Ropex CIRUS UPT-6011 User manual

CIRUS
Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: www.ropex.de
74321-Bietigheim-Bissingen (Germany) Data subject to change
22.7.20
UPT-6011
GB
The UPT-6011 temperature controller is a key component in an ULTRA-PULSE system, because
it is responsible for all heat management functions, i.e. controlling the temperature of the heating
element.
Important features
• Microprocessor technology
• Complete control via PROFINET interface (2 x RJ-45)
• Automatic zero calibration (AUTOCAL)
• Automatic configuration of the secondary voltage and current ranges (AUTORANGE)
• Automatic frequency adjustment
• Large current and voltage range
• Booster connection as standard
• 0…10VDC analog output for ACTUAL temperature
• Alarm function with error diagnosis
• Heatsaling element alloy and temperature range selectable
• Cooling system monitored
Operating
instructions

Page 2 UPT-6011
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heating element . . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Standards / CE marking . . . . . . . . . . . 4
1.7 Warranty provisions . . . . . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 System description . . . . . . . . . . . . . . . . . . . 5
3.1 Temperature controller . . . . . . . . . . . . 5
3.2 Current transformer . . . . . . . . . . . . . . . 6
3.3 Booster . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Accessories and modifications . . . . . . . . . 6
4.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
4.2 Modifications (MODs) . . . . . . . . . . . . . 7
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Installation steps . . . . . . . . . . . . . . . . 10
7.2 Installation steps . . . . . . . . . . . . . . . . 10
7.3 Installation procedure . . . . . . . . . . . . 10
7.4 Power supply . . . . . . . . . . . . . . . . . . . 12
7.5 Line filter . . . . . . . . . . . . . . . . . . . . . . 13
7.6 Current transformer PEX-W3 . . . . . . 13
7.7 Wiring diagram (standard) . . . . . . . . . 14
7.8 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 15
8 Startup and operation . . . . . . . . . . . . . . . . 16
8.1 View of the controller . . . . . . . . . . . . . 16
8.2 Controller configuration . . . . . . . . . . . 16
8.3 Heating element . . . . . . . . . . . . . . . . 18
8.4 Startup procedure . . . . . . . . . . . . . . . 18
9 Controller functions . . . . . . . . . . . . . . . . . 20
9.1 LEDs and controls . . . . . . . . . . . . . . . 20
9.2 EtherNet/IP communication . . . . . . . . 22
9.3 Device description file (EDS) . . . . . . . 22
9.4 Communication protocol . . . . . . . . . . 23
9.5 Input data . . . . . . . . . . . . . . . . . . . . . . 23
9.6 Output data . . . . . . . . . . . . . . . . . . . . 25
9.7 Parameter object (class: 0x0F) . . . . . 27
9.8 Undervoltage detection . . . . . . . . . . . 36
9.9 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 36
9.10 Booster connection . . . . . . . . . . . . . . 37
9.11 Diagnostic interface / visualization
software . . . . . . . . . . . . . . . . . . . . . . . 37
9.12 Total cycle counter . . . . . . . . . . . . . . 38
9.13 Operating hours counter . . . . . . . . . . 38
9.14 Data memory for error
messages and AUTOCAL . . . . . . . . . 38
9.15 Integrated clock
(date and time) . . . . . . . . . . . . . . . . . 38
9.16 System monitoring / alarm output . . . 39
9.17 Error messages . . . . . . . . . . . . . . . . . 40
9.18 Fault areas and causes . . . . . . . . . . . 43
10 Factory settings . . . . . . . . . . . . . . . . . . . . . 45
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 45
12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 46
13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Safety and warning notes
UPT-6011 Page 3
1 Safety and warning notes
This CIRUS-Temperaturregler is manufactured
according to DIN EN 61010-1. In the course of its
manufacture it passed through quality assurance,
whereby it was subjected to extensive inspections and
tests.
It left the factory in perfect condition.
The recommendations and warning notes contained in
these operating instructions must be complied with, in
order to guarantee safe operation.
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational
safety. Installation and maintenance may only be
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
1.1 Use
CIRUS temperature controllers may only be used for
heating and temperature control of heatsealing
elements which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance or use contrary to
the intended purpose, there is a risk that
safety will be impaired or that the heatsealing
element, electrical wiring, transformer etc. will
overheat. Ensuring such compliance is the
personal responsibility of the user.
1.2 Heating element
The temperature coefficient of a CIRUS-Temperatur-
regler is specially adapted to CIRUS heating elements.
The controller is not allowed to be operated
with any other heatsealing bands because
they could be overheated and damaged beyond
repair.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one section bobbin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.
Incorrect installation of the impulse
transformer impairs electrical safety.
1.4 Current transformer PEX-W2/-W3
The current transformer supplied with the CIRUS-
Temperaturregler is an integral part of the control
system.
Only the original ROPEX PEX-W2 or PEX-W3
current transformer may be used. Other
transformers may cause the equipment to
malfunction.
The current transformer may only be operated if it is
connected to the CIRUS-Temperaturregler correctly
(see section 9, "Startup and operation"). The relevant
safety instructions contained in section 8.3, "Power
supply", must be obeyed. External monitoring modules
can be used in order to additionally increase operating
safety. They are not included in the scope of supply of
the standard control system and are described in a
separate document.
1.5 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.6 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
!
!
!
!

Application
Page 4 UPT-6011
1.6 Standards / CE marking
The controller described here complies with the
following standards, provisions and directives:
Compliance with these standards and provisions is only
guaranteed if original accessories and/or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
1.7 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
2 Application
This CIRUS temperatue controller is an integral part of
the "series 6000". Its sole purpose is to control the tem-
perature of CIRUS/UPT heating elements, wich are
used mainly for Impulse-heatsealing PP and RE films.
The most important applications are packaging
machines, pouch-making machines, splicers,
machines for making pharmaceutical and medical pro-
ducts etc.
DIN EN 61010-1:2001
(2006/95/EG)
Safety requirements for electrical
equipment for measurement,
control and laboratory use
(low-voltage directive):
pollution degree 2,
protection class II,
measurement category I
(for UR and IR terminals)
DIN EN 60204-1
(2006/42/EG)
Electrical equipment of
machines (machinery directive)
EN 55011:1998 + A1:1999 +
A2:2002
EN 61000-3-2:2006-04
EN 61000-3-3:1995-01 +
A1:2001 + A2:2005-11
(2004/108/EG)
EMC genery emissions:
Group 1, Class A
EN 61000-6-2:2005
(2004/108/EG)
EMC generic immunity:
Class A (ESDs, RF radiation,
bursts, surges)
Exception:
Line voltage interruption acc.
EN 61000-4-11 is not fulfilled
(This leads to a designated error
message of the controller)

System description
UPT-6011 Page 5
3 System description
The basic design of the overall system is shown in the
diagram above.
CIRUS heating elements, and in particular UPT heating
elements, are high-performance systems which ope-
rate efficiently and reliably providing all the components
in the control loop are optimally tuned to one another –
and to the task at hand. Exact compliance with the
installation and wiring instructions is essential. The
system has been evolved and optimized by ROPEX
GmbH in an intensive development process. Users
who follow our technical recommendations will profit
from the unique functionality of this technology, which
reduces the customer's effort for installation, commis-
sioning and maintenance to a minimum.
3.1 Temperature controller
The controller calculates the resistance of the heating
element by measuring the current and voltage at a high
sampling rate (= line frequency), compares it with the
set point and – if the difference is not 0 – adjusts the
heating current with the help of a phase angle-con-
trolled transformer so that set = actual.
The fact that purely electrical variables are measured in
quick succession and the small mass of the heating

Accessories and modifications
Page 6 UPT-6011
layer of the UPT heating element together result in a
highly dynamic, thermo-electrical control loop.
Thanks to its microprocessor based technology, the
controller features an optimized control algorithm as
well as numerous functions tailored to the various
tasks, such as "AUTOCAL", ALARM with fault dia-
gnosis etc. These are described in detail below.
The CIRUS temperatue controller UPT-6011 is
equipped with two EtherNet/IP interfaces. These inter-
faces can be used to control all the controller functions
and interrogate controller information.
The ACTUAL temperature of the heating element is
supplied to the EtherNet/IP interface and to an analog
0 to 10V DC output. The real heating element tempera-
ture can thus be displayed on an external temperature
meter (e.g. ATR-x).
The UPT-6011 features an integrated fault diagnosis
function, which tests both the external system (heating
element, wiring etc.) and the internal electronics and
outputs a selective error message in case of a fault.
To increase operational safety and interference immu-
nity, all EtherNet/IP signals are electrically isolated
from the controller and the heating circuit.
The compact design of the CIRUS temperatue con-
troller UPT-6011 and the plug-in connections make this
controller easy to install.
3.2 Current transformer
The PEX-W2 or PEX-W3 current transformer supplied
with the CIRUS UPT-6011 controller is an integral part
of the control system. Only this original ROPEX current
transformer is allowed to be used.
Never attempt to operate the current transformer with
open connections!
3.3 Booster
If the maximum load exceeds the rated current of the
controller (section 5 "Technical data" on page 8), an
external switching amplifier (booster) must be used
(section 4.1 "Accessories" on page 6).
The other system components – UPT sealing bars,
transformers, filter, cooler etc. – are described in sepa-
rate brochures.
4 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the CIRUS temperatue con-
troller UPT-6011. They allow it to be optimally adapted
to your specific heatsealing application and to your
plant's design and operating philosophy.
4.1 Accessories
The products described below are only a few of the
wide range of accessories available for CIRUS tempe-
rature controllers ("Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Analog indication of the ACTUAL temperature of the heating element in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
in impulse mode.

Accessories and modifications
UPT-6011 Page 7
4.2 Modifications (MODs)
Owing to its universal design, the CIRUS temperatue
controller UPT-6011 is suitable for a very wide range of
heatsealing applications.
One modification (MOD) is available for the CIRUS
temperatue controller UPT-6011 for implementing spe-
cial applications.
MOD 01
Amplifier for low secondary voltages
(UR= 0.25…16VAC). This modification is necessary,
for example, for very short or low-resistance heating
elements.
Digital temperature meter DTR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Digital indication of the ACTUAL temperature of the heating element in °C, with
HOLD function.
Line filter LF-xx480
Essential in order to ensure CE conformity.
Optimized for the CIRUS temperatue controller.
Impulse transformer ITR-x
Designed according to VDE 0570/EN 61558 with a one section bobbin.
Optimized for impulse operation with CIRUS temperature controllers.
Specified according to the heatsealing application
(ROPEX Application Report).
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL tempe-
ratures in real time.
Booster B-xxx400
External switching amplifier, necessary for high primary currents (continuous
current > 5A, pulsed current > 25A).
Monitoring current transformer
For detecting frame short-circuits on the heating element.
Used as an alternative to the standard PEX-W2/-W3 current transformer.
Measurement cable UML-1
twisted measurement cable for the UR-voltage measurement.
Trailing cable, halogene und silicone free.

Technical data
Page 8 UPT-6011
5 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm) acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Line voltage 400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
Depending on the version selected (section 12 "How to order" on page 46)
Power supply system Balanced TN or TT system, max. 415VAC
Installation category III
Operation in a potential-free system (e.g. an IT system) is only per-
mitted after consultation with ROPEX.
Line frequency 47…63 Hz, automatic adjustment to frequencies in this range
24VDC supply
voltage
Terminals 19+20
24VDC, Imax = 200mA
Tolerance: ±10%
Measuring range Secondary voltage UR: 0.4…120VAC
Secondary current IR: 30…500A (with PEX-W2/-W3 current transformer)
ROPEX Application report
EtherNet/IP
interface
2 Ethernet switch ports RJ45
Wiring: IEC61784-5-3
Baud rate: 10 or 100MHz
Data transport layer: Ethernet II, IEEE 802.3
Addressing: DHCP or selectable with rotary coding switch
ACD and DLR support: Yes
Heatsealing element
type and temperature
range
The temperature range and temperature coefficient settings can also be specified
by means of the ROPEX visualization software (section 9.11 "Diagnostic
interface / visualization software" on page 37) in addition to the rotary coding
switch or the EtherNet/IP interface (see below):
Temperature range: 200°C, 300°C, 400°C, or 500°C
Temperature coefficient: 400…4000ppm/K (variable setting range)
Two different ranges can be set with the rotary coding switch or via the EtherNet/
IP interface:
Temperature coefficient 1700ppm/K, 0…300°C (CIRUS)
Temperature coefficient 1700ppm/K, 0…500°C (CIRUS)
Analog output
(actual value)
Terminals 17+18
0…10VDC, Imax =5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% plus 50mV
Fault relay
Terminals 12, 13, 14
Umax = 30V (DC/AC), Imax = 0.2A, changeover contact, potential-free
Cuttent consumption
(primary current of
impulse
transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
!

Dimensions
UPT-6011 Page 9
6 Dimensions
Power dissipation Max. 20W
Ambient temperature +5…+45°C
Degree of protection IP20
Installation A minimum safety clearance of 20mm all round
(e.g. from other devices and wiring) must be
allowed when installing the controller.
The moving clip required for fastening must be
facing down for mounting on a horizontal top hat
rail.
End holders to mechanically fix the controller must be fitted at both ends for
mounting on a vertical top hat rail.
Weight Approx. 0.5kg (incl. connector plug-in parts)
Housing material Plastic, polycarbonate, UL-94-V0
Connecting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors
Screw terminals: Clamping torque: 0.5…0.6Nm
(Screw driver size: SZS 0.6x3.5mm)
If ferrules are used, they must be crimped in accordance
with DIN 46228 and IEC / EN 60947-1.
This is essential for proper electrical contact in the terminals.
!
75.0 90.0
113.0
135.0

Installation
Page 10 UPT-6011
7Installation
See also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
7.1 Installation steps
1. Please refer to the safety and warning notes
(section 1 "Safety and warning notes" on page 3).
2. The information provided in the customized ROPEX
Application Report, which is prepared by ROPEX
specifically for each application, should be heeded
at all times.
3. All electrical components, such as the controller, the
impulse transformer and the line filter, should be
installed as close as possible to the UPT sealing
bar(s) in order to avoid long wires.
4. Connect the voltage measurement cable UR directly
to the UPT sealing bar and lay it twisted to the con-
troller (UML-1 voltage measurement cable
section 4 "Accessories and modifications" on
page 6).
5. Ensure an adequate cable cross-section for the pri-
mary and secondary circuits (Application Report).
6. Use only ROPEX impulse transformers or transfor-
mers approved by ROPEX. Please note the power,
the duty cycle and the primary and secondary
voltages (Application Report).
7.2 Installation steps
1. Please refer to the safety and warning notes
(section 1 "Safety and warning notes" on page 3).
2. The information provided in the customized ROPEX
Application Report, which is prepared by ROPEX
specifically for each application, should be heeded
at all times.
3. All electrical components, such as the controller, the
impulse transformer and the line filter, should be
installed as close as possible to the UPT sealing
bar(s) in order to avoid long wires.
4. Connect the voltage measurement cable UR directly
to the UPT sealing bar and lay it twisted to the con-
troller (UML-1 voltage measurement cable
section 4 "Accessories and modifications" on
page 6).
5. Ensure an adequate cable cross-section for the pri-
mary and secondary circuits (Application Report).
6. Use only ROPEX impulse transformers or transfor-
mers approved by ROPEX. Please note the power,
the duty cycle and the primary and secondary
voltages (Application Report).
7.3 Installation procedure
Proceed as follows to install the CIRUS temperatue
controller UPT-6011:
1. Switch off the line voltage and verify that the circuit
is de-energized.
2. The supply voltage specified on the nameplate of
the CIRUS temperatue controller must be identical
to the line voltage that is present in the plant or
machine. The line frequency is automatically
detected by the CIRUS temperatue controller in the
range from 47Hz...63Hz.
3. Install the CIRUS temperatue controller in the
electrical cabinet on a standard top hat rail (DIN
TS35 rail, according to DIN EN 50022). If several
controllers are installed on one top hat rail, the
minimum clearance specified in section 5 "Technical
data" on page 8 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 7.4 "Power supply" on page 12,
section 7.7 "Wiring diagram (standard)" on page 14
and the ROPEX Application Report. The information
provided in section 7.4 "Power supply" on page 12
must also be heeded additionally.
An overcurrent protective device (e.g. a fuse) with a
maximum rating of 10A must be fitted when the
controller is installed provided this is adequate for
the heatsealing application. If not, two separate
overcurrent protective devices should be provided,
one for the controller and one for the application
(ROPEX Application report).
The minimum possible specification for this device
must be entered 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. Connect the CIRUS temperatue controller to the
!

Installation
UPT-6011 Page 11
EtherNet/IP-Scanner using a cable according to.
Check the tightness of all the system connec-
tions, including the terminals for the impulse
transformer windings.
6. Make sure that the wiring conforms to the relevant
national and international installation regulations.
!

Installation
Page 12 UPT-6011
7.4 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
400VAC
50/60Hz
Over-current protection
Double-pole circuit-breaker or fuses,
(ROPEX Application Report)
Short-circuit protection only.
RESISTRON-Temperaturreglers 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-Temperaturregler
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 VDE 0570/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).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
These wires must always be twisted (>20turns/meter).
These wires must be twisted (>20turns/meter)
if several control loops are laid together ("crosstalk").
Twisting (>20turns/meter) is recommended to
improve EMC.

Installation
UPT-6011 Page 13
7.5 Line filter
To comply with EMC directives – corresponding to
EN 50081-1 and EN 50082-2 – RESISTRON control
loops must be operated with line filters.
These filters damp the reaction of the phase-angle con-
trol on the line and protect the controller against line
disturbances.
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
RESISTRON control loops. Providing that they are
installed and wired correctly, they guarantee com-
pliance with the EMC limit values.
You can find the exact specification of the line filter in
the ROPEX Application Report calculated for your par-
ticular heatsealing application.
For more technical information: "Line filter" docu-
mentation.
It is permissible to supply several CIRUS
control loops with a single line filter, provi-
ding the total current does not exceed the
maximum current of the filter.
The wiring instructions contained in section 7.4 "Power
supply" on page 12 must be observed.
7.6 Current transformer PEX-W3
The PEX-W3 current transformer supplied with the
RESISTRON temperature controller is an integral part
of the control system. The current transformer may only
be operated if it is connected to the temperature con-
troller correctly (section 7.4 "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. 1m
ROPEX
temperature
controller
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Installation
Page 14 UPT-6011
7.7 Wiring diagram (standard)
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
14
13
12
ALARM OUTPUT
max. 30V / 0.2A
19
Ethernet
PORT 1 (RJ45)
TX-
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
20
24V
IN 5V
OUT
Ethernet
module
electrically
isolated
R
11
9
10
8
4
3
2
1
IR
UR
15
16
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10VDC
0V
(Internal ground)
No external
grounding allowed!
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
6
Shield
Current transformer
PEX-W2/-W3
twisted
Impulse
transformer
Heat-
sealing
band
sec.
U2
prim.
U1
5
7NC
NC
LINE
Line filter LF-xx480
V+
V-
24VDC POWER SUPPLY
UPT-6011

Installation
UPT-6011 Page 15
7.8 Wiring diagram with booster
connection
8
7
5
4
6
3
2
1
RX-
RX+
TX+
14
13
12
19
Ethernet
PORT 1 (RJ45)
TX-
20
24V
IN 5V
OUT
R
11
9
10
8
4
3
2
1
IR
UR
15
16
18
17
°C
ATR
_
+
6
Shield
twisted
Max. length 1m
NC
NC
ALARM OUTPUT
max. 30V / 0.2A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
ANALOG OUTPUT
+0...10VDC
0V
(Internal ground)
No external
grounding allowed!
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Current transformer
PEX-W2/-W3
twisted
Impulse
transformer
Heat-
sealing
band
sec.
U2
prim.
U1
Ethernet
module
electrically
isolated
Termination
5
7NC
NC
LINE
Booster
24
IN OUT
13
Line filter LF-xx480
V+
V-
24VDC POWER SUPPLY
UPT-6011

Startup and operation
Page 16 UPT-6011
8 Startup and operation
8.1 View of the controller
8.2 Controller configuration
The controller must be switched off in order
to configure the coding switches and plug-in
jumpers.
8.2.1 Configuration of the secondary
voltage and current ranges
The secondary voltage and current ranges are
automatically configured by the automatic calibration
function (AUTOCAL). The voltage is configured in the
range from 0.4VAC to 120VAC and the current in the
range from 30A to 500A. If the voltage and / or current
are outside of the permissible range, a detailed error
message appears on the controller ( see section 9.17
"Error messages" on page 40).
If the secondary current I2 is less than 30A, the sec-
ondary high-current wire must be laid twice (or several
times) through the PEX-W2 or PEX-W3 current trans-
former (ROPEX Application Report).
Term ina ls
LEDs
Coding switches
Nameplate
Wiring diagram
and plug-in jumpers
EtherNet/IP-
connectors
!
2x

Startup and operation
UPT-6011 Page 17
8.2.2 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 9.7
"Parameter object (class: 0x0F)" on page 27).
If the switch is set to "9", more temperature ranges and
alloys can be selected by means of the ROPEX
visualization software (see section 9.11 "Diagnostic
interface / visualization software" on page 37).
8.2.3 Configuration of the rotary coding
switch for the IP address
These coding switches allow you to set the least signif-
icant byte in the IP address of the UPT-6011 in the
PROFINET network to a value between 0x01 and
0xFD. A new setting does not take effect until the next
time the controller 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 "01…FE" switch positions allow an IP address to
be assigned, or the DHCP client switched on and off,
via the PROFINET interface either using a software tool
(e.g. Rockwell's "BOOTP / 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.
0
5
1
2
3
4
6
7
8
9
0
5
1
2
3
4
6
7
8
9
Switch
position
0
4
300°C
500°C
1700ppm/K
1700ppm/K
(CIRUS)
(CIRUS)
Tem p.
range
Tem p.
coefficient
Band
alloy
0 = Factory settings
SWITCH POS.
0
4
9
TEMP. RANGE
300°C
500°C
PC CONFIGURATION
ALLOY
1700ppm/K (CIRUS)
1700ppm/K (CIRUS)
9 PC-CONFIGURATION
!
Rotary coding
switch IP address
00 The last IP address assigned is
static
01…FD 192.168.001.1…253
FE The configuration is determined
by the PC visualization software
FF The last configuration assigned
is erased
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 18 UPT-6011
8.2.4 Configuring the fault relay
If the jumper is not inserted – or if it is
incorrectly inserted – an error message
appears when the controller is switched on
(section 9.17 "Error messages" on page 40).
If the "Fault relay de-energized at alarm / PC CONFIG-
URATION" position is selected, the behavior of the
alarm output can be configured in more detail by means
of the ROPEX visualization software (see
section 9.11 "Diagnostic interface / visualization soft-
ware" on page 37).
8.3 Heating element
8.3.1 General
The heating element is a key component in the control
loop, since it is both a heating element and 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 applied for this system neces-
sitates a heating element alloy with a suitable tempera-
ture coefficient TCR, i.e. one whose resistance
increases as the temperature rises.
Too low a TCR leads to oscillation or uncontrolled hea-
ting.
When heating elements with a higher TCR are used,
the controller must be calibrated for this.
The base resistance of the heating elements
rises continuously during operation (con-
struction-conditioned). Due to this the AUTOCAL
function must be executed every 100.000 sealing
cyles for preventing measurement failures of the
ACTUAL temperature.
8.3.2 Replacing the heating element
All power supply leads must be disconnected from the
CIRUS temperatue controller in order to replace the
heating element.
The heating element must be replaced in
accordance with the instructions provided by
the manufacturer.
Each time the heating element is replaced, the zero
point must be calibrated with the AUTOCAL function
(section 9.5.1 "Automatic zero calibration
"AUTOCAL" (AC)" on page 24) while the element ele-
ment is still cold. The correction factor Co
(section 9.7.8 "Correction factor Co" on page 33)
must be adjusted too. With this procedure the produc-
tion-related resistance tolerances of the heating ele-
ment will be compensated.
8.4 Startup procedure
Please also refer to section 1 "Safety and warning
notes" on page 3 and section 2 "Application" on
page 4.
Installation and startup may only be per-
formed by technically trained, skilled per-
sons who are familiar with the associated risks and
warranty provisions.
8.4.1 Initial startup
Prerequisites: The controller must be correctly installed
and connected (section 7 "Installation" on page 10).
Proceed as follows to start up the controller for the first
time:
0
5
1
2
3
4
6
7
8
9
Alarm relay de-
energized by alarm/
PC-CONFIGURATION.
Alarm relay energized
by alarm.
(factory setting)
CONFIGURATION
ALARM OUTPUT
DE-ENERGIZED / PC
AT ALARM
ENERGIZED
!
!
!
!

Startup and operation
UPT-6011 Page 19
1. Switch off the line voltage and verify that all circuits
are de-energized.
2. The supply voltage specified on the nameplate of
the controller must be identical to the line voltage
that is present in the plant or machine. The line fre-
quency is automatically detected by the tempera-
ture controller in the range from 47…63Hz.
3. Link the device master file (EDS) into the
PROFINET scanner (section 9.3), then select the
required parameters, make the connections, assign
an IP address, and start the communication.
4. Make sure the "ST" bit is not set.
5. Switch on the line voltage and the 24VDC 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 indicate that the controller is being
powered up correctly.
If the red "ALARM" LED lights up for 0.3s in
addition to the yellow "AUTOCAL" LED when
the voltage is switched on, the configuration of this
controller has been changed by means of the
visualization software (section 9.11 "Diagnostic
interface / visualization software" on page 37). 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/IP protocol
(section 9.4 "Communication protocol" on
page 23). The yellow "AUTOCAL" LED lights up for
the duration of the calibration process (approx.
10…15s). The "AA" bit (AUTOCAL active) is
additionally set and a voltage of approx. 0VDC
appears at the actual value output (terminals
17+18). If an ATR-x is connected, it indicates
0…3°C.
When the zero point has been calibrated, the
"AUTOCAL" LED goes out and a voltage of
0.66VDC (300°C range) or 0.4VDC (500°C range)
appears at the actual value output instead. If an
ATR-x is connected, it must be set to "Z".
If the zero point has not been successfully
calibrated, the "AL" bit (alarm active) is set and the
red "ALARM" LED blinks slowly (1Hz). In this case
the controller configuration is incorrect (
section 8.2 "Controller configuration" on page 16
and ROPEX Application Report). Repeat the
calibration after the controller has been configured
correctly.
9. When the zero point has been successfully
calibrated, specify a defined temperature by means
of the EtherNet/IP protocol (set point) and set the
"ST" bit. The "RA" bit (controller 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/IP protocol) has a harmonious motion,
in other words it must not jump abruptly, fluctuate, or
deviate temporarily in the wrong direction. This kind
of behavior would indicate that the UR measurement
cable has been laid incorrectly.
If an error message is displayed, please proceed as
described in section 9.17 "Error messages" on
page 40.
10.The heatup process and the temperature control
must be optimized by means of setting the correc-
tion factor Co in the parameter data (EDS file) or the
parameter object (section 9.7.8 "Correction factor
Co" on page 33) now. With this setting the manu-
facturing process related tolerances of the heating
element are compensated.
"ALARM" LED "OUTPUT"
LED ACTION
OFF Short pulses
every 1.2s
Go to 8
BLINKS fast
(4Hz)
OFF Go to 8
LIT
continuously
OFF Error code 901
(Error group: 7):
No line voltage /
sync signal
(section 9.2)
Otherwise:
Error diagnosis
(section 9.17)
!
The controller is now ready

Controller functions
Page 20 UPT-6011
9 Controller functions
See also section 7.4 "Power supply" on page 12.
9.1 LEDs and controls
In addition to the functions shown in the diagram
above, various controller operating states are indicated
by the LEDs. These states are described in detail in the
table below:
12
13
14
15 16
17
18
9 8
6
5
10
11
7
20 19 4
3
2
1
www.ROPEX.de
R
RX/TX
(yellow LED)
LINK
(green LED)
Lit or blinking if Ethernet
frames are transmitted.
Lit if connection exists to
Ethernet.
AUTOCAL
(yellow LED)
OUTPUT
(Green LED)
HEAT
(yellow LED)
ALARM
(Red LED)
Lit while AUTOCAL process is
executing.
Indicates pulses in
measurement mode. In control
mode, luminous intensity is
proportional to heating current.
Lit during heating phase.
Lit or blinking to indicate fault.
NETWORK
STATUS
(red/green)
MODULE
STATUS
(Red/green)
BUS PWR OK
(green LED)
24V SUPPLY
(Green LED)
Lit (green) if connection exists
to EtherNet/IP scanner; lit (red)
to indicate network error.
Lit (green) if there are no
communication errors.
Lit if internal 5VDC power
supply for EtherNet/IP interface
is OK.
Lit if external 24VDC power
supply is present.