Ropex RESISTRON RES-406 Operating Instructions Manual Download Page 60

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How to order

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RES-406

Version 1

How to order

Pictures exemplary.

For more accessories:



"Accessories" leaflet

Contr. RES - 406 /

. . .

VAC

115

: Power supply 115VAC, P/N 740601

230

: Power supply 230VAC, P/N 740602

400

: Power supply 400VAC, P/N 740603

Scope of supply: Controller includes connector plug-in

parts (without current transformer)

Modification MOD . . (optional, if required)

e.g.

: MOD 01, P/N 800001 (Amplifier for low voltage)

Please indicate the article numbers of the controller and the required modifications
(optional) in all orders,

e.g. RES-406/ MOD 01

(controller for 400VAC power supply with amplifier for low voltage)
P/N 800001 must be ordered

Current transformer PEX-W4

P/N 885106

Line filter LF- . . 480

: Continuous current 6A, 480VAC, P/N 885500

: 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

Temp. meter ATR- .

: 300°C range, P/N 882130

: 500°C range, P/N 882150

Booster B- . . .

075415

: Max. pulse load 75A, 415VAC, P/N 885302

100415

: Max. pulse load 100A, 400VAC, P/N 885304

Summary of Contents for RESISTRON RES-406

Page 1: ...PROFIBUS DP interface Automatic zero calibration AUTOCAL Automatic optimization AUTOTUNE Automatic configuration of the secondary voltage and current ranges AUTORANGE as of February 2006 Automatic phase angle compensation AUTOCOMP as of February 2006 Automatic frequency adjustment Booster connection as standard 0 10VDC analog output for ACTUAL temperature Alarm function with fault diagnosis Heatse...

Page 2: ...nd burning in the heat sealing band 18 6 4 Startup procedure 19 7 Controller functions 22 7 1 Indicators and controls 22 7 2 PROFIBUS communication up to Jan 2006 as of Feb 2006 24 7 3 Device master file GSD 24 7 4 PROFIBUS protocol 26 7 5 Input data 28 7 6 Output data 30 7 7 Parameter data 34 7 8 DPV1 protocol extension as of GSD Version v2 0 42 7 9 Temperature indication actual value output 45 7...

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: ...n 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 ...

Page 8: ...he line voltage and verify that the circuit is de energized 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 RESISTRON temperature controller in the range from 47Hz 63Hz 3 Install the RESISTRON temperature controller in the electri...

Page 9: ...ller to the PROFIBUS master using a cable according to IEC 61158 Check the tightness of all the system connections including the terminals for the impulse trans former windings 6 Make sure that the wiring conforms to the relevant national and international installation regulations ...

Page 10: ...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 No push on connectors Twisted Current measuring wires IR R Connect U measuring wires directly to heatsea...

Page 11: ... 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 12: ...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 11 must be observed Example drawing for LF 06480 5 ...

Page 13: ...1 RES 406 Page 13 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 14: ...ly M24 5 24V IN 5V OUT PROFIBUS controller electrically isolated 11 9 10 8 4 3 2 1 15 16 18 17 C ATR _ ANALOG OUTPUT 0 10VDC Ground Must be grounded externally to prevent electrostatic charging 0V Internnal ground No external grounding allowed 0V Internnal ground No external grounding allowed R IR UR Current transformer twisted Impulse transformer Heat sealing band LINE Line filter LF xx480 sec U2...

Page 15: ...ATR _ ANALOG OUTPUT 0 10VDC Ground Must be grounded externally to prevent electrostatic charging R Current transformer twisted Impulse transformer IR UR Heat sealing band LINE Booster NC NC 2 4 IN OUT 1 3 Line filter LF xx480 sec U2 prim U1 24VDC GND NC A 5V VP DGND RTS B Shield POWER SUPPLY 24V pwr supply P24 GND pwr supply M24 0V Internnal ground No external grounding allowed 0V Internnal ground...

Page 16: ... 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 a detailed error message appears on the controller see section 7 16 Error messages on page 49 Configuration with coding switches up to January 2006 Set the DIP switches for matching the secondary voltage U2 and the secondary curr...

Page 17: ...h is set to 9 as of February 2006 more temperature ranges and alloys can be selected by means of the ROPEX visualization software see section 7 11 Diagnostic interface visualization software as of February 2006 on page 47 3 2 1 4 5 ON OFF 1 10V 6 60V 20 120V ON OFF OFF OFF ON OFF OFF OFF ON 30 100A 60 200A 120 400A OFF ON ON OFF OFF ON DIP switch DIP switch 1 2 U2 I2 3 4 5 3 2 1 4 5 4 3 ON OFF U V...

Page 18: ...ng band The heatsealing band is a key component in the control loop since it is both a heating element and a sensor The geometry of the heatsealing band 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 necessitates a heatsealing band alloy with a suitable tem...

Page 19: ...onnected section 5 Installation on page 8 Proceed as follows to start up the controller for the first time 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 frequency is automatically detected by the temperature controlle...

Page 20: ...nnected 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 calibrated successfully the AL bit alarm active is set and the red ALARM LED blinks slowly 1Hz In this case the controller configu...

Page 21: ...wrong direction This kind of behavior would indicate that the UR measuring wire have been wired incorrectly If an error code is displayed please proceed as described in section 7 16 Error messages on page 49 12 Burn in the heatsealing band section 6 3 Replacing and burning in the heatsealing band on page 18 and repeat the AUTOCAL function 6 4 2 Restart after replacing the heatsealing band To repla...

Page 22: ...CHANGE OUTPUT green LED HEAT yellow LED yellow LED AUTOCAL ALARM red LED green LED 24V SUPPLY BUS PWR OK µC PWR OK green LED DATA EXC green LED green LED Lights up or blinks to indicate an alarm Lit during heating phase Indicates pulses in measurement mode In control mode luminous intensity is proportional to heating current Remains lit for duration of AUTOCAL process Remains lit while Profibus da...

Page 23: ... too low HEAT yellow START requested but function disabled 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 7 16 DATA EXCHANGE green Communication with PROFIBUS master active Green LED remains lit as long as power supply is on Yel...

Page 24: ...anufactured as of February 2006 are installed in an older machine e g in order to carry out repairs this new controller function can lead to unwanted error codes when the line voltage is switched off depending on the PLC program Permanently disconnecting the 24VDC power supply terminals 5 7 and PROFIBUS connector pins 7 2 results in the same behavior as on older controllers manufactured up to Janu...

Page 25: ...nt to use all features of the controller make sure that the appropriate version of the device master file is used Since production date 06 02 the required device master file version is printed on the housing of the temperature controller required GSD version ...

Page 26: ...d the status information and has the following structure 7 4 2 Compact protocol with 10 Bit error code The 10 Bit error codes are available on all controllers manufactured as of July 24 2006 and supplied with GSD Version v1 6 These error codes must be activated in the parameter data section 7 7 9 Error code format on page 38 The 16 bit input data from the PROFIBUS master to the RES 406 contains th...

Page 27: ... Error code format on page 38 The extended protocol transfers 2x16bits The 2x16 bit input data contains the set point in word and the con trol functions in word Spare Set point AC temperature Name 0 0 0 0 0 0 0 Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Spare Control function Name 0 0 0 0 0 0 0 0 0 0 0 0 MP RS ST AC Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Actual value signed Name VZ Bit no ...

Page 28: ...ure on page 36 It can be specified in the 0 40 C range The value selected for the calibration temperature must be entered in the Set point AC temperature input data when the AUTOCAL function is activated AC bit 1 This selected value must remain entered until the AUTOCAL function has finished If the specified temperature is too high greater than 40 C or if the selected value varies an error message...

Page 29: ...start request is not processed if the AUTOCAL function is active the controller has reported an alarm the set point is less than 20 C higher than the calibration temperature or the RS bit is set In all these cases the HEAT LED blinks The heating process is terminated if the ST bit is reset or if a PROFIBUS fault occurs The ST bit is only accepted if the AUTOCAL function is deactivated and there ar...

Page 30: ...tarted it only evaluates the MP bit if the system test including the func tional test of the heating circuit is successful This can take several 100 ms The MP bit is available on all controllers manufactured as of July 14 2003 and supplied with GSD Version v1 3 7 5 5 Set point A set point of up to 300 C or 500 C is allowed depending on the selected temperature range section 7 7 1 Temperature range...

Page 31: ...emperature reached status bit TE bit the actual temperature is evaluated independently of the control mode 3 Active if Tact Tset with latch function as of software revision 100 available Factory setting for software revision 100 102 A heatsealing cycle starts when the ST bit is set The TO bit is set when the actual temperature reaches the temperature tolerance band for the first time during a heat...

Page 32: ...erance band are adjustable to max 99K on controllers manufactured as of February 2006 and supplied with GSD Version v1 5 On older controllers the limits are adjustable to max 20K 7 6 6 Controller active RA The RES 406 has processed the START request successfully and entered the control mode if the RA bit 1 7 6 7 Sign VZ In the compact protocol the sign bit indicates whether the actual value is pos...

Page 33: ...ignaled AL bit 1 the error code allows the exact cause to be determined The Error code format parameter determines whether two or three digit error codes are output If two digit error codes are specified some faults are grouped together three digit error codes enable a fault to be identified more precisely In the compact protocol the error code appears instead of the actual value in bits 0 3 error...

Page 34: ...r tolerance band limits for temperature monitoring the calibration temperature and the optional heating time limit It is transferred from the PROFIBUS master to the RES 406 each time the system is started up If the parameter data is changed during operation the RES 406 performs a reset The PROFIBUS communication is not interrupted The parameter data has the following structure No Function De fault...

Page 35: ...osis delay time 100ms steps as of Feb 2006 and GSD Version v2 0 0s 0 99 0 9 9s 20 21 Heatup timeout 100ms steps as of Feb 2006 and GSD Version v2 0 0s 0 999 0 99 9s 22 AUTOCOMP as of Feb 2006 and GSD Version v2 0 off off on AUTO 23 TO bit Temperatur OK as of Feb 2006 and GSD Version v2 0 active if Tact Tset off active if Tact Tset active if Tact Tset with latch 24 Hold mode as of Feb 2006 and GSD ...

Page 36: ...2 0 on page 39 7 7 3 Upper temperature OK threshold Upper threshold value for the OK window Refer section 7 6 5 Temperature OK TO on page 31 and section 7 7 11 Temperature diagnosis as of GSD Version v2 0 on page 39 7 7 4 Variable calibration temperature The calibration temperature is set to 20 C as default You can change it to another value between 0 C and 40 C in order to adapt it to the tempera...

Page 37: ...ed Although the extended controller diagnosis ist deactivated there is the fault diagnosis which is coded in the pro tocol This paramter is available on all controllers manufactured as of June 17 2002 and supplied with GSD Version v1 2 DPV1 protocol extension alarm model The extended device diagnostic functionality is not available with the DPV1 protocol extension and GSD Version v2 0 or higher se...

Page 38: ...sate the phase angle displacement between the UR and IR measuring signals for special heatsealing applications ROPEX Application Report The AUTOCOMP function is provided for this purpose The follwing settings are possibe 1 off Factory setting The AUTOCOMP function is switched off 2 on It is executed whenever the AUTOCAL function section 7 16 Error messages on page 49 is run twice in quick successi...

Page 39: ...default setting AUTOCOMP off 7 7 11 Temperature diagnosis as of GSD Version v2 0 An additional temperature diagnosis can be activated by means of the PROFIBUS parameter data or the DPV1 protocol extension The RES 406 checks whether the ACTUAL temperature is within a settable tolerance band OK window on either side of the SET temperature The lower and upper tolerance band limits are the same like i...

Page 40: ...and upper tolerance band limits cannot be set in the ROPEX visualization software The same limits apply as for the TO bit They can only be set by means of the PROIBUS parameter data section 7 7 Parameter data on page 34 or the DPV1 protocol extension section 7 8 DPV1 pro tocol extension as of GSD Version v2 0 on page 42 7 7 12 Heatup timeout as of GSD Version v2 0 An additional heatup timeout can ...

Page 41: ...n The ACTUAL temperature that was valid at the end of the last heatsealing phase is always indicated as a digital value When the controller is switched on the real ACTUAL temperature is indicated until the end of the first heating phase 3 2 s It causes the current ACTUAL temperature to be displayed as a digital value for an additional 2 seconds at the end of a heatsealing phase This temperature is...

Page 42: ...nsion section 7 8 DPV1 protocol extension as of GSD Version v2 0 on page 42 default setting Hold mode off 7 8 DPV1 protocol extension as of GSD Version v2 0 Text in preparation 7 8 1 Identification and maintenance I M functions Text in preparation 7 8 2 DPV1 alarm model Text in preparation ACTUAL temp 1 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...

Page 43: ... you must remember to transfer all parameters that deviate from the static configuration again after restarting the controller or the bus Please contact the manufacturer for more information about how your PLC system supports the DPV1 protocol extension DPV1 parameter table of the RES 406 Default values are printed bold cursive Slot Index Parameter Value range x 255 I M functions IM0 Article numbe...

Page 44: ...erature diagnosis 0 deactivated 1 activated 1 19 Temperature diagnosis delay time 0 1s steps 0 99 0 1 20 Heatup timeout 0 1s steps 0 999 0 1 22 AUTOCOMP 0 off 1 on 2 AUTO as of software revision 105 1 23 TO bit Temperature OK 0 off 1 active if Tact Tset 2 active if Tact Tset with latch 1 24 Hold mode 0 off 1 on 2 2s Slot Index Parameter Value range ...

Page 45: ...ES 406 supplies an analog 0 10VDC signal which is proportional to the real ACTUAL temperature at ter minals 17 18 Voltage values 0VDC 0 C 10VDC 300 C ATR 3 or 500 C ATR 5 depending on the controller configuration RES 406 0 10VDC Actual value output 0 10VDC max 5mA Temperature meter e g ATR 3 17 18 0V ...

Page 46: ... as the heating rate set point reached within the specified time cooling of the heatsealing band etc to be evaluated This meter moreover permits disturbances in the control loop loose connections contacting or wiring problems as well as any line disturbances to be observed extremely effectively and interpreted accordingly The same applies if mutual interference occurs between several neighboring c...

Page 47: ...ows a data connection to be set up to the ROPEX visualization software using the ROPEX communi cation interface CI USB 1 Only a ROPEX comunication interface is allowed to be connected to the diagnostic interface Con necting another device e g a telephone cable could result in malfunctions or damage to the con troller The ROPEX visualization software is described in a separate document 7 12 Total c...

Page 48: ... 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 error codes 8 9 as of February 2006 also 104 106 211 302 303 2 Blinks slowly 1Hz The system configuration is incorrect and the zero calibration AUTOCAL function was unsuccessful section 6 2 Controller configu...

Page 49: ...oller e g a PLC in order to avoid false alarms 7 16 Error messages In addition to the fault diagnosis which is coded in the protocol you can also access the PROFIBUS diagnostics function extended controller diagnosis The error codes appear in the configuring tool in plain text because they are stored in the device master file The table below shows how the analog voltage values correspond with the ...

Page 50: ...ault area Fault areas 4 107 2 66 Temperature step down Fault areas loose contact Fault areas loose contact 108 Temperature step up 307 Temperature too high low section 7 7 11 308 309 310 5 201 3 33 No line frequency line fre quency fluctuates Check power supply Check power supply 202 Line frequency too high fluctuates 203 Line frequency too low fluctuates 6 304 4 00 Heatup time too long section 7 ...

Page 51: ...ion if machine started for first time Action if machine already operated HS band not changed 8 104 5 33 10 Current signal incorrect incorrect impulse trans former specification Perform AUTOCAL check transformer specifi cation fault areas Fault areas loose contact 105 Voltage signal incorrect incorrect impulse trans former specification 106 Current and voltage signals incorrect incorrect impulse tr...

Page 52: ...ect no calibration possible Fault area check configuration Fault areas loose contact 11 112 7 33 10 Voltage signal incorrect no calibration possible Fault area check configuration Fault areas loose contact 12 113 8 00 10 Current voltage signals incorrect no calibration possible Fault area check configuration Fault areas loose contact 13 114 8 66 10 Temperature fluctuates no calibration possible Pe...

Page 53: ...ture step 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 Energized De Energized gets energized with START signal voltage v...

Page 54: ...ff point 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 Contacting to heatsealing band defective Total short circuit Heatsealing band installed incorrectl...

Page 55: ... for alarm output not connected or incorrectly connected DIP switches for secondary voltage U2 and current I2 up to January 2006 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 control lers manufactured as of February 2006 Rotary coding switch for heatsealing band alloy and temperature range Heatsealing band alloy Alloy A20 ...

Page 56: ...er data or the DPV1 protocol extension Rotary coding switches for station address Station address 01dec Automatic phase angle compensation AUTOCOMP X AUTOCOMP off Temperature diagnosis X Temperature diagnosis deactivated Heatup timeout X Heatup timeout deactivated 0 0 5 5 1 1 2 2 3 3 4 4 6 6 7 7 8 8 9 9 x 1 x 10 Top of housing ...

Page 57: ...nce 10 10 The 24VDC Supply voltage can be fed either via terminals 5 and 7 or via the PROFIBUS plug at pins 2 and 7 PROFIBUS DP interface Baud rates 9 6kbaud 19 2kbaud 45 45kbaud 93 75kbaud 187 5kbaud 500kbaud 1 5Mbaud 3Mbaud 6Mbaud 12Mbaud Plug acc to IEC 61158 Heatsealing band type and temperature range All controllers manufactured as of February 2006 The temperature range and temperature coeffi...

Page 58: ...nstalled on one top hat rail DIN TS35 rail a clearance of at least 20mm should be allowed between them The moving clip required for fastening must be facing down for mounting on a horizontal top 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 polycarb...

Page 59: ...e range of heatsealing applications One modification MOD is available for the RESISTRON temperature controller RES 406 for implementing spe cial applications The modifications must be ordered separately 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 75 0 90 0 113 0 135 0 ...

Page 60: ...e numbers of the controller and the required modifications optional in all orders e g RES 406 400VAC MOD 01 controller for 400VAC power supply with amplifier for low voltage P N 740603 800001 must be ordered 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...

Page 61: ...ce master file GSD 24 Diagnostic interface 47 Dimensions 59 DIP switches 16 Disposal 5 DPV1 protocol extension 42 E Error code format 38 Error messages 49 Extended controller diagnosis 37 External switching amplifier 15 F Factory settings 55 Fault areas 54 Fault diagnosis 8 Fuse 11 G GSD 24 H Heatsealing band type 57 Heatup timeout 40 I Impulse heatsealing method 7 Impulse transformer 11 60 Input ...

Page 62: ...tage U2 16 Set point 30 Start 29 START bit 21 Startup 16 System diagnostics 47 System monitoring 48 T TCR 3 18 TE bit 30 Temperature coefficient 3 18 Temperature control 7 Temperature diagnosis 39 Temperature indication 45 Temperature meter 46 60 Temperature OK 31 Temperature range 17 57 Temperature reached 30 TO bit 31 Total cycle counter 47 Transformer 4 11 60 Transportation 4 Type of constructi...

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