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Ropex RESISTRON RES-408 Operating Instructions Manual Download Page 60

Maintenance

Page 60

RES-408

Version 1

[X] As of June 2006:
Only in ROPEX visualization software

13

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 con-
troller can be removed with dry compressed air.

Automatic
phase compensation
(AUTOCOMP)
[X]

AUTOCOMP: OFF

Measuring impulse 
duration

[X]

Measuring impulse duration: 1.7ms

Temperature
diagnosis

[X]

Temperature diagnosis: OFF

Heatup
timeout

[X]

Heatup timeout: OFF

Summary of Contents for RESISTRON RES-408

Page 1: ... zero calibration AUTOCAL Automatic optimization AUTOTUNE Automatic configuration of the secondary voltage and current ranges AUTORANGE as of May 2006 Automatic phase angle compensation AUTOCOMP as of June 2006 Automatic frequency adjustment Wide current and voltage range 0 10VDC analog output for ACTUAL temperature 24VDC control signals for START and PREHEAT with electrical isolation Alarm functi...

Page 2: ...ontroller functions 30 11 1 Indicators and controls 30 11 2 Display 33 11 3 Navigation in the menus 34 11 4 Menu structure 35 11 5 Menu steps 36 11 6 Temperature setting set point selection 38 11 7 Temperature indication actual value output 38 11 8 Automatic zero calibration AUTOCAL 40 11 9 Heating to the heatsealing temperature HEAT 41 11 10 PREHEAT signal 43 11 11 Hold mode 44 11 12 Temperature ...

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: ...culated with the help of these measurements is dis played and compared with the set point The primary voltage of the impulse transformer is adjusted by phase angle control if the measured values deviate from the set point The resulting change in the current through the heatsealing band leads to a change in the band temperature and thus also its resistance This change is measured and evaluated by t...

Page 8: ...onditions such as overheating of the heatsealing band The temperature can be set on the separate T 408 1 or T 400 operator terminal The real heatsealing band temperature is also visualized on the operator terminal The RES 408 RESISTRON temperature controller features an integrated fault diagnosis function which tests both the external system heatsealing band wiring etc and the internal electronics...

Page 9: ...L temperature of the heatsealing band in C The meter damping of the unit is optimized for the abrupt temperature changes that occur in impulse mode Digital temperature meter DTR x For front panel mounting or mounting on a top hat rail DIN TS35 rail Digital indication of the ACTUAL temperature of the heatsealing band in C with HOLD function Line filter Essential in order to ensure CE conformity Opt...

Page 10: ...ion is necessary for example for very short or low resistance heatsealing bands MOD 26 Additional terminal for connecting an external switching amplifier booster This modification is necessary for high primary currents continuous current 5A pulsed current 25A MOD 37 up to May 2006 Additional rotary coding switch for the heatsealing band alloy and the temperature range Various heatsealing band allo...

Page 11: ... temperature range and alloy as of June 2006 on page 26 Switch position Temp range Temp coefficient Band alloy 0 5 1 2 3 4 6 7 8 9 0 5 1 2 3 4 6 7 8 9 0 1 4 5 8 300 C 300 C 500 C 500 C 300 C 1100ppm K 780ppm K 1100ppm K 780ppm K 3500ppm K e g A20 e g L e g A20 e g L 0 Factory settings SWITCH POS 1 0 4 5 8 TEMP RANGE 300 C 300 C 500 C 500 C 300 C ALLOY 780ppm K 1100ppm K L A20 1100ppm K A20 780ppm ...

Page 12: ...tic adjustment to frequencies in this range Heatsealing band type and temperature range Controllers manufactured as of June 2006 The temperature range and temperature coefficient settings can also be specified in the ROPEX visualization software section 11 19 Diagnostic interface vis ualization software as of June 2006 on page 51 in addition to using the rotary coding switch see below Temperature ...

Page 13: ...ed Alarm relay Terminals 12 13 14 Umax 30V DC AC Imax 0 2A changeover contact potential free Can be inverted by means of a plug in jumper Maximum load primary current of impulse transformer Imax 5A duty cycle 100 Imax 25A duty cycle 20 Power loss max 22W Ambient temperature 5 45 C Degree of protection IP20 Installation If several controllers are installed on one top hat rail DIN TS35 rail a cleara...

Page 14: ...tibility Page 14 RES 408 Version 1 Please pay attention to the controller and terminal versions when ordering spare parts The controller may have to be exchanged together with the terminal Refer to the compatibility table below ...

Page 15: ...l T 408 1 Art No 885441 RES 408 230VAC 740842 RES 408 400VAC 740843 Controller type Art No Compatible with RES 408 0 3 115VAC 740801 or 740831 Terminal T 400 Art No 885440 RES 408 0 3 230VAC 740802 or 740832 RES 408 0 3 400VAC 740803 or 740833 RES 408 0 5 xxxVAC 740805 740806 740807 740835 740836 or 740837 RES 408 1 x xxxVAC 740811 740812 740813 740815 740816 or 740817 75 0 90 0 113 0 135 0 ...

Page 16: ...l DIN TS35 rail according to DIN EN 50022 If several controllers are installed on one top hat rail the minimum clearance specified in section 6 Technical data on page 12 must be allowed between them 4 Install the terminal in the front panel cutout It is fastened by means of four clips which snap onto the side of the terminal housing 5 Connect the controller and terminal together with the cable pro...

Page 17: ...408 Page 17 Check the tightness of all system connections including the terminals for the impulse transformer winding wires 7 Make sure that the wiring conforms to the relevant national and international installation regulations ...

Page 18: ...nds 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 hea...

Page 19: ... 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 20: ...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 9 3 Power supply on page 19 must be observed Example drawing for LF 06480 9 ...

Page 21: ...1 RES 408 Page 21 9 5 1 PEX W4 9 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 22: ...4VDC Signal ALARM OUTPUT max 30V 0 2A ANALOG OUTPUT 0 10VDC Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging Display and operation panel Up to production date March 2003 the standard output power circuit terminals 3 4 has NO function when the booster connection MOD 26 is installed As of April 2003 the terminals 3 4 are active too when the booster connection is...

Page 23: ...ration panel Up to production date March 2003 the standard output power circuit terminals 3 4 has NO function when the booster connection MOD 26 is installed As of April 2003 the terminals 3 4 are active too when the booster connection is installed Current transformer Impulse transformer Heat sealing band LINE Booster Line filter LF xx480 sec twisted Ground for 24VDC signals Must be grounded exter...

Page 24: ...rtup and operation 10 1 View of the controller RES 408 controller T 400 or T 408 1 terminal Terminals Wiring diagram LEDs Coding switches and plug in jumpers Nameplate Connection for terminal Display Operator keys Cable connection Fixing Nameplate clips 4x ...

Page 25: ...age appears on the controller see section 11 21 Error messages on page 52 Configuration with coding switches up to May 2006 Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to the correct position for your application You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your particular application If the seco...

Page 26: ...ected If the plug in jumper is not inserted on controllers manufactured as of June 2006 or if it is incorrectly inserted an error message appears when the controller is switched on section 11 21 Error mes sages on page 52 If the Alarm relay de energized by alarm PC CONFIGURATION position is selected as of June 2006 the behavior of the alarm output can be configured more finely in the ROPEX visuali...

Page 27: ...cause the TCR has been altered irreversibly 10 3 2 Burning in the heatsealing band If a new heatsealing band has been used the zero point is first of all calibrated while the band is still cold by acti vating the AUTOCAL function on the controller When the AUTOCAL function has finished the controller out puts a voltage equivalent to a temperature of 20 C at the actual value output Adjust the set p...

Page 28: ...oltage 6 When the voltage is switched on the yellow AUTOCAL LED lights up for approximately 0 3 seconds on all controllers manufactured as of June 2006 to indicate that the controller is being powered up correctly Controllers manufactured as of June 2006 If the red ALARM LED lights up for 0 3s in addition to the yellow AUTOCAL LED when the voltage is switched on the configuration of this controlle...

Page 29: ...uration on page 25 and ROPEX Applica tion Report Repeat the calibration after the controller has been configured correctly 9 When the zero point has been calibrated successfully select a defined SET temperature and activate the START signal HEAT The SEALHEAT LED on the terminal then lights up The ACTUAL temperature appears on the display The heating and control process can now be observed The cont...

Page 30: ...w HEAT requested but function is locked START executing OUTPUT green In control mode luminous intensity is proportional to heating current ALARM red Configuration error AUTOCAL not possible Controller calibrated incor rectly run AUTOCAL Fault section 11 21 4 3 2 1 9 8 6 5 10 11 7 12 13 14 15 16 17 18 RESISTRON RES 408 Made in Germany ROPEX Tel 49 0 7142 7776 0 Temperature controller Yellow LED rem...

Page 31: ...set after alarm Heatung up temp control to set temperature active PREHEAT active Hold mode active HOLD PREHEAT SEALHEAT ENTER HAND RESET ROPEX 2 3 T 408 1 LED display 5 characters UP and DOWN keys for setting values Press 2 sec Slow change Hold 2 sec Fast change MENU key for advancing to next menu step or switching menu Press 2 sec Next menu step Hold 2 sec Return to home position ...

Page 32: ...lit when power supply is ok OUTPUT POWER ON ROPEX TERMINAL MENU key for advancing to next menu step or switching menu Press 2 sec Next menu step Hold 2 sec Return to home position 1 Red Green LED 2 Yellow LED 3 Green LED Red during heating up Green set temp achieved PREHEAT active Hold mode active UP and DOWN keys for setting values Press 2 sec Slow change Hold 2 sec Fast change LED display 5 char...

Page 33: ...tings are entered on the controller and no error message is indicated the display is in the home position in other words it shows the ACTUAL temperature 11 2 3 Settings menu The required parameters are set in the Settings menu section 11 4 Menu structure on page 35 11 2 4 Error messages The fault diagnosis function of the controller is always active If a fault is detected it is indicated on the di...

Page 34: ...he home position if you do not press any keys for a period of 30s There is no automatic return after 30s from AC AutoCal or AL ALarm 11 3 2 Navigation in menus with an alarm If an alarm is indicated the terminal display shows the Alarm menu Some faults can be acknowledged by pressing the RESET key section 11 20 System monitoring alarm output on page 51 In this case the display switches back to the...

Page 35: ... Version 1 RES 408 Page 35 11 4 Menu structure Autocal AC Autocal PH Preheat temp SH Heatsealing temp Home position Power up message Fault Autocal AC Autocal C AL Alarm Autocomp AP Autocomp 1 2 1 AUTOCOMP OFF 2 AUTOCOMP ON ...

Page 36: ...y the controller version 300 C or 500 C Controllers manufactured as of June 2006 The maximum selectable set point is limited by the rotary coding switch alloy range and or the PC vis ualization software Controllers manufactured up to May 2006 0 300 C or 0 500 C Controllers manufactured as of June 2006 0 40 C maximum tem perature PH PreHeat Preheat tempera ture The required preheat temperature PREH...

Page 37: ...sage is dis played instead Controllers manufactured up to May 2006 Setting not possible Controllers manufactured as of June 2006 0 40 C AP AutocomP Automatic phase compensation AUTOCOMP Pressing the ENTER key starts the AUTO COMP function If the ENTER key is not pressed within 2s the display returns to the home position This step is automatically displayed if the AUTOCAL function is successfully e...

Page 38: ... heating and control process can thus be observed at any time AL ALarm Alarm menu If an alarm is indicated the controller shows the Alarm menu Some faults can be acknowledged by pressing the RESET key In this case the con troller switches back to the home position If the fault can be rectified by executing the AUTOCAL function you can select the AC AutoCal menu step directly by briefly pressing th...

Page 39: ...ltage values 0VDC 0 C 10VDC 300 C or 500 C depending on the controller configuration The relationship between the change in the output voltage and the ACTUAL temperature is linear RES 408 17 max 5mA 18 0V R 33ohm Actual value output 0 10VDC 0 10VDC Temperature meter e g ATR 3 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 40: ...e impulse transformer External grounding is not allowed If this warning is ignored the controller will be damaged by frame currents Contact voltage protection must be installed at the terminals of the external temperature meter 11 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 AU...

Page 41: ...set actual comparison is performed immediately and the heatsealing band is heated to the SET temperature the PREHEAT signal must be deactivated 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 display is in the home position on controllers manufactured up to December 2000 the s...

Page 42: ...on 1 If a PREHEAT signal is used it must be deactivated during the heating and control process If not the heatsealing band is heated to the set preheat temperature instead of the heatsealing tempera ture section 11 10 PREHEAT signal on page 43 ...

Page 43: ...ing range is not available on controllers manufactured as of June 2006 The PREHEAT signal is activated by applying a 24VDC signal at terminals 7 6 The heatsealing band is heated to the preheat temperature if the START and PREHEAT signals are active In this case the PREHEAT LED on the T 400 or T 408 1 terminal lights up The heatsealing band is heated to the set preheat temperature if the HAND key i...

Page 44: ...on 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 powered up the real ACTUAL temperature is shown until the end of the first heating phase 3 On2 This setting is available on controllers manufactured as of June 2006 It causes the current ACTUAL temperature to be displayed for an additional 2 seconds at the...

Page 45: ...ler SW revision 106 and ter minal SW revision 103 As of controller software revision 106 AND terminal software revision 103 the unit for the temperature indication and value selection can be switched between C Celsius and F Fahrenheit The unit is switched by pressing ACTUAL temperature START signal 24VDC T t t 0 0 Hold OFF T t 0 ACTUAL indication Hold On T t 0 Hold On2 T t 0 Hold Hold Hold Hold En...

Page 46: ...lue selection in Fahrenheit F Up to controller software revision 105 and or terminal software revision 102 only Celsius C can be specified on the controller as the temperature unit The degree unit can be changed on the controller without interrupting operation If you specify temperature indication and value selection in Fahrenheit F the controller still uses Celsius C internally Value steps are th...

Page 47: ...n Report The AUTOCOMP function is provided for this purpose The following settings are possible 1 OFF Factory settings The AUTOCOMP function is deactivated 2 ON The AUTOCOMP function is activated by pressing the ENTER key after the AUTOCAL function has been successfully executed section 11 8 Automatic zero calibration AUTOCAL on page 40 The interval after the end of the AUTOCAL function must be le...

Page 48: ...ing AUTO COMP off 11 15 Temperature diagnosis as of June 2006 An additional temperature diagnosis can be activated in the ROPEX visualization software section 11 19 Diagnostic interface visualization software as of June 2006 on page 51 The RES 408 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 ...

Page 49: ...ay time has elapsed The temperature diagnosis function can thus be selectively deactivated e g if the temperature drops temporarily owing to the closure of the sealing jaws 11 16 Heatup timeout as of June 2006 An additional heatup timeout can be activated in the ROPEX visualization software section 11 19 Diagnostic interface visualization software as of June 2006 on page 51 This timeout starts whe...

Page 50: ...troller must be immediately switched off 11 18 Undervoltage detection as of June 2006 Trouble free operation of the temperature controller is guaranteed within the line voltage tolerance range specified in section 6 Technical data on page 12 If a line voltage which is less than the lower limit of the permissible range occurs the controller is switched to a standby mode No more heatsealing processe...

Page 51: ...nd selective error messages Both the external wiring and the internal system are monitored These features crucially support the system owner in localizing the cause of an abnormal operating state A system fault is reported or differentiated by means of the following indications A Error message on the terminal display The cause of a fault can be localized quickly and easily with the help of the err...

Page 52: ...is purpose in the 0 10VDC range each of which is assigned an error code section 11 21 Error messages on page 52 If a state that requires AUTOCAL occurs or if the controller configuration is incorrect error codes 104 106 111 114 211 302 303 the actual value output jumps back and forth at 1Hz between the voltage value that corresponds to this error and the end of the scale 10VDC i e 300 C or 500 C I...

Page 53: ...06 The error messages are differentiated even more finely in the controller The error codes described below can be displayed in the ROPEX visualization software section 11 19 Diagnostic interface visualization software as of June 2006 on page 51 to facilitate troubleshooting If the actual value output is evaluated in order to identify an error message in the higher level con troller for instance t...

Page 54: ...ontroller Check plug in jumper Cause I R signal missing U R signal missing U R and I R signals missing Temperature step down Temperature step up Temperature too low high section 11 15 Frequency fluctuation inadmissible line frequency Heatup time too long section 11 16 Int faut contr defective Triac defective Int faut contr defective Int faut contr defective Int faut contr defective Plug in jumper ...

Page 55: ... transformer Fault area Run AUTOCAL and or fault area loose contact Run AUTOCAL Cause I R signals incorrect incorrect specification of impulse transformer U R signals incorrect incorrect specification of impulse transformer U R and or I R signals incorrect incorrect specification of impulse transformer Temperature too low AUTOCAL wasn t per formed loose contact ambient temp fluctuates temperature ...

Page 56: ...uration Fault area check configuration Fault area check configuration Cause I R signal incorrect calibration not possible U R signal incorrect calibration not possible U R and I R signals incorrect calibration not possible Temperature fluctuates calibration not possible Line voltage too low Kap 11 18 Communication error Kap 11 17 STATUS of alarm relay factory set Warning De Energized Fault Energiz...

Page 57: ...ck configuration Fault areas check configuration Cause I R signal missing U R signal missing U R and I R signals missing Temperature 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 incorr...

Page 58: ...UR pickoff point 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 inc...

Page 59: ...DIP switches for secondary voltage U2 and current I2 up to May 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 June 2006 Rotary coding switch for heatsealing band alloy and temperature range as of June 2006 Heatsealing band alloy Alloy A20 Temperature range 300 C Maximum temperature 300 C...

Page 60: ...ning of the terminals including the terminals for the winding connections on the impulse transformer is recommended Dust deposits on the con troller can be removed with dry compressed air Automatic phase compensation AUTOCOMP X AUTOCOMP OFF Measuring impulse duration X Measuring impulse duration 1 7ms Temperature diagnosis X Temperature diagnosis OFF Heatup timeout X Heatup timeout OFF ...

Page 61: ...0 Modification MOD optional if required e g 01 MOD 01 Art No 800001 amplifier for low voltage 26 MOD 26 Art No 800026 booster connection Please indicate the article numbers of the controller and the required modifications in all orders e g RES 408 400VAC MOD 26 controller for 400VAC power supply with booster connection Art Nos 740843 800026 must be ordered Current transformer PEX W3 Art No 885105 ...

Page 62: ...Version 1 For more accessories Accessories leaflet Temperature meter ATR 3 300 C range Art No 882130 5 500 C range Art No 882150 Booster B 400 075 Max pulse load 75A 400VAC Art No 885301 100 Max pulse load 100A 400VAC Art No 885304 ...

Page 63: ...ges 52 External switching amplifier 10 F Factory settings 59 Fahrenheit F 45 Fault areas 58 Fault diagnosis 8 Fuse 19 H HEAT 29 41 Heatsealing band type 12 Heatsealing temperature 41 Heatup timeout 49 How to order 61 I Impulse heatsealing method 7 Impulse transformer 9 19 61 Installation 13 16 Installation procedure 16 Installation regulations 17 L Line filter 4 9 19 20 61 Line frequency 8 12 Line...

Page 64: ...ol 7 Temperature diagnosis 48 49 Temperature indication 9 38 Temperature meter 40 62 Temperature range 12 26 Temperature setting 38 Temperature unit 45 Transformer 4 9 19 61 Transportation 4 Type of construction 12 U Undervoltage detection 50 V View of the controller 24 Visualization software 51 W Wiring 17 19 Wiring diagram 22 ...

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