Ropex RES-430/115 Operating Instructions Manual Download Page 16 | Manualshive

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Startup and operation

Page 16

RES-430

9

Startup and operation

9.1

View of the controller

9.1.1

Motherboard

9.1.2

Front view of the terminal

Connector for terminal

Terminals

Nameplate

Terminals

Connector
for piggyback module
(optional data interface)

Nameplate

Connecting cables

Operator keys

Mounting clamps

Display

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Summary of Contents for RES-430/115

Page 1: ...s multilingual Automatic zero calibration AUTOCAL Automatic optimization AUTOTUNE Automatic frequency adjustment Secondary control Heatsealing band alloy and temperature range selectable Time control heatsealing time and cooling time settable Configurable relay output e g end of cycle Time or temperature controlled cooling phase 0 10VDC analog output for ACTUAL temperature Load cell interface for ...

Page 2: ... control timer function 18 9 4 Temperaturediagnosis 22 9 5 Load cell interface temperature sensor 23 9 6 Heatsealing band 24 9 7 Startup procedure 25 10 Controller functions 27 10 1 Indicators and controls 27 10 2 Display 27 10 3 Navigation in the menus 29 10 4 Menu structure 31 10 5 Two digit numbering system up to SW revision 006 33 10 6 Temperature setting set point selection 34 10 7 Temperatur...

Page 3: ...ecified as follows e g Alloy 20 TCR 1100 ppm K NOREX TCR 3500 ppm K The RESISTRON temperature controller must be set and coded according to the temperature coefficient of the heatsealing band The use of incorrect alloys with too low a temperature coefficient and incorrect coding of the RESISTRON temperature controller leads to uncontrolled heating and ultimately to burn out of the heatsealing band...

Page 4: ...er 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 Application This RESISTRON temperature controller is an integral part of the series 400 the outstanding feature of which is its microprocessor technology All RESISTRON temperature controllers are used to control the temperature of heating el...

Page 5: ...s automatically to the controlled system High precision thanks to further improved control accuracy and linearization of the heatsealing band characteristic High flexibility Secondary voltage range from 12V to 42V current range from 20A to 90A Automatic adjustment to the line frequency in the range from 47Hz to 63Hz Increased protection against dangerous conditions such as overheating of the heats...

Page 6: ...o modifications are available for the RESISTRON temperature controller RES 430 5 2 Optional data interface piggyback module A serial data interface piggyback module is optionally available for the RES 430 controller This module can be ordered separately and retrofitted onto the motherboard It is connected to a PC by means of a serial data cable ª section 13 How to order on page 48 ...

Page 7: ...rocessing in another PC program In addition the software permits the values in the Configuration and Settings menus to be transferred to the controller or read from it This visualization software is described in a separate document Female connector 5 pole Male connector 5 pole Sub D connector 9 pole for serial data cable 4x spacer RES 430 motherboard Piggyback module Latching Snap on Connect the o...

Page 8: ...former Terminals 5 6 7 8 Two heatsealing bands Isec max 90A per heatsealing band Imax 45A One heatsealing band Isec max 70A If only one heatsealing band is used terminals 7 8 must be externally jumpered with a high current cable in order to avoid malfunctions or damage to the controller Min load current Up to SW revision 007 Isec min 30A SW revision 008 or higher Isec min 20A Analog output actual ...

Page 9: ...unting Display terminal Installed in front panel cutout with W x H 138 0 2 x 68 0 2 mm Fastened with clamps Weight Motherboard Approx 0 5kg incl connector plug in parts Display terminal Approx 0 4kg Housing material Display terminal Black plastic type Noryl SE1 GFN2 Connecting cables Type cross sections Terminals 4 9 Rigid or flexible 0 2 4 0mm AWG 24 10 with screw terminals Terminals 1 3 10 27 Ri...

Page 10: ...f 6mm must be used to fasten the printed circuit board on the underside All national and international regulations must be complied with Connector Piggyback module 6 x fixing hole optional data interface for T 430 terminal Specified component heights for connectors incl plug in parts 105 0 210 0 110 0 3 0 3 0 3 0 3 0 Diameter 3 2mm ...

Page 11: ... cutout RES 430 Page 11 7 2 Display terminal 144 72 Outline dimensions of front frame Panel cutout 138 x 68 0 2 0 2 4 58 9 136 66 144 Front panel Connecting cable length 250mm Rubber seal Mounting clamp Connector Front frame ...

Page 12: ...eps on page 12 must be heeded additionally Check the tightness of all the system connections including the terminals for the impulse transformer windings 6 Make sure that the wiring conforms to the relevant national and international installation regulations 8 2 Installation steps The following points should be heeded in addition to the information provided in the ROPEX Application Report when ins...

Page 13: ...r and the machine wiring ª ROPEX Application Report Do not lay the filter supply wires line side parallel to the filter output wires load side RES 430 RESISTRON temperature controller 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 m...

Page 14: ... ONE heatsealing band is used output terminals 7 8 must be jumped with a high current cable in order to avoid malfunctions or damage of the controller Step 240 in the Configuration menu must be set to Double for this purpose Band 1 Band 2 Heatsealing band Load cell interface and temperature sensor FOOT SWITCH Fuse Main switch Impulse transformer ANALOG OUTPUT ACTUAL temperature of heatsealing band...

Page 15: ...in switch Band 1 Band 2 Heatsealing band Impulse transformer Load cell interface and temperature sensor IMPORTANT If only ONE heatsealing band is used output terminals 7 8 must be jumped with a high current cable in order to avoid malfunctions or damage of the controller Step 240 in the Configuration menu must be set to Double for this purpose Line Solenoid ANALOG OUTPUT ACTUAL temperature of heat...

Page 16: ...ation 9 1 View of the controller 9 1 1 Motherboard 9 1 2 Front view of the terminal Connector for terminal Terminals Nameplate Terminals Connector for piggyback module optional data interface Nameplate Connecting cables Operator keys Mounting clamps Display ...

Page 17: ...gs with step 202 in the Configuration menu Only the language setting step 201 in the Configuration menu remains unchanged Please refer to section 11 Factory settings on page 46 for more information about the factory settings If the controller settings are unknown when it is started up for the first time the factory settings must be restored in order to prevent malfunctions 9 2 3 Configuration of t...

Page 18: ...upted If time control is on activating the START signal starts the internally parameterized timeout This timeout comprises Starting delay delay at the beginning of the heating phase Heating phase heating and control process Cooling phase Relay K1 or optional solenoid drive function It is only possible to start a heating process with the HAND key on the controller The timeout of the internal time c...

Page 19: ...fined as the factory setting In this case the heating process begins as soon as the START signal is activated 9 3 3 Setting the heatsealing time The heatsealing time can be set in the range from 0 to 99 9s with step 104 in the Settings menu The factory setting is 1 0s 9 3 4 Setting the cooling mode Various criteria for the end of the cooling phase can be specified with step 210 in the Configuratio...

Page 20: ...oling phase of the internal timeout ends when the ACTUAL temperature falls to the specified percentage of the SET temperature This value can be set between 40 and 100 The factory setting is 40 3 Cooling time in s if setting with menu step 210 Time The cooling phase ends when the specified time elapses This time can be set between 0 and 99 9s The factory setting is 10 0s 9 3 6 Setting the start of ...

Page 21: ... the solenoid drive closes at the end of the heating phase and opens again at the end of the cooling phase This configuration permits air cooling to be activated with relay K1 or the solenoid drive during the cooling phase for instance 4 End of cycle impulse The normally open contact of relay K1 or the solenoid drive closes at the end of the parameterized timeout i e at the end of the cooling phas...

Page 22: ...s ends at the end of the parameterized heatsealing phase As of SW revision 008 The temperature diagnosis function can be activated and deactivated with step 217 in the Configuration menu The following settings are possible 1 OFF Temperature diagnosis deactivated 2 ON Temperature diagnosis activated If the temperature diagnosis function is activated an additional delay time between 0 and 9 9s can b...

Page 23: ...cted load cell is inside a settable tolerance band OK window The upper and lower limit values can be changed separately by means of steps 242 243 in the Configuration menu If the measured force is outside the specified tolerance during the parameterized monitoring time the heatsealing cycle is immediately interrupted and an alarm is indicated on the display This monitoring function serves among ot...

Page 24: ...eded If a heatsealing cycle is in progress it is interrupted The temperature monitoring function is activated 3s after the controller is switched on If a temperature sensor is not connected or if the sensor connecting cable is defective an alarm is output by the controller after 3s assuming the temperature sensor has been activated with step 241 The sensor temperature measurement described here se...

Page 25: ... properties stabilized The burn in effect described here does not occur if the heatsealing band has already been thermally pretreated by the manufacturer 9 6 3 Replacing the heatsealing band All power supply leads must be disconnected from the RESISTRON temperature controller in order to replace the heatsealing band The heatsealing band must be replaced in accordance with the instructions provided...

Page 26: ...ure heatsealing temperature with step 101 in the Settings menu and activate the START signal HEAT Alternatively you can start a heatsealing process by pressing the HAND key assuming step 213 has not been locked in the Configuration menu and the display is in the home position The indication of the ACTUAL temperature on the display digital value and dynamic bar permits the heating and control proce...

Page 27: ...sage A power up message appears on the display for approximately 2 seconds when the controller is switched on This message also includes details of the software version ENTER HAND RESET ROPEX RESISTRON MENU key for advancing to next menu step or switching menu Press 2 sec Next menu step Hold 2 sec Return to home position ENTER function HAND function RESET function ENTER key Save values Manual mode...

Page 28: ...ucture on page 31 10 2 4 Alarm signals The fault diagnosis function of the controller is always active If a fault is detected it is indicated on the display immediately in the form of an alarm signal ª section 10 18 System monitoring alarm output on page 42 Icon indicates that NO contact of additional Specified heatsealing temperature SET temperature relay K1 is closed Measured ACTUAL temperature ...

Page 29: ... alarm is not active In this case the Alarm menu is opened instead If the display is in the home position or an alarm is indicated and you press the MENU key for longer than 2s you are taken directly to the configuration level starting at step 201 In addition you always return to the home position if you do not press any keys for a period of 30s There is no automatic return after 30s from AUTOCAL ...

Page 30: ... briefly pressing the MENU key 2s You can then activate the AUTOCAL function by pressing the ENTER key ª section 10 8 Automatic zero calibration AUTOCAL on page 35 If you press the MENU key for longer than 2s in the Alarm menu you are taken directly to the configuration level starting at step 201 You can return from the Configuration menu to the Alarm menu either by pressing the MENU key for longe...

Page 31: ...0 Cooling mode 212 Relay K1 function 213 Lock HAND key 207 Set point reached 205 Temperature range Settings Configuration 1 Force sensor active 2 Force sensor not active 3 Time control OFF 4 Time control ON 5 TCR not variable 6 TCR variable 211 Start of sealing time Fault 215 Alarm relay Display actual force 1 2 204 Temp coefficient 214 Cycles 107 Autocal 102 Preheating temp Autocal 5 6 209 Time c...

Page 32: ...245 Reference force 247 Force diagnosis 244 Force tare Configuration 1 Force sensor or force and tem perature sensor active 2 Temp sensor active 3 No sensors active 4 Temp sensor not active 243 Maximum force 1 2 249 Foot switch hold time Continued from previous page 246 Max sensor temp 3 2 4 Back to home position ...

Page 33: ...r section 10 4 Menu structure on page 31 Menu Menu step Numbering up to SW revision 006 Numbering as of SW revision 007 Settings menu Heatsealing temperature 1 101 Starting delay 3 103 Heatsealing time 4 104 Cooling value 5 105 Hold mode 6 106 AUTOCAL 7 107 Configuration menu Language 20 201 Factory settings 21 202 Alloy TCR 22 203 Var temp coeff 23 204 Temperature range 24 205 Maximum temperature...

Page 34: ...nce it has been entered 10 7 Temperature indication actual value output If the display is in the home position the ACTUAL temperature is indicated there as a digital value and as a dynamic bar The heating and control process can thus be monitored at any time In addition the RES 430 outputs an analog 0 10VDC signal which is proportional to the real ACTUAL temperature at terminals 10 11 Voltage valu...

Page 35: ...ing the ENTER key The initial temperature ambient temperature of the heatsealing bar s which is currently valid for calibration can be set beforehand in the 0 40 C range using the UP and DOWN keys The zero point is calibrated in the factory to 20 C The automatic calibration process takes around 10 15 seconds The heatsealing band is not heated until the calibration process has finished The message ...

Page 36: ...activated again Among other things this permits the closing movement of the sealing jaws to be started by briefly activating and deactivating the FOOT SWITCH signal The hold time is deactivated if the value entered is 0 factory setting The time control must energize relay K1 within the parameterized hold time activation of the START signal If not the controller indicates an alarm 10 11 START signa...

Page 37: ...ler you must set Double with step 240 The controller will otherwise be overloaded and damaged beyond repair If you change the configuration with step 240 you must run the AUTOCAL function with step 107 If not the controller will no longer function correctly 10 14 Hold mode The behavior of the digital indication of the ACTUAL temperature in the home position can be changed with step 206 in the Sett...

Page 38: ...ble all changes to values parameters in the Configuration menu This prevents the controller configuration from being tampered with by unauthorized persons The Configuration menu can be locked or unlocked by pressing the MENU key for 2seconds while the power up message is displayed after switching on the controller ª section 10 2 1 Power up message on page 27 The display then shows a message confir...

Page 39: ... is less than the lower limit of the permissible range occurs the controller is switched to a standby mode No more heatsealing processes take place and no more measuring impulses are generated The display changes to indicate this The main menu is displayed again and operation is resumed when the input voltage returns to the specified tolerance range The standby mode is indicated by 0 C corresponds...

Page 40: ... foot switch can then be opened again but the jaws remain closed 3 The heating process must begin immediately without a starting delay 4 The heatsealing time t2 1s must begin when the ACTUAL temperature reaches 95 of the SET temperature T 180 C 5 The heatsealing bands are not heated any further at the end of the heatsealing phase i e at the end of the heatsealing time The cooling phase begins 6 Th...

Page 41: ...should be undertaken in the specified order Then ACTUAL temp START signal 180 C t t OFF 0 80 C 1s t Open Relay K1 Closed 95 of 180 C ON FOOT SWITCH OFF ON signal t Step in Configuration menu Setting 210 Cooling mode Absolute 211 Start of heatsealing time When temperature reached 212 Relay K1 function When start signal present Step in Settings menu Setting 101 Heatsealing temperature 180 C 103 Star...

Page 42: ...els are offered for this purpose in the 0 10VDC range each of which is assigned an error code ª section 10 19 Error messages on page 42 If a state that requires AUTOCAL occurs or if the controller configuration is incorrect error codes 104 106 111 114 or 211 the actual value output jumps back and forth at 1Hz between the voltage value that corresponds to this error and the end of the scale 10VDC i...

Page 43: ...ing Voltage and current signals missing Temperature step down Temperature step up Temperature too low Temperature too high Frequency fluctuation inadmissible line frequency Internal fault Closing force too low Closing force too high Force sensor missing Temperature sensor defective Sensor temperature too high Temperature sensor missing Hold time exceeded Internal fault controller defective Temp 50...

Page 44: ...Impulse transformer incorrectly sized Temperature too low Temperature too high Calibration failed loose contact ambient temperature fluctuations Data error Current signal incorrect calibration not possible Voltage signal incorrect calibration not possible Current and voltage signals incorrect calibration not Temperature fluctuations calibration not possible Temp 500 C C 266 ª500 300 ª500 333 ª500 ...

Page 45: ...ault replace controller f Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc g Parallel circuit interrupted Wire break heatsealing band break Contacting to heatsealing band defective h Total short circuit Heatsealing band installed incorrectly insulation at heatsealing bar ends missing or incorrectly installed Conducting part byp...

Page 46: ...he Configuration menu Step 203 Alloy TCR 1100ppm Alloy 20 Step 204 Variable temp coeff 1100ppm Step 205 Temperature range 300 C Step 206 Maximum temperature 300 C Step 207 Set point reached 10K Step 208 Set point exceeded 10K Step 210 Cooling mode Absolute Step 211 Start of heatsealing time When temperature reached Step 212 Relay K1 function Active when START signal present Step 213 Lock HAND key ...

Page 47: ...tore customer settings Selecting this option restores the customer settings that were saved as described in 2 When the controller is first delivered the customer settings are identical to the Ropex settings After pressing the ENTER key in this menu step you are asked to confirm the new settings safety query Another message appears if you now confirm these settings by pressing the ENTER key for app...

Page 48: ...ludes connector plug in parts and T 430 terminal Line filter LF 06480 Continuous current 6A 480VAC Art No 885500 Impulse transformer See ROPEX Application Report for design and ordering information Optional data interface piggyback module Art No 743099 Sub D connecting cable for optional data interface for connection to piggyback module Length 2m Art No 884202 Length 5m Art No 884205 Length 10m Ar...

Page 49: ...OT SWITCH signal 36 I Impulse heatsealing method 4 Impulse transformer 13 48 Installation 9 12 Installation procedure 12 Installation regulations 12 L Line filter 13 48 Line frequency 5 8 Line voltage 8 Load cell interface 8 23 Load current 8 Locking Configuration menu 38 Locking HAND key 38 M Maintenance 47 Manual mode 34 Modifications 6 O Overheating of heatsealing band 5 P Piggyback module 6 Po...

Page 50: ...Index Page 50 RES 430 V View 16 Visualization software 7 W Wiring 12 13 Wiring diagram with relay K1 14 Wiring diagram with solenoid drive 15 ...

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