Ropex RESISTRON RES-402 Operating Instructions Manual Download Page 1

Page: 1 / 33

ROPEX Industrie-Elektronik GmbH

Tel.: +49 (0)7142-7776-0

E-Mail:

[email protected]

Adolf-Heim-Str. 4

Fax: +49 (0)7142-7776-211

Internet:

https://ropex.de

74321 Bietigheim-Bissingen (Germany)

Data subject to change

24.7.20

Version 1

RESISTRON

RES-402

Important features

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)

• Automatic configuration of the secondary voltage and current ranges

(AUTORANGE, as of January 2006)

• Automatic frequency adjustment

• Temperature range: 300°C

• Electrically isolated analog input for set point selection with potentiometer or 0…10VDC

• Electrically isolated 0…10VDC analog output for ACTUAL temperature

• 24VDC control signals for START, AUTOCAL and RESET with electrical isolation

• Alarm function

Operating

Instructions

Summary of Contents for RESISTRON RES-402

Page 1: ...ibration AUTOCAL Automatic optimization AUTOTUNE Automatic configuration of the secondary voltage and current ranges AUTORANGE as of January 2006 Automatic frequency adjustment Temperature range 300 C Electrically isolated analog input for set point selection with potentiometer or 0 10VDC Electrically isolated 0 10VDC analog output for ACTUAL temperature 24VDC control signals for START AUTOCAL and...

Page 2: ...Wiring diagram 14 6 Startup and operation 14 6 1 View of the controller 15 6 2 Controller configuration 15 6 3 Replacing and burning in the heat sealing band 16 6 4 Startup procedure 17 7 Controller functions 19 7 1 Indicators and controls 19 7 2 Temperature setting set point selection 20 7 3 Temperature indication actual value output 22 7 4 Automatic zero calibration AUTOCAL 23 7 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: ... also its resistance This change is measured and evaluated by the RESISTRON temper ature controller The control loop is closed ACTUAL temperature SET temperature Even minute thermal loads on the heat sealing 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...

Page 8: ...llation procedure Proceed as follows to install the RESISTRON temperature controller RES 402 1 Switch off the line voltage and verify that all circuits are deenergized 2 The supply voltage specified on the nameplate of the RESISTRON temperature 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 co...

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 402 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: ...ary voltage Since the inputs and outputs of the RES 402 are electrically isolated a 24VDC auxiliary voltage must be applied to terminals 14 13 The auxiliary voltage has a maximum current input of 1 0A and it is also protected against reverse polarity ...

Page 14: ...ansformer Impulse transformer Heat sealing band LINE Line filter LF xx480 sec Twisted U2 prim U1 RESET with 24VDC signal START HEAT with 24VDC signal CH1 ALARM OUTPUT 24VDC ANALOG OUTPUT real temperatur 0 10VDC ANALOG INPUT set point 0 10VDC Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Internal ground No external grounding allowed 0V Internal ground No ...

Page 15: ... configured in the range from 0 4VAC to 80VAC and the current in the range from 30A to 500A If the voltage and or the current is outside the permissible range a detailed error message appears on the controller see section 7 9 Error messages on page 27 Configuration with coding switches up to December 2005 Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to th...

Page 16: ...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 be corrected after a few heating cycles i e the AUTOCAL function must be repeated The burn in effect described here does not occur if the heatse...

Page 17: ...frequency is automatically detected by the temperature controller in the range from 47 to 63Hz 3 In the case of controllers manufactured up to December 2005 the settings of the DIP switches on the controller are indicated in the ROPEX Application Report and depend on the heatsealing band that is used section 6 2 Controller configuration on page 15 4 Make sure that no START signal is present 5 Appl...

Page 18: ...minal 15 and apply the START signal HEAT The HEAT LED 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 follows a harmonious curve in other words it must not jump abruptly fluctuate or deviate temporarily in the wrong direction This kind of ...

Page 19: ... 5 Button for manual activation of AUTOCAL function zero calibration Do not press unless heatsealing band is cold RESISTRON RES 402 Made in Germany ROPEX Tel 49 0 7142 7776 0 Temperature controller AUTOCAL OUTPUT HEAT ALARM Yellow LED remains lit for duration of AUTOCAL process Green LED indicates pulses in measure ment mode In control mode luminous intensity is proportional to heating current Yel...

Page 20: ...e SET temperature is linear Setting range 0VDC 0 C 10VDC 300 C Please refer to section 7 3 Temperature indication actual value output on page 22 for a circuit diagram LED Blinks slowly 1Hz Blinks fast 4Hz Lit continuously AUTOCAL yellow RESET active START and AUTOCAL functions are locked AUTOCAL requested but function is locked AUTOCAL executing HEAT yellow HEAT requested but function is locked ST...

Page 21: ...sed 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 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 If a potentiometer is not connected...

Page 22: ... the heatsealing band The characteristics of the ROPEX ATR 3 temperature meter size scaling dynamic response are ideally suited to this application and this instrument should therefore always be used section 12 How to order on page 31 It not only facilitates SET ACTUAL comparisons but also enables other criteria such as the heating rate set point reached within the specified time cooling of the he...

Page 23: ...L Owing to the automatic zero calibration AUTOCAL function there is no need to adjust the zero point manually on the controller This function matches the controller to the current and voltage signals that are present in the system and calibrates it to a value of 20 C You should always wait for the heatsealing band and the bar to cool down to ambient temperature before activating the AUTOCAL functi...

Page 24: ...n is executed automatically providing the cooling rate has fallen below the above mentioned value 3 If the START signal 24VDC is active the AUTOCAL function is not executed HEAT LED lit 4 If the RESET signal 24VDC is active the AUTOCAL function is not executed 5 If the controller has already operated correctly at least once after starting up the AUTOCAL function cannot be activated if the ALARM LE...

Page 25: ...tely 0VDC while the RESET signal is being activated This may be interpreted by the higher level controller e g a PLC as feedback The AUTOCAL function is not aborted if the RESET signal is activated while it is still executing The controller performs an internal initialization run lasting approximately 500ms after the RESET signal is deactivated The next heatsealing process cannot be started until ...

Page 26: ... software features that facilitate fault diagnosis Both the external wiring and the internal system are monitored A system fault is reported or differentiated by means of the following indications A Red ALARM LED on the controller with 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 fu...

Page 27: ...le causes Load circuit interrupted after UR pickoff point Wire break heatsealing band break Contact to heatsealing band defective Current transformer signal inter rupted IR measuring wires from current transformer interrupted Primary circuit interrupted Wire break triac in controller defective Primary winding of impulse transformer interrupted Secondary circuit interrupted before UR pickoff point ...

Page 28: ...permissible range from 0 4 80VAC IR signal incorrect Up to Dec 2005 DIP switches 4 5 configured incorrectly I2 range As of Jan 2006 I2 outside permissible range 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 ...

Page 29: ...frequency 47 63Hz automatic adjustment to frequencies in this range Auxiliary voltage Terminals 14 13 24VDC 20 10 reverse polarity protected Current input max 1 0A Heatsealing band type and temperature range Default value 300 C Alloy A20 Analog input set point Terminals 15 12 0 10VDC Imax 5mA electrically isolated Equivalent to 0 300 C or with an external PD 3 precision potentiometer R 2kohms 0 2k...

Page 30: ...hat rail End holders to mechanical fix the controller must be fitted at both ends for moun ting 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 Terminals 1 4 Rigid or flexible 0 2 2 5mm AWG 24 12 Terminals 5 18 Rigid or flexible 0 2 1 5mm AWG 24 16 Plug in connectors If ferrules are us...

Page 31: ...740205 230 Power supply 230VAC P N 740206 400 Power supply 400VAC P N 740207 Scope of supply Controller includes connector plug in parts without current transformer Please indicate the part 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 Re...

Page 32: ...e transformer 10 31 Installation 8 30 Installation procedure 8 Installation regulations 8 L Line filter 4 10 11 31 Line frequency 7 29 Line voltage 29 31 M Maintenance 4 29 Modifications 30 MODs 30 O Over current protection 10 Overheating of heatsealing band 7 P PEX W4 31 PEX W4 W5 4 11 Potentiometer 21 31 Power dissipation 29 Power supply 10 Principle of operation 7 R Reasons for locked AUTOCAL f...

Page 33: ...Index Version 1 RES 402 Page 33 Visualization software 26 W Wiring 8 10 Wiring diagram 14 ...

Search results

Summary of Contents for RESISTRON RES-402

Reviews:

Related manuals for RESISTRON RES-402

Brands by name

Popular brands

Ropex RESISTRON RES-402, Operating Instructions Manual

Search results

Summary of Contents for RESISTRON RES-402

Reviews:

Related manuals for RESISTRON RES-402

Brands by name

Popular brands