Ropex CIRUS UPT-6012, Operating Instructions Manual

Page 1: ...mplete control via EtherCAT interface1 2 x RJ 45 Automatic zeroing AUTOCAL Automatic configuration of the secondary voltage and current range AUTORANGE Automatic frequency adaptation Booster output standard Analogue output 0 10 VDC for ACTUAL temperature Alarm function with error diagnosis Heating element alloy and temperature range can be selected Cooling system monitored Wide voltage range for t...

Page 2: ...evice 15 7 2 Device configuration 15 7 3 Heating element 17 7 4 Commissioning rules 18 8 Device functions 19 8 1 LEDs and controls 19 8 2 EtherCAT communication 20 8 3 EtherCAT Slave Information ESI 21 8 4 Communication protocol 21 8 5 Input data 22 8 6 Output data 24 8 7 Object dictionary 28 8 8 Integrated web server 38 8 9 Undervoltage detection 42 8 10 Temperature meter actual value output 43 8...

Page 3: ...d 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 t...

Page 4: ...ion 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 th...

Page 5: ...om 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 an...

Page 6: ...nstructions 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 heatin...

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

Page 8: ...urement cable see How to order on page 56 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 9: ...ve 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 CIR...

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

Page 12: ...te 12 UPT 6012 Version 2 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 13: ...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 6012 ...

Page 14: ...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 6012 ...

Page 15: ...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 47 If the secondary current I2 is less than 30 A the secondary high current wire must be laid twice or several times th...

Page 16: ...AT network to a value between 0x0000 and 0x00FF A new setting does not take effect until the next time the controller is switched on The preset Device ID of the UPT 6012 is configured as follows depending on the settings of the rotary coding switches rotary coding switch Device ID 00 FF 0x0000 0x00FF 0 5 1 2 3 4 6 7 8 9 AUX CONFIGURATION ALARM OUTPUT ENERGIZED AT ALARM DE ENERGIZED SWITCH POS 4 0 ...

Page 17: ...ller 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 measuring errors 7 3 2 Repla...

Page 18: ... The green ECAT_RUN LED lights up to indicate an active EtherCAT communication 7 One of the following states then appears 8 Activate the AUTOCAL function while the heating element is still cold by setting the AC bit AUTOCAL in the EtherCAT protocol section 8 4 Communication protocol on page 21 The yellow AUTOCAL LED lights up for the duration of the calibration process approx 10 15 s The AA bit AU...

Page 19: ... 6012 ECAT ERROR red LED ECAT RUN BUS POWER 24V POWER green LED green LED green LED Lit or blinking to indicate EtherCAT network errors Lit as long as there are no communication errors Lit if external 24VDC power supply is present Lit if internal power supply for EtherCAT interface is OK 12 13 14 1516 17 18 9 8 6 5 10 11 7 4 3 2 1 OUT IN L A L A Vis ua l OUTPUT HEAT ALARM ECAT ERROR ECAT RUN BUS P...

Page 20: ...ge again and setting the RS bit section 8 5 3 Reset RS on page 23 You can easily process the error code that appears if the line voltage is switched off or suppress switching of the alarm relay in the PLC program LED Blinks slowly 1 Hz Blinks fast 4 Hz Lit continuously AUTOCAL yellow RS bit set reset AUTOCAL requested but function blocked e g START active AUTOCAL executing LED blinks at a differen...

Page 21: ...of 2x16 bit input words and 3x16 bit output words from the point of view of the controller This protocol separates the set point and the actual value of the UPT 6012 from the status infor mation and the control functions to simplify decoding by the EtherCAT master 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 co...

Page 22: ... AUTOCAL request AC bit 1 is executed by the controller provided the AUTOCAL function is not blocked The automatic calibration takes around 10 15 seconds The heating element is not heated during this period The yellow LED on the front panel lights up while the AUTOCAL function is executing and the controller shows AUTOCAL active AA bit 1 in the output data The actual value output terminals 17 18 c...

Page 23: ...alue output changes to 0 3 C i e approximately 0 VDC and the SA bit is set in order to set the RS bit The AUTOCAL function is not cancelled if the RS bit is set while it is executing The controller performs an internal initialization lasting approximately 500 ms after the RS bit is reset The next heatsealing process cannot be started until it has finished If a Kb contactor is used to deactivate th...

Page 24: ...nnel assign ment they can be changed at any time simply by selecting the appropriate channel If the application does not require any format changes the channel can remain set to 0 In this case the temper ature controller behaves in exactly the same way as older models where different calibration data records are not supported It is possible to switch to another channel during the AUTOCAL function ...

Page 25: ...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 control mode 3 Active when Tact Tset with latch function A heatsealing cycle starts when the ...

Page 26: ...nterruptions occur during the 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 8 6 12 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 fau...

Page 27: ...12 Seite 27 8 6 13 Error codes If a fault is signalled AL bit 1 you can determine the exact cause with the help of the error code The error code is contained in the third word at bit positions 0 9 section 8 19 Error messages on page 47 ...

Page 28: ...e RO 0 0 6 255 UINT8 10F3 03 Newest Acknowledged Message RW 0 0 6 255 UINT8 10F3 04 New Messages Available RO 0 0 false 1 true BOOL 10F3 05 Flags RW 0 UINT32 10F8 Timestamp Object RO 0 UINT32 1600 00 RxPDO RO 9 UINT8 1600 01 SubIndex 001 RO 0x20000110 UINT32 1600 02 SubIndex 002 RO 0x20000201 UINT32 1600 03 SubIndex 003 RO 0x20000301 UINT32 1600 04 SubIndex 004 RO 0x20000401 UINT32 1600 05 SubInde...

Page 29: ...T8 1C00 02 SubIndex 002 RO 2 UINT8 1C00 03 SubIndex 003 RO 3 UINT8 1C00 04 SubIndex 004 RO 4 UINT8 1C00 05 SubIndex 005 RO 0 UINT8 1C00 06 SubIndex 006 RO 0 UINT8 1C00 07 SubIndex 007 RO 0 UINT8 1C00 08 SubIndex 008 RO 0 UINT8 1C12 00 SyncManager 2 PDO Assignement RO 1 UINT8 1C12 01 SubIndex 001 RO 0x1600 UINT16 1C13 00 SyncManager 3 PDO Assignement RO 1 UINT8 1C13 01 SubIndex 001 RO 0x1A00 UINT16...

Page 30: ...e RO 0 0 999 UINT16 3000 0F Start temperature RO 99 99 999 INT16 4000 Alloy Temperature range RW 10 0 4 9 10 11 8 7 1 UINT8 4001 Lower temperature limit RW 10K 3 99 K UINT8 4002 Upper temperature limit RW 10K 3 99 K UINT8 4003 00 Calibration temperature 1 vari able RO 8 UINT8 4003 01 SubIndex 001 RW 20 C 1 0 40 C INT8 4003 02 SubIndex 002 RW 20 C 1 0 40 C INT8 4003 03 SubIndex 003 RW 20 C 1 0 40 C...

Page 31: ...T16 400A 00 Temperature coefficient RO 8 UINT8 400A 01 SubIndex 001 RW 1700 ppm K 400 4000 ppm K UINT16 400A 02 SubIndex 002 RW 1700 ppm K 400 4000 ppm K UINT16 400A 03 SubIndex 003 RW 1700 ppm K 400 4000 ppm K UINT16 400A 04 SubIndex 004 RW 1700 ppm K 400 4000 ppm K UINT16 400A 05 SubIndex 005 RW 1700 ppm K 400 4000 ppm K UINT16 400A 06 SubIndex 006 RW 1700 ppm K 400 4000 ppm K UINT16 400A 07 Sub...

Page 32: ...32 4305 03 SubIndex 003 RW 0 0 999999999 UINT32 4305 04 SubIndex 004 RW 0 0 999999999 UINT32 4305 05 SubIndex 005 RW 0 0 999999999 UINT32 4305 06 SubIndex 006 RW 0 0 999999999 UINT32 4305 07 SubIndex 007 RW 0 0 999999999 UINT32 4305 08 SubIndex 008 RW 0 0 999999999 UINT32 4306 00 Calibration deviation RO UINT8 4306 01 SubIndex 001 RW 0 10000 10000 100 00 100 00 INT16 4306 02 SubIndex 002 RW 0 1000...

Page 33: ... 0 6553 5mΩ UINT16 4308 07 SubIndex 007 RO 0 0 65535 0 6553 5mΩ UINT16 4308 08 SubIndex 008 RO 0 0 65535 0 6553 5mΩ UINT16 4309 00 Initial calibration resistance RO 8 UINT8 4309 01 SubIndex 001 RO 0 0 65535 0 6553 5mΩ UINT16 4309 02 SubIndex 002 RO 0 0 65535 0 6553 5mΩ UINT16 4309 03 SubIndex 003 RO 0 0 65535 0 6553 5mΩ UINT16 4309 04 SubIndex 005 RO 0 0 65535 0 6553 5mΩ UINT16 4309 05 SubIndex 00...

Page 34: ...d during operation In this case the cali bration temperature 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 AU...

Page 35: ...actor with this parameter Proceed as follows to determine the optimum correction factor Co 1 Controller settings Set temperature 160 180 C Sealing time 0 20 0 30 s 2 Heating impulses ST bit 1 Proceed as described in section 8 5 2 Start ST on page 23 Slowly increase the correction factor starting either with the lowest value 50 or with the value recommended in the ROPEX Application Report minus 25 ...

Page 36: ... checks whether the actual temperature is within a settable tolerance band OK window either side of the set tempera ture The high and low tolerance limits are the same as for the Temperature OK function TO bit section 8 6 6 Temperature OK TO on page 25 The limits are set to 10 K and 10 K by default If the ACTUAL temperature is inside the specified tolerance band when the START signal is activated ...

Page 37: ...efault setting heatup timeout off 8 7 12 Hold mode The ACTUAL temperature output via the EtherCAT protocol can be configured in the parameter data ESI file as follows 1 Off factory setting The ACTUAL temperature is always output in real time 2 On The ACTUAL temperature that was valid at the end of the last heatsealing phase is output When the controller is switched on the real ACTUAL temperature i...

Page 38: ...sion 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 c...

Page 39: ...e This 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 22 are shown in the left hand column the outputs section 8 6 Output data on page 24 in the middle column and the current status of all device LEDs section 8 1 LEDs and controls on page 19 in the right hand column 8 8 3 Paramete...

Page 40: ...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 47 Each error code is explained in a tooltip when you hover over it briefly The data can also be ex...

Page 41: ...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 42: ...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 53 If the 24 VDC supply voltage drops below the permitted lo...

Page 43: ...pending on the device configuration The relationship between the change in the output voltage and the ACTUAL temperature is linear UPT 6012 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 44: ...og output is used to display a selective error message section 8 19 Error mes sages on page 47 8 11 Booster connection The UPT 6012 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 45: ... for error messages and AUTOCAL To simplify error diagnoses during operation the UPT 6012 controller has a data memory for error messages section 8 19 Error messages on page 47 and executed AUTOCAL functions section 8 5 1 Automatic zero calibration AUTOCAL AC on page 22 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 46: ...ever 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 ident...

Page 47: ...eset until the RS bit is reset Invalid error 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 Diagnosis history object ...

Page 48: ...rea 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 10 308 309 310 201 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 11 Perform...

Page 49: ...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 50: ...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 51: ... 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 52: ...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 53: ... VDC supply voltage Terminals 5 7 24 VDC Imax 200mA Tolerance 10 SELV or PELV 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 EtherCAT interface 2 Ethernet switch ports RJ45 Wiring IEC 61784 5 3 Data transfer rate 100 MHz Data transport layer Ethernet II IEEE 802 3 Addressing...

Page 54: ...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 55: ...wide range of heatsealing applications One modification MOD is available for the CIRUS temperature controller UPT 6012 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 56: ...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 57: ...er Version 2 UPT 6012 Seite 57 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 58: ...te 45 Degree of protection 54 Dimensions 55 Disposal 5 E Error code format 35 Error diagnosis 7 Error messages 47 External switching amplifier 14 F Factory settings 52 Fault 24 Fault areas 51 Fuse 10 H Heating element 3 17 Heating element type 53 Heatup timeout 37 I Impulse transformer 3 10 56 Input data 22 Installation 8 54 Installation procedure 8 Installation regulations 9 L Line filter 4 10 11...

Page 59: ...s 44 System monitoring 46 T TCR 17 TE bit 25 Temperature achieved 25 Temperature coefficient 17 Temperature diagnosis 36 37 Temperature meter 44 56 Temperature OK 25 Temperature range 16 53 Thermal impulse process 5 Time 45 Timestamp 45 TO bit 25 Transformer 3 10 56 Transportation 5 Type of construction 53 U UL file 54 USB interface 44 V View of the device 15 Visualization software 44 W Web server...