Ropex CIRUS UPT-640 User manual

CIRUS
Industrie-Elektronik GmbH TelТел: +49/(0)7142/7776-0 E-MailЭл. почта: [email protected]
Gansäcker 21 FaxФакс: +49/(0)7142/7776-211 InternetИнтернет: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany)(Германия)(Alemania) Data subject to changeПраво на
5.12.13
UPT-640
(as of SW 100)
GB
The UPT-640 temperature controller is a key component in an ULTRA-PULSE system, because it
is responsible for all heat management functions, i.e. controlling the temperature of the heating
element and ensuring that this highly dynamic impulse heatsealing method is accurately timed.
Important features
• Microprocessor technology
• LC display (green), 4 lines, 20 characters, (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 programmable parameters
• Configurable relay output, e.g. "end of cycle"
• Time or temperature-controlled cooling phase
• Signal output for "Temperature OK"
• 0…10VDC analog input for set point selection, electrically isolated
• 0…10VDC analog output for ACTUAL temperature, electrically isolated
• 24VDC control inputs for START, AUTOCAL, RELEASE and RESET, electrically isolated
• Alarm function with fault diagnosis
• Cooling system monitored
Operating
Instructions

2 UPT-640 (as of SW 100)
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heating element . . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Standards / CE marking . . . . . . . . . . . 4
1.7 Warranty provisions . . . . . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 System description . . . . . . . . . . . . . . . . . . . 5
3.1 Temperature controller . . . . . . . . . . . . 5
3.2 Current transformer PEX-W2/-W3 . . . . 6
3.3 Booster . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Accessories and modifications . . . . . . . . . 7
4.1 Accessories . . . . . . . . . . . . . . . . . . . . . 7
4.2 Modifications (MODs) . . . . . . . . . . . . . 8
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
6 Dimensions/front panel cutout . . . . . . . . . 11
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.1 Installation steps . . . . . . . . . . . . . . . . 12
7.2 Installation procedure . . . . . . . . . . . . 12
7.3 Power supply . . . . . . . . . . . . . . . . . . . 13
7.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 14
7.5 Current transformer PEX-W3 . . . . . . 14
7.6 Wiring diagram (standard) . . . . . . . . . 15
7.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 16
8 Startup and operation . . . . . . . . . . . . . . . . 17
8.1 Front view of the controller . . . . . . . . 17
8.2 Rear view of the controller . . . . . . . . . 17
8.3 Controller configuration . . . . . . . . . . . 18
8.4 Heating element . . . . . . . . . . . . . . . . 21
8.5 Startup procedure . . . . . . . . . . . . . . . 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 Co . . . . . . . . . . . . . 34
9.12 Maximum starting temperature . . . . . 35
9.13 Cycle counter . . . . . . . . . . . . . . . . . . . 35
9.14 Hold mode . . . . . . . . . . . . . . . . . . . . . 35
9.15 Measuring impulse duration . . . . . . . 36
9.16 Locking the "HAND" key . . . . . . . . . . 36
9.17 Temperature unit
Celsius / Fahrenheit
(as of software revision 103) . . . . . . . 36
9.18 Disabling the Configuration menu . . . 37
9.19 Setting the display brightness
(VF display only) . . . . . . . . . . . . . . . . 37
9.20 Undervoltage detection . . . . . . . . . . . 37
9.21 Diagnostic interface/visualization
software . . . . . . . . . . . . . . . . . . . . . . . 38
9.22 Booster connection . . . . . . . . . . . . . . 38
9.23 Time control (timer function) . . . . . . . 38
9.24 Release impulse . . . . . . . . . . . . . . . . 44
9.25 System monitoring/alarm output . . . . 46
9.26 Error messages . . . . . . . . . . . . . . . . . 46
9.27 Fault areas and causes . . . . . . . . . . . 50
10 Factory settings . . . . . . . . . . . . . . . . . . . . . 51
10.1 Customer settings . . . . . . . . . . . . . . . 52
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 52
12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 53
13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Safety and warning notes
UPT-640 (as of SW 100) 3
1 Safety and warning notes
This CIRUS temperature controller is manufactured
according to DIN EN 61010-1. In the course of its
manufacture it passed through quality assurance,
whereby it was subjected to extensive inspections and
tests.
It left the factory in perfect condition.
The recommendations and warning notes contained in
these operating instructions must be complied with, in
order to guarantee safe operation.
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational
safety. Installation and maintenance may only be
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
1.1 Use
CIRUS temperature controllers may only be used for
heating and temperature control of heatsealing
elements which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance or use contrary to
the intended purpose, there is a risk that
safety will be impaired or that the heatsealing
element, electrical wiring, transformer etc. will
overheat. Ensuring such compliance is the
personal responsibility of the user.
1.2 Heating element
The temperature coefficient of a CIRUS temperature
controller is specially adapted to CIRUS heating ele-
ments.
The controller is not allowed to be operated
with any other heatsealing bands because
they could be overheated and damaged beyond
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 installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.
Incorrect installation of the impulse
transformer impairs electrical safety.
1.4 Current transformer PEX-W2/-W3
The current transformer supplied with the CIRUS
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2 or PEX-W3
current transformer may be used. Other
transformers may cause the equipment to
malfunction.
The current transformer may only be operated if it is
connected to the CIRUS temperature controller
correctly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
"Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
operating safety. They are not included in the scope of
supply of the standard control system and are
described in a separate document.
1.5 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.6 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
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Application
4 UPT-640 (as of SW 100)
1.6 Standards / CE marking
The controller described here complies with the
following standards, provisions and directives:
Compliance with these standards and provisions is only
guaranteed if original accessories and/or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
1.7 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, 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 CIRUS temperature controller is an integral part of
the "series 600". Its sole purpose is to control the tem-
perature of CIRUS/UPT heating elements, which are
used mainly for impulse-heatsealing PP and PE films.
The most important applications are packaging
machines, pouch-making machines, splicers,
machines for making pharmaceutical and medical pro-
ducts etc.
DIN EN 61010-1:2001
(2006/95/EG)
Safety requirements for electrical
equipment for measurement,
control and laboratory use
(low-voltage directive):
pollution degree 2,
protection class II,
measurement category I
(for URand IRterminals)
DIN EN 60204-1
(2006/42/EG)
Electrical equipment of
machines (machinery directive)
EN 55011:1998 + A1:1999 +
A2:2002
EN 61000-3-2:2006-04
EN 61000-3-3:1995-01 +
A1:2001 + A2:2005-11
(2004/108/EG)
EMC genery emissions:
Group 1, Class A
EN 61000-6-2:2005
(2004/108/EG)
EMC generic immunity:
Class A (ESDs, RF radiation,
bursts, surges)
Exception:
Line voltage interruption acc.
EN 61000-4-11 is not fulfilled
(This leads to a designated error
message of the controller)

System description
UPT-640 (as of SW 100) 5
3 System description
The basic design of the overall system is shown in the
diagram above.
CIRUS heating elements, and in particular UPT heating
elements, are high-performance systems which ope-
rate efficiently and reliably providing all the components
in the control loop are optimally tuned to one another –
and to the task at hand. Exact compliance with the
installation and wiring instructions 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, 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 rate (= line frequency), compares it with the
set point and – if the difference is not 0 – adjusts the
heating current with the help of a phase angle-con-
trolled transformer so that set = actual.
The fact that purely electrical variables are measured in
quick succession and the small mass of the heating

System description
6 UPT-640 (as of SW 100)
layer of the UPT heating element together result in a
highly dynamic, thermo-electrical control loop.
Thanks to its microprocessor based technology, the
controller features an optimized control algorithm as
well as numerous functions tailored to the various
tasks, such as "AUTOCAL", TIMER functions,
RELEASE IMPULSE, ALARM with fault diagnosis etc.
These are described in detail below.
An easy-to-read, 4-line, multilingual display visualizes
all parameters, measured values and states. The con-
troller can also interact with external controllers (PLC,
IPC etc.) via the analog INPUTS and OUTPUTS.
The UPT-640 (as of 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 original ROPEX
current transformer is allowed to be used.
Never attempt to operate the current transformer with
open connections!
3.3 Booster
If the maximum load exceeds the rated current of the
controller (section 5 "Technical data" on page 9), an
external switching amplifier (booster) must be used
(section 4.1 "Accessories" on page 7).
The other system components – UPT sealing bars,
transformers, filter, cooler etc. – are described in sepa-
rate brochures.

Accessories and modifications
UPT-640 (as of SW 100) 7
4 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the CIRUS temperature con-
troller UPT-640 (as of SW 100). They allow it to be opti-
mally adapted to your specific heatsealing application
and to your plant's design and operating philosophy.
4.1 Accessories
The products described below are only a few of the
wide range of accessories available for CIRUS tempe-
rature controllers ("Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35).
Analog indication of the ACTUAL temperature of the heatsealing band in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
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-section bobbin.
Optimized for impulse operation with CIRUS temperature controllers.
Specified according to the heatsealing application
(ROPEX Application Report).
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL tempe-
ratures in real time.
Booster B-xxx400
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).

Accessories and modifications
8 UPT-640 (as of SW 100)
4.2 Modifications (MODs)
Owing to its universal design, the CIRUS temperature
controller UPT-640 (as of SW 100) is suitable for a very
wide range of heatsealing applications.
One modification (MOD) is available for the CIRUS
temperature controller UPT-640 (as of SW 100) for
implementing special applications.
MOD 01
Amplifier for low secondary voltages
(UR= 0.25…16VAC). This modification is necessary,
for example, for very short or low-resistance heating
elements.
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard 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 electrical cabinet, for
instance, where it is only accessible to authorized persons.
Lockable door TUER-S/K-1
Transparent door (with lock) for mounting on the bezel of the controller. The display
is clearly legible at all times. The keyboard can only be operated, however, by autho-
rized persons in possession of a key.
Measurement cable UML-1
Twisted measurement cable for the URvoltage measurement.
Trailing cable, halogen and silicone-free.

Technical data
UPT-640 (as of SW 100) 9
5 Technical data
Type of construction Housing for front panel mounting
Dimensions (W x H): 144 x 72mm; depth: 161mm (incl. terminals)
Line voltage 400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
depending on device version (Kap. 12 „How to order“ auf Seite 53)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
typeandtemperature
range
The temperature range and temperature coefficient can be set independently of
one another in the Configuration menu:
Temperature range: 200°C, 300°C,
400°C, 500°C (as of SW revision 102)
Temperature coefficient: 400…4000ppm (variable setting range)
Set point selection/
analog input
Terminals 20+23
Via the Settings menu in the controller or the electrically isolated analog input:
Input resistance: 40kohms, reverse polarity-protected
0…10VDC, equivalent to 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, Imax =5mA
Switching output
for „"Output 1"/
Temp. OK" signal
Terminals 20+21
Umax = 30VDC, Imax =50mA
UON < 2V (saturation voltage)
Transistor conductive if the temperature is inside the tolerance band.
Alarm relay
Terminals 5+6
Contact, potential-free, Umax = 30V (DC/AC), Imax =0.2A
Relay K1
Terminals 16, 17, 18
Changeover contact, potential-free, Umax = 240VAC/100VDC, Imax =1.5A
Interference suppression with 47nF / 560ohms for each terminal
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power dissipation max. 25W
Display LC display (green), 4 lines, 20 characters, alternatively:
VF display (blue), 4 lines, 20 characters
Ambient temperature +5…+45°C

Technical data
10 UPT-640 (as of SW 100)
Degree of protection Front: IP42 (IP65 with transparent front cover, Art. No. 887000)
Back: IP20
Installation Installed in front panel cutout with (W x H) 138(+-0.2) x68
(+-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…2.5mm² (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.
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