Ropex RESISTRON RES-401 Operating Instructions Manual Download Page 9

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Installation

Version 1

RES-401

Page 9

5.2

Installation steps

Line

Impulse

transformer

Current transformer
PEX-W2/-W3

U (prim.)

Heatsealing band R= f (T)

U (sec.)

Controller

Temperature

meter

ATR-x

Digital
potentiometer
PD-x

Avoid long

cables

Heatseal element

with coppered ends

Use heatseal bands with

suitable temperature coefficient

20mm clearance if several

controllers installed on

one top hat rail

Note

polarity

No additional

resistance

in secondary

circuit

Dimension
transformer correctly

- Secondary voltage
- Power

- Duty cycle

Configure

DIP switches

correctly

Sufficient wire

cross-section

push-on
connectors

Twisted

Current measuring

wires IR

Connect U measuring

wires directly to

heatsealing band ends

Line filter

LF-xx480

Note

direction

of rotation

Note

number

of turns

(up to Sept. 2005)

Summary of Contents for RESISTRON RES-401

Page 1: ...RESISTRON RES 401 Important features Automatic zero calibration AUTOCAL Automatic optimization AUTOTUNE Automatic configuration of the secondary voltage and current ranges AUTORANGE as of October 2005 Automatic frequency adjustment Set point selection with potentiometer Temperature range 300 C 0 10VDC analog output for ACTUAL temperature Activated with contact or 24VDC signal Alarm function Operat...

Page 2: ...ng diagram 13 5 7 Startup and operation 13 5 8 View of the controller 14 5 9 Controller configuration 14 5 10 Replacing and burning in the heat sealing band 15 5 11 Startup procedure 16 6 Controller functions 18 6 1 Indicators and controls 18 6 2 Temperature setting set point selection 20 6 3 Temperature indication actual value output 21 6 4 Automatic zero calibration AUTOCAL 22 6 5 START signal H...

Page 3: ...g bands 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 band electrical wiring transformer etc will overheat This is the personal responsibility of the user 1 3 Heatsealing band The...

Page 4: ... instructions contained in section Power supply must be observed External monitoring modules can be used in order to additionally increase operating safety They are not included in the scope of supply of the standard control system and are described in a separate document 1 6 Line filter ROPEX provides line filters in different power classes The ROPEX application report lists the suitable line fil...

Page 5: ...ally 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...

Page 6: ...ry 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 b...

Page 7: ...the heat sealing band are detected and can be corrected quickly and precisely A highly high response thermo electric control loop is formed which is highly accurate because purely electrical variables are measured at a high sampling rate A high secondary current can be controlled because power is controlled on the primary side of the transformer This allows optimum adaptation to the load and to th...

Page 8: ...ature controller must be identical to the line voltage that is present in the plant or machine The line frequency is automatically detected by the RESISTRON temperature controller in the range from 47Hz 63Hz 3 Install the RESISTRON temperature 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 ...

Page 9: ...ith suitable temperature coefficient 20mm clearance if several controllers installed on one top hat rail Note polarity No additional resistance in secondary circuit Dimension transformer correctly Secondary voltage Power Duty cycle Configure DIP switches correctly Sufficient wire cross section No push on connectors Twisted Current measuring wires IR R Connect U measuring wires directly to heatseal...

Page 10: ... side RESISTRON 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 ...

Page 11: ...rt calculated for your particular heatsealing application For more technical 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 5 3 Power supply on page 10 must be observed Example drawing for LF 06480 5 ...

Page 12: ...RES 401 Version 1 5 5 1 PEX W4 5 5 2 PEX W5 Mounting on DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 Snap on for DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 terminal block terminal wires 14 60 24 75 14 23 28 26 39 12 ...

Page 13: ...troller RES 401 GND 13 12 5 6 8 11 9 10 7 START HEAT with contact 14 15 18 17 16 cw 2K SET POINT POTENTIOMETER PD 3 Cable shielded C ATR _ ANALOG OUTPUT 0 10VDC 2 1 4 3 Current transformer twisted Impuls transformer Heat sealing band LINE Line filter LF xx480 sec U2 prim U1 0V Internal ground No external grounding allowed 0V Internal ground No external grounding allowed 0V Internal ground No exter...

Page 14: ...red 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 the current is outside the permissible range an error message appears on the controller see section 6 8 Error messages on page 25 Configuration with coding switches up to September 2005 Set the DIP switches for matching t...

Page 15: ... are used the controller must be calibrated for this The first time the heatsealing band is heated to approximately 200 250 C the standard alloy undergoes a once only resistance change burn in effect The cold resistance of the heatsealing band is reduced by approximately 2 3 However this at first glance slight resistance change results in a zero point error of 20 30 C The zero point must therefore...

Page 16: ...d 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 frequency is automatically detected by the temperature controller in the range from 47 63Hz 3 In the case of controllers manufactured up to September 2005 the settings of the DIP switches on the controller are indicated in the ROPEX Application ...

Page 17: ...lly set a defined temperature on the set point potentiometer and activate the START signal HEAT The HEAT LED then lights up up to September 2005 the twin color LED HEAT then 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 has a harmonious motio...

Page 18: ...een LED indicates pulses in measure ment mode In control mode luminous intensity is proportional to heating current Yellow LED lit during heating phase Red LED lights up or blinks to indicate ALARM 4 3 2 1 9 8 6 5 10 11 7 12 13 14 15 16 17 18 Button for manual activation of AUTOCAL function zero calibration Do not press unless heatsealing band is cold ROPEX INDUSTRIE ELEKTRONIK RESISTRON μP Contro...

Page 19: ...abled START executing OUTPUT green In control mode the luminous intensity is proportional to the heating current ALARM red Configuration error AUTOCAL not possible Controller calibrated incor rectly run AUTOCAL Fault section 6 8 LED Meaning Function Blinks lits green In control mode the luminous intensity is proportional to the heating current Measure Control mode Blinks red green alternately AUTO...

Page 20: ...tection must be installed External grounding is not allowed If this warning is ignored the controller will be damaged by frame currents If a ROPEX PD 3 precision potentiometer is used the SET temperature can be adjusted exactly with the help of the digital display in the window of the dial The number which appears on the display corresponds to the SET temperature in C The set point that is selecte...

Page 21: ...UAL temperature at terminals 14 15 Voltage values 0VDC 0 C 10VDC 300 C ATR 3 The relationship between the change in the output voltage and the ACTUAL temperature is linear RES 401 0 10VDC 0V Actual value output 0 10VDC max 5mA Temperature meter ATR 3 14 15 R 33Ohm 0 300 C range 1 2 3 4 5 6 7 8 9 10 300 Temperature T C 20 C ZERO VDC Voltage U 60 90 120 150 180 210 240 270 0 66V ...

Page 22: ...e terminals of the external temperature meter touch voltage protection must be installed If an alarm is signaled the voltage at the analog output at terminals 14 15 changes between 0VDC and 10VDC with 1Hz 6 4 Automatic zero calibration AUTOCAL Because of the automatic zero calibration AUTOCAL function there is no need to adjust the zero point manually on the controller This function matches the co...

Page 23: ...T LED lit 4 If the controller has already operated correctly at least once after starting up the AUTOCAL function cannot be activated if the ALARM LED is lit continuously up to September 2005 If the twin color LED lit continu ously If the AUTOCAL function is disabled and if you attempt to activate it then the AUTOCAL LED blinks up to September 2005 The twin color LED lits red for 1s except case 4 ...

Page 24: ...sealing temperature must be greater than 40 C If not the heatsealing band will not be heated up as of October 2005 HEAT LED blinks 6 6 Diagnostic interface visualization software as of October 2005 An interface with a 6 pole Modular Jack RJ 12 is provided for system diagnostics and process visualization This interface allows a data connection to be set up to the ROPEX visualization software using ...

Page 25: ...indications A Red ALARM LED on the controller three states 1 Blinks fast 4Hz The AUTOCAL function should be executed 2 Blinks slowly 1Hz The system configuration is incorrect and the zero calibration AUTOCAL function was unsuccessful 3 Lit continuously This indicates that a fault is preventing the controller from being started As a rule it refers to an external wiring fault An alarm can only be re...

Page 26: ...nt Wire break Secondary winding of impulse transformer interrupted UR signal missing Measuring wires 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 Contact to heatsealing band defective Total short circuit Heatsealing band installed incorrectly insulat...

Page 27: ...ange from 30 500A Turns through current transformer incorrect Check number of turns two or more turns required for currents 30A Internal controller fault Hardware fault replace controller DIP switches for secondary voltage U2 and current I2 up toSeptember 2005 U2 6 60VAC I2 30 100A DIP switches 2 ON 1 3 4 5 OFF These switches are automatically set by the AUTORANGE function on all controllers manuf...

Page 28: ...rsion 400VAC 15 415VAC 10 equivalent to 340 456VAC All controllers manufactured up to December 2003 115VAC 230VAC or 400VAC tolerance 10 15 depending on version selected section 11 How to order on page 30 Line frequency 47 63Hz automatic adjustment to frequencies in this range Heatsealing band type and temperature range Temperature coefficient 1100ppm 0 300 C e g Alloy A20 Set point selection Term...

Page 29: ... down for mounting on a horizontal top hat rail End holders to mechanical fix the controller must be fitted at both ends for mounting on a vertical top hat rail Weight Approx 0 7kg incl connector plug in parts Housing material Plastic polycarbonate UL 94 V0 Connecting cables Type cross sections Rigid or flexible 0 2 2 5mm AWG 24 12 Plug in If ferrules are used they must be crimped in accordance wi...

Page 30: ...n parts without current transformer Please indicate the article numbers in all orders Current transformer PEX W4 P N 885106 Line filter LF 480 06 Continuous current 6A 480VAC P N 885500 35 Continuous current 35A 480VAC P N 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communiction interface CI USB 1 P N 885650 Potentiometer PD 3 For 300 C range P N 881...

Page 31: ...10 30 Installation 8 29 Installation procedure 8 Installation regulations 8 L Line filter 4 10 11 30 Line frequency 7 28 Line voltage 28 M Maintenance 4 Modifications 29 MODs 29 O Over current protection 10 Overheating of heatsealing band 7 P PEX W4 30 PEX W4 W5 4 11 Potentiometer 20 30 Power dissipation 28 Power supply 10 30 Principle of operation 7 R Replacing the heatsealing band 16 17 S Second...

Page 32: ...Index Page 32 RES 401 Version 1 Wiring diagram 13 ...

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