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Dimensions

Version 1

UPT-6006

Page 57

Dimensions

Modifications (MODs)

The CIRUS

temperature controller UPT-6006 is suitable for very many sealing applications due to its universal

design.
A device modification (MOD) is available for the CIRUS

temperature controller UPT-6006 to implement special

applications.
The modifications must be ordered separately.

MOD 01

Supplemental booster for small secondary voltages (U

= 0.2…60 VAC). This modification is necessary for very

short or low-resistance heating elements, for example.

75.0

90.0

Содержание CIRUS UPT-6006

Страница 1: ...the temperature of the heating element Important features PROFIBUS DP interface for complete regulator control 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...

Страница 2: ...ew 15 7 2 Device configuration 15 7 3 Heating element 17 7 4 Commissioning rules 18 8 Device functions 19 8 1 Display and operating elements 19 8 2 PROFIBUS communication 20 8 3 Device master data file GSD 20 8 4 PROFIBUS protocol 21 8 5 Input data 25 8 6 Output data 28 8 7 Parameter data 31 8 8 DPV1 protocol expansions 39 8 9 Undervoltage detection 44 8 10 Temperature display actual value output ...

Страница 3: ... 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 observed In case of non observance or use contrary to...

Страница 4: ...on report lists the suitable line filter which can be ordered accordingly 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 as well as the separate documentation enclosed with the...

Страница 5: ...m 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 electrical and...

Страница 6: ...structions 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...

Страница 7: ...ternal system heating element wiring etc and the internal electronics A differentiated error message is output through the PROFIBUS interface in case of malfunction To increase operational security and immunity to interference all PROFIBUS signals from the controller and heating circuit are electrically isolated Adjustment for different heating element alloys and setting of the temperature range t...

Страница 8: ...rement cable see How to order on page 58 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 600...

Страница 9: ... 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 CIRUS...

Страница 10: ...es 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 du...

Страница 11: ...n 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 10 must be observed Example drawing for LF 06480 ...

Страница 12: ...ge 12 UPT 6006 Version 1 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 ...

Страница 13: ... P24 GND pwr supply M24 5 PROFIBUS controller electrically isolated 11 9 10 8 4 3 2 1 15 16 R IR UR Current transformer twisted Impulse transformer Heating element LINE Line filter BOOSTER OUTPUT sec U2 prim U1 ALARM OUTPUT max 30 V 0 2 A Ground Must be groun ded externally to prevent electrostatic charging 18 17 C ATR _ ANALOG OUTPUT 0 10 VDC 14 13 12 6 V V 24 VDC POWER SUPPLY ...

Страница 14: ...r supply M24 5 PROFIBUS controller electrically isolated 11 9 10 8 4 3 2 1 15 16 R IR UR Current transformer twisted Impulse transformer LINE Line filter sec U2 prim U1 ALARM OUTPUT max 30 V 0 2 A Ground Must be groun ded externally to prevent electrostatic charging 18 17 C ATR _ ANALOG OUTPUT 0 10 VDC 14 13 12 6 Booster 2 4 IN OUT 1 3 twisted Max length 1 m NC NC V V 24 VDC POWER SUPPLY Heating e...

Страница 15: ...L is carried out Configuration takes place in the voltage range of 0 4 VAC to 120 VAC and in the current range from 30 A to 500 A If voltage and or current is outside the allowed range a detailed error message is output by the controller see section 8 19 Error messages on page 49 For secondary currents I2 less than 30 A the secondary high current line must be guided 2 times or several times throug...

Страница 16: ...o 00 is set on the rotary coding switches and the 24 VDC power supply of the UPT 6006 is switched off and back on again the stored address assigned through SSA is erased and the controller uses the set station address In switch set ting 00 the standard address is then 126 again With the help of address setting via the rotary coding switch it is possible to carry out a device change in an existing ...

Страница 17: ...r TCR is used the controller must be calibrated for it The CIRUS temperature controller is suitable for temperature coefficients in the range 400 4000 ppm K The base resistance of the heating element increases continuously during operation owing to the design The AUTOCAL function must therefore be run again approximately every 100 000 heat sealing cycles in order to prevent ACTUAL temperature meas...

Страница 18: ... USB interface for visualisation software ROPEXvisual on page 46 The con troller s configuration must be checked to avoid malfunctions before continuing with commissioning 7 The green DATA EXCHANGE LED lights up when the PROFIBUS communication is active 8 The following statuses can then result 9 With a cold heating element activate the AUTOCAL function by setting the AC bit AUTOCAL in the PROFIBUS...

Страница 19: ...related tolerances of the heating element are compensated 8 Device functions See also section 6 6 Connection diagram standard on page 13 8 1 Display and operating elements yellow LED OUTPUT HEAT green LED AUTOCAL ALARM yellow LED red LED Indicates pulses in measurement mode In control mode luminous intensity is proportional to heating current Lit while AUTOCAL process is executing Lit or blinking ...

Страница 20: ...ter to be designed interpret the content of the GSD files of the slaves and generate from them a master parameter set for the PROFIBUS master which performs the user data traffic The file ROxy07EA GSD xy GSD version e g 30 for version v3 0 of the UPT 6006 contains all information about the controller necessary for design e g the possible baud rates parameter descriptions alarm messages etc The GSD...

Страница 21: ...or output data complete 2x16 bit for input and 4x16 bit for output data The protocol is determined during project design by selection of the corresponding module compact expanded or complete The compact protocol enables efficient communication with the UPT 6006 In the expanded pro tocol the setpoint and actual value of the UPT 6006 are separated from the status information and control func tions s...

Страница 22: ...cture 8 4 3 Expanded protocol with 4 bit error number In the expanded protocol 2x16 bits are transmitted The 2x16 bit input data contain the setpoint value in the word and the control functions in the word Error no with AL 1 Status information Actual value compact with AL 0 Name AA AG AL TE TO RA VZ A3 A2 A1 A0 Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Control function Reserve Setpoint value AC...

Страница 23: ...lue in the word and the error number and status information in the word Actual value with prefix Name VZ Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Reserve Error no Reserve Status information Name 0 0 0 0 A3 A2 A1 A0 0 0 AA AG AL TE TO RA Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Reserve Setpoint value AC temperature Name 0 0 0 0 0 0 0 Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Reserve Chan...

Страница 24: ...the word and the control functions in the word Reserve Setpoint value AC temperature Name 0 0 0 0 0 0 0 Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Reserve Channel Reserve Control function Name 0 0 0 0 0 CH2 CH1 CH0 0 0 0 MA MP RS ST AC Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Actual value with prefix Name Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Reserve Channel Status information Name 0 ...

Страница 25: ...re on page 33 If no parameter data are transmitted from the PROFIBUS master the standard value is 20 C With some PROFIBUS masters the parameter data cannot be changed during operation Adjustment of the cali bration data to the current ambient conditions in the machines is therefore not possible The calibration temperature with the appropriate setting in the parameter data section 8 7 4 Variable ca...

Страница 26: ...L function is not executed in case of an activated RESET bit RS bit 1 5 Directly after the controller is switched on the AUTOCAL function cannot be performed if the error numbers 101 103 201 203 9xx appear section 8 19 Error messages on page 49 If the controller worked cor rectly at least once after being switched on the AUTOCAL function is not possible if the error numbers 201 203 9xx appeared If...

Страница 27: ... the controller is immediately active again no initialisation phase is run through After the controller is switched on the MP bit is not evaluated by the controller until the system check incl function check of the heating circuit has been successfully completed This can take several 100 ms 8 5 6 Master AUTOCAL MA Setting of this control bit starts the calibration process just as in section 8 5 2 ...

Страница 28: ... active or the heating element is still in the cooling off phase 8 6 3 Alarm active AL If the AL bit is set an alarm was triggered and not reset yet The error number provides information about the exact cause of the error section 8 19 Error messages on page 49 8 6 4 Warning active WA This bit can be set in addition to the AL bit If the WA bit is set a warning is output to indicate the current faul...

Страница 29: ...cle latch function see Image b The switching status of the TO bit can thus be queried after resetting of the ST bit and before the start of the next sealing cycle The TO bit can only be set over the parameter data in the PROFIBUS master also over DPV1 Setting over the ROPEX visualisation software is not possible The tolerance limits can be set up to max 99 K 8 6 7 Regulation active RA The UPT 6006...

Страница 30: ...st start temperature This is the temperature measured directly before execution of the start com mand ST bit 1 This measurement value can be used to evaluate the cooling The value is valid only during the heating phase ST bit 1 Outside of this phase the value 99 C is output with which it can be differentiated whether or not the value is valid The value range lies between 20 C and 500 C 8 6 14 Erro...

Страница 31: ...erved 4 Temperature range alloy 10 0 4 9 10 11 5 Lower threshold for temperature OK 10 K 3 99 K 6 Upper threshold for temperature OK 10 K 3 99 K 7 Calibration temperature 20 C 1 0 40 C 8 Heating time limit 100 ms units 0 0 99 0 9 9 s 9 Expanded device diagnosis Activated Deactivated Activated 10 Measurement impulse duration 17 17 30 1 7 3 0 ms 11 Data format High Low Byte Intel High Low Byte Intel...

Страница 32: ...ure channel 4 20 C 1 0 40 C 41 Correction factor channel4 100 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 channel5 100 25 200 46 47 Temperature coefficient channel 5 1700 ppm K 400 4000 ppm K 48 Calibration temperature channel 6 20 C 1 0 40 C 49 Correction factor channel 6 100 25 200 50 51 Temperat...

Страница 33: ...machines is therefore not possible The calibration temperature can therefore be released for setting through the input data by specifying the value 1 in the parameter data Specification of the calibration temperature is then made through the input data Setpoint AC temperature section 8 5 2 AUTOCAL autom zeroing AC on page 25 After a change of the calibration temperature the AUTOCAL function must b...

Страница 34: ...ent impulse beyond the standard 1 7ms 8 7 8 Data format The format of the cyclically replaced process data section 8 4 PROFIBUS protocol on page 21 can be changed Depending on the type of PROFIBUS master used it may be necessary to switch the high byte bits 15 8 and low byte bits 7 0 against each other For Siemens controllers the setting Low high byte Motorola is recommended 8 7 9 Error number for...

Страница 35: ... idea is to prevent the UPT sealing bar from being destroyed The maximum value of the setting range is limited by the specified maximum value and the set temperature range Both values are selected in the parameter data The range of this value is defined by the maximum temperature or the selected temperature range Both values are available in the parameter data GSD file or in the DPV1 protocol expa...

Страница 36: ...ile or through the DPV1 protocol expansion After the lower tolerance band limit is exceeded the temperature diagnosis is switched on only after the parameterised delay time has expired As a result the temperature diagnosis can be intentionally suppressed such as during a temperature drop caused by closing the tool The lower and upper tolerance band limits cannot be set through the ROPEX visualisat...

Страница 37: ...rent at the end of the last sealing phase is output After the con troller is switched on the real ACTUAL temperature is displayed until the end of the first heating phase 3 2 sec This causes the current ACTUAL temperature to be output over the PROFIBUS protocol for an additional 2 seconds at the end of a sealing phase Then the ACTUAL temperature is output in real time until the end of the next sea...

Страница 38: ...t be made in the parameter data section 8 7 Parameter data on page 31 or through the DPV1 protocol expansion section 8 8 DPV1 protocol expansions on page 39 Standard set ting Hold mode off ACTUAL temperature ST bit 1 T t t 0 0 Hold off T t 0 ACTUAL indication Hold on T t 0 Hold 2 s T t 0 Hold Hold Hold Hold End of heatsealing phase 2 s 2 s ...

Страница 39: ...vated or activated for SFM1 The grey coloured data correspond to the standard diagnosis the black data depict the expanded diagnosis data DPV0 mode Expanded device diagnosis active Coming 08 0C 00 00 06 13 06 81 00 D1 67 00 Going 00 0C 00 00 06 13 06 81 00 DA 00 00 Expanded device diagnosis SFM Coming 08 0C 00 00 06 13 06 81 00 C1 67 00 06 81 00 00 67 00 Going 00 0C 00 00 06 13 06 81 00 CA 00 00 0...

Страница 40: ...ocol expansion DPV1 parameter table of the UPT 6006 Standard values are printed in bold italics Slot Index Parameter Range of values 0 255 I M functions Article number serial number ver sion numbers manufacturer ID 0 0 Cyclic data section 8 4 PROFIBUS protocol on page 21 1 4 Alloy range 0 1700 ppm K 300 C 4 1700 ppm K 500 C 9 PC configuration 10 Rotary encoder switch 11 variable 1 5 Lower temperat...

Страница 41: ... 1 400 4000 ppm K 1700 1 32 Calibration temperature channel 2 1 0 40 C 20 1 33 Correction factor channel 2 25 200 100 1 34 35 Temperature coefficient channel 2 400 4000 ppm K 1700 1 36 Calibration temperature channel 3 1 0 40 C 20 1 37 Correction factor channel 3 25 200 100 1 38 39 Temperature coefficient channel 3 400 4000 ppm K 1700 1 40 Calibration temperature channel 4 1 0 40 C 20 1 41 Correct...

Страница 42: ...ernal real time clock read access always delivers whole multi ples of 1000 When writing parts of 1000 are ignored 0 59000 1 102 Time Minutes 0 59 1 103 Time Hours 0 23 1 104 Date Days day of the week not sup ported in the upper 3 bits 1 31 1 105 Date Month 1 12 1 106 Date Year 0 99 1 107 110 Operating hours 0 1 h 0 999999999 0 99999999 9 h 1 111 114 Not resettable total cycles counter 0 999999999 ...

Страница 43: ...0 1 212 213 Calibration data deviation 0 01 channel 6 10000 10000 0 100 00 100 00 1 214 215 Calibration data deviation 0 01 channel 7 10000 10000 0 100 00 100 00 1 216 Conductor through current transformer 1 9 1 1 217 218 Calibration resistance 0 1 mΩ channel 0 0 65535 0 0 6553 5 mΩ 1 219 220 Calibration resistance 0 1 mΩ channel 1 0 65535 0 0 6553 5 mΩ 1 221 222 Calibration resistance 0 1 mΩ chan...

Страница 44: ...he SA bit is set in the status word for the cyclic output data Trouble free operation of the controller is only guaranteed within the specified tolerance range of the input voltage An external voltage monitor must be connected to prevent low line or 24 VDC supply voltage from resulting in defective heatseals 1 237 238 Initial calibration resistance 0 1 mΩ channel 2 0 65535 0 0 6553 5 mΩ 1 239 240 ...

Страница 45: ...lation between the change in the output voltage and the ACTUAL temperature is linear A display instrument can be attached to this output for visualisation of the heating element temperature UPT 6006 Actual value output 0 10 VDC 18 17 0 V Temperature meter e g ATR 3 0 10 VDC max 5 mA 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 ...

Страница 46: ...6 has a connection for an external switching amplifier booster as standard This connec tion at the terminals 15 16 is required at high primary currents constant current 5 A impulse current 25 A The switching amplifier must be connected in accordance with section 6 7 Connection diagram with booster con nection on page 14 The connection line to the external switching amplifier must not exceed a leng...

Страница 47: ...d AUTOCAL To make error diagnosis easier in ongoing operation the controller UPT 6006 has data storage for error messages section 8 19 Error messages on page 49 and executed AUTOCAL procedures section 8 5 2 AUTOCAL autom zeroing AC on page 25 The last 400 messages are stored These can be read out and displayed with the ROPEX visualisation software section 8 12 USB interface for visualisation softw...

Страница 48: ...tput To increase operational safety and avoid incorrect sealing this controller has hardware and software measures for differentiated error messages and diagnosis Both the outer wiring and the internal system are monitored thereby This feature helps the operator considerably in localising a defective operating status A system malfunction is reported or differentiated through the following elements...

Страница 49: ...higher level controller e g PLC to avoid false alarms 8 19 Error messages Besides the error diagnosis coded in the protocol the PROFIBUS diagnosis expanded device diagnosis can also be accessed The error numbers appear as plain text in the project design tool as they are stored in the GSD file The following table shows the assignment of the output error numbers to the errors that occur In addition...

Страница 50: ...r ranges 4 107 2 66 Temperature jump down ward Error ranges Loose connection Error ranges Loose connection 108 Temperature jump upward 307 Temperature too low high chap 8 7 12 308 309 310 5 201 3 33 Network frequency missing fluctuates Check network Check network 202 Network frequency too large fluctuates 203 Network frequency too small fluctuates 6 304 4 00 Heat up time too long chap 8 7 13 Perfo...

Страница 51: ... Measure if machine in operation heating ele ment not changed 8 104 5 33 10 Current signal incorrect Impulse transformer incor rectly sized Perform AUTOCAL Check transformer speci fication Error ranges Error ranges Loose connection 105 Voltage signal incorrect Impulse transformer incor rectly sized 106 Voltage and current signal incorrect Impulse transformer incor rectly sized 302 Temperature too ...

Страница 52: ...configuration Error ranges Loose connection 11 112 7 33 10 Voltage signal incorrect Calibration not possible Error range Check configuration Error ranges Loose connection 12 113 8 00 10 Voltage current signal incor rect Calibration not possible Error ranges Check configuration Error ranges Loose connection 13 114 8 66 10 Temperature fluctuates Calibration not possible Perform AUTOCAL and or Error ...

Страница 53: ...ckup point Wire break Primary coil of the impulse transformer interrupted UR signal missing Measurement line interrupted Partial short circuit Delta R Heating element is partially bridged through a conducting part hold down device safety rail etc Interruption of the parallel circuit Wire break heating element break Contacting at the heating element defective Complete short circuit Heating element ...

Страница 54: ...coder switch Position 0 Slide switch for Alarm relay Alarm relay active in case of alarm Rotary encoder switch for Station address Station address 01dec Temperature diag nosis X Temperature diagnosis deactivated Heat up time moni toring X Heat up time monitoring deactivated Malfunc tion range Explanations Possible causes 0 5 1 2 3 4 6 7 8 9 AUX CONFIGURATION ALARM OUTPUT ENERGIZED AT ALARM DE ENER...

Страница 55: ... frequency 47 63 Hz automatic frequency adjustment in this range Current consumption Primary current of the impulse transformer Imax 5 A ED 100 Imax 25 A ED 20 duration of play 1 min 24 VDC power supply Terminal 5 7 or PROFIBUS plug pin 2 7 24 VDC Imax 100 mA Tolerance 10 SELV or PELV supplied from maximum 300 VAC Cat II The 24 VDC power supply can be supplied via terminal 5 and 7 or via the PROFI...

Страница 56: ...14 Umax 30 V DC AC Imax 0 2 A changeover contact voltage free Power loss Max 20 W Ambient conditions Maximum altitude 2000 m Ambient temperature 5 45 C Maximum relative humidity 80 at temperatures up to 31 C decreasing line arly to 50 relative humidity at 45 C Degree of protection IP 20 Mounting If several devices are mounted on a hat rail a min imum distance of 20 mm must be maintained When mount...

Страница 57: ... its universal design A device modification MOD is available for the CIRUS temperature controller UPT 6006 to implement special applications The modifications must be ordered separately MOD 01 Supplemental booster for small secondary voltages UR 0 2 60 VAC This modification is necessary for very short or low resistance heating elements for example 75 0 90 0 113 0 135 0 ...

Страница 58: ...1 Current transformer 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 ...

Страница 59: ...der Version 1 UPT 6006 Page 59 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 ...

Страница 60: ...diagnosis 34 Device view 15 Dimensions 57 Disposal 5 DPV1 protocol expansion 39 E Error diagnosis 7 Error messages 49 Error number format 31 34 Error ranges 53 Expanded device diagnosis 34 External switching amplifier 14 F Factory settings 54 Fuse 10 G GSD file 20 H Heating element 3 17 Heating element type 56 Heat up time monitoring 36 High altitude 56 Humidity 56 I Impulse transformer 3 10 58 In...

Страница 61: ...placing the heating element 17 Reset 26 ROPEXvisual 46 RS bit 27 S Setpoint 28 Standby mode 44 Start 26 START bit 18 Start temperature 35 System diagnosis 46 System monitoring 48 T TCR 17 TE bit 28 Temperature coefficient 17 Temperature diagnosis 35 36 Temperature display 45 46 58 Temperature OK 28 Temperature range 16 56 Temperature reached 28 Thermal impulse process 5 Time 47 Time stamp 47 TO Bi...

Страница 62: ...Index Page 62 UPT 6006 Version 1 ...

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