Ropex CIRUS UPT-6011 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
03.12.21 Version 5
UPT-6011
The CIRUS®Temperature Controller UPT-6011 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 EtherNet/IPTM interface (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…480 V1(as from 02/2021)
• Eight channels for administration of various calibration values
• Micro-USB interface for ROPEXvisual®
• cULus approval
1. Standard: 415 V, optional and on request: 480 V
Operating
instructions

Version 5 UPT-6011 Page 2
Contents
1 Revision list . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 General information . . . . . . . . . . . . . . . . . . 3
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 4
2.3 Heating element . . . . . . . . . . . . . . . . . 4
2.4 Impulse transformer . . . . . . . . . . . . . . 4
2.5 Current transformer PEX-W4/-W5 . . . . 4
2.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 5
2.7 Standards / CE marking . . . . . . . . . . . 5
2.8 Maintenance . . . . . . . . . . . . . . . . . . . . 6
2.9 Transportation . . . . . . . . . . . . . . . . . . . 6
2.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 6
2.11 DECLARATION OF CONFORMITY . . 7
3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 System description . . . . . . . . . . . . . . . . . . . 8
4.1 Functional principle . . . . . . . . . . . . . . . 9
5 Device features . . . . . . . . . . . . . . . . . . . . . . 9
6 Mounting and installation . . . . . . . . . . . . . 10
6.1 Installation notes . . . . . . . . . . . . . . . . 10
6.2 Installation procedure . . . . . . . . . . . . 10
6.3 Power supply . . . . . . . . . . . . . . . . . . . 12
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 13
6.5 Current transformer PEX-W4/-W5 . . . 13
6.6 Wiring diagram (standard) . . . . . . . . . 15
6.7 Wiring diagram with booster connection
16
7 Startup and operation . . . . . . . . . . . . . . . . 17
7.1 View of the device . . . . . . . . . . . . . . . 17
7.2 Device configuration . . . . . . . . . . . . . 17
7.3 Heating element . . . . . . . . . . . . . . . . 19
7.4 Commissioning rules . . . . . . . . . . . . . 20
8 Device functions . . . . . . . . . . . . . . . . . . . . 22
8.1 LEDs and controls . . . . . . . . . . . . . . . 22
8.2 EtherNet/IPTM communication . . . . . . 23
8.3 Device description file (EDS) . . . . . . . 23
8.4 Communication protocol . . . . . . . . . . 24
8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 24
8.6 Output data . . . . . . . . . . . . . . . . . . . . 27
8.7 Parameter object (class: 0x0F) . . . . . 31
8.8 Integrated web server . . . . . . . . . . . . 59
8.9 Undervoltage detection . . . . . . . . . . . 62
8.10 Temperature meter (actual value output)
63
8.11 Booster connection . . . . . . . . . . . . . . 64
8.12 USB interface for visualization software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 65
8.13 AUX interface . . . . . . . . . . . . . . . . . . 65
8.14 Total cycle counter . . . . . . . . . . . . . . 65
8.15 Operating hours counter . . . . . . . . . . 65
8.16 Data memory for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 66
8.17 Built-in clock (date and time) . . . . . . . 66
8.18 System monitoring / alarm output . . . 66
8.19 Error messages . . . . . . . . . . . . . . . . . 67
8.20 Fault areas and causes . . . . . . . . . . . 71
9 Factory settings . . . . . . . . . . . . . . . . . . . . . 72
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 73
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 75
12 Modifications (MODs) . . . . . . . . . . . . . . . . 75
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 76
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Revision list
Page 3 UPT-6011 Version 5
1 Revision list
2 General information
This CIRUS®Temperature Controller is manufactured according to 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
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 31
• Extension of parameter object with instances 62 to 78: absolute calibration resistances
page 45
• Extension of integrated webserver: presentation of calibration values
section 8.8.6 "Calibration page" on page 62
• Updating of how to order
section 13 "How to order" on page 76
4 • Extension of parameter object: Restart delay after Reset (instance 79)
section 8.7 "Parameter object (class: 0x0F)" on page 31
• New: section 8.7.14 "Restart delay after Reset" on page 58
• Extension of parameter object with instances 80 and 81 for the TCR Calculator
section 8.7 "Parameter object (class: 0x0F)" on page 31
• New: section 8.7.2 "TCR Calculator" on page 53
• New: Voltage supply range changed to max. 480 VAC1(as from 02/2021)
section 10 "Technical data" on page 73
1. Standard: 415 VAC, optional and on request: 480 VAC
5 • Addition: LED AC blinks slowly: waiting for line voltage
section 8.1 "LEDs and controls" on page 22
• Addition: list „The AUTOCAL function is blocked:“
section 8.5.1 "Automatic zero calibration AUTOCAL (AC)" on page 25
• Addition: note
section 8.6.3 "Alarm active (AL)" on page 27
• Addition: function of Bit SA
section 8.6.9 "Standby active (SA)" on page 29
• Updating the data type (Attribute ID 1) for instances 80 und 81
section 8.7 "Parameter object (class: 0x0F)" on page 31
• Distinction: voltage alarm relay for UL approval, 24 V supply inrush current and control mode
section 10 "Technical data" on page 73

General information
Version 5 UPT-6011 Page 4
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
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
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General information
Page 5 UPT-6011 Version 5
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 5. 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:
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.
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 URand IRterminals)
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.

General information
Version 5 UPT-6011 Page 6
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!
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General information
Page 7 UPT-6011 Version 5
2.11 DECLARATION OF CONFORMITY
We hereby declare that the following device has been developed and manufactured in conformance with the direc-
tives cited below:
Compliant with following standards and directives:
Note:
This declaration of conformity certifies that the device/electronic itself complies with the above-mentioned direc-
tives. The CE mark on the device/electronic does not relieve the machinery manufacturer of his duty to verify the
conformity of the completely installed, wired and operationally ready system in the machine with the EMC directive.
Comments:
RESISTRON/CIRUS temperature controllers are not independently operable devices. They are used by the
machinery manufacturer to form a sealing system by adding EMC-relevant components such as filters, transfor-
mers, heatsealing bands and wiring. The final configuration may vary significantly in terms of performance and
physical dimensions. All information provided by us in connection with the line filter is merely intended as a guide
and is based on a typical measuring setup. It serves to demonstrate that compliance with the EMC directive can
be achieved by using a line filter that is suitable for the overall system. The line filter and current transformer must,
however, be determined on the basis of the respective application. We also wish to point out that the transformer
which is used must be designed in accordance with VDE 0551/EN 61558 or UL 5058 for safety reasons.
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)
Designation: RESISTRON/CIRUS temperature controller with accessories
Type: With line filter and current transformer
Operating principle: Impulse sealing of films and plastics
EN 61010-1 Safety requirements for electrical equipment, control, and laboratory use
2014/35/EU Low voltage directive
2014/30/EU Electromagnetic compatibility directive
2011/65/EU RoHS directive
July 12, 2020
J. Kühner (CEO)

Application
Version 5 UPT-6011 Page 8
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.
4 System description
Sample depiction
The basic design of the overall system is shown in the diagram above.

Device features
Page 9 UPT-6011 Version 5
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.
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-6011 is equipped with a EtherNet/IPTM 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 EtherNet/IPTM interface and through an
analogue output 0…10 VDC. The real heating element temperature can be visualised on an external display
instrument (e.g. ATR-x) or via the operating unit of the machine controller.
The UPT-6011 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 EtherNet/IPTM interface in
case of malfunction.
To increase operational security and immunity to interference, all EtherNet/IPTM 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 EtherNet/IPTM
interface.
Temperature impulse
Current impulses
Time
Temperature/Current

Mounting and installation
Version 5 UPT-6011 Page 10
The compact design of the CIRUS®Temperature Controller UPT-6011 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 480 VAC1(as from 02/2021)
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
• Comprehensive error diagnosis over the EtherNet/IPTM 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 76.).
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-6011:
1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
1. Standard: 415 VAC, optional and on request: 480 VAC
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Mounting and installation
Page 11 UPT-6011 Version 5
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 73 must be allowed between them.
3. Wire the system in accordance with the instructions in section 6.1 "Installation notes" on page 10, section 6.6
"Wiring diagram (standard)" on page 15, and the ROPEX Application Report. The information provided in
section 6.1 "Installation notes" on page 10 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.
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 EtherNet/IPTM scanner 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.
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Mounting and installation
Version 5 UPT-6011 Page 12
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
Page 13 UPT-6011 Version 5
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 12 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 12).
!
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 5 UPT-6011 Page 14
6.5.1 PEX-W4
6.5.2 PEX-W5
Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (EN 50022).
If the high-current wire cannot be routed through the opening provided, an HCB-1 high-current rail must be used.
Snap-on for DIN-rail 35 x 7,5 mm or 35 x 15 mm (EN 60715)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Mounting and installation
Page 15 UPT-6011 Version 5
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
Te r mi nat io n
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V
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-6011

Mounting and installation
Version 5 UPT-6011 Page 16
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
Te r mi nat io n
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V
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-6011

Startup and operation
Page 17 UPT-6011 Version 5
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 67).
If the secondary current I2is 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
EtherNet/IPTM
ports
!
2x

Startup and operation
Version 5 UPT-6011 Page 18
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 object (class: 0x0F)" on page 31).
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 65).
7.2.3 Configuration of the rotary coding switch for the IP address
These coding switches allow you to set the least significant byte in the IP address of the UPT-6011 in the EtherNet/
IPTM network to a value between 0x01 and 0xFD. A new setting does not take effect until the next time the con-
troller is switched on. The preset IP address of the UPT-6011 is configured as follows, depending on the settings
of the rotary coding switches:
The "00" switch position allow an IP address to be assigned, or the DHCP client switched on and off, via the
EtherNet/IPTM interface either using a software tool (e.g. Rockwell’s "BOOT / P-DHCP Server") or by manually
accessing the TCP / IP object. These settings are stored in the controller. However, when the power supply to the
controller is momentarily interrupted, the stored values are only used if the rotary coding switches are set to "00".
All other switch positions cause the stored values to be temporarily overwritten.
Rotary coding switch IP address
00 DHCP client active or if DHCP client was deactivated: Last IP
address assigned is static
01…FD 192.168.001.1…253
FE Configuration determined by PC visualization software
FF Last configuration assigned is 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
IP address selectable.
00 = Factory settings
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
0...F
0...F
IP address static or
obtained from DHCP
IP address preset to
PC configuration
01...FD
00
FE
192.168.001.XX
“Out of the box” config.FF

Startup and operation
Page 19 UPT-6011 Version 5
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 65).
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 8.5.1 "Automatic
zero calibration AUTOCAL (AC)" on page 25) and set the correction factor Co (section 8.7.9 "Correction factor
Co" on page 54). 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
A
larm relay contact
closed by alarm.
(factory setting)
!
!
!

Startup and operation
Version 5 UPT-6011 Page 20
7.4 Commissioning rules
Observe here section 2 "General information" on page 3 and section 3 "Application" on page 8.
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 10).
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 IP address with the rotary coding switches or assign it using a DHCP server
(section 7.2 "Device configuration" on page 17).
3. Link the device description file (EDS) into the EtherNet/IPTM scanner (section 8.3), then select the required
parameters, make the connections, assign an IP address, 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.
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 65). In order to
avoid malfunctions, please check the controller configuration before continuing the startup procedure.
7. One of the following states then appears:
8. Activate the AUTOCAL function while the heating element is still cold by setting the AC bit (AUTOCAL) in the
EtherNet/IPTM protocol (section 8.4 "Communication protocol" on page 24). The yellow "AUTOCAL" LED
lights up for the duration of the calibration process (approx. 10…15 s). The AA bit (AUTOCAL active) is addi-
tionally set and a voltage of 0 VDC appears at the actual value output (terminals 17+18). If an ATR-x is con-
nected, 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
slowly (1 Hz). In this case the controller configuration is incorrect (section 7.2 "Device configuration" on
page 17, ROPEX Application Report). Repeat the calibration after correcting the controller configuration.
9. After the zero point has been successfully calibrated, specify a defined temperature by means of the EtherNet/
IPTM 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 EtherNet/IPTM protocol) is a regular curve, in other words it must not jump
"ALARM" LED "OUTPUT" LED ACTION
OFF Short impulses every 0.4 seconds Go to step 8
BLINKS fast (4 Hz) OFF Go to step 8
LIT continuously OFF Error diagnosis (section 8.19)
!
!