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1. Be Mode Toos Options Hap sie of alala 5 pee p Expected Applied Read rst Applied gt Sel Applied on E 0 3 a a HT 20 a 4 1000 a Gi D T Y T 0 z Eu T f mor T S al al ail ms 2 a z 4 v T a 7 4 230 H a vu T k T Y T 0 S Eu T ST 1000 T 7 v H D 7 Z 230 H 1000 T amp T 0 T 0 L G T SIT 100 T Ala lee 10 T D 7 ol 10 EJ a A0 i000 0 TE T Y T 0 n Eu T ae soo T 0 T H T C T TRT T OoOo e El mli pre Connection Firmware Hardware status version version Check that the NS IRS is well connected and that the firmware version is the right one List of firmware versions according to the model and usage Model Use Firmware Hardware NS IRS Standard 5 18 20 NS IRS SDL 20 16 101 IRS 12 Standard 5 18 20 See SUPERVISOR Users manual for information about firmware upgrade and product configuration 35 OLICORP IRS SERIES 07 02 2013 Step 5 Automation strategy for 20 X Programs Voltage regulation mode The automation strategy describes the different possible solutions to control the power system with the PLC o Starting the regulation oven on off o Sending the power settings for the oven o Treating the data from the NS IRS alarms
2. LED ON OFF 1 Profibus DP running No datagram exchange 2 MPU running MPU error firmware 3 400 V ON 400 V OFF 4 24 VDC on 24 VDC off 56
3. Model Rth C W NS IRS with cooling option 0 17 NS IRS Standard with no cooling option 0 28 Maximum internal temperature Electronics systems usually run at temperatures ranging from 70 to 85 for digital electronics and higher for power electronics The limiting elements in the NS IRS are the electromechanical breakers used to protect the cables from the NS IRS to the ovens This limit is 70C for the breaker used in the NS IRS Running conditions Model Power loss Rth Temp Rise Max temp Max temp Max outside At 30 kW On breaker On heatsink temp NS IRS 55 0 28 15 4 70 70 54 NS IRS Fan 55 0 17 9 4 70 70 60 The maximum temperature outside given in the previous table is valid if the mechanical integration of the system in the machine is done in good conditions By good conditions we mean that the system must be installed in a non confined volume to allow natural convection to occur conditions should be performed If the box is enclosed in a cabinet or a closed volume some additional test in real 24 OLICORP IRS SERIES 07 02 2013 PART 3 USING THE NS IRS in 6 STEPS 25 OLICORP IRS SERIES 07 02 2013 Step 0 Machine cabling The following scheme describes the usual architecture of the electrical supply in the machine for the IRS and NS IRS systems GO Main switch of the machine d 4 T 24V 24V SE a5
4. PLC Digital Digital d d d 24V mcu Input output ya i Breaker 4 D Contactor b 24V G D O Hier by q PWRorIRS PWR orlRS PWRorIRS Oven up to 10 Lamps Oven up to 10 Lamps Oven up to 10 Lamps www olicorp ch 26 OLICORP IRS SERIES 07 02 2013 Advised circuitry and cabling for NS IRS OTN N N BREAKER 4 POLES SIEMENS SVL 1708 1EA43 0ABt IEC or 3 VL 1108 1KM30 OAB1 UL CSA 25 KA short circut breaking CONTACTOR 4 POLES SIEMENS SIRIUS 3 RT 1346 18840 Step 1 Product Identification The product identification is located inside the NS IRS cabinet on the outer side of the door oUcon CE 1207 Geneva Switzerland G waw olicorp ch 4 b C us RS 10 Serial _ Date Software Version Power controler for IR ovens Single Phase 360 500 VAC 65 47 63Hz 10 channels with max 7 5 A channel Serial number of the NS IRS WARNING MORE THAN ONE LIVE CIRCUIT Soe Diagram and manufacturing date AVERTISSEMENT CET EQUIPEMENT REN Necessary for any technical FERME PLUSIEURS CIRCUITS SOUS TENSION Voir le sch ma support co ntact WARNING SEPARATE OVERCURRENT PROTEC TIONS IS REQUIRED TO BE PROVIDED IN AC CORDANCE WITH THE NATIONAL ELECTRICAL CODES Factory firmw
5. FLASH MEMORY serial number ramps settings Fast Logic OverLoad protection FIRMWARE Controls regulation MICRO KERNEL Controls Communications PF Controls the programs DP Serial execution and the memory Can be updated Permanent regulation mode zero setting SP camimunication mode RAM MEMORY or Power settings Lamps characteristics IRS a We To a e z 515751219 bjr Ea 21 a T R s 5 2 Z g S ZIS 3 e a E 2 Z le g 2 Q e ll amp OL STEP7 Step 7 module to facilitate the PWR integration PLC automation Sends the settings for each lamp in Watts Read the lamps resistances and process the alarm messages Starts and stops the regulation this program is maintened by the customers volatil To ensure the maximal flexibility the different programs used with the NS IRS are distributed between The NS IRS itself to retain recurrent settings or store special algorithms The machine s PLC that starts stops the regulation and sends the desired settings A PC or LapTop that can be used for maintenance purpose 12 OLICORP IRS SERIES 07 02 2013 PC based software SUPERVISOR This program is used to connect a PC to a single NS IRS using a serial or USB link The program is used to test the NS IRS to monitor the status of the regulator and to upgrad
6. 10 OLICORP IRS SERIES 07 02 2013 Stainless steel X X Static cooling X X Fan Cooling Option Option Single hardware X X configuration for both regulation modes Phase angle Advanced single cycle Adjustable ramps for lamps pre warming Power regulation VamsXlinst Sel X X Sel Se Voltage regulation V RMS Overload and surge protection X gt lt x KKK Dead lamp detection X Temperature survey X Turns off the regulation if Tinside gt 70 C Power supply survey Yes and an alarm is sent if the power to the lamp is not reached GSD 2 0 2 0 Min power lamp 10 10 Max power lamp Nom Nom Serial control X X USB control X Bluetooth control Option Datalog Option Update firmware soft X X Upgrade features X X soft POWER PLUG Fast plug terminator HAN1 00A from HARTING OVEN PLUG Fast plug terminator HAN32 from HARTING 24 DC PROFIBUS DP Ecofast from HARTING 11 OLICORP IRS SERIES 07 02 2013 Software architecture IBM Compatible SUPERVISOR Serial communication based controller resistances and alerts Used also to upgrade the firmware and to write specific settings in the flash memory Can send regulation settings to the IRS and read
7. 0 0 I SETTING _Setal D o Seal 43 OLICORP IRS SERIES 07 02 2013 2 ett El PWR24 Hardware Settings Regulation Identification Current Configuration New Configuration Hardware Version 12 Update Running Mode Running Mode m od e MainMaxVolts g17 V 700 900 V G Single Cycle Single Cycle MainMaxAmps 1212 S 4 10 20 4 C Phase Angle fs ID TEST SUPERVISOR J Fr D Aka From Setting for Broken Lamp Broken Lamp Resistan ce of SrvVoltages Nominal Powers pacen 200 gt Factor 200 gt lam ps New New Tick 16 Tick 16 il 1 CG Burst Firing Burst Firing D t ti n 7 0 Lj Threshold 100 Threshold 100 e ec 10 2 E 0 Lo Power 50 W Power 50 W settin g for th e Z mo broken lamp 5 Sir C s sr C 7 Am mm 2 a Warm up 3 710 a setting o C 49 HL 49 _Setall_ 0 Set All Set All Firmware update The latest versions of the firmware are available on our web site from the download section From the update window you can select the desired firmware olc file and transfer it to the NS NS IRS It takes about 10 sec to transfer the olc file to the NS IRS The NS IRS must be rebooted once the installation is finished Firmware Update Firmware Update Source File Source File DAIRS IAS10 Dossier technique IRSTO Logiciels68KIR Select DAIASWIAS10 Dossier technique IRSTONLogiciels E8R IR Select PW
8. OLICORP IRS SERIES 07 02 2013 Longueur donn es 1011 12 Output M gt S Unit Word H Coh rence sur donn es compl tes OxEB 11101011 PITTI ts Longueur donn es 1011 12 Output M gt S Unit Word Coh rence sur donn es compl tes IRS_PWR_STD12_SHORT INPUT 5 WORDS OUTPUT 13 WORDS OxD4 OxEO OXxEB OxD4 11010100 Pl Itt Data Length 0100 pe SS Input Slave gt Master Type Word Coherent check Data Length 0000 Output M gt S Type Word Coherent check OxEB 11101011 L 1 1 Data Length 1011 12 Output M gt S Type Word Coherent check 49 OLICORP IRS SERIES 07 02 2013 Input Datagram S gt M 5 words Command Reserved P not Ok BL Sqr Vrms 0 1 2 3 4 5 6 7 Byte 0 Command byte content bit Meaning 1 Reserved 10 Reserved 100 Reserved 1000 1 Alarm Overload Read Only 0 Normal state 10000 1 Regulation ON ON Command acknowledge 0 Regulation OFF 100000 1 Alarm CutOut Breaker Read Only 0 Normal state 1000000 1 Alarm OverHeat Read Only 0 Normal state 10000000 1 Alarm SectorDefault Read Only 0 Normal state Byte 2 and 3 P not Ok byte content 1 bit per lamp The bit is turned to 1 when
9. Procedure Turn main power on Use the Calibrate Voltage button to calibrate the voltage according to the supplied voltage Vrms expected CrtMM 844 Expected 0 Offset 0 m heoritical value of Offset when no load I Offset Inst Set Offset No current in Sensor Step 1 Turn power on Oven Off Tune the Offset to get Inst 0 10 m U Inst Read Offset Step 2 Turn power and 24DC off Replace black and green wires on CNT by a 10k resistor Current should be set at 3000 m If using 5k current will be 6000 m Turn 24 DC and then Power on Do current calibration connecteur LEM carte mpu 1 AC power on set the Offset Expected the way is to obtain linst 0 2 Plug the Current Calibrator and enter the value 3000 in inst expected then set Calibrate Current With the current calibrator WO12 1 you have 1 precision 07 02 2013 black red white 15v 15v signal Instead of using the current calibrator you can use a calibrate Arms ampmeter and measure the current through a resistance resistance calibrate ampmeter 46 OLICORP IRS SERIES 07 02 2013 Profibus DP For PROGRAMS 5 X Overview The NS IRS power regulator from OLICORP is a PROFIBUS DP slave which runs accordingly to the Profibus DP specifications defined inthe standards EN 50170 DIN 19245 Part 3 On this type of network
10. By doing that we will obtain even more better results that will allow us to work with higher currents and to suppress the filtering for zero crossing and advanced single cycle regulation Flickering The other negative effect that could occur is the flickering This effect is different from the lamp flickering mentioned earlier in this document Lamps flickering is the variation of luminance of the lamp due to the alternative cooling and warming of the filament when the current is on or off during zero crossing and in a limited way during advanced single cycle The present flickering is related to the variation of power supply voltage due to the variation of the load The power regulation affects in several ways the power supply the total load on the supply when lamps are on will affect the supply voltage This effect depends on the power consumed by the ovens and on the quality strength of the supply This effect is constant along the time and doesn t affect the EM compliance The variation of the load along the time related to the variation of the power settings will also affect the supply voltage and introduce some variations related to the change of the settings This effect is slow usually for the PET process the settings are quite even along time and doesn t affect the EM compliance The regulation itself may affect the supply when many lamps are shut down or started simultaneously in the regulation algorithm
11. the MASTER DEVICES control the data communication on the bus while the SLAVES DEVICES only answer the requests from the masters The master may be A Programmable Logical controller PLCs A PC with a Profibus DP interface The OLICORP NS IRS module has been successfully tested with several masters Siemens PLCs SIMATIC 400 Siemens PLCs SIMATIC 300 B amp R PLCs Omron CJ1M SST profibus master card PC solution with a windows based user interface SST PFB SLC profibus scanner module for Allen Bradley SLC PLCs Procedure to use a NS IRS regulator with a PLC 1 Initialisation The GSD file provided by OLICORP contains a standardized description of the NS IRS regulator which enables the automatic detection of the NS IRS regulator by the master The GSD file olic0594 gsd from our web site should be used Note The name of the GSD must be olic0594 gsd to work properly When downloading the latest version of the gsd from our site please rename it if necessary 2 incoporate the different slaves in the project With the Siemens environment it is simply done by the NS IRS slave from the slave list to the profibus network in the STEP7 programming interface According to the GSD The type of the slave is IRPC12 60 The profibus identification is 0x0594 Two protocols can be selected IRS_PWR_STD12 IRS_PWR_STD12_SHORT The slave ID is set using the ID wheels on the main MPU board Turn off on the 24 DC sup
12. For instance in the zero crossing regulation mode several lamps may be off simultaneously during several periods and induce an effect onto the power supply Moreover in this type of regulation the temperature of the filament will have enough time to cool down With a cooler filament the resistance will fall quickly leading to a huge current at the next active period The NS IRS system are already optimised with respect to these problems First we propose the advanced single cycle mode that ensures an even distribution of the periods to reduce filament cooling effects Secondly our algorithm avoids correlations between the different channels by shifting the off period for each lamp The total load on the supply is thus quite even 23 OLICORP IRS SERIES 07 02 2013 Running conditions and cooling Performances Like any electrical device the NS IRS systems have power losses The power loss in the NS IRS is around 0 15 of the nominal power 30kW P loss IRS 55 W Rth Any thermodynamics system is characterized by its thermal resistance Rth The Rth gives the temperature rise of an isolated system with respect to the outside when a given energy is released in this system T out Power X Watt gt Rth Tin Tin Tout X Rth Exemple If Rth 0 2 C W and the loss in the s ystem is 100 W then Tin Tout 20 The NS IRS has 2 different Rth depending on the usage of the fan cooling option
13. alarm on the NS IRS by turning the regulation off Start regulation again The system should NOT be reset and restarted automatically You MUST check the origin of the problem before starting again the power If not you may o Endanger the technicians working around the machine o Damage the system by applying to much thermal stress onto the components CutOut message The breaker will turn off when more than 32 A is applied to a group of 4 lamps Remark the breaker is C curve breaker Fast transient states with high current will not turn the breaker off Before turning the system on again you have to follow this procedure Take care that the power supply is off no power Check that there is not physical default on the electric circuitry Check the state of breakers inside the cabinet and turn them ON Turn the Power supply on Reset the alarm on the NS IRS by turning the regulation off Start regulation again You MUST check the origin of the problem before starting again the power If not you may o Endanger the technicians working around the machine o Damage the system by applying to much thermal stress onto the components 20 OLICORP IRS SERIES 07 02 2013 Resistance measurement closed loop regulation and dead lamps detection Why do we need to measure the resistance As it has been written in previous sections the lamps resistance is quickly changing according to the temperature of t
14. on Voltage and Current Warm up ramps for tungsten lamps Profibus DP communications Voltage limitation to protect the lamps Online Lamps resistance measurement Power supply quality monitoring Monitoring and recording of power supply variations Installation is simplified by the means of Fast connecting terminators 3 points fixation OLICORP IRS SERIES 07 02 2013 How do the NS IRS systems compare to existing solutions Totally integrated solution The NS IRS system is a complete power cabinet by itself It includes the regulation controller the power regulation stage thyristors and an integrated overload protection all integrated in an IP65 cabinet This concept makes it easy to connect and to mount Maintenance is also greatly facilitated by suppressing complex electrical cabinets by small plug and play single units Closed loop regulation for power regulation Vus Riamps By measuring the current and the voltage as well it is possible to know the exact power sent to the resistive loads Doing this will avoid any power fluctuations due to the resistance spread or to the power supply irregularity On line Load fault detection By measuring the load resistance and the system is able to detect load faults This point is especially important for the blow moulding machines with a large number of lamps Load impedance on line monitoring and recording The system is able to record the changes in the lamps res
15. the Ns IRS can not apply the required power to the given lamp 4 bits reserved V1 V2 V12 Rs1 E Rs4 bitO bit 11 12 15 Byte 4 and 5 BL Dead Lamp byte content 1 bit per lamp The bit is turned to 1 when the NS IRS detects a load fault L1 L2 L12 Rs1 f Rs4 bitO bitt 11 12 15 Byte 6 9 Sqr Vrms byte content Square V rms read by the NS IRS 50 OLICORP IRS SERIES 07 02 2013 Output datagram M gt S 37 Word WORD 1 Byte 0 Command byte content bit Meaning 1 Reserved 10 Reserved 100 Reserved 1000 Not used Read Only 10000 1 Regulation ON 0 Regulation OFF 100000 Not used Read Only 1000000 Not used Read Only 10000000 Not used Read Only WORD 1 Byte 1 NOT USED WORD 2 WORD 13 Power expressed in Watts to be applied to each channel WORD 14 25 Service voltage of the lamps WORD 26 37 Nominal power W of the lamps In version IRSPWR_STD_SHORT the words 14 37 are not used Summary Basic steps to start the regulation STD12 protocol Set the Service voltage for the loads Set the nominal power for the loads Set the desired power for the loads Start the regulation Set the power for other lamps or modify the desired power 00000 51 OLICORP IRS SERIES 07 02 2013 Profibus DP For Programs 20 X Overview T
16. 8 OLICORP IRS SERIES 07 02 2013 Integrated WARM UP ramps As a consequence of the cold lamps low resistance the current at start up may rise quickly leading to an overload gt 200 A if all lamps are turned on simultaneously To solve this problem one a warm up algorithm included in the firmware This feature should be configured according to the lamps used in the oven In Supervisor program it is possible to set 2 parameters Power The Power applied to the lamp during the warm up phase Threshold Duration of the warm up expressed in half Sine cycles Exemple 3 KW 400 VAC lamps Power 3000 W Threshold 200 During 200 half periods 2 seconds at 50Hz the first lamp will be warmed up with 3000 W Then it will switch to the desired power with the standard regulation mode phase angle or adv single cycle and it will start to warm the second lamp with 3000 W during 200 half periods 19 gt gt PE gt gt PE OLICORP IRS SERIES 07 02 2013 Shortcuts and overloads Overload message Whenever the total admitted current goes above 200 A the system will emit an Overload alarm and stop the regulation Before turning the system on again you have to follow this procedure Take care that the power supply is off no power Check that there is not physical default on the electric circuitry Check the state of breakers inside the cabinet and turn them ON Turn the Power supply on Reset the
17. BOM http Avww olicorp ch support Available from HARTING AG www harting com The Pin connection is done as follow Lamp 4 5 6 7 8 9 10 11 12 N eo In 4 5 6 7 8 9 10 11 12 N oo Out 24 25 26 27 28 29 30 31 32 17 18 19 30 OLICORP IRS SERIES 07 02 2013 Load 9 9 32 Load 1 1 24 Load 10 10 17 31 OLICORP IRS SERIES 07 02 2013 DC Power supply and Profibus terminators The 24 VDC 220 350 mA power supply and the Profibus connection come all in a single Harting terminator Each NS IRS has 2 connectors one for input the second to chain to the next device Profibus Profibus Shielding Shielding EJA EE If you need to purchase directly the terminators please use the following BOM http Avww olicorp cl support pdf bom_harting pdf Available from HARTING AG www harting com 32 OLICORP IRS SERIES 07 02 2013 Profibus termination Depending on the position of the NS IRS slave on the bus you will have to set the two jumpers as shown on the following diagram to terminate the bus using the right impedance In that case the wires between the MPU and the remaining unused connector should be unplugged The Jumpers are set The bus is terminated The Jumpers are not set The bus is not terminated As an alternative a bus terminator can be plugged outside of the cabinet In that case the wires m
18. OLICORP IRS SERIES 07 02 2013 IRS POWER CONTROLLER FOR IR OVENS NS IRS TECHNICAL MANUAL V 1 0 OLICORP Montbrillant 26 CH 1201 Geneva Switzerland Phone 41 22 309 15 40 Local support is available Worldwide Check on www olicorp ch OLICORP IRS SERIES 07 02 2013 CE relevant European directiVeS eennnneneneeneenneneneneeneeneenennnnenenns 4 Low Voltage companta rss ta an en nn te M ENEAN ESE E EREE Pat detre ete 4 EMC Complia ne vi 5888 E me eek ae ne eet ie ieee ie ee eee i stades 4 CE Lab l E AE E ee hea E A nd AL tina Gated Pan Ra ne 4 CSA CUS MarkKing 15 55 55 ess ntseter ete rade er en need en mnn ones andvecbaedeeaeteasd edecteeeceo vas 4 Profibus standard compliance sese sevessss esse sese esec rere sees ee seene nenen ennenen nenen eee d Safety and security ASPCCHS cesse sse ss eee cece ee esse eree sneer neee ennenen ennenen nenes 5 SYMONS Shs om ieee en a en ner An UMR UN seau ennui bak egtmeie stank ini 5 DA OLY ET nee EEE CPE ER PE PE Sn A ee tee nA M IE 5 PART 1 DISCOVERING THE NS IRS sssssssssssssssssssssssssssssssssssssssssssessssD What is the NS IRS system 7 sese sees esse eee sees es seene nenen nenen neee 7 The NS IRS is the top of the art solution to control power on IR ovens 7 How do the NS IRS systems compare to existing solutions 8 Totaly integrated Solution tis ci Ge sa
19. PROGRAMS 5 nn YZS Vve Oare rie ria taa R ERRUER RNET 47 OVEIVICW css ren rh rene ev pate nn tue dat caceue dat red d ment dey dat ene dai OA dernier 47 Procedure to use a NS IRS regulator with a PLC 47 Protocol description and datagram format 48 Summary Basic steps to start the regulation STD12 protocol 51 Profibus DP For Programs 20 X nenn nenen nenen ennenen nenen 52 OVE VIEW Sie lent ent ined valde de sr Ariel en 52 Procedure to use a NS IRS regulator with a PLC eee 52 Protocol description and datagram format 54 Summary Basic steps to start the regulation 55 EDS AEA EE A AEE a AES E A E ere tee Ste D Ou Ses eue Demo non SUN S fenetre one 56 OLICORP IRS SERIES 07 02 2013 CE relevant European directives Low Voltage compliance The NS IRS products carry the CE mark in compliance with the essential requirements of the European Low Voltage Directive 73 23 EEC of 19 2 73 amended by the directive 93 68 EEC of 22 7 93 The NS IRS products installed and used in compliance with the procedures described in the present document meet the essential requirements of the European Low Voltage Directive EMC compliance The NS IRS products are compliant with the EMC requirements with respect to the European directives 89 336 EEC of the 05 03 89 amended by the 91 263 EEC 92 31 EEC 93 68 EEC 93 97 EEC The enforce
20. R24 Firmware Source File Firmware PWR24 Firmware Source File Firmware Version 1051 Version 514 Version 514 Version 514 Size 21344 Size 25692 Size 25692 Size 25692 CRC lt H CRC 7101 CRC F 7101 CRC 701 Update 44 OLICORP IRS SERIES 07 02 2013 Calibration To ensure a good process quality the NS IRS calibration have to be check Voltage calibration Use a calibrate VRMS Voltmeter Calibration Interface Measure the voltage between the two phases inside the NS IRS Enter the value and tick Calibrate voltage He a Vrms read and Vrms expected mus be the same Nm Epes enter the l 7 Procedure Turn main power on Use the Calibrate Voltage button to value calibrate the voltage according to the supplied voltage Vrms expected CriMMy 817 Offset 0 m Expected 0 m I Inst 0 m Expected 0 m Theoritical value of Offset when no load 0 I Offset Inst Calibrate Current Step 1 Turn power on Oven Off Tune the Offset to get Inst 0 10 mA I Inst Read Offset Step 2 Turn power and 24DC off Replace black and green wires on CNT by a 10k resistor Current should be set at 3000 m If using 5k current will be 6000 m Turn 24 DC and then Power on Do current calibration 45 OLICORP IRS SERIES Current calibration R Calibration Interface Vims read by IRS PWR Vims Expected Calibrate Voltage
21. RS It takes a few seconds to connect The program has two modes mode menu The monitor mode The control mode The monitor mode is used to monitor the settings of the NS IRS This function can be used once or ina repetitive way pooling In this mode the program returns the power applied to each lamp PWE the resistance measured for each lamp RM the service voltage set for each lamp SRVV the nominal power set for each lamp MAXP the status of the oven On off the measured supply voltage SV Inthe control mode it is possible to control the regulation by sending the different settings to the NS IRS SRVV MAXP PW run on off Beside these standard uses the program is also used to configure the NS IRS or to get factory EL PWEZA He rae Settings re information menu tools gt hardware information HAvsevesin fr C up Running mode Running Mode 817 V 700 900 V fi Single Cycle Single Cycle 1212 x A00 20 A Phase Angle ene version ae F eee Broken Lamp Broken Lamp MainMaxVolts and MainMaxamps are TERE aa ae constants used to tune the NS IRS New New Curent Tick TE Tick ID Serial number Burst Firing Threshold Power Read Write Current configuration for the regulation mode and of the lamps pre warming ramps FACTORY Read only
22. System calibration The calibration is done by OLICORP at factory Starting the regulation To start the regulation the PLC has to send o The desired power of nominal power applied for each lamp Pe o The start stop command Which should be set to Start of course Treating the information back from the NS IRS The PLC has to treat the information coming back from the NS IRS o The supply Voltage SV Volts o The alarms Overload Cutout Overheat Sector default o The lamps states Broken or not for the ones that are ON Stopping the regulation To stop the regulation the PLC has to send o The start stop command Which should be set to Stop of course System Shutdown The main supply must be switched off first Otherwise this step doesn t require any specific action 36 OLICORP IRS SERIES 07 02 2013 Exceptions Exception Effects An alarm is emitted The regulation can be stopped Critical sector default Vsuppy lt 320 V The regulation stops An alarm is sent to the Master The system needs a software reset to restart regulation off and then on again Sector Default Vsupply lt 360 V An alarm is sent to the PLC Dead lamp An alarm is sent to the Master The regulation is stopped on this channel Overload The regulation stops An alarm is sent to gt 200 A the Master The system needs a software reset to restart regulation o
23. are responsible for the flickering effect which occurs because of the lamps temperature fluctuation over the time The flickering has a negative effect on the lamps lifetime as well as on the lighting homogeneity Removing one 1 2 period corresponds to a signal shutdown during 10ms in the load Depending onthe lamps geometry the temperature of the load will fall from a few Kelvins which is enough to cause a small flickering It is thus really important to work with lamps adapted to the process We recommend strongly to choose the lamps with a nominal power close to the expected settings Conclusion By taking into account these different points it appears that the phase angle regulation which keeps an even filament temperature along the time is certainly the best alternative for regulation But as the phase angle affects EMC compliance and induces additional costs related to EMC filtering it can be necessary to use advanced single cycle instead This second way to regulate the power is also efficient when the expected power is close to the lamp s nominal power But when the power is decreasing flickering effects will occur and spoil the spectrum We thus suggest to use it to save money and ensure EMC compliance but we also recommend to adapt the lamps nominal power with respect to the settings that will be applied to these lamps The best results will be achieved if the setting remains over 80 of the nominal power 1
24. are version AVERTISSEMENT LE GIRGUIT DOIT ETRE MUN May have been upgraded D UNE PROTECTION DISTINCTE CONTRE LES SURINTENSITES CONFORMEMENT AU CODE NA by the customer TIONAL DE L ELECTRICITE 27 OLICORP IRS SERIES 07 02 2013 Step 2 Mechanical mounting Mechanical configuration of the NS IRS for integration into machines The following diagram describes the NS IRS mechanical design Mounting points M6 silentblocks required Dimensions Please note that IGES model is available from our Website S 427 55 Attention The NS IRS system must be installed in a non confined place so that natural convection will ensure a sufficient cooling of the system 28 OLICORP IRS SERIES 07 02 2013 OQUICORP 29 OLICORP IRS SERIES 07 02 2013 Step 3 Electrical connections AC Power supply The NS IRS modules are single phase devices They sustain up to 96 amps under 185 530 VAC 47 63 Hz The NS IRS terminators are compatible with HARTING HANAXIAL 100A terminators If you need to purchase directly the terminators please use the following BOM http Avww olicorp ch support Available from HARTING AG www harting com Connection to the Oven The NS IRS modules are using HAN32 terminator from HARTING If you need to purchase directly the terminators please use the following
25. ation of the NS IRS for integration into machines 28 Step 3 Electrical connections nn nsnrnnnsrsssrsneenmennnnenenneneeneennnneeneneeenennnnneenenee 30 AG POWGrSUDPIV EE TS Me E AOE Dune Te de tnt Den TT 30 Connection tO the Oven cick iin er nn Ai a eG AN AR ead 30 DC Power supply and Profibus terminators 32 PrOfbUS T rmMINatION Es nt creck ated nn mr kas beget sated Adee O nb a 33 PROBUS DEEE re RE Re rim eaten cee kt aaa a ati 33 Step 4 Checking the NS IRS configuration ssnnseneeneenennnnseneeneens 34 PROCCOU Re A mirada coh ete Oat E A Seats A a DES 34 List of firmware versions according to the model and usage 35 Step 5 Automation strategy for 20 X Programs Voltage regulation mode 36 System CalibratiON secs Acasa neo diner tite tee tine tentent uate cet 36 Starting the regulation siens 36 Treating the information back from the NS IRS e eee eee e e ee 36 Stopping the regulation sise 36 SYSTEM S NUTdOWN Este lakes cca anaa tiat Tean rea errant tte bee nds rt 36 EGIPT Ea ATE EA E a Ten nt d ee Us eee lien Rs SR 37 Step 5 Automation strategy for 5 X Programs Power regulation mode 38 System CONfIgUrAtiON 25 rss iini nets teens Re dinde dns Rent ane tienne noter tante arte Nan datant Ent 38 System initialisation at start up sise 38 Sta
26. ay stay plugged but the jumpers on the MPU shouldn t be set Profibus ID The Profibus ID is set using the two wheels on the left of the MPU The PROFIBUS_DP address is displayed in a hexadecimal format PFBadar SW1value 16 SW2value Example PFBadar 1 16 5 PFBaddr 21 The addresses between 1 and 125 are available for the slaves NOTE The address is read during the boot So after change to the Profibus address one has to turn off on the 24 DC supply before using it 33 OLICORP IRS SERIES 07 02 2013 Step 4 Checking the NS IRS configuration To do so one has to install the latest version of the SUPERVISOR program onto a PC windows 95 XP and connect to the NS IRS using a null modem cable The SUPERVISOR is available in the support section of our web site http www olicorp ch DB9 connector for the RS232 connection or USB connector for USB connection Procedure 1 Start the SUPERVISOR program 2 Connect a null modem cable or USB cable to the NS IRS 3 Turnthe 24VDC on On the NS IRS the LEDs 2 and 4 must be ON 34 OLICORP IRS SERIES 07 02 2013 6 2 mnm tnt t U veo i fs f mico 7 On the SUPERVISOR The informative Icons should appear on the lower right of the window
27. circuits closure or opening Current Channel i afew volts T 568 V Voltage power supply no filter The phase angle regulation mode is highly affected by the harmonics problem especially when the current is turned on near the top of the phase A Specific EMC filter must be added to ensure EMC compliance Contact our technical support center for more information But the harmonics may have more subtile causes For instance with zero crossing or advanced single cycle a bad synchronisation of the command with the power supply zero will induce some harmonics Even without any error on the localisation of the zero there could be some harmonics due to the thyristors themselves when they are started with a really low signal level This effect is really small but could be increased by correlation effects between the different channels Bad synchronisation of the zero Current Channel i Real Zero fake zero 22 OLICORP IRS SERIES 07 02 2013 Thyristors oscillation at startup 100 us To suppress these effects we have introduced a highly accurate zero detection algorithm which is able to set the zero with 1 us accuracy As it the NS IRS is EMC compliant with the zero crossing and advanced single cycle algorithms for currents ranging from 16 A to 75 A even without any filtering stage Inthe future the thyristors will be replaced by a new type of component that will suppress also the oscillation at startup
28. cknowledge 0 Regulation OFF 1 Alarm CutOut Breaker COUT 0 Normal state _ 1 Alarm OverHeat Se 0 Normal state SCT D 1 Alarm SectorDefault 0 Normal state Byte 1 reserved This byte is not used Byte 2 3 Vrms byte content The supply voltage measured by the NS IRS Byte 4 and 5 Dead Lamps bytes content 1 bit per lamp The bit is turned to 1 when the NS IRS detects a load fault Li iv ys ES het ese kee E Reserved L10 L9 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Byte4 Byte5 54 OLICORP IRS SERIES 07 02 2013 Output datagram M gt S 11 bytes Cmd L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 10 Byte 0 Command byte content Byte 1 10 Settings in Percents to be applied to each channel Reserved ON OFF Reserved 6 4 2 1 Bits Meaning ON OFF 1 Regulation ON 0 Regulation OFF These values should not exceed 100 If it does the setting 100 is applied Summary Basic steps to start the regulation Set the desired power for the loads Start the regulation Set the power for other lamps or modify the desired power 55 OLICORP IRS SERIES 07 02 2013
29. e teeta le Maiti eh PEREA ENANA ARKIT 8 Closed loop regulation for power regulation V pms Rampe eerie p treen sales nids 8 Or line Eoad fault detecto ma 388 8 eit eee nee ae ee A ees 8 Load impedance on line monitoring and recording sss esse eee eee eee eee 8 Mu lti chANnelS 4 enr RE A adaa Rte de Rein te E a L naine 8 Power supply monitoring usines 8 Scalability and modularity sisi 8 Profibus DP Communications sise 8 Multiple regulation algorithms ss 8 Hardware and software versions sese ress ee ress ee renee nesne ennenen nenen 10 K 9 T b VErSIONS Er mit messes re ie a dr teste nee Genre R 10 Software architecture TE 12 PC D sed SONWArE Sirius Nains einen dteas Pence te den nee dion Seeds 13 Blue Tooth communication xs se ee ee eee e ee ee ee e ee 12 PLG ele lT TTT T 12 PART 2 NS IRS SYSTEM FEATURES ssesssssessssssssssssssssssssssssssssssssess 14 Cabling and lamps strategy ss rese sees serene ennenen neee nenen neee 15 NS IRS Absolute maximum ratings 15 REGULATION MODES ES San ne nr nur 16 Phase angle regulation 5e t ee eee bev caked men aa art real 16 Zero crossing and advanced single cycle regulation 17 CONCIUSION 2 a iranien han dire aa choveacencontzadebatubeshenssatdancndaneaciesmadelabebestaueeatlavotdada st 18 Integrated WARM UP ramps ssssesss esse esse cesses resse ress eee sese eenn ennenen nenen enne
30. e the firmware The NS IRS intrinsic settings can also be set using this program More information is given later in this document and in the SUPERVISOR User s manual Blue Tooth communication The NS IRS can be optionally equipped with a Bluetooth dongle allowing to connect to the NS IRS using wireless communications PLC Program This program synchronises the regulation start stop with the machine cycle and sends the power settings Watts to the NS IRS according to the users needs Different communication modes are available over profibus DP and thus different PLC programming strategies can be used More information is given later in this document 13 OLICORP IRS SERIES 07 02 2013 PART 2 NS IRS SYSTEM FEATURES OLICORP IRS SERIES 07 02 2013 Cabling and lamps strategy It is possible to use the NS IRS cabinet with several types of lamps and with different cabling topologies The NS IRS automatically limits the Voltage sent to the lamp according to the type of lamp It is thus possible to use 400 VAC lamps on 480 VAC supply The total current regulated by the power cabinet cannot exceed 65A for NS IRS and 75 A for the IRS12 The total current channel cannot exceed 7 5 A channel for both products The Overload current is set to 200 A NS IRS Absolute maximum ratings The NS IRS is accepting input voltage between 185 VAC and 530 VAC with frequencies ranging between 47 a
31. ff and then on Temperature to high The regulation stops An alarm is sent to the Master Software treatment of the exception Profibus down The regulation is stopped and will start oE again when the Profibus DP will be back Z S 24 VDC down Should never happen when main supply is on The regulation stops PLC failure If the Profibus watchdog is not affected No treatment the NS IRS cannot see it The regulation goes on 24 VDC starts after the HV supply Should never happen Non deterministic It can damage the electronics The current in one channel is higher than 10 A continuously but the total current remains below 200 A We cannot detect that After a while the related thyristor will be damaged 37 OLICORP IRS SERIES 07 02 2013 Step 5 Automation strategy for 5 X Programs Power regulation mode The automation strategy describes the different possible solutions to control the power system with the PLC o Starting the regulation oven on off o Sending the power settings for the oven o Treating the data from the NS IRS alarms measured resistances System configuration Before doing anything with the NS IRS regulator it will be necessary to configure the basic functions of the device Regulation mode Phase angle advanced single cycle Ramps Validation of the integrated ramping function to warm the lamps Turning on or off the resistance mea
32. ground to avoid any electrical discharge that could damage either device RS232 DB9 connector To connect the cable you have to open the cabinet and then to plug to the female connector onto the MPU card Pay attention to push softly when you plug the connector If necessary the cable can be connected disconnected while the MPU is on 24 VDC on Installing the software The SUPERVISOR is available from our Website Once unzipped run the setup exe program to install it onto you Windows system Configuring the software There is only one thing to configure You have to choose in the option gt Com Port menu the COM Port which connects the PC to the NS IRS 42 OLICORP IRS SERIES 07 02 2013 Using the software The SUPERVISOR interface looks like the following figure E OLICORP IRS PWR SUPERVISOR VERSION 10 3 File Mode Tools Options Help RIRI Power Lamps Configuration Settings SRVVoltage and PNOM Command Panel Expected Settings S a Applied d J a Ss has a l 2 el o 400 o oj le LL JU oj a o 3 a D amp aL m N N S S S re gt 4 TOUNIN UTU UTU UTU ER i SDL Release Ba Fw v10 51 Hw v101 The connection status is summarized on the lower right part of the window Once started the program tries to connect to the NS I
33. he NS IRS power regulator from OLICORP is a PROFIBUS DP slave which runs accordingly to the Profibus DP specifications defined in the standards EN 50170 DIN 19245 Part 3 The Profibus DP certification is pending On this type of network the MASTER DEVICES control the data communication on the bus while the Slaves devices only answer the requests from the masters The master may be A Programmable Logical controller PLCs A PC with a Profibus DP interface The OLICORP NS IRS module is a Profibus slave that has been successfully tested with several masters Siemens PLCs SIMATIC 400 Siemens PLCs SIMATIC 300 SST profibus master card PC solution with a windows based user interface SST PFB SLC profibus scanner module for Allen Bradley SLC PLCs Procedure to use a NS IRS regulator with a PLC 4 Initialisation The GSD file provided by OLICORP contains a standardized description of the NS IRS regulator which enables the automatic configuration of the NS IRS regulator by the master The GSD file olic0594 gsd from our web site should be used Note The name of the GSD must be olic0594 gsd to work properly When downloading the latest version of the GSD from our site please rename it if necessary 5 Incorporate the different slaves in the project With the Siemens environment it is simply done by the NS IRS slave from the slave list to the Profibus network in the STEP7 programming interface Accord
34. he filament This temperature will strongly be related to the RMS voltage applied to the lamp For a more accurate process it is necessary to account for these variation in the regulation What is done by the NS IRS The purpose of the NS IRS is to regulate power The NS IRS measures continuously both the voltage and the current applied to the different lamps From this measurement the NS IRS calculates the RMS Voltage that should be sent to the lamps with the purpose to control accurately the RMS Power dissipated in the lamps From the instantaneous Current and Voltage it is possible to compute the instantaneous value of the resistance for each lamp Inthe standard implementation of the NS IRS software this value is transmitted to the Profibus DP for further monitoring It is also possible to use only the nominal resistance of the lamps in the power regulation algorithm To do so one has to select the Use Rnom option when configuring the NS IRS internal settings PC supervisor setting 21 OLICORP IRS SERIES 07 02 2013 EMC compliance Harmonics and Flicker standards As from Jan 1st 2001 compliance with the Harmonics and Flicker standards becomes a mandatory part of the EMC Directive This applies to all products within the scope of these standards For rated currents from 16A to 75A per phase IEC EN61000 3 4 applies Harmonics The Harmonics are generated by brutal changes in the current shape due to
35. he regulation algorithms section Zero crossing and advanced single cycle regulation In this mode the regulation is done by removing an entire number of half periods evenly distributed onto a 1s period 100 half periods The commutation of the thyristors is synchronous with the power to avoid EMC perturbations The regulation accuracy is over 1 The lamps may flicker Basic description of the algorithm The regulation is done using two quantities o Pis period Integrated power during 2 period o LX400 P period Energy in the latest 100 periods Using these two quantities the number of periods to be removed within the next 100 periods is calculated The X100 P period gives the global number of periods to be removed while the PD period IS Used to correct low frequencies fluctuation of the input signal The removed half period are distributed evenly to smooth the temperature variation of the filament along the time IN V SIGNAL After Signal shaping Measurement of R for a given channel OUT I SIGNAL f fV LV NA SIGNAL REMOVED 17 OLICORP IRS SERIES 07 02 2013 Applications The accuracy of the advanced single cycle is poor compared to the phase angle regulation It can hardly be better than 1 However this accuracy is good enough for the basic PET process The main problems are related to the removal of several successive half periods These holes
36. ing to the GSD The type of the slave is IRPC12 60 The Profibus identification is 0x0594 The length of users parameters is 5 bytes but are not used No extended diagnostic is used The length of data exchange datagrams is e 6 bytes IN Slave gt Master e 11 bytes OUT Master gt Slave The slave ID is set using the ID wheels on the main MPU board Turn off on the 24 DC supply to reload the new address 52 OLICORP IRS SERIES 07 02 2013 At this point the Profibus DP network should be initialised and should work correctly The master is starting to exchange empty datagrams with the NS IRS slaves If this exchange is successful the Profibus LED onto the MPU card turns to green 6 Start communication by sending commands and receiving data to from the NS IRS Then the communication is done through simple datagram exchanges between the master and the slaves 53 OLICORP IRS SERIES 07 02 2013 Protocol description and datagram format e Input Datagram S gt M 6 bytes Command Reserved Vrms Dead Lamps 0 1 2 3 4 5 Byte 0 Command byte content SCT_D OVRHT C_OUT ON OFF OVRL OUT_R Reserved 7 6 5 4 3 2 1 0 Bits Meaning 1 Notif Sector Out of Range OUT_R Sector lt 360Vrms 0 Normal state 1 Alarm Overload Electronic OVRL Breaker 0 Normal state 1 Regulation ON ON ON OFF Command a
37. istance This information may be used to survey the aging of the lamp Multi channels The NS IRS controls up to 10 channels IRS12 Models are available for 12 channels regulation Power supply monitoring Inthe 2013 version of the NS IRS the electrical characteristics of the power supply are monitored to record the variations on the Voltage and current to detect transient signals and abnormal events Scalability and modularity The NS IRS system is designed to be mount directly onto the machine nearby the oven This concept is thus highly modular Profibus DP Communications The NS IRS modules are certified Profibus DP slaves and can both receive settings and send alerts from to the PLCs connected to this field bus Multiple regulation algorithms The NS IRS system currently supports phase angle zero crossing and advanced single cycle OLICORP IRS SERIES 07 02 2013 380 500 V 50 60 HZ NS IRS brings a total control on the heating process gt Power and voltage regulation e Closed loop on supply voltage e Closed loop on lamps resistance e Lamps controlled individually e Lamps resistance monitoring e logging of changes in the lamps resistance to ease the determination of their lifetime e Fast detection of dead lamps e deterministic overload protection e Running from 185 up to 530 VAC e Possibility t
38. k Z S 24 VDC down Should never happen when main supply is on The regulation stops PLC failure If the Profibus watch dog is not affected the NS IRS can not see it The regulation goes on 24 VDC starts after the HV supply Should never happen Non deterministic It can damage the electronics The current in one channel is higher than 7 5 A continuously but the total current remains below 200 A We can not detect that After a while the thyristor will be damaged 1 Available only with fw2 45 and gt Prior to this firmware the regulation was stopped 40 OLICORP IRS SERIES 07 02 2013 Part 4 Technical complements 41 OLICORP IRS SERIES 07 02 2013 RS232 and USB connection Firmware update and NS IRS serial control Overview The RS232 connection is used for maintenance purpose To use the RS232 connection you need a null modem cable with an RS232 DB9 male connector on the IRS side and the OL PWR24COM program The USB connexion is available with CPU board with version higher than WE4 4 To connect to the NS IRS simply plug an USB cable between the PC and CPU While connected it will be possible to o control the regulation for test purpose o upload download the firmware o set the NS IRS main parameters Hardware connection When connecting the computer to the NS IRS module through the serial link you have to pay attention to have both devices wired to the same
39. lf period This method is accurate and one can achieve a precision of less than 0 3 I SIGNAL REMOVED be controlled with an accuracy of 1 us A filter must be integrated into the NS IRS cabinet for the EMC compliance Benefits from phase angle regulation 00000 High accuracy The 6 angle can Almost no variation of the temperature of the filament along the time Possibility to run with European and American power supplies indifferently Possibility to run with 220 400 and 480 VAC lamps indifferently Possibility to use 220 V lamps onto 400 and 480 supplies and 400 V lamps onto 480 V supplies Problems related to phase angle regulation 16 OLICORP IRS SERIES 07 02 2013 The main problem related to phase angle regulation is the EMC compliance For small systems the use of a dedicated EM filter ensures the compliance with EMC standard Above 200kW when using several NS IRS modules we have to consider also the machine design For instance a machine with poorly shielded cables from the regulators to the ovens may cause pick up and correlated effects that could spoil the EM characteristics of the machine A new type of power stage is actually tested It uses a microsecond shifting algorithm between the different systems to reduce the correlated effects and ensure a fully E M compliance up to the MW even for poorly shielded machines More information is available in the EMC section and in t
40. ment of this directive is done by standards EN60204 EN50081 2 and EN50081 3 EM compliance has been certified by an approved EMC testing laboratory Certificates are available upon request More details about EM compliance are given later in this document CE Label By fulfilling the requirements of the Low voltage and EMC regulations the NS IRS products are compliant with the CE directives CSA CUS Marking The NS IRS products CSA UL compliance has been investigated by the CSA laboratories in Toronto Canada May 2007 File number 1871799 Profibus standard compliance The NS IRS carries the Profibus DP compliance label and is listed by the PNO organization under reference IRPC1012 with id number 0594Hex gt Pe BP OLICORP IRS SERIES 07 02 2013 Safety and security aspects Symbols This symbol means that failure to take note of the information given in this manual may have serious consequences for the safety of the personnel or may result in electrocution This symbol means that failure to take note of the information given in this manual may have serious consequences for the installation lead to incorrect operation of the product or may damage the product Safety The installation configuration commissioning and maintenance of the NS IRS products must only be carried out by personnel qualified and trained to work with low voltage electrical equipment in an industrial environment The front door sho
41. nd 63 Hz Power supply Voltage VAC 10 Lamp Nominal Voltage Vrms 208 230 980 ss 400 Green Maximal power W for lamps for a given Power supply voltage and lamp nominal voltage The minimal setting per channel is 10 of the nominal power of the lamp in power regulation mode This limit is set to avoid current bursts with tungsten lamps as the Resistance of the lamp may slightly decrease when running at low power 15 OLICOR P IRS SERIES 07 02 2013 REGULATION MODES Phase angle regulation The phase angle regulation relies on a powerful algorithm that monitors both the voltage and the current going through each load and then calculate the power dissipated in these loads By knowing this exact power the system is able to evaluate the ratio of the signal which should be removed to reach the targeted power in the lamps Moreover this online monitoring of the current and voltage is used to compute the exact resistance of the lamps and then to detect dead lamps The phase angle is defined as 6 which is the delay while the circuit must remain opened for each half period The greater 0 is the less energy remains in the signal IN V SIGNAL After Signal shaping APAAMNADAA Measurem for a given channel entof R OUT I SIGNAL For each half period the current i is analysed to compute the 8 angle for the next ha
42. nen 19 Shortcuts and Overloads T 20 Overload MOSS AGES itia esmori raa aa ds eocdusahendend gecovss seed levels EEAO EEEa a Ea akaa 20 Ie 0161 iue e T E EEA E TAA E E T 20 Resistance measurement closed loop regulation and dead lamps detection 21 Why do we need to measure the resistance 7 21 What iis done by the NSIR Z ci csrs s deetseehcote sada mn woesnecha oteuade coves detre ee lente ae 21 EMC compliance 5 Mrs sine nn is vantveds cececies a aena aSa 22 Harmonics and Flicker standards 22 FIARMONICS hrs H 1 691202257 ated den RTS Yayla aa Yada 232 La avia yR Ray Laan a Re alaa n yag 22 22 ST Ta TTT TTT TT 23 Running conditions and cooling ss ee cesses rese ee neee nenen nen eee 24 Performances ire ne OA papa H Mahle cleo saa ee 24 RIRES Re tt An el Met ne De D DU ne BR EU ant ee UN AN ee nunc E 24 Maximum internal temperature si 24 RUANNYCONAIIONS enr aye nates ee EE E EE baer Mn acer da te Ok nites ao eee de etes Ua 24 PART 3 USING THE NS IRS IN 6 STEPS mmemennnennnnnnnnnnnt 29 OLICORP IRS SERIES 07 02 2013 Step 0 Machine Cabling iaeiei see cevecee tetsu seen aaaea pees veestecwelstucesseeceecbesauieesstexetceestiueesdee 26 Step 1 Product Identification ssssnnsrreeneenenennneneeneeneenennneneenenee 27 Step 2 Mechanical mounting ns nsssssssssrersennnnenenneenennennnseneneeeeenennseneenenes 28 Mechanical configur
43. o use low voltage lamps on higher voltage supplies e Over voltage protection e Data logging monitoring consumption follow up e harmonics suppressor HMI PC Ecran plat OLICORP IRS SERIES 07 02 2013 Hardware and software versions NS IRS10 versions One Hardware Two Softwares The NS IRS operates 2 programs The version 5 x used on standard blow molding machines The version 20 x used on Sidel machines From 01 2013 ALL former 10 channels models will be replaced by the WO25 X version PWR24B gt WO25 X Software V5 X PWRSDL gt WO25 X Software V20 X IRS10 STD gt WO25 X Software V5 X IRS10 SDL gt WO25 X Software V20 x Features WO 2 1 WO 25 x IRS 12 NS IRS STD SIDEL and STD Release date Mar 2009 01 2013 Firmware V5 18 V5 18 or V20 16 Isupply A 70 70 Imax thy A 7 5 7 5 Nohannel 12 10 NE 185 530 VAC Frequency 47 63 Hz Nes 24 VDC 10 learo A 0 25 0 25 loverload 200 A Additional breaker for 32A C curve back line protection Interrupting capacity 6KA Running conditions 5 456 5 556 Non confined with T 5 RMS over 24h 8 80 HR n c Storage 20 60 5 95 HR Accel 10G 11ms 2 times s Protection IP65 Temperature rise inside the cabinet at 23 9 50 full power with respect to outside Power loss 70 W 55 W Size HxWxD 430X312X188 430x312x150m mm m Weight 15 4 kg 12 5 kg
44. ply to reload the new address At this point the Profibus DP network should be initialised and should work correctly The master is starting to exchange empty datagrams with the NS IRS slaves If this exchange is successful the profibus LED onto the MPU card turns to green A7 OLICORP IRS SERIES 07 02 2013 3 Start communication by sending commands and receiving data to from the NS IRS Then the communication is done through simple datagram exchanges between the master and the slaves See next section Protocol description and datagram format Configuration datagram The configuration datagram is built according to the GSD description Two type of protocols are available on the NS IRS and PWR systems IRS_PWR_STD12 IRS_PWR_STD12_SHORT The SHORT version is used to simplify and optimize the exchange by suppressing the information about SRVV and Pmax 2 x 12 words are suppressed in the datagram To work with this version on has to set these values manually with the OLPWR24COM software and to save them in the ROM memory of the NS IRS during system installation IRS_PWR_STD12 INPUT 5 WORDS OUTPUT 37 WORDS OxD4 OxEC OxEB OxEB OxD4 11010100 ILI Tt Data Length 0100 Input Slave gt Master Type Word Coherent check OxEC 11101100 ILI tt Longueur donn es 1011 13 mn us Output M gt S Unit Word Coh rence sur donn es compl tes 48
45. rofibusDP section Starting the regulation To start the regulation the PLC has to send o the desired power for each lamp PW Watts o the start stop command Treating the information back from the NS IRS The PLC has to treat the information coming back from the NS IRS Measured resistances RM Ohms The Applied Power PWE Watt The supply Voltage SV Volts square The alarms Overload Overheat sector default Dead lamp O O Or O System Shutdown This step doesn t require any specific action 39 OLICORP IRS SERIES 07 02 2013 Exceptions Exception Effect Software treatment of the exception An alarm is emitted The regulation can be stopped Sector Default Vsupply lt 100V during more than 1 second The regulation stops An alarm is sent to the PLC The system needs a software reset to restart regulation off and then on Power not reach Power applied lt power expected The regulation goes on an alarm is sent to the PLC Dead lamp The regulation goes on an alarmis sent to the PLC OverLoad The regulation stops An alarm is sent to gt 200 A the PLC The system needs a software reset to restart regulation off and then on Temperature to high The regulation stops An alarm is sent to the PLC Profibus down The regulation is stopped and will start No treatment gt oE again when the Profibus DP will be bac
46. rting the regulation sise 39 Treating the information back from the NS IRS s eee eee e e ee 39 OSYSLEM ES AUTONET RE te states nn E EA 39 EXCO DUO MS US Gant cia Pee cage TS Gare toas geuald ade Sen nee eine dense do A 40 PART 4 TECHNICAL COMPLEMENTS sssssssssssssssssssssssssssssssssssssssssesssdi RS232 and USB connection Firmware update and NS IRS serial control 42 OVETVICW net masser EE nd inst Une eds ae Re En des Te sad ans cette dass dents near sm se 42 Hardware Connections nc iaka E Mae dd den date nee Rd Taran seen ane 42 Installing the Software So iore MAN Mt A rt ne dagen tient Ocean ne eue O Ei 42 Configuring the software users 42 Usingith SOftWwar arrene ae r TE ein anti nd sante den ee tenant ne ea Rene Menu tn es 43 Firmware Updat srl Red E sudden nd aaa GR EA REA een AT Es 44 CalibraAtiOn Oe E ETEA A E A ft ania Laa we EA AT ATEA E IE TETE EA TTET EEEE 45 To ensure a good process quality the NS IRS calibration have to be check 45 Voltage calDralon aen sre a en n EAE E E R EA SEL ne nine de teach 45 Use a calibrate VRMS Voltmeter sisi 45 Measure the voltage between the two phases inside the NS IRS eceeeeeeeeeeeeeeeeeeeeeeees 45 Enter the value and tick Calibrate voltage 45 Vrms read and Vrms expected mus be the SAME ss eee eee cece eee 45 Current calibration inv tags dune rae 92 Yea eevee a ved od nea eas 46 Profibus DP For
47. surement Voltage and current calibration Optional Preseting the regulation parameters lamps service voltage lamps nominal power 00000 This configuration is either done by OLICORP at factory according to users specifications or can be done while mounting the NS IRS using the serial bus or USB connexion and the SUPERVISOR program The system configuration MUST be done from the PC using the SUPERVISOR or OLPWR24COM programs The Other steps can be done either from the PLC or from the PC System initialisation at start up If not done during initial system configuration at system start up the basic parameters used by the regulator must be sent by the PLC or PC to the NS IRS These parameters are o the lamps service voltage SRVV Volts o the lamps nominal power MaxP Watts they are related to the basic configuration of the oven 38 OLICORP IRS SERIES 07 02 2013 This step can be avoided if one stores these values directly on the control board The SUPERVISOR software used to configure the settings of the NS IRS has an option to set SRVV and MaxP in the ROM memory of the NS IRS If this option is used it is even possible to select a simplified Profibus DP protocole IRSPWR_STD_SHORT instead of IRSPWR_STD to ease the programming of the PLC by suppressing the parameters SRVV and MaxP in the Profibus Protocole More about that in the P
48. uld not be opened except by competent technicians when connecting or disconnecting the device Electrical isolation must be ensured between the equipment and the power supply In both off and on modes the NS IRS regulator doesn t ensure isolation from the power supply One should pay attention to the fact that electrical shock may occure when touching the lamps or the cables coming from the NS IRS It is thus recommended to turn off the power supply 400 V within 2 sec following the end of regulation OLICORP IRS SERIES 07 02 2013 PART 1 DISCOVERING THE NS IRS OLICORP IRS SERIES 07 02 2013 What is the NS IRS system The NS IRS is the top of the art solution to control power on IR ovens The NS IRS system aims to control up to 10 InfraRed lamps Its modular design turns to be optimised for the control of IR ovens on blow molding machines The NS IRS is designed a IP65 cabinet that can be mounted in the machine nearby the oven The NS IRS replaces the successful PWR and IRS systems that has been widely used on blow moulding machines since 2002 More than 45 000 PWRs and IRSs actually run around the world The NS IRS 10 channels Single phase input ground 185 530 VAC 50 60 Hz Max Total 65 A Max channel 7 5 A RMS Advanced features Phase angle and advanced single cycle modes zero crossing Dead Lamps detection and Load Resistance monitoring Closed loop regulation Power regulation based

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