Ropex Resistron RES-407 Operating Instructions Manual Download Page 1

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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-407

Important features

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)

• Automatic configuration of the secondary voltage and current ranges

(AUTORANGE, as of April 2005)

• Automatic phase angle compensation (AUTOCOMP, as of April 2005)

• Automatic frequency adjustment

• 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 with fault diagnosis

• Heatsealing band alloy and temperature range selectable as standard (as of June 2003)

Operating

Instructions

Summary of Contents for Resistron RES-407

Page 1: ...on of the secondary voltage and current ranges AUTORANGE as of April 2005 Automatic phase angle compensation AUTOCOMP as of April 2005 Automatic frequency adjustment 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 Al...

Page 2: ...nd operation 17 6 1 View of the controller 17 6 2 Controller configuration 17 6 3 Replacing and burning in the heat sealing band 19 6 4 Startup procedure 20 7 Controller functions 22 7 1 Indicators and controls 22 7 2 Temperature setting set point selection 23 7 3 Temperature indication actual value output 25 7 4 Automatic zero calibration AUTOCAL 26 7 5 START signal HEAT 27 7 6 RESET signal 28 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: ...s 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 ...

Page 8: ...easy to install 5 Installation See also section 1 General information on page 3 Installation and startup may only be performed by technically trained skilled persons who are familiar with the associated risks and warranty provisions 5 1 Installation procedure Proceed as follows to install the RESISTRON temperature controller RES 407 1 Switch off the line voltage and verify that all circuits are de...

Page 9: ...th 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 heatseali...

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 407 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 407 are electrically isolated a 24VDC auxiliary voltage must be applied to terminals 12 13 The auxiliary voltage has a maximum current input of 1 0A and it is also protected against reverse polarity ...

Page 14: ...xx480 prim U1 RESET with 24VDC signal START HEAT with 24VDC signal AUTOCAL with 24VDC signal 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 R 9 8 UR Current transformer Heat sealing band sec Twisted 0V Internal ground No external grounding allowed 0V Internal ground No ex...

Page 15: ...int 0 10VDC Auxiliary supply R 9 8 UR Booster NC NC 2 2 4 IN OUT 1 1 3 4 3 16 15 14 cw 2K OPTION SET POINT POTENTIOMETER PD 3 or PD 5 Current transformer Impulse transformer Heat sealing band LINE Line filter LF xx480 sec Twisted 0V Internal ground No external grounding allowed 0V Internal ground No external grounding allowed U2 prim U1 RES 407 also with MOD 01 Ground for 24VDC signals Must be gro...

Page 16: ...OD 40 cannot be used in combination with MOD 26 booster connection manufactured prior to March 2005 MOD 46 cannot be used in combination with MOD 40 BOOSTER 19 20 4 3 2 1 Additional terminals in housing cover for MOD 26 booster connection AUTOCAL OUTPUT HEAT ALARM RES 407 Imax 50mA 24VDC GND GND 24VDC 4 3 2 1 Additional terminals in housing cover for MOD 40 Temp reached signal or MOD 46 Temp OK si...

Page 17: ...TOCAL 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 a detailed error message appears on the controller see section 7 13 Error messages on page 34 Configuration with coding switches up to March 2005 Set the DIP switches for matching the secondary voltage U2 and the seconda...

Page 18: ...re temperature ranges and alloys can be selected by means of the ROPEX visualization software see section 7 11 Diagnostic interface visualization software as of April 2005 on page 33 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 2 1 10 SWITCH ON Factory settings 2x 0...

Page 19: ...e 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 be correcte...

Page 20: ... 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 Con troller configuration on page 17 4 Make sure that no START signal is present 5 Apply the auxiliary voltage 24VDC 6 Switch on the line voltage 7 When the voltage is switched on the yellow AUTOCAL LED lights up for approximately 0 3 se...

Page 21: ...s 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 behavior would indicate that the UR measuring wires have been laid incor rectly If an error message...

Page 22: ...ure 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 AUTOCAL OUTPUT HEAT ALARM 4 3 2 1 9 8 6 5 10 11 7 12 13 14 15 16 17 18 Green 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 l...

Page 23: ...C 10VDC 300 C or 500 C depending on the contr configuration Please refer to section 7 3 Temperature indication actual value output on page 25 for a circuit diagram LED Blinks slowly 1Hz Blinks fast 4Hz Lit continuously AUTOCAL yellow RESET active START and AUTOCAL functions are locked as of April 2005 AUTOCAL requested but function is locked as of April 2005 AUTOCAL executing HEAT yellow HEAT requ...

Page 24: ...d 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 o...

Page 25: ...17 14 Voltage values 0VDC 0 C 10VDC 300 C ATR 3 or 500 C ATR 5 depending on the contr configuration The relationship between the change in the output voltage and the ACTUAL temperature is linear RES 407 17 max 5mA 14 GND 33ohms Actual value output 0 10VDC 0 10VDC Temperature meter e g ATR x 13 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 ...

Page 26: ...This function matches the controller to the current and voltage signals that are present in the system The zero point is calibrated in the factory to the initial temperature ambient temperature 20 C You should always wait for the heatsealing band and the bar to cool down to ambient temperature before activating the AUTOCAL function Variable initial temperature On controllers manufactured as of Apr...

Page 27: ...AL function cannot be not activated if the heatsealing band cools down at a rate of more than 0 1K s If the control signal is activated the function 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 e...

Page 28: ...e alarm output is switched if the START signal is activated while an error message is indicating error codes 104 106 111 114 211 302 or 303 up to March 2005 error codes 8 12 section 7 13 Error messages on page 34 The heatsealing band is no longer heated up 7 6 RESET signal The RESISTRON temperature controller RES 407 can be reset by means of an external RESET signal at terminals 7 14 As a result A...

Page 29: ...gized again 200ms at the latest after the RESET signal is deactivated note the contactor switching and delay times If it is energized too late an error message will be output by the controller 7 7 Measuring impulse duration as of April 2005 The length of the measuring impulses generated by the controller can be set with the parameter It may be nec essary to set a measuring impulse that is longer t...

Page 30: ...e end of the first AUTOCAL function and the start of the second AUTOCAL must be shorter than 2 0s The second AUTOCAL function only takes around 2 0s and incorporates the AUTOCOMP function If the interval between the two AUTOCAL functions is longer than 2 0s AUTOCAL is executed normally again the second time The OUTPUT LED blinks repeatedly when the AUTOCOMP function is executed and the actual valu...

Page 31: ...e tolerance band OK window on either side of the SET temperature The lower and upper tolerance band limits are configured in the factory to 10K and 10K These values can be set independently of one another in the ROPEX visualization software If the actual temperature is inside the specified tolerance band when the START signal is activated the temper ature diagnosis is activated as well If the ACTU...

Page 32: ...ng to the closure of the sealing jaws The values that can be set in the ROPEX visualization software for the upper and lower tolerance band are iden tical to those for the Temperature OK signal MOD 46 7 10 Heatup timeout as of April 2005 An additional heatup timeout can be activated in the ROPEX visualization software section 7 11 Diagnostic interface visualization software as of April 2005 on pag...

Page 33: ...selective error messages Both the external wiring and the internal system are monitored These features assist the operator in identifying the cause of abnormal operations 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 error codes 104 106 211 302 303 up t...

Page 34: ...3 Error messages on page 34 An alarm can only be reset by applying a RESET signal or by switching the controller off and then on again If an error message is reset using the RESET signal the RESET signal must be deactivated first Invalid error messages may appear when the controller is switched off owing to the undefined oper ating state This must be taken into account when they are evaluated by t...

Page 35: ...ent voltage signals Fault area Fault areas 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 9 308 309 310 201 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 304 4 00 Heatup time too lon...

Page 36: ...ction if machine started for first time Action if machine already operated HS band not changed 104 5 33 10 Current signal incorrect incorrect impulse transformer specification Perform AUTOCAL check transformer specifi cation fault areas Fault areas loose contact 105 Voltage signal incorrect incorrect impulse transformer specification 106 Current and voltage signals incorrect incorrect impulse tran...

Page 37: ...rect no calibration possible Fault area check configuration Fault areas loose contact 112 7 33 10 Voltage signal incorrect no calibration possible Fault area check configuration Fault areas loose contact 113 8 00 10 Current voltage signals incor rect no calibration possible Fault area check configuration Fault areas loose contact 114 8 66 10 Temperature fluctuates no calibration possible Perform A...

Page 38: ...perature 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 Closed Open does not close until START signal voltage value a...

Page 39: ... 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 Contact to heatsealing band defective Total short circuit Heatsealing band installed incorrectly ins...

Page 40: ...cted DIP switches for secondary voltage U2 and current I2 up to March 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 control lers manufactured as of April 2005 Rotary coding switch for heatsealing band alloy and temperature range as of June 2003 Heatsealing band alloy Alloy A20 Temperature range 300 C Maximum temperatu...

Page 41: ...05 With ROPEX visualization software only Measuring impuse duration X Measuring impulse length 1 7ms Temp OK signal as of April 2005 With MOD 46 only X Tolerance band 10K 10K Temperature diagnosis X Temperature diagnosis OFF Heatup timeout X Heatup timeout OFF ...

Page 42: ...nd type and temperature range All controllers manufactured as of April 2005 The temperature range and temperature coefficient settings can also be specified by means of the ROPEX visualization software section 7 11 Diagnostic inter face visualization software as of April 2005 on page 33 in addition to the rotary coding switch see below Temperature range 200 C 300 C 400 C or 500 C Temperature coeff...

Page 43: ... cycle 100 Imax 25A duty cycle 20 Power dissipation max 20W Ambient temperature 5 45 C Degree of protection IP20 Installation If several controllers are installed 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 controll...

Page 44: ...supplied for all modifications 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 MOD 21 Inverts the alarm signal terminal 18 If an alarm is signaled the alarm output is switched to open condition LOW If the controller does not report an alarm a 24VDC voltag...

Page 45: ...erature reached signal This output signal is activated when the ACTUAL tempera ture of the heatsealing band exceeds 95 of the SET heatsealing temperature It can be used to monitor the pro cess for example or to control the closure of the heatsealing bars MOD 40 cannot be used in combination with MOD 26 booster connection manufactured prior to March 2005 Switch position Temp range Temp coefficient ...

Page 46: ...tput signal is activated as well see graph below If the actual temperature leaves the tolerance band the output signal is deactivated again The output signal then remains deactivated even if the actual temperature subsequently returns to the tolerance band It is thus possible to check as part of the monitoring concept for instance whether the output signal is still active at the end of the heatsea...

Page 47: ...ate the part numbers of the controller and the required modifications optional in all orders e g RES 407 400VAC MOD 26 controller for 400VAC power supply with booster connection P N 740703 800026 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 Re...

Page 48: ...How to order Page 48 RES 407 Version 1 For more accessories Accessories leaflet Booster B 075415 Max pulse load 75A 415VAC P N 885302 100400 Max pulse load 100A 400VAC P N 885304 ...

Page 49: ...Heatsealing band type 42 Heatup timeout 32 How to order 47 I Impulse heatsealing method 7 Impulse transformer 10 47 Installation 8 43 Installation procedure 8 Installation regulations 8 L Line filter 4 10 11 47 Line frequency 7 42 Line voltage 42 47 M Maintenance 4 42 Measuring impulse duration 29 Modifications 15 16 44 47 MODs 15 16 44 47 O Over current protection 10 Overheating of heatsealing ba...

Page 50: ...mperature meter 25 26 47 Temperature OK signal 16 43 Temperature range 18 42 Temperature reached signal 16 43 45 Temperature setting 23 Transformer 4 10 47 Transportation 4 Type of construction 42 V View of the controller 17 Visualization software 33 W Wiring 8 10 Wiring diagram 14 ...

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