Ropex CIRUS UPT-6006 User manual

CIRUS
ROPEX Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: https://ropex.de
74321 Bietigheim-Bissingen (Germany) Data subject to change
7.11.19 Version 1
UPT-6006
The CIRUS® temperature controller UPT-6006 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.
Important features
• PROFIBUS DP interface for complete regulator control
• Automatic zeroing (AUTOCAL)
• Automatic configuration of the secondary voltage and current range (AUTORANGE)
• Automatic frequency adaptation
• Booster output standard
• Analogue output 0…10 VDC for ACTUAL temperature
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Cooling system monitored
• Wide voltage range for the use of 110…415 V
• Eight channels for administration of various calibration values
• Micro-USB interface for ROPEXvisual®
User Guide

Page 2 UPT-6006 Version 1
Contents
1 Revision list . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 General information . . . . . . . . . . . . . . . . . . 3
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
2.3 Heating element . . . . . . . . . . . . . . . . . 3
2.4 Impulse transformer . . . . . . . . . . . . . . 3
2.5 Current transformer PEX-W4/-W5 . . . . 4
2.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Standards / CE marking . . . . . . . . . . . 4
2.8 Maintenance . . . . . . . . . . . . . . . . . . . . 5
2.9 Transportation . . . . . . . . . . . . . . . . . . . 5
2.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 System description . . . . . . . . . . . . . . . . . . . 6
4.1 Functional principle . . . . . . . . . . . . . . . 6
5 Device features . . . . . . . . . . . . . . . . . . . . . . 7
6 Mounting and installation . . . . . . . . . . . . . . 8
6.1 Installation notes . . . . . . . . . . . . . . . . . 8
6.2 Installation procedure . . . . . . . . . . . . . 8
6.3 Power supply . . . . . . . . . . . . . . . . . . . 10
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 11
6.5 Current transformer PEX-W4/-W5 . . . 11
6.6 Connection diagram (standard) . . . . . 13
6.7 Connection diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 14
7 Commissioning and operation . . . . . . . . . 15
7.1 Device view . . . . . . . . . . . . . . . . . . . . 15
7.2 Device configuration . . . . . . . . . . . . . 15
7.3 Heating element . . . . . . . . . . . . . . . . 17
7.4 Commissioning rules . . . . . . . . . . . . . 18
8 Device functions . . . . . . . . . . . . . . . . . . . . 19
8.1 Display and operating elements . . . . 19
8.2 PROFIBUS communication . . . . . . . . 20
8.3 Device master data file (GSD) . . . . . . 20
8.4 PROFIBUS protocol . . . . . . . . . . . . . 21
8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 25
8.6 Output data . . . . . . . . . . . . . . . . . . . . 28
8.7 Parameter data . . . . . . . . . . . . . . . . . 31
8.8 DPV1 protocol expansions . . . . . . . . 39
8.9 Undervoltage detection . . . . . . . . . . . 44
8.10 Temperature display (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 45
8.11 Booster connection . . . . . . . . . . . . . . 46
8.12 USB interface for visualisation software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 46
8.13 AUX interface . . . . . . . . . . . . . . . . . . 47
8.14 Total cycles counter . . . . . . . . . . . . . . 47
8.15 Operating hours counter . . . . . . . . . . 47
8.16 Data storage for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 47
8.17 Integrated clock (date and time) . . . . 47
8.18 System monitoring/alarm output . . . . 48
8.19 Error messages . . . . . . . . . . . . . . . . . 49
8.20 Error ranges and causes . . . . . . . . . . 53
9Factory settings. . . . . . . . . . . . . . . . . . . . . 54
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 55
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 57
12 Modifications (MODs) . . . . . . . . . . . . . . . . 57
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 58
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Revision list
Version 1 UPT-6006 Page 3
1 Revision list
2 General information
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. As
a result of this, the product left our factory in perfect condition.
Please carefully read through the operating manual before using the CIRUS® temperature controller. Keep the
operating manual for later reference and make sure that information and functions important for the user are avail-
able.
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.
2.1 Copyright
All contents, in particular texts, photographs and graphics, are protected by copyright. All rights, including to rep-
lication, publication, editing and translation, are reserved.
2.2 Intended use
CIRUS® temperature controllers may only be used for heating and temperature control of heatsealing elements
which are expressly approved for them, and providing the regulations, notes and warnings contained in these
instructions are observed.
In case of non-observance or use contrary to the intended purpose, there is a risk that safety will be impaired or
that the heatsealing element, electrical wiring, transformer etc. will overheat. This is the personal responsibility of
the user.
2.3 Heating element
The temperature coefficient of a CIRUS® temperature controller is specially adapted to CIRUS heating elements.
The CIRUS® temperature controller is not allowed to be operated with any other heatsealing ele-
ments because they could be overheated and damaged beyond repair.
2.4 Impulse transformer
A suitable impulse transformer is necessary in order to guarantee trouble-free operation of the control loop. This
transformer must be designed according to EN 61558 (isolating transformer with reinforced insulation) and have
a one section bobbin. When the impulse transformer is installed, suitable touch protection must be provided in
Version Changes
1 • Creation of documentation
!

General information
Page 4 UPT-6006 Version 1
accordance with the national installation regulations for electrical equipment. In addition to this, water, cleaning
solutions and conductive fluids must be prevented from seeping into the transformer.
Incorrect installation of the impulse transformer impairs electrical safety.
2.5 Current transformer PEX-W4/-W5
The current transformer supplied with the CIRUS® temperature controller is an integral part of the control system.
Only the original ROPEX PEX-W4 or PEX-W5 current transformer may be used. Other transformers may cause
the equipment to malfunction.
The current transformer may only be operated if it is correctly connected to the CIRUS® temperature controller
(see section "Startup and operation"). The relevant safety instructions contained in section "Power supply", must
be observed. 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.
2.6 Line filter
ROPEX provides line filters in different power classes. The ROPEX application report lists the suitable line filter
which can be ordered accordingly.
The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions
mentioned in section 2.7 "Standards / CE marking" on page 4. This device must be installed and connected
according to the instructions contained in section "Power supply" as well as the separate documentation enclosed
with the line filter.
2.7 Standards / CE marking
The controller described here complies with the following standards, provisions and directives:
DIN EN 61010-1:2001 (2014/35/EU) Safety requirements for electrical equipment for meas-
urement, control and laboratory use (low-voltage direc-
tive):
pollution degree 2, protection class I, measurement
category I (for UR and IR terminals)
DIN EN 60204-1 (2006/42/EG) Electrical equipment of machines (machinery directive)
EN 55011:2009+A1:2010
EN 61000-3-2:2006-04+A1:2009+A2:2009
EN 61000-3-3:2008
EN 61000-6-4:2007+A1:2011
(2014/30/EU)
EMC generic emissions:
Group 1, Class A
EN 61000-6-2:2005 (2014/30/EU) EMC generic immunity:
Class A (ESD, RFI, burst, surge)
Exception:
Line voltage interruption acc. to EN 61000-4-11 is not
fulfilled (this leads to a designated error message of the
controller)
2011/65/EU Directive on the restriction of the use of certain haz-
ardous substances in electrical and electronic equip-
ment.

Application
Version 1 UPT-6006 Page 5
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 fulfills 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 "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.
2.8 Maintenance
The controller requires no special maintenance. Regular inspection and / or tightening of the terminals – including
the terminals for the winding connections on the impulse transformer – is recommended. Dust deposits on the con-
troller can be removed with dry compressed air.
Dust deposits and dirt from liquids result in a loss of function. Accordingly, installation in a switch
cabinet or terminal cabined with IP54 is recommended.
2.9 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible damage.
2.10 Disposal
This device is subject to Directive 2012/19/EU concerning the reduction of the increasing amount of
waste electrical and electronic equipment and the disposal of such waste in an environmentally
sound way.
To guarantee proper disposal and / or the recover of reusable material, please take the device to a
designated municipal collection point and observe local regulations.
Careless, uncontrolled disposal can cause damage to the environment and human health. By
ensuring that your product is disposed of or recycled in a responsible way, you can help protect the
environment and human health.
This device must not be disposed of as residual waste!
3 Application
This CIRUS® temperature controller is an integral part of the "series 6000". Its sole purpose is to control the tem-
perature of CIRUS/UPT heating elements.The main application area is sealing or cutting of thermoplastics using
the thermal impulse process.
The most common application areas are:
• vertical and horizontal form-fill-seal machines (VFFS and HFFS)
• bagging, filling and sealing machines
• bag-production machines
• foil welding devices
!
!

System description
Page 6 UPT-6006 Version 1
• foil splicer
•etc.
4 System description
Sample depiction
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 operate
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, commissioning and maintenance to a minimum.
4.1 Functional principle
The controller determines the resistance of the heating element by measuring the current and voltage at a high
sampling rate (corresponds to the 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 controlled transformer so that set = actual.

Device features
Version 1 UPT-6006 Page 7
A highly dynamic thermoelectric control loop is established in this way because purely electrical variables are
measured in rapid succession and the heating layer of the UPT heating element has a small mass.
Thanks to the microprocessor based technology, the controller has an optimized control algorithm as well as
numerous functions tailored to specific tasks such as AUTOCAL, ALARM with error diagnosis etc. These are
described in detail below.
5 Device features
The CIRUS® temperature controller UPT-6006 is equipped with a PROFIBUS-DP interface. Through this inter-
face, all functions and parameters can be parameterised by means of the higher level machine controller. In addi-
tion, important controller information is queried and can be processed accordingly.
The ACTUAL temperature of the heating element is output through the PROFIBUS interface and through an ana-
logue output 0…10 VDC. The real heating element temperature can be visualised on an external display instru-
ment (e.g. ATR-x) or via the operating unit of the machine controller.
The UPT-6006 has an integrated error diagnosis that checks both the external system (heating element, wiring,
etc.) and the internal electronics. A differentiated error message is output through the PROFIBUS interface in case
of malfunction.
To increase operational security and immunity to interference, all PROFIBUS signals from the controller and
heating circuit are electrically isolated.
Adjustment for different heating element alloys and setting of the temperature range to be used (0…300 °C or
0…500 °C) can be made through coding switches on the temperature controller itself or through the PROFIBUS
interface.
The compact design of the CIRUS® temperature controller UPT-6006 as well as the plug-in connecting terminals
make mounting and installation easier.
An overview of the most important features and functions:
• Easy calibration of the heating element through AUTOCAL, the automatic zero-point setting.
• Eight channels permit switching of the calibration parameters during tool change.
• High flexibility: The AUTORANGE function covers a secondary voltage range of 0.4 V to 120 V and a current
range of 30 A to 500 A.
• Automatic adjustment to the network frequency in the range of 47 Hz to 63 Hz.
• Wide voltage range for flexible use from 110 VAC to 415 VAC
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
Temperature impulse
Current impulses
Time
Temperature/Current

Mounting and installation
Page 8 UPT-6006 Version 1
• Comprehensive error diagnosis over the PROFIBUS-DP interface
• Booster output available for connecting a switching amplifier
• High process security through comprehensive options for evaluating the parameter data (e.g. temperature
diagnosis or heat-up time monitoring)
6 Mounting and installation
See also section 2 "General information" on page 3.
Mounting, installation and startup may only be performed by authorized persons who have received
suitable instruction and are familiar with the associated risks and warranty provisions.
The supply voltage to the machine side must lie within the permitted voltage and frequency range
of the CIRUS® temperature controller. Otherwise, there is the danger of a defect.
6.1 Installation notes
1. Please refer to the safety and warning notes (“General information” on page 3.).
2. The information provided in the customized ROPEX Application Report, which is specifically prepared by
ROPEX for each application, must be observed.
3. All electrical components such as the controller, impulse transformer, and line filter, should be installed as close
as possible to the UPT sealing bar(s) in order to avoid unnecessarily long cables.
4. Connect the voltage measurement cable UR directly to the UPT sealing bar and lay it twisted to the controller
(for the UML-1 voltage measurement cable see “How to order” on page 58.).
5. Ensure an adequate cable cross-section for the primary and secondary circuits (Ä Application Report).
6. Use only ROPEX impulse transformers or transformers approved by ROPEX. Please note the power, duty
cycle, and primary and secondary voltages (Ä Application Report).
6.2 Installation procedure
Proceed as follows to install the CIRUS® temperature controller UPT-6006:
1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
2. Mount the CIRUS® temperature controller on a standard top hat rail (TS35 rail according to DIN EN 50022) in
the electrical cabinet. If several controllers are mounted on one rail, the minimum clearance specified in
section 10 "Technical data" on page 55 must be allowed between them.
3. Wire the system in accordance with the instructions in section 6.1 "Installation notes" on page 8, section 6.6
"Connection diagram (standard)" on page 13, and the ROPEX Application Report. The information provided in
section 6.1 "Installation notes" on page 8 must also be observed.
Wires used for control or measuring connections must always be laid inside the building.
4. An overcurrent protective device with a maximum rating of 10 A must be fitted when the device is installed, e.g.:
- Miniature circuit breaker to EN 60898 (B, C, D, K, or Z characteristic)
- Miniature circuit breaker to UL 489 (*) (B, C, D, K, or Z characteristic)
- Fuse gG to IEC 60269
- Class CC or Class J fuse to UL 248 (*)
The overcurrent protective devices marked (*) should be used in installations conforming to UL standards.
!
!

Mounting and installation
Version 1 UPT-6006 Page 9
If one such device is not adequate for the heatsealing application, two separate overcurrent protective devices
should be provided – one for the controller and one for the application (ROPEX Application Report).
The overcurrent protective device must be located directly adjacent to the controller.
The minimum possible specification for this device is indicated in the ROPEX Application Report based on the
calculated currents. If a larger overcurrent protective device is fitted, you must match the current carrying
capacity of the other components accordingly (e.g. cables, impulse transformer etc.).
5. A disconnecting device must be provided when the system is installed; it must be marked as belonging to the
system and fitted in a readily accessible position.
If a miniature circuit breaker is used, it can also perform the function of this device.
6. Connect the CIRUS® temperature controller to thePROFIBUS-Master using a suitable cable compliant to
IEC 61158.
Check that all system connections – including the terminals for the impulse transformer windings
– are securely attached.
7. Make sure the wiring conforms to all relevant national and international installation regulations.
!

Mounting and installation
Page 10 UPT-6006 Version 1
6.3 Power supply
ROPEX
temperature
controller
UR
IR
R
PRIM.
U1
Kb
Ka
SEC.
U2
LINE
I > I >
GND/
Earth
N (L2)
L1 (L1)
LINE
FILTER
ON
OFF
Kc
3
3
3
1
Short wires
2
2
Line
Over-current protection
Double-pole circuit-breaker or fuses (ROPEX Applica-
tion Report).
Short-circuit protection only. CIRUS® temperature
controller not protected.
!
Relay Ka
For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".
Line filter
The filter type and size must be determined according to
the load, the transformer and the machine wiring
(ROPEX Application Report).
Do not run the filter supply wires (line side) parallel
to the filter output wires (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, duty cycle and voltage values must be deter-
mined individually according to the application (ROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ROPEX Application Report).
Wires must always be twisted (min. 20 turns/meter).
These wires must be twisted (min. 20 turns/meter)
if several control loops are laid together ("crosstalk").
Twisting (min. 20 turns/meter) is recommended to
improve EMC.

Mounting and installation
Version 1 UPT-6006 Page 11
6.4 Line filter
To comply with EMC directives – corresponding to EN 50081-1 and EN 50082-2 – CIRUS control loops must be
operated with line filters.
These filters damp the reaction of the phase-angle control on the line and protect the controller against line distur-
bances.
The use of a suitable line filter is part of the standards conformity and a prerequisite of the CE mark.
ROPEX line filters are specially optimized for use in CIRUS control loops. Providing that they are installed and
wired correctly, they guarantee compliance with the EMC limit values.
You can find the exact specification of the line filter in the ROPEX Application 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:
6.5 Current transformer PEX-W4/-W5
The PEX-W4/-W5 current transformer supplied with the CIRUS® temperature controller is an integral part of the
control system. The current transformer may only be operated if it is connected to the temperature controller cor-
rectly (section 6.3 "Power supply" on page 10).
!
LINE
PE
Large cross-section
wire to ground
Large cross-section
wire to ground
Large frame contact surface
Do not lay parallel Mounting plate (galvanized)
max. 1 m
ROPEX
temperature
controller

Mounting and installation
Page 12 UPT-6006 Version 1
6.5.1 PEX-W4
6.5.2 PEX-W5
Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022).
Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Mounting and installation
Version 1 UPT-6006 Page 13
6.6 Connection diagram (standard)
UPT-6006
9
8
7
6
5
4
3
2
1
NC
A
(+5 V) VP
DGND
NC
B
NC
7
PROFIBUS-PLUG
SUB-D / 9-POLE
(+24 V pwr. supp.) P24
(GND pwr. supply) M24
5
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Current transformer
twisted
Impulse
transformer
Heating
element
LINE
Line filter
BOOSTER
OUTPUT
sec.
U2
prim.
U1
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be groun-
ded externally
to prevent
electrostatic
charging!
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6
V+
V-
24 VDC POWER
SUPPLY

Mounting and installation
Page 14 UPT-6006 Version 1
6.7 Connection diagram with booster connection
UPT-6006
9
8
7
6
5
4
3
2
1
NC
A
(+5 V) VP
DGND
NC
B
NC
7
PROFIBUS-PLUG
SUB-D / 9-POLE
(+24 V pwr. supp.) P24
(GND pwr. supply) M24
5
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Current transformer
twisted
Impulse
transformer
LINE
Line filter
sec.
U2
prim.
U1
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be groun-
ded externally
to prevent
electrostatic
charging!
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6
Booster
24
IN OUT
13
twisted
Max. length 1 m
NC
NC
V+
V-
24 VDC POWER
SUPPLY
Heating
element

Commissioning and operation
Version 1 UPT-6006 Page 15
7 Commissioning and operation
7.1 Device view
7.2 Device configuration
The controller must be switched off to configure the coding switch and the slide switch.
7.2.1 Configuration of the ranges for secondary voltage and current
The ranges for secondary voltage and current are configured automatically when automatic calibration
(AUTOCAL) is carried out. Configuration takes place in the voltage range of 0.4 VAC to 120 VAC and in the current
range from 30 A to 500 A. If voltage and/or current is outside the allowed range, a detailed error message is output
by the controller (see section 8.19 "Error messages" on page 49).
For secondary currents I2 less than 30 A, the secondary high-current line must be guided 2 times (or several times)
through the transformer PEX-W4 or PEX-W5 (ROPEX application report).
Connection terminals
Display LEDs
Coding and
Rating plate
Terminal plan
slide switches
USB interface
PROFIBUS
connection socket
!
2x

Commissioning and operation
Page 16 UPT-6006 Version 1
7.2.2 Configuration of the rotary coding switch for temperature range and alloy
The setting of the rotary coding switch for temperature range and alloy can be overwritten by the
parameter data (section 8.7 "Parameter data" on page 31).
When the switch position “9” is selected, additional temperature ranges and alloys can be set through the ROPEX
visualisation software (section 8.12 "USB interface for visualisation software ROPEXvisual®" on page 46).
7.2.3 Configuration of the station address
On these two rotary coding switches, the station address of the UPT-6006 can be set in the PROFIBUS network
from 1 to 99. Changes do not become effective until after switch-on.
With the switch setting 00, the station address with a class 2 master can be set over PROFIBUS with the SSA
service (set slave address). If no address has been assigned, the device has the standard address 126. The
address assigned through SSA remains stored in the device. As soon as a station address not equal to 00 is set
on the rotary coding switches and the 24 VDC power supply of the UPT-6006 is switched off and back on again,
the stored address assigned through SSA is erased and the controller uses the set station address. In switch set-
ting 00, the standard address is then 126 again.
With the help of address setting via the rotary coding switch, it is possible to carry out a device change in an
existing machine without a programming tool. Only the same setting of the rotary coding switch can be made in
the replacement device.
Rotary encoder switch Station address
00 Changeable through SSA in the range 0…126
01…99 • Fixed address in the range 1…99
• Stored address is reset to 126
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°C
300°C
PC CONFIGURATION
1700ppm/K
1700ppm/K
(
)
CIRU
S
(
)
CIRU
S
0
5
1
2
3
4
6
7
8
9
Switch
position
0
4
300°C
500°C
1700ppm/K
1700ppm/K
(CIRUS)
(CIRUS)
Temp.
range
Temp.
coefficient
Heating element
alloy
0 = Factory settings
9 PC-CONFIGURATION
TEMP. COEFFICIENT
!
0
0
0
0
5
5
5
5
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
6
6
6
6
7
7
7
7
8
8
8
8
9
9
9
9
PROFIBUS
STATION ADDRESS
x 1
x 10
Station address in PROFIBUS network between
0 and 99.
01 = Factory setting

Commissioning and operation
Version 1 UPT-6006 Page 17
7.2.4 Configuration of the alarm relay
When the “Alarm relay contact opens with Alarm/PC CONFIGURATION” is selected, additional configurations for
the behaviour of the alarm output can be set through the ROPEX visualisation software (section 8.12 "USB
interface for visualisation software ROPEXvisual®" on page 46).
7.3 Heating element
7.3.1 General
The heating element is a key component in the control loop because it is not only a heating element but also a
sensor. The geometry of the heating element is too complex to be discussed at length here. We shall therefore
only refer to a few of the most important physical and electrical properties.
The measuring principle used for this system requires a heating element alloy with a suitable temperature coeffi-
cient TCR, i.e. one whose resistance increases as the temperature rises.
Too low a TCR leads to oscillation or uncontrolled heating.
If a heating element with a higher TCR is used, the controller must be calibrated for it.
The CIRUS® temperature controller is suitable for temperature coefficients in the range 400…4000 ppm/K.
The base resistance of the heating element increases continuously during operation (owing to the
design). The AUTOCAL function must therefore be run again approximately every 100,000 heat-
sealing cycles in order to prevent ACTUAL temperature measuring errors.
7.3.2 Replacing the heating element
The supply voltage (all poles) must be disconnected from the CIRUS® temperature controller in
order to replace the heating element.
The heating element must be replaced in accordance with the instructions provided by the manu-
facturer.
Each time the heating element is replaced, you must run the "AUTOCAL" function (section 8.5.2 "AUTOCAL
autom. zeroing (AC)" on page 25) and set the correction factor Co (section 8.7.10 "Correction factor Co" on
page 34). Any production-related resistance tolerances of the heating element are compensated in this way.
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENER GIZED
(AT ALARM)
DE-ENERGIZED
A
larm relay contact
opened by alarm/
PC-CONFIGURATION
A
larm relay contact
closed by alarm.
(factory setting)
!
!
!

Commissioning and operation
Page 18 UPT-6006 Version 1
7.4 Commissioning rules
Observe here section 2 "General information" on page 3 and section 3 "Application" on page 5.
Mounting, installation and commissioning may only be performed by qualified and trained persons
who are familiar with the related hazards and warranty stipulations.
7.4.1 Initial startup
Requirement: Device is correctly mounted and connected (section 6 "Mounting and installation" on page 8).
Proceed as follows when starting up the controller for the first time:
1. Switch off network voltage and 24 VDC power supply; verify lack of voltage.
2. Set desired station address in the PROFIBUS network (section 7.2 "Device configuration" on page 15).
3. Integrate GSD file in the PROFIBUS master (chap. 8.3) and select desired communication module (protocol
“compact”, “expanded” or “complete”), possibly change parameter data and start communication.
4. Make sure that the higher-level controller does not send values not equal to zero to the CIRUS® temperature
controller.
5. Switch on the network voltage and 24 VDC power supply in any order.
6. After the voltage is switched on, the yellow “AUTOCAL” LED lights up for about 0.3 seconds and displays the
correct switch-on process of the controller. As long as no network voltage is present, this LED flashes slowly
(1 Hz).
At switch-on, if in addition to the yellow “AUTOCAL” LED the red “ALARM” LED lights up for
0.3…1.5 seconds, the configuration with the visualisation software has been changed for this con-
troller (section 8.12 "USB interface for visualisation software ROPEXvisual®" on page 46). The con-
troller’s configuration must be checked to avoid malfunctions before continuing with commissioning.
7. The green “DATA EXCHANGE” LED lights up when the PROFIBUS communication is active.
8. The following statuses can then result:
9. With a cold heating element, activate the AUTOCAL function by setting the ACbit (AUTOCAL) in the
PROFIBUS protocol (section 8.4 "PROFIBUS protocol" on page 21). The yellow “AUTOCAL” LED lights up
for the duration of the calibration process (approx. 10…15seconds). During this process, the AA bit (AUTOCAL
active) is set and a voltage of 0 VDC is output on the actual value output (terminal 17+18). A connected ATR-x
shows 0…3 °C.
After zeroing is completed, the “AUTOCAL” turns off and the AA bit is erased again. A voltage of 0.66 VDC (in
300 °C range and Autocal temperature = 20 °C) or 0.4 VDC (in 500 °C range) is reached at the actual value
output. A connected ATR x must be on the “Z” marking.
If zeroing is not performed correctly, the AL bit (Alarm active) is set and the red “ALARM” LED flashes slowly
(1 Hz). Then the configuration of the controller is not correct (section 7.2 "Device configuration" on page 15,
ROPEX application report). After the device configuration is correct, perform zeroing again.
10.After successful zeroing, specify a defined temperature over the PROFIBUS protocol (setpoint) and set the
ST bit. The RA bit (Regulation active) is now active and the “HEAT” LED illuminated. The heat-up and control
procedure can be observed at the actual value output:
“ALARM” LED “OUTPUT” LED MEASURE
OFF Short pulses every 0.4 seconds Continue with item 9
FLASHES quickly (4 Hz) OFF Continue with item 9
Permanently ON OFF Error diagnosis (chap. 8.19)
!
!

Device functions
Version 1 UPT-6006 Page 19
It is functioning correctly when the temperature (i.e. signal change at the analogue output or the actual value
in the PROFIBUS protocol) is steady, that is, does not jump, oscillate or even go briefly in the wrong direction.
Such action indicates an incorrect placement of the UR measurement line.
When an error message is issued, proceed according to section 8.19 "Error messages" on page 49.
11.The heatup process and the temperature control must be optimized by means of setting the correction factor
Co in the PROFIBUS parameter data (GSD file) or in the DPV1 protocol extension (section 8.7.10 "Correc-
tion factor Co" on page 34) now. With this setting the manufacturing process related tolerances of the heating
element are compensated.
8 Device functions
See also section 6.6 "Connection diagram (standard)" on page 13.
8.1 Display and operating elements
(yellow LED)
OUTPUT
HEAT
(green LED)
AUTOCAL
ALARM
(yellow LED)
(red LED)
Indicates pulses in
measurement mode. In control
mode, luminous intensity is
proportional to heating current.
Lit while AUTOCAL process is
executing.
Lit or blinking to indicate fault.
Lit during heating phase.
BUS FAILURE
(red/green
LED)
DATA EXCH
(red/green
LED)
(green )LED
BUS POWER
(green )LED
24 V POWER
Lit or blinking if no connection
exists to PROFINET.
Lit if internal power supply for
PROFINET interface is OK.
Lit (green) while data exchange
with PROFINET controller.
Lit if external 24 VDC power
supply is present.
12 13 14 15 16 17 18
9
8
6
5
10
11
7
4
3
2
1
Visual
!
AC
HEAT
OUTPUT
ALARM
BUS FAILURE
DATA EXCHANGE
BUS POWER
24 V POWER
www. .deROPEX
Made in Germany
PROFIBUS
UPT-6006

Device functions
Page 20 UPT-6006 Version 1
The LEDs display additional operating statuses of the controller besides the functions in the above illustration.
These are shown in detail in the following table:
The following descriptions contain only device-specific functions. Please consult your PLC descrip-
tion for general information for the PROFIBUS and system configuration.
8.2 PROFIBUS communication
The controller can communicate over the PROFIBUS interface if 24 VDC voltage supply is present.
As long as no network voltage is present, the controller remains in an inactive status.
But interruption of the network voltage (e.g. by being switched off when a door is opened) triggers the error mes-
sage 201 (error group no. 7, network voltage/sync signal is missing) and the Alarm relay switches. This is caused
by the lack of network voltage. The error message can be deleted after the network voltage is switched on again
by activating the RS bit (section 8.5.4 "Reset (RS)" on page 26).
The error message or switching of the Alarm relay – caused by switching off the network voltage – can be pro-
cessed or suppressed in the PLC program without difficulty.
8.3 Device master data file (GSD)
Design tools for the PROFIBUS master to be designed interpret the content of the GSD files of the slaves and
generate from them a master parameter set for the PROFIBUS master which performs the user data traffic. The
file ROxy07EA.GSD (xy: GSD version; e.g. “30” for version “v3.0”) of the UPT-6006 contains all information about
the controller necessary for design, e.g. the possible baud rates, parameter descriptions, alarm messages, etc.
The GSD files in German (.GSG) and English (.GSD or .GSE) as well as the related image files .DIB for status
visualisation can be requested by e-mail ([e-mail]) or downloaded from our homepage (https://
ropex.de).
LED Flashes slowly (1 Hz) Flashes quickly (4 Hz) On permanently
AUTOCAL
(yellow)
No PROFIBUS communi-
cation or RS bit set (reset)
AUTOCAL requested, but
function is blocked AUTOCAL is carried out
LED flashes with a different frequency:
Incorrect (too low) supply voltage
HEAT
(yellow) —START requested,
But function is blocked START is carried out
OUTPUT
(green) In control operation, the light intensity is proportional to the heating current.
ALARM
(red)
Configuration error,
AUTOCAL not possible
Controller incorrectly cali-
brated, carry out
AUTOCAL
Error, chap. 8.19
BUS FAILURE
(red)
Incorrect or no configura-
tion of the I/O data
Incorrect or no parameteri-
sation
Communication with
PROFIBUS master inter-
rupted
DATA EXCHANGE
(green) —
Communication with
PROFIBUS master active,
Clear mode
Communication with
PROFIBUS master active
!