Ropex RES-445 Operating Instructions Manual Download Page 2

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RES-445

Contents

Safety and warning notes

. . . . . . . . . . . . . . 3

1.1

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2

Heatsealing band . . . . . . . . . . . . . . . . 3

1.3

Impulse transformer . . . . . . . . . . . . . . 3

1.4

Current transformer PEX-W2 . . . . . . . 3

1.5

Line filter . . . . . . . . . . . . . . . . . . . . . . . 4

1.6

Warranty provisions . . . . . . . . . . . . . . . 4

1.7

Standards / CE marking . . . . . . . . . . . 4

Application

. . . . . . . . . . . . . . . . . . . . . . . . . . 4

Principle of operation

. . . . . . . . . . . . . . . . . 5

Description of the controller

. . . . . . . . . . . 6

Accessories and modifications

. . . . . . . . . 6

5.1

Accessories . . . . . . . . . . . . . . . . . . . . . 6

5.2

Modifications (MODs) . . . . . . . . . . . . . 8

Technical data

. . . . . . . . . . . . . . . . . . . . . . . 9

Dimensions/front panel cutout

. . . . . . . . . 11

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . 12

8.1

Installation procedure . . . . . . . . . . . . 12

8.2

Installation steps . . . . . . . . . . . . . . . . 13

8.3

Power supply . . . . . . . . . . . . . . . . . . . 14

8.4

Line filter . . . . . . . . . . . . . . . . . . . . . . 15

8.5

Current transformer PEX-W2 . . . . . . 15

8.6

Wiring diagram (standard) . . . . . . . . . 16

8.7

Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 17

Startup and operation

. . . . . . . . . . . . . . . . 18

9.1

Front view of the controller . . . . . . . . 18

9.2

Rear view of the controller . . . . . . . . . 18

9.3

Controller configuration . . . . . . . . . . . 18

9.4

Heatsealing band . . . . . . . . . . . . . . . 20

9.5

Startup procedure . . . . . . . . . . . . . . . 21

Controller functions

. . . . . . . . . . . . . . . . . 23

10.1 Indicators and controls  . . . . . . . . . . . 23
10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 23
10.3 Navigation in the menus  . . . . . . . . . . 25
10.4 Menu structure . . . . . . . . . . . . . . . . . . 27
10.5 Menu steps  . . . . . . . . . . . . . . . . . . . . 28
10.6 Temperature setting (set point

selection) . . . . . . . . . . . . . . . . . . . . . . 33

10.7 Temperature indication/actual value

output . . . . . . . . . . . . . . . . . . . . . . . . . 34

10.8 Automatic zero calibration

(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 35

10.9 "START" signal (HEAT) . . . . . . . . . . . 36
10.10 "PREHEAT" signal (preheating without

time control) . . . . . . . . . . . . . . . . . . . . 37

10.11 "RESET" signal  . . . . . . . . . . . . . . . . . 38
10.12 "Temperature OK" signal . . . . . . . . . . 38
10.13 Cycle counter . . . . . . . . . . . . . . . . . . .  39
10.14 Hold mode . . . . . . . . . . . . . . . . . . . . . 39
10.15 Disabling the Configuration menu . . .  41
10.16 Setting the display brightness

(VF display only) . . . . . . . . . . . . . . . . 41

10.17 Undervoltage detection  . . . . . . . . . . . 41
10.18 Booster connection  . . . . . . . . . . . . . . 42
10.19 Time control (timer function)  . . . . . . . 42
10.20 System monitoring/alarm output  . . . . 48
10.21 Error messages . . . . . . . . . . . . . . . . . 49
10.22 Fault areas and causes . . . . . . . . . . . 51

Factory settings

. . . . . . . . . . . . . . . . . . . . . 52

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . 53

How to order

. . . . . . . . . . . . . . . . . . . . . . . . 54

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Summary of Contents for RES-445

Page 1: ...omatic frequency adjustment Large current and voltage range Booster connection as standard Heatsealing band alloy and temperature range selectable Time control heatsealing time and cooling time settable Preheating Configurable relay output e g end of cycle Time or temperature controlled cooling phase Signal output for Temperature OK 0 10VDC analog input for set point selection electrically isolate...

Page 2: ...the controller 18 9 3 Controller configuration 18 9 4 Heatsealing band 20 9 5 Startup procedure 21 10 Controller functions 23 10 1 Indicators and controls 23 10 2 Display 23 10 3 Navigation in the menus 25 10 4 Menu structure 27 10 5 Menu steps 28 10 6 Temperature setting set point selection 33 10 7 Temperature indication actual value output 34 10 8 Automatic zero calibration AUTOCAL 35 10 9 START...

Page 3: ...oy 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 The heatsealing bands tha...

Page 4: ...ty 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 provisi...

Page 5: ...ds on the heatsealing band are detected and can be corrected quickly and precisely The thermoelectric control loop which is formed has a highly dynamic response because purely electrical variables are measured at a high sampling rate A high secondary current can be controlled with only minimal power loss because power is controlled on the primary side of the transformer This allows optimum adaptat...

Page 6: ... temperature meter e g ATR x The RESISTRON temperature controller RES 445 also features an integrated fault diagnosis function which tests both the external system heatsealing band wiring etc and the internal electronics and outputs a selective error message in case of a fault To increase operational safety and interference immunity all 24VDC logic signals are electrically isolated from the contro...

Page 7: ...ernative to the standard PEX W2 current transformer Transparent front cover TFA 1 For increasing the degree of protection on the front of the controller to IP65 Also facilitates applications in the food technology sector GMP Adapter for top hat rail mounting HS Adapter 01 For mounting the RESISTRON temperature controller RES 445 on a top hat rail DIN TS35 Allows the controller to be installed in t...

Page 8: ...cations MOD are available for the RESISTRON temperature controller RES 445 for implementing special applications MOD 01 Amplifier for low secondary voltages UR 0 25 16VAC This modification is necessary for example for very short or low resistance heatsealing bands MOD 33 Software revision 010 or higher Important heatsealing process data can be output and logged via a serial RS232 interface MOD 33 ...

Page 9: ...sion 019 or higher Temperature coefficient 700ppm 0 300 C SW revision 019 or higher Temperature coefficient 780ppm e g Alloy L 0 200 C 0 300 C 0 400 C 0 500 C SW revision 011 or higher Temperature coefficient 870ppm 0 300 C SW revision 019 or higher Temperature coefficient 980ppm 0 300 C SW revision 019 or higher Temperature coefficient 1100ppm e g Alloy 20 0 200 C 0 300 C 0 400 C 0 500 C Temperat...

Page 10: ...display green 4 lines 20 characters alternatively VF display blue 4 lines 20 characters Ambient temperature 5 45 C Degree of protection Front IP42 IP65 with transparent front cover Art No 887000 Back IP20 Installation Installed in front panel cutout with W x H 138 0 2 x 68 0 2 mm Fastened with clips Weight Approx 1 0kg incl connector plug in parts Housing material Black plastic type Noryl SE1 GFN2...

Page 11: ...ensions front panel cutout 29 132 9 136 66 144 72 front panel terminal blocks terminal wires rubber seal mounting clamp terminal blocks terminal wires outline dimensions front frame panel cutout 138 x 68 0 2 0 2 DIP switch to select U I 2 2 front frame ...

Page 12: ...n the plant or machine The line frequency is automatically detected by the temperature controller in the range from 47Hz to 63Hz 3 Install the RESISTRON temperature controller in the front panel cutout It is fastened by means of two clips which snap onto the side of the controller housing 4 Wire the system in accordance with the instructions in Kap 8 3 Power supply auf Seite 14 Kap 8 6 Wiring diag...

Page 13: ... suitable temperature coefficient No additional resistance in secondary circuit Dimension transformer correctly Secondary voltage Power Duty cycle Sufficient wire cross section No push on connectors Twisted Current measuring wires IR R Connect U measuring wires directly to heatsealing band ends Line filter LF xx480 Note number of turns Controller OPTION Temperature meter ATR x Note polarity Config...

Page 14: ...tput wires load side RESISTRON temperature controller belonging to the series 4xx Relay K2 Load break all pole e g in combination with the alarm output of the 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 mus...

Page 15: ...chnical information Line filter documentation It is permissible to supply several RESISTRON 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 8 3 Power supply on page 14 must be observed 8 5 Current transformer PEX W2 The PEX W2 current transformer supplied with the RESISTRON temperatur...

Page 16: ...CH1 with contact START HEAT with 24VDC signal PREHEAT CH1 with 24VDC signal ALARM OUTPUT max 50V 0 2A RELAY K1 100VDC 1 5A 240VAC 1 5A GND GND Contact closed or opened by ALARM see configuration Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Intern ground No external grounding allowed R Impulse transformer IR UR Current transformer PEX W2 twisted Heat sea...

Page 17: ...with contact START HEAT with 24VDC signal PREHEAT CH1 with 24VDC signal ALARM OUTPUT max 50V 0 2A RELAY K1 100VDC 1 5A 240VAC 1 5A GND GND Contact closed or opened by ALARM see configuration Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Intern ground No external grounding allowed R Impulse transformer IR UR Current transformer PEX W2 twisted Heat sealing...

Page 18: ... order to configure the DIP switches Nameplate Terminals Wiring diagram DIP switches on rear of controller Operator keys Clips Display 1 2 3 4 5 6 7 8 9 10 11 19 20 21 22 23 24 25 26 3 2 1 4 5 18 17 16 1 2 3 4 5 ROPEX 19 20 21 22 23 24 25 26 U V 2 I2 A 1 10 6 60 20 120 30 100 60 200 120 400 OFF OFF OFF ON ON ON DIP SWITCH ON 1 16 17 18 K1 U1 4 5 6 7 8 9 10 11 12 13 14 15 3 2 1 4 5 ON OFF DIP SWITC...

Page 19: ...3 Restoring the factory settings The internal controller settings can be reset to the factory settings with step 21 in the Configuration menu Only the language setting step 20 in the Configuration menu remains unchanged Please refer to Kap 11 Factory settings auf Seite 52 for more information about the factory settings If the controller settings are unknown when it is started up for the first time...

Page 20: ...ary controller settings are explained in the detailed functional descriptions in Kap 10 5 Menu steps auf Seite 28 and Kap 10 19 Time control timer function auf Seite 42 They are only allowed to be entered by technically trained persons The timer function is activated with step 26 in the Configuration menu 9 3 6 Relay K1 without time control The function of relay K1 is specified with step 29 in the...

Page 21: ... burned in and the change in the alloy properties stabilized The burn in effect described here does not occur if the heatsealing band has already been thermally pretreated by the manufacturer 9 4 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 acc...

Page 22: ...ivate the START signal HEAT Alternatively a heatsealing process can be started by pressing the HAND key display in home position The indication of the ACTUAL temperature on the display digital value and dynamic bar permits the heating and control process to be monitored The controller is functioning correctly if the temperature indicated on the display has a continuous curve in other words it must...

Page 23: ...s 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 Reset after alarm UP and DOWN keys for setting values Press 2 sec Slow change Hold 2 sec Fast change LC display 4 lines multilingual isplay 4 ...

Page 24: ...4 Menu structure auf Seite 27 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 Kap 10 20 System monitoring alarm output auf Seite 48 Icon indicates that NO contact of additional Specified heatsealing temperature SET temperature relay K1 is closed Measured ACTUAL temp...

Page 25: ...er 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 20 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 26: ...briefly pressing the MENU key 2s You can then activate the AUTOCAL function by pressing the ENTER key Kap 10 8 Automatic zero calibration AUTOCAL auf Seite 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 20 You can return from the Configuration menu to the Alarm menu either by pressing the MENU key for longer than...

Page 27: ...ng delay 2 Preheating temp 1 Heatsealing temp Home position Power up message 25 Set point exceeded 26 Time control 27 Cooling mode 29 Relay K1 function 30 Cycles 31 Alarm relay 32 Meas imp length 24 Set point reached 23 Max temperature Settings Configuration 1 2 1 Time control ON 2 Time control OFF 1 2 28 Start of sealing time Fault MOD 1 only Autocal 7 Autocal 33 Analog output ...

Page 28: ...nalog input terminals 20 23 and an internal heatsealing temperature step 1 are specified simultaneously the higher of the two temperatures is used and indicated in the main menu Depends on setting of step 22 0 40 C maximum temperature step 23 2 Preheating temperature The required preheating temperature can be set with the UP and DOWN keys The maximum temperature step 23 applies to both the heatsea...

Page 29: ...ed by Hold This procedure is repeated for every cycle and the displayed value is updated The word Hold is invisible for 100ms before the value is updated If you select the 2 second hold function the display changes back from hold mode to the actual value in real time after 2 seconds The hold function is then activated again for 2 seconds at the end of the next cycle ON OFF 2 s 7 Autocal The AUTOCA...

Page 30: ... the required operating range This also determines the scale for the bar display and the analog output Availability depends on SW revision TCR 410ppm 300 C TCR 460ppm 300 C TCR 510ppm 300 C TCR 570ppm 300 C TCR 630ppm 300 C TCR 700ppm 300 C TCR 780ppm 200 C TCR 780ppm 300 C TCR 780ppm 400 C TCR 780ppm 500 C TCR 870ppm 300 C TCR 980ppm 300 C TCR 1100ppm 200 C TCR 1100ppm 300 C TCR 1100ppm 400 C TCR...

Page 31: ...the required cooling mode Absolute The cycle ends if the actual value falls below the cooling temperature set here Absolute in C Relative The cycle ends if the actual value falls below the relative cooling temperature percentage of the set point set here Relative in Time The cycle ends when the set cooling time has elapsed This function can only be selected if time control step 26 is active Time i...

Page 32: ...ength of the momentary impulse can be shortened by applying the start signal during the impulse Relay K1 generates end of cycle impulse 30 Cycles The number of heating impulses not manual impulses is counted and displayed with this menu step The counter can be reset either by pressing the ENTER key or by restoring the factory settings Reset with ENTER key 31 Alarm relay This menu step permits the ...

Page 33: ...h step 22 The set point that is selected for the heatsealing temperature must be greater than 40 C If not the heatsealing band will not be heated up when the START signal is activated or the HAND key is pressed The set heatsealing temperature is displayed in the main menu once it has been entered If the heatsealing temperature is specified via the analog input at terminals 20 23 the external volta...

Page 34: ...nly the two temperature ranges 300 C and 500 C appear at this actual value output If a temperature range of 200 C is set for the controller with step 22 in the Configuration menu it appears at this output in the 0 300 C range A 400 C temperature range is indicated as 0 500 C An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing band The c...

Page 35: ...s setting is possible as of software revision 017 A fixed 10VDC reference voltage is output at the actual value output 10 8 Automatic zero calibration AUTOCAL Owing to the automatic zero calibration AUTOCAL function there is no need to adjust the zero point manually on the controller The AUTOCAL function matches the controller to the current and voltage signals that are present in the system This ...

Page 36: ...n Configuration menu step 26 1 Time control off deactivated When the START signal is activated the controller internal set actual comparison is enabled immediately and the heatsealing band is heated up to the SET temperature It remains at this temperature until the signal is deactivated again This process can also be started independently of the START signal by pressing the HAND key while the disp...

Page 37: ...means of a 24VDC signal at terminals 20 22 By means of a control contact at terminals 2 19 The START signal is disabled as long as the AUTOCAL function is executing in the Settings menu with step 7 The value that is selected for the preheating temperature step 2 in the Settings menu must be greater than 40 C If not the heatsealing band will not be heated up The alarm relay is switched if the PREHE...

Page 38: ...d if one is in progress No more measuring impulses are generated An alarm signal is reset if one is present The AUTOCAL function is not aborted if the RESET signal is activated while it is still executing The controller executes an internal initialization for approximately 500ms after the RESET signal is deactivated The next heatsealing process cannot be started until it has finished If a contacto...

Page 39: ... to 0 if the ENTER key is pressed or if the maximum count of 999 999 999 cycles is exceeded 10 14 Hold mode The behavior of the digital indication of the ACTUAL temperature in the home position can be changed with step 6 in the Settings menu The following settings are possible 1 OFF If the main menu is visible on the display the real ACTUAL temperature is always indicated 2 ON If the display is in...

Page 40: ...amic bar and the actual value output The various hold modes are shown below The word Hold appears on the display if a temperature value is indicated in hold mode It disappears for approximately 100ms whenever the hold value is updated ACTUAL temp START signal 24VDC T t t 0 0 Hold OFF T t 0 ACTUAL indication Hold ON T t 0 Hold 2 s T t 0 Hold Hold Hold Hold End of heating phase 2 s 2 s ...

Page 41: ...tness VF display only Software revision 019 or higher If the display is in the home position the brightness of the VF display blue can be set in 4 steps 25 50 75 100 with the UP and DOWN keys The factory setting is 75 The life of the VF display can be prolonged by reducing the brightness 10 17 Undervoltage detection Trouble free operation of the temperature controller is guaranteed within the line...

Page 42: ...ernal timeout is started by activating the START signal In this setting however the START signal must remain activated until the end of the parameterized cooling phase If the START signal is deactivated before the end of the cooling phase or if the RESET signal is activated the timeout is interrupted If time control is on activating the START signal starts the internally parameterized timeout This...

Page 43: ...licitly delayed by entering a starting delay time with step 3 in the Settings menu e g in order to bridge the closing time of the heatsealing bars When the START signal is activated the controller waits for the time specified with this menu step to elapse before commencing the heating process The starting delay can be set in the range from 0 to 9 9s A delay of 0s is defined as the factory setting ...

Page 44: ...when ACTUAL temperature 108 C 3 Time The cooling phase ends after a specified time in seconds and is independent of the ACTUAL temperature This cooling time can be set with step 5 in the Settings menu The various cooling modes are shown below 10 19 5 Setting the cooling value After the cooling phase has been configured with step 27 in the Configuration menu Kap 10 19 4 Setting the cooling mode auf...

Page 45: ... with step 28 in the Configuration menu The following settings are possible 1 When heating starts The parameterized heatsealing time starts as soon as the set starting delay elapses Settings menu step 3 If the starting delay 0s the heatsealing time begins as soon as the START signal is activated 2 When temperature reached Once again the heating process starts as soon as the set starting delay elap...

Page 46: ...ase This configuration permits air cooling to be activated with relay K1 during the cooling phase for instance 4 End of cycle impulse The normally open contact of relay K1 closes at the end of the parameterized timeout i e at the end of the cooling phase and opens again after approximately 500ms If a START signal is activated while relay K1 is still closed the relay opens again immediately The pos...

Page 47: ...erated L sealer with a solenoid valve The heatsealing process is started by means of a foot switch The functional sequence is as follows 1 The controller receives the START signal for internal time control via the foot switch 2 The heating process must begin immediately without a starting delay 3 When the ACTUAL temperature reaches 95 of the SET temperature T 180 C the normally open contact of rel...

Page 48: ...ct closes however if a START signal is activated in this state CLOSED if error code 101 103 107 108 201 203 801 or 9xx appears If the alarm relay is configured differently from the factory setting Kap 9 3 7 Configuration of the alarm relay auf Seite 20 these states are inverted C Error code output via the 0 to 10VDC actual value output terminals 20 24 Since a temperature indication is no longer ne...

Page 49: ...n be reset by pressing the RESET key by activating the RESET signal at terminals 20 26 Kap 10 11 RESET signal auf Seite 38 or by switching the controller off and then on again 10 21 Error messages The table below shows how the analog voltage values that appear at the actual value output are assigned to the faults that have occurred It also describes each fault and the required corrective action Th...

Page 50: ...Frequency fluctuation inadmissible line frequency Internal fault Internal fault controller defective U R and or I R signal incorrect Data error I R signal incorrect calibration not possible U R signal incorrect calibration not possible U R and I R signals incorrect calibration not possible STATUS of alarm relay factory set Closed Open does not close until START signal voltage value at actual value...

Page 51: ...int Wire break Secondary winding of impulse transformer interrupted UR signal missing Measuring wire interrupted Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heatsealing band break Contacting to heatsealing band defective Total short circuit Heatsealing band installed incorrectly insu...

Page 52: ...ep 5 Cooling value Cooling time 10 s Absolute cooling temperature 50 C Relative cooling temperature 40 of heatsealing temperature Step 6 Hold mode OFF Step 7 AUTOCAL temperature 20 C Configuration menu Step 20 Language German This selection is NOT changed if the factory settings are restored with step 21 in the Configuration menu Step 22 Alloy range Alloy 20 max 300 C Step 23 Maximum temperature 3...

Page 53: ...if the factory settings are restored 12 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 controller can be removed with dry compressed air ...

Page 54: ...ional if required e g 01 MOD 01 Art No 800001 amplifier for low voltage Please indicate the article numbers of the controller and the required modifications optional in all orders e g RES 445 L 400VAC MOD 01 controller with LC display for 400VAC line voltage and amplifier for low voltage Art Nos 744513 800001 must be ordered Current transformer PEX W2 Art No 885104 Line filter LF 480 06 Continuous...

Page 55: ...ngs 19 52 Fault areas 51 Fault diagnosis 6 Front cover 7 H HEAT 22 36 Heatsealing band type 9 Hold mode 39 I Impulse heatsealing method 4 Impulse transformer 7 14 54 Installation 10 12 Installation procedure 12 Installation regulations 12 L Line filter 7 14 15 54 Line frequency 6 9 Line voltage 9 M Maintenance 53 Manual mode 33 Measurement cable 7 Modifications 8 54 MODs 8 54 Monitoring current tr...

Page 56: ...Page 56 RES 445 Temperature setting 33 Time control 20 Timer function 20 36 Transformer 3 7 14 54 Type of construction 9 U Undervoltage detection 41 V View of controller 18 W Wiring 12 14 Wiring diagram 16 17 ...

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