Ropex RESISTRON RES-420 Operating Instructions Manual Download Page 1

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12.1.09

RESISTRON

RES-420

Important features

• Microprocessor technology

• LC display (green), 4 lines, 20 characters, (multilingual)

Alternatively:
VF display (blue), 4 lines, 20 characters, (multilingual)

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)

• Automatic configuration of the secondary voltage and current ranges

(AUTORANGE, as of software revision 100)

• Automatic phase angle compensation (AUTOCOMP, as of software revision 100)

• Automatic frequency adjustment

• Large current and voltage range

• Booster connection as standard

• Heatsealing band alloy and temperature range selectable

• Alarm function with fault diagnosis

Identical design to and compatible with RES-210, -211, -220, -221

Operating

Instructions

Summary of Contents for RESISTRON RES-420

Page 1: ...TOTUNE Automatic configuration of the secondary voltage and current ranges AUTORANGE as of software revision 100 Automatic phase angle compensation AUTOCOMP as of software revision 100 Automatic frequency adjustment Large current and voltage range Booster connection as standard Heatsealing band alloy and temperature range selectable Alarm function with fault diagnosis Identical design to and compa...

Page 2: ...s 24 10 2 Display 25 10 3 Navigation in the menus 26 10 4 Menu structure 28 10 5 Two digit numbering system up to software revision 027 30 10 6 Menu steps 31 10 7 Temperature setting set point selection 35 10 8 Temperature indication 35 10 9 Automatic zero calibration AUTOCAL 35 10 10 START signal HEAT 35 10 11 Cycle counter 36 10 12 Hold mode 36 10 13 Measuring impulse duration as of software rev...

Page 3: ...ified as follows e g Alloy 20 TCR 1100 ppm K NOREX TCR 3500 ppm K The RESISTRON temperature controller must be set and coded according to the temperature coefficient of the heatsealing band The use of incorrect alloys with a too low temperature coefficient and incorrect coding of the RESISTRON temperature controller lead to uncontrolled heating and ultimately to burn out of the heatsealing band Th...

Page 4: ...the user s own responsibility The CE marking on the controller confirms that the device itself complies with the above mentioned standards It does not imply however that the overall system also fulfils these standards It is the responsibility of the machine manufacturer and of the user to verify the completely installed wired and operationally ready system in the machine with regard to its conform...

Page 5: ...oads on the heatse aling 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 high sampling rate A high secondary current can be controlled with only minimal power loss because power is controlled on the primary side of the transformer This allows optimum adap...

Page 6: ... is represented on an LC display with 4 lines and 20 characters Devices with a VF display are available as an option Various display languages can be selected The real heatsealing band temperature is visualized on the display both as a digital number in C and in the form of a dynamic bar The RESISTRON temperature controller RES 420 also features an integrated fault diagnosis function which tests b...

Page 7: ...bobbin Optimized for impulse operation with RESISTRON temperature controllers Specified according to the heatsealing application ROPEX Application Report Communication interface CI USB 1 Interface for connecting a RESISTRON temperature controller with diagnostic inter face DIAG to the PC USB port Associated PC visualization software for dis playing setting and configuration data and for recording ...

Page 8: ...modification is only recommended for existing applications The PC visualization software section 10 20 Diagnostic interface visualization software as of software revision 100 on page 39 should be used for all new applications Adapter for top hat rail mounting HS Adapter 01 For mounting the RESISTRON temperature controller RES 420 on a top hat rail DIN TS35 Allows the controller to be installed in ...

Page 9: ...ent can be set independently of one another in the Configuration menu Temperature range 200 C 300 C 400 C or 500 C Temperature coefficient 400 4000ppm variable setting range Up to software revision 027 Several different ranges can be selected on the controller in the Configuration menu Temperature coefficient 410ppm 0 300 C SW revision 021 or higher Temperature coefficient 460ppm 0 300 C SW revisi...

Page 10: ...e 4 lines 20 characters Ambient temperature 5 45 C Degree of protection Front IP42 IP65 with transparent front cover Art No 887000 Back IP20 Installation Installed in front panel cutout with W x H 138 0 2 x 68 0 2 mm Fastened with clips Weight Approx 1 0kg incl connector plug in parts Housing material Black plastic type Noryl SE1 GFN2 Connecting cable Type cross sections Rigid or flexible 0 2 2 5m...

Page 11: ...20 Page 11 7 Dimensions front panel cutout 29 132 9 136 66 144 72 138 x 68 0 2 0 2 front panel terminal wires rubber seal mounting clamp terminal blocks outline dimensions front frame panel cutout DIP switch to select U I 2 2 front frame ...

Page 12: ...n the plant or machine The line frequency is automati cally detected by the temperature controller in the range from 47Hz to 63Hz 3 Install the RESISTRON temperature controller in the front panel cutout It is fastened by means of two clips which snap onto the side of the controller housing 4 Wire the system in accordance with the instructions in Kap 8 3 Power supply auf Seite 14 Kap 8 6 Wiring dia...

Page 13: ...le temperature coefficient No additional resistance in secondary circuit Dimension transformer correctly Secondary voltage Power Duty cycle Sufficient wire cross section No push on connectors Twisted Current measuring wires IR R Connect U measuring wires directly to heatsealing band ends Line filter LF xx480 Note number of turns Controller OPTION Temperature meter ATR x Note polarity Configure DIP...

Page 14: ...ler belonging to the 4xx Series Relay Kb Load break all pole e g in combination with the alarm output of the temperature controller When using a series resistor RV 1 the relay Kb shall be installed Impulse Transformer Designed according to VDE 0570 EN 61558 isolating transformer with reinforced insulation Connect core to ground Use transformers with a one section bobbin The power duty cycle and vo...

Page 15: ...application For more technical information Line filter docu mentation 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 8 3 Power supply on page 14 must be observed 8 5 Current transformer PEX W3 The PEX W3 current transformer supplied with ...

Page 16: ...3 15 14 Line filter LF xx480 IR UR 0V 1 2 Current transformer PEX W2 W3 twisted Heat sealing band Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging sec U2 prim U1 5 6 ALARM OUTPUT max 50V 0 2A Contact closed or opened by ALARM see configuration 0V Internnal ground No external grounding allowed 0V Internnal ground No external grounding allowed up to production d...

Page 17: ...R 1 2 Current transformer PEX W2 W3 twisted Heat sealing band Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Internnal ground No external grounding allowed 0V Internnal ground No external grounding allowed LINE Booster NC NC 2 4 IN OUT 1 3 Line filter LF xx480 0V sec U2 prim U1 5 6 ALARM OUTPUT max 50V 0 2A Contact closed or opened by ALARM see configurat...

Page 18: ...erminals Wiring diagram Diagnostic interface on rear of controller Operator keys Clips Display 50V 0 2A ROPEX 1 U1 4 5 6 7 8 9 10 11 12 13 14 15 RES 420 PRIM START 24VDC START CONTACT BOOSTER ALARM GND FILTER N L1 PE L1 L2 only with filter 2 3 R U R I R U2 SEC 0V DIAG AUTO RANGE R U 2 I 0 4 120V 30 500A Printed wiring diagram Terminals Diagnostic interface Terminals ...

Page 19: ...current in the range from 30A to 500A If the voltage and or the current is outside the permissible range a detailed error mes sage appears on the controller s section 10 24 Fault areas and causes on page 44 Configuration with coding switches up to software revision 027 Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to the correct position for your applicati...

Page 20: ...tory set tings must be restored in order to prevent malfunc tions 9 3 4 Configuration of the alloy and the temperature range up to software revision 027 These parameters are set with step 22 in the Configu ration menu Several different ranges can be selected 1 Temperature coefficient 410ppm 0 300 C software revision 021 or higher 2 Temperature coefficient 460ppm 0 300 C software revision 019 or hi...

Page 21: ...can be 200 C 300 C Factory setting 400 C or 500 C 9 3 7 Temperature diagnosis as of software revision 100 The temperature diagnosis function can be activated by means of step 217 in the Configuration menu The RES 420 then checks whether the ACTUAL tempera ture is inside a specifiable tolerance band OK window on either side of the SET temperature The lower and upper limits of the tole rance band ca...

Page 22: ...ly 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 chap 9 4 2 Burning in the heatsealing band page 22 One very important design feature is the copper or silver plating of the heatsealing band ends Cold ends allow the temperature to be controlled accurately and increase the life ...

Page 23: ...p correctly 7 One of the following states then appears 8 Set the controller configuration as described in Kap 9 3 Controller configuration auf Seite 19 The following settings are always required 9 Activate the AUTOCAL function while the heatse aling band is still cold with step 7 in the Settings menu The progress of the calibration process is indicated by a counter on the display approx 10 15s Whe...

Page 24: ...Always use a heatsealing band with the cor rect alloy dimensions and copper plating in order to avoid malfunctions and overheating Continue with section 9 5 1 steps 9 and 10 10 Controller functions See also Kap 8 6 Wiring diagram standard auf Seite 16 10 1 Indicators and controls The controller is now ready ENTER HAND RESET ROPEX RESISTRON RES 4 MENU key for advancing to next menu step or switchin...

Page 25: ...dicates the SET temperature as a digital value and the ACTUAL temperature as a digital value and a dynamic bar 10 2 3 Settings Configuration menus The required parameters are set on two menu levels the Settings control menu and the Configuration menu Kap 10 4 Menu structure auf Seite 28 Company name optional customer specific Software ID number Controller type RES 420 Specified heatsealing tempera...

Page 26: ...2s By pressing the key for longer 2s you can return to the home position from anywhere in the menu structure providing a controller alarm is not active In this case the Alarm menu is opened instead If the display is in the home position or an alarm is indi cated and you press the MENU key for longer than 2s you are taken directly to the configuration level starting at step 201 20 In addition you a...

Page 27: ... pressing the MENU key 2s You can then activate the AUTOCAL function by pressing the ENTER key section 10 9 Automatic zero cali bration AUTOCAL on page 35 If you press the MENU key for longer than 2s in the Alarm menu you are taken directly to the configuration level starting at step 201 20 You can return from the Configuration menu to the Alarm menu either by pres sing the MENU key for longer tha...

Page 28: ...eded 206 Max temperature 210 Cooling mode 212 Relay K1 function 213 Lock HAND key 207 Set point reached 205 Temperature range Settings Configuration 3 AUTOCOMP OFF 4 AUTOCOMP ON 5 TCR variable 6 TCR not variable 211 Start of sealing time Fault 215 Alarm relay 204 Temp coefficient 214 Cycles 107 Autocal 102 Preheating temp Autocal 5 6 209 Time control 1 2 216 Analog output 1 2 217 Temp diagnosis 21...

Page 29: ...Controller functions RES 420 Page 29 221 Autocomp 220 Meas imp length 219 Heatup timeout Configuration 222 Output 1 Continued from previous page Back to home position 225 Temperature unit ...

Page 30: ...vision 100 and are described in chap 9 Startup and opera tion page 18 and section 10 4 Menu structure on page 28 respectively The new three digit menu step numbers are described first in all relevant sections of this document The older two digit numbers are indi cated afterwards in square brackets e g step 201 20 Menu Menu steps Numbering up to software revision 027 Numbering as of software revisi...

Page 31: ...formation in the home position is replaced by Hold This procedure is repeated for every cycle and the displayed value is updated The word Hold is invisible for 100ms before the value is updated If you select the 2 second hold function the dis play changes back from hold mode to the actual value in real time after 2 seconds The hold function is then activated again for 2 seconds at the end of the n...

Page 32: ...ftware revision 015 or higher also French Spanish Dutch Danish Finnish Swedish Greek Turkish Software revision 024 or higher also Portuguese 202 21 Factory settings The controller can be reset to the factory settings by pressing the ENTER key section 11 Factory settings on page 46 In addition as of software revision 100 The UP and DOWN keys can be used to select whether The controller should be re...

Page 33: ...ed on the basis of this setting Please be very careful to select the heat sealing band material with the correct alloy Availability depends on software revision TCR 780ppm TCR 1100ppm TCR 3500ppm variable 204 Temperature coefficient If you selected Variable with step 203 you can specify the temperature coefficient of the heatse aling band material here in 10ppm increments using the UP and DOWN key...

Page 34: ...en the actual temperature enters the tolerance band The temperature timeout and fault output are not activated until after the delay time has elapsed This step can only be selected if the temperature diagnosis function step 217 is active 0 99 9s 219 Heatup timeout If the actual temperature is outside the tolerance band when the specified time elapses after the START signal has been activated a fau...

Page 35: ...heatsealing band is not heated until the calibration process has finished The message Calibration Please wait appears on the display while the AUTOCAL function is execu ting and a counter counts down from 13 to 0 If the temperature of the heatsealing band varies on controllers as of software revision 100 the AUTOCAL function is executed a maximum of three times If the function still cannot be term...

Page 36: ... The cycle counter is reset to 0 if the ENTER key is pressed or if the maximum count of 999 999 999 cycles is exceeded 10 12 Hold mode The behavior of the digital indication of the ACTUAL temperature in the home position can be changed with step 106 2 in the Settings menu The following set tings are possible 1 OFF Factory setting If the main menu is visible on the display the real ACTUAL temperatu...

Page 37: ...n be parameterized with step 221 as followed 1 OFF Factory setting 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 10 9 Auto matic zero calibration AUTOCAL on page 35 The interval after the end of the AUTOCAL func tion must be less than 2 0s Start AUTOCOMP Start with ENTER appea...

Page 38: ... unit can be changed on the con troller without interrupting operation If you specify temperature indication and value selection in Fahrenheit F the con troller still uses Celsius C internally Value steps are therefore possible with this function owing to the conversion from Celsius to Fahrenheit 10 17 Disabling the Configuration menu Software revision 010 or higher It is possible to disable all c...

Page 39: ...layed again and operation is resumed when the input voltage returns to the speci fied tolerance range The alarm relay terminals 5 6 is only switched by an undervoltage condition in controllers up to and inclu ding software revision 008 The alarm relay in control lers with a higher software revision number is not swit ched if an undervoltage condition occurs Trouble free operation of the controller...

Page 40: ...reas and causes on page 44 for a list of the possible error codes B Alarm relay relay contact terminals 5 6 This contact is set in the factory as follows OPEN if error code 104 106 111 113 or 211 is displayed The contact closes however if a START signal is activated in this state CLOSED if error code 101 103 107 108 201 203 801 or 9xx appears If the alarm relay is configured differently from the f...

Page 41: ...controller Replace controller Replace controller Replace controller Replace controller 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 9 3 7 Frequency fluctuation inadmissible line frequency Heatup time too long section 9 3 8 Int faut contr defective Triac defective Int faut cont...

Page 42: ...L 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 too high AUTOCAL wasn t per formed...

Page 43: ...ea check configuration 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 Ext calibration temperature too high Ext calibration temperature fluctuates STATUS of alarm relay factory set Warn...

Page 44: ...e transformer interrupted Secondary circuit interrupted before 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 ba...

Page 45: ...d incorrectly I2 range As of software revision 100 I2 outside permissible range from 30 500A Turns through PEX W2 W3 cur rent transformer incorrect Check number of turns two or more turns required for currents 30A Internal controller fault Hardware fault replace controller Fault area Explanation Possible causes ...

Page 46: ...ches 2 ON 1 3 4 5 OFF These switches are automatically set by the AUT ORANGE function on all controllers as of software revision 100 Settings menu No 101 1 Heatsealing temperature 0 C No 106 2 Hold mode OFF No 107 3 AUTOCAL temperature 20 C Configuration menu No 201 20 Language German This selection is NOT changed if the factory settings are restored with step 202 21 in the Config menu No 203 204 ...

Page 47: ...e controller in this way 3 Restore customer settings Selecting this option restores the customer set tings that were saved as described in 2 When the controller is first delivered the customer settings are identical to the Ropex settings After pressing the ENTER key in this menu step you are asked to confirm the new settings safety query Another message appears if you now confirm these settings by...

Page 48: ...tion MOD optional if required e g 01 MOD 01 Art No 800001 amplifier for low voltage Please indicate the article numbers of the controller and the required modifications optional in all orders e g RES 420 L 400VAC MOD 01 controller with LC display for 400VAC line voltage and amplifier for low voltage Art Nos 742013 800001 must be ordered Current transformer PEX W3 Art No 885105 Line filter LF 480 0...

Page 49: ...40 External switching amplifier 7 17 F Factory settings 20 46 Fahrenheit F 38 Fault areas 44 Fault diagnosis 6 Front cover 7 H HEAT 23 35 Heatsealing band type 9 Heatup timeout 22 Hold mode 36 I Impulse heatsealing method 4 Impulse transformer 7 14 48 Installation 10 12 Installation procedure 12 Installation regulations 12 L Line filter 7 14 15 48 Line frequency 6 9 Line voltage 9 Locking the HAND...

Page 50: ...nosis 21 Temperature indication 35 Temperature range 9 20 21 Temperature setting 35 Temperature unit 38 Transformer 3 7 14 48 Type of construction 9 U Undervoltage detection 39 V View of controller 18 Visualization software 39 W Wiring 12 14 Wiring diagram 16 17 ...

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