Run AUTOCAL Cause I R signals incorrect incorrect specification of impulse transformer U R signals incorrect incorrect specification of impulse transformer U R and or I R signals incorrect incorrect specification of impulse transformer Temperature too low AUTOCAL wasn t per formed loose contact ambient temp fluctuates temperature too high ...

Page 49: ... check configuration Fault area check configuration Fault area check configuration Cause I R signal incorrect calibration not possible U R signal incorrect calibration not possible U R and I R signals incorrect calibration not possible Temperature fluctuates calibration not possible Ext calibration temperature too high Ext calibration temperature fluctuates STATUS of alarm relay factory set Warnin...

Page 50: ...pickoff point Wire break Secondary winding of impulse transformer interrupted UR signal missing Measuring wire interrupted Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heatsealing band break Contacting to heatsealing band defective Total short circuit Heatsealing band installed incorr...

Page 51: ...tion 0s Configuration menu No 201 Language German This selection is NOT changed if the factory settings are restored with step 202 in the Config menu No 203 Alloy 1700ppm No 204 Temperature range max 300 C No 206 Maximum temperature 300 C No 207 Set point reached 10K No 208 Set point exceeded 10K No 209 Time control OFF No 210 Cooling mode Absolute No 212 Relay K1 function Active when temperature ...

Page 52: ...er in this way 3 Restore customer settings Selecting this option restores the customer set tings that were saved as described in 2 When the controller is first delivered the customer settings are identical to the Ropex settings After pressing the ENTER key in this menu step you are asked to confirm the new settings safety query Another message appears if you now confirm these settings by pressing ...

Page 53: ...e controller and the required modifications optional in all orders e g UPT 640 L 400VAC MOD 01 controller for 400VAC power supply with amplifier for low voltage Art No 664013 800001 must be ordered Current transformer PEX W3 Art No 885105 Line filter LF 480 06 Continuous current 6A 480VAC Art No 885500 35 Continuous current 35A 480VAC Art No 885506 Impulse transformer See ROPEX Application Report ...

Page 54: ...3 Display brightness 37 E Error messages 46 External switching amplifier 7 16 F Factory settings 18 51 Fahrenheit F 36 Fault areas 50 Front cover 8 Fuse 13 H HEAT 22 33 Heating element 3 4 21 Heatsealing band type 9 Heatsealing time 40 Heatup timeout 20 Hold mode 35 I Impulse transformer 3 7 13 53 Installation 10 12 L Line filter 3 7 13 14 53 Line frequency 9 Line voltage 9 Locking the HAND key 36...

Page 55: ...perature meter 7 31 53 Temperature OK 9 Temperature OK signal 9 Temperature range 9 18 Temperature setting 30 Temperature unit 36 Time control 18 Timer function 18 33 Transformer 3 7 13 53 Type of construction 9 U Undervoltage detection 37 V View of controller 17 Visualization software 38 W Wiring 12 13 Wiring diagram 15 16 ...

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Ropex CIRUS UPT-640, Operating Instructions Manual

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