Ropex CIRUS UPT-6010 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) Technische Änderungen vorbehalten
7.11.19 Version 2
UPT-6010
The CIRUS® temperature controller UPT-6010 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
• Complete control via PROFINET interface („Conformance Class C“, IO/RT and IRT acc. to IEC
61784-2) (2 x RJ-45)
• Automatic zeroing (AUTOCAL)
• Automatic configuration of the secondary voltage and current range (AUTORANGE)
• Automatic frequency adaptation
• Booster output standard
• Analogue output 0…10 VDC for ACTUAL temperature
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Cooling system monitored
• Wide voltage range for the use of 110…415 V
• Eight channels for administration of various calibration values
• Micro-USB interface for ROPEXvisual®
• cULus approval
Operating
instructions

Seite 2 UPT-6010 Version 2
Contents
1 Revision list . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 General information . . . . . . . . . . . . . . . . . . 3
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
2.3 Heating element . . . . . . . . . . . . . . . . . 4
2.4 Impulse transformer . . . . . . . . . . . . . . 4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 System description . . . . . . . . . . . . . . . . . . . 7
4.1 Functional principle . . . . . . . . . . . . . . . 7
5 Device features . . . . . . . . . . . . . . . . . . . . . . 8
6 Mounting and installation . . . . . . . . . . . . . . 9
6.1 Installation notes . . . . . . . . . . . . . . . . . 9
6.2 Installation procedure . . . . . . . . . . . . . 9
6.3 Power supply . . . . . . . . . . . . . . . . . . . 11
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12
6.5 Current transformer PEX-W4/-W5 . . . 12
6.6 Wiring diagram (standard) . . . . . . . . . 14
6.7 Wiring diagram with booster connection
15
7 Startup and operation . . . . . . . . . . . . . . . . 16
7.1 View of the device . . . . . . . . . . . . . . . 16
7.2 Device configuration . . . . . . . . . . . . . 16
7.3 Heating element . . . . . . . . . . . . . . . . 18
7.4 Commissioning rules . . . . . . . . . . . . . 19
8 Device functions . . . . . . . . . . . . . . . . . . . . 21
8.1 LEDs and controls . . . . . . . . . . . . . . . 21
8.2 PROFINET communication . . . . . . . . 22
8.3 Device master file (GSDML) . . . . . . . 22
8.4 Communication protocol . . . . . . . . . . 23
8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 24
8.6 Output data . . . . . . . . . . . . . . . . . . . . 26
8.7 Parameter data . . . . . . . . . . . . . . . . . 29
8.8 Integrated web server . . . . . . . . . . . . 37
8.9 Undervoltage detection . . . . . . . . . . . 41
8.10 Temperature meter (actual value output)
42
8.11 Booster connection . . . . . . . . . . . . . . 43
8.12 USB interface for visualization software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 43
8.13 AUX interface . . . . . . . . . . . . . . . . . . 44
8.14 Total cycle counter . . . . . . . . . . . . . . 44
8.15 Operating hours counter . . . . . . . . . . 44
8.16 Data memory for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 44
8.17 Built-in clock (date and time) . . . . . . . 44
8.18 System monitoring / alarm output . . . 45
8.19 Error messages . . . . . . . . . . . . . . . . . 46
8.20 Fault areas and causes . . . . . . . . . . . 50
9Factory settings. . . . . . . . . . . . . . . . . . . . . 51
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 52
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 54
12 Modifications (MODs) . . . . . . . . . . . . . . . . 54
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 55
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Revision list
Version 2 UPT-6010 Seite 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.
Version Change
1 • Creation of documentation
2 • Change to one column layout
• ROPEX logo changed
• Covering page with important features
• Additions in general information
section 2 "General information" on page 3
• Addition in Communication protocol: Status bit measurement interruption
section 8.6.10 "Measurement interruption (MU)" on page 28
• Extension of slot 1, subslots 4 with index 16 to 48: absolute calibration resistances
page 31
• Extension integrated webserver: presentation of calibration values
section 8.8.6 "Calibration page" on page 40
• Updating of how to order
section 13 "How to order" on page 55

General information
Seite 4 UPT-6010 Version 2
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
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)
!

General information
Version 2 UPT-6010 Seite 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.
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
Seite 6 UPT-6010 Version 2
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
• foil splicer
•etc.
!

System description
Version 2 UPT-6010 Seite 7
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
Seite 8 UPT-6010 Version 2
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-6010 is equipped with a PROFINET interface. Through this interface, all
functions and parameters can be parameterised by means of the higher level machine controller. In addition,
important controller information is queried and can be processed accordingly.
The ACTUAL temperature of the heating element is output through the PROFINET 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-6010 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 PROFINET interface in case
of malfunction.
To increase operational security and immunity to interference, all PROFINET 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 PROFINET
interface.
The compact design of the CIRUS® temperature controller UPT-6010 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
Version 2 UPT-6010 Seite 9
• Comprehensive error diagnosis over the PROFINET 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 55.).
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-6010:
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 52 must be allowed between them.
3. Wire the system in accordance with the instructions in section 6.1 "Installation notes" on page 9, section 6.6
"Wiring diagram (standard)" on page 14, and the ROPEX Application Report. The information provided in
section 6.1 "Installation notes" on page 9 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
Seite 10 UPT-6010 Version 2
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 the PROFINET controller using a suitable (standard compliant)
cable.
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
Version 2 UPT-6010 Seite 11
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
Seite 12 UPT-6010 Version 2
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 11 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 11).
!
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
Version 2 UPT-6010 Seite 13
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
Seite 14 UPT-6010 Version 2
6.6 Wiring diagram (standard)
14
13
12
7
5
Ethernet
module
18
17
6
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Impulse
transformer
Heating
element
LINE
sec.
U2
prim.
U1
Line filter
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
BOOSTER
OUTPUT
Current
transformer
V+
V-
24 VDC POWER
SUPPLY
twisted
UPT-6010

Mounting and installation
Version 2 UPT-6010 Seite 15
6.7 Wiring diagram with booster connection
R
Current
transformer
Impulse
transformer
LINE
11
9
10
8
4
3
2
1
IR
UR
15
16
twisted
Booster
IN OUT
13
Line filter
NC
NC
14
13
12
7
5
Ethernet
module
18
17
6
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
Heating
element
sec.
U2
prim.
U1
twisted
Max. length 1m
24
V+
V-
24 VDC POWER
SUPPLY
UPT-6010

Startup and operation
Seite 16 UPT-6010 Version 2
7 Startup and operation
7.1 View of the device
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 secondary voltage and current ranges
The secondary voltage and current ranges are automatically configured during the automatic calibration function
(AUTOCAL). The voltage is configured in the range from 0.4 VAC to 120 VAC and the current in the range from
30 A to 500 A. If the voltage and / or current are outside of the permissible range, a detailed error message
appears on the controller (section 8.19 "Error messages" on page 46).
If the secondary current I2 is less than 30 A, the secondary high-current wire must be laid twice (or several times)
through the PEX-W4 or PEX-W5 current transformer (ROPEX Application Report).
Connection terminals
LEDs
Nameplate
Terminal plan
USB interface
Coding and slide
switches
PROFINET
ports
!
2x

Startup and operation
Version 2 UPT-6010 Seite 17
7.2.2 Configuration of the rotary coding switch for the temperature range and alloy
The setting of the rotary coding switch for the temperature range and alloy can be overwritten with
the parameter data (section 8.7 "Parameter data" on page 29).
If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization software
(section 8.12 "USB interface for visualization software ROPEXvisual®" on page 43).
7.2.3 Configuration of the rotary coding switches for device names
These coding switches can be used to specify the names of the UPT-6010 devices in the PROFINET network. A
new setting does not take effect until the next time the controller is switched on.
The preset device name "UPT-6010" is configured as follows, depending on the settings of the rotary coding
switches:
By assigning device names using rotary coding switches, you can replace a device in an existing machine without
a programming tool. Simply configure the replacement device with the same switch settings.
If the UPT-6010 was named using a suitable PROFINET tool (e.g. Siemens STEP7), the preset device name can
be erased by means of the rotary coding switches. To do this, make sure the controller is de-energized, then set
the switches to 0xFF and switch the controller on again. It is sufficient to supply the controller with 24 VDC. No
connection is required to the PROFINET network. After the device name has been successfully erased, the red
DATA EXCHANGE LED blinks at approx. 4 Hz. The power supply to the controller must then be momentarily inter-
rupted in order for the new switch settings to take effect.
Rotary coding switch Device name
00 Last name assigned is static
01…FE UPT-6010-01…UPT-6010-FE
FF Last device name assigned and I&M data erased
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
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1
Station name selectable.
00 = Factory settings
0...F
0...F
(Controller_type: RES-5010 / UPT-6010)
Device name selectable
by PROFINET config tool
Device name preset to
“Controller_type - XX”
Erase name
00
01...FE
FF
0
0
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1

Startup and operation
Seite 18 UPT-6010 Version 2
In addition to the device name, restoring the factory settings by setting the rotary coding switch to
"0xFF" also erases all I&M data in the memory.
In order to assign the device name via the PROFINET interface (e.g. using a programming tool), the
rotary coding switch must be set to "0x00".
Note: By using a configuring tool (e.g. Siemens STEP7) to specify the PROFINET topology, you can also assign
a name automatically if the controller does not already have a device name when it is switched on. In this case,
the PLC automatically assigns it the name stored in the project.
7.2.4 Configuration of the alarm relay
If the switch is set to "Alarm relay de-energized at alarm / PC CONFIGURATION", you can select more alarm
output configurations in the ROPEX visualization software (section 8.12 "USB interface for visualization soft-
ware ROPEXvisual®" on page 43).
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.
!
!
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)
!
!
!

Startup and operation
Version 2 UPT-6010 Seite 19
Each time the heating element is replaced, you must run the "AUTOCAL" function (section 8.5.1 "Automatic
zero calibration AUTOCAL (AC)" on page 24) and set the correction factor Co (section 8.7.9 "Correction factor
Co" on page 34). Any production-related resistance tolerances of the heating element are compensated in this
way.
7.4 Commissioning rules
Observe here section 2 "General information" on page 3 and section 3 "Application" on page 6.
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 9).
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. Either set the desired device name with the rotary coding switches or assign it using a suitable PROFINET tool.
3. Link the device master file (GSDML) into the PROFINET controller (section 8.3), then select the required
parameters, assign a name to the device, and start the 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 line voltage and the 24 VDC auxiliary supply (the order is arbitrary).
6. When the voltage is switched on, the yellow "AUTOCAL" LED lights up for approximately 0.3 seconds to indi-
cate that the controller is being powered up correctly. The red "BUS FAILURE" LED lights up as long as no
PROFINET communication is active. It does not go out again until it detects an active communication.
If the red "ALARM" LED lights up for 0.3…1.5 s when the voltage is switched on in addition to the
yellow "AUTOCAL" LED, the configuration of this controller has been changed in the visualization
software (section 8.12 "USB interface for visualization software ROPEXvisual®" on page 43). In order to
avoid malfunctions, please check the controller configuration before continuing the startup procedure.
7. The green "DATA EXCHANGE" LED lights up to indicate an active PROFINET communication.
8. One of the following states then appears:
9. Activate the AUTOCAL function while the heating element is still cold by setting the AC bit (AUTOCAL) in the
PROFINET protocol (section 8.4 "Communication protocol" on page 23). The yellow "AUTOCAL" LED lights
up for the duration of the calibration process (approx. 10…15 s). The AA bit (AUTOCAL active) is additionally
set and a voltage of 0 VDC appears at the actual value output (terminals 17+18). If an ATR-x is connected, it
indicates 0…3 °C.
After the zero point has been calibrated, the "AUTOCAL" LED goes out and the AA bit is reset. A voltage of
0.66 VDC (300 °C range and AUTOCAL temperature = 20 °C) or 0.4 VDC (500 °C range) appears at the
actual value output. If an ATR-x is connected, it must be set to "Z".
If the zero point was not calibrated successfully, the AL bit (alarm active) is set and the red "ALARM" LED blinks
"ALARM" LED "OUTPUT" LED ACTION
OFF Short impulses every 0.4 seconds Go to step 9
BLINKS fast (4 Hz) OFF Go to step 9
LIT continuously OFF Error diagnosis (section 8.19)
!
!

Startup and operation
Seite 20 UPT-6010 Version 2
slowly (1 Hz). In this case the controller configuration is incorrect (section 7.2 "Device configuration" on
page 16, ROPEX Application Report). Repeat the calibration after correcting the controller configuration.
10.After the zero point has been successfully calibrated, specify a defined temperature by means of the
PROFINET protocol (set point) and set the ST bit. The RA bit (control active) is then activated and the "HEAT"
LED lights up. The heating and control process can be observed at the actual value output.
The controller is functioning correctly if the temperature (which corresponds to the signal change at the analog
output or the actual value in the PROFINET protocol) is a regular curve, in other words it must not jump
abruptly, fluctuate, or temporarily deviate in the wrong direction. This kind of behaviour would indicate that the
UR measurement cable was laid incorrectly.
If an error code is displayed, proceed as described in section 8.19 "Error messages" on page 46.
11.Optimize the heating and control process either by adjusting the correction factor Co in the parameter data
(GSDML file) or using the acyclic services (section 8.7.9 "Correction factor Co" on page 34). Any production-
related resistance tolerances of the heating element are compensated in this way.