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Ropex RESISTRON RES-440, Operating Instructions Manual

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Ropex RESISTRON RES-440 Operating Instructions Manual Download Page 23

Startup and operation

Version 1

RES-440

Page 23

9

Startup and operation

9.1

Front view of the controller

9.2

Rear view of the controller

As of software revision 100:

Nameplate

Terminals
Wiring diagram
Diagnostic interface
(on rear of controller)

Operator keys

Clips

 
Display

1

2

3

4

5

6

7

8

9 10 11

19 20 21 22 23 24 25 26

18

17

16

30V / 0,2A

ROPEX

19 20 21 22 23 24 25 26

1

16 17 18

K1

U

1

4 5 6 7 8 9 10 11

12 13 14 15

PRIM.

START

24VDC

STAR

T

CO

NT

A

C

T

BOOSTER

ALARM

GND

FILTER

N    (L1)

(PE)

L1  (L2)

 

(o

n

ly

 w

ith

 fi

lte

r)

2 3

R

U

R

I

R

U

2

SEC.

0V

AUTO

RANGE

R

U

2

I

0,4 - 120V

30 - 500A

RES-440

DIAG

PR

EH

EA

T

24

VD

C

TEM

P. O

K

GN

D

TEMP.OUT

0 -10VDC

PR

EH

EA

T

CO

NT

AC

T

0V

Printed wiring diagram

Terminals

Diagnostic interface

Terminals

Summary of Contents for RESISTRON RES-440

Page 1: ...c 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 Time control heatsealing time and cooling time settable Preheating Configurable ...

Page 2: ...35 10 2 Display 35 10 3 Navigation in the menus 37 10 4 Menu structure 39 10 5 Two digit numbering system up to soft ware revision 027 41 10 6 Menu steps 42 10 7 Temperature setting set point selection 50 10 8 Temperature indication actual value output 51 10 9 Automatic zero calibration AUTOCAL 53 10 10 START signal HEAT 54 10 11 PREHEAT signal preheating 55 10 12 Cycle counter 57 10 13 Hold mode ...

Page 3: ...Version 1 RES 440 Page 3 12 Maintenance 85 13 How to order 86 14 Index 88 ...

Page 4: ...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 5: ... 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 6: ...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 7: ...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 8: ...he temperature calculated 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 ...

Page 9: ...he range from 47Hz to 63Hz Increased protection against dangerous conditions such as overheating of the heatsealing band A time control timer function integrated in the controller enables the complete heatsealing process to be con trolled on simple machines such as table heatsealing tools A configurable relay output can be used to drive motors energize magnets etc The process data is represented o...

Page 10: ... RESISTRON temperature controller RES 440 They allow it to be optimally adapted to your specific heatsealing application and to your plant s design and operating philosophy 5 1 Accessories The products described below are only a few of the wide range of accessories available for RESISTRON tem perature controllers Accessories leaflet Analog temperature meter ATR x For front panel mounting or mounti...

Page 11: ...25A Monitoringcurrent transformer For detecting frame short circuits on the heatsealing band Used as an alternative to the standard PEX W2 W3 current transformer Transparent front cover TFA 1 For increasing the degree of protection on the front of the controller to IP65 Also facilitates applications in the food technology sector GMP Adapter for top hat rail mounting HS Adapter 01 For mounting the ...

Page 12: ...tsealing bands MOD 33 Software revision 010 or higher Important heatsealing process data can be output and logged via a serial RS232 interface MOD 33 documen tation This modification is only recommended for existing applications The PC visualization software section 10 21 Diagnostic interface visualization software as of software revision 100 on page 63 should be used for all new applications ...

Page 13: ...perature coefficient 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 ...

Page 14: ...ssion with 47nF 560ohms for each terminal Maximum load primary current of impulse transformer Imax 5A duty cycle 100 Imax 25A duty cycle 20 Power dissipation max 25W Display LC display green 4 lines 20 characters alternatively VF display blue 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 Insta...

Page 15: ...7 Dimensions front panel cutout 29 132 9 136 66 144 72 front panel terminal blocks terminal wires rubber seal mounting clamp terminal blocks terminal wires outline dimensions front frame panel cutout 138 x 68 0 2 0 2 DIP switch to select U I 2 2 front frame ...

Page 16: ...n the plant or machine The line frequency is automatically 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 section 8 3 Power supply on page 18 section 8 6 Wirin...

Page 17: ...uitable 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 Configur...

Page 18: ... 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 19: ...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 8 3 Power supply on page 18 must be observed Example drawing for LF 06480 8 ...

Page 20: ...RES 440 Version 1 8 5 1 PEX W4 8 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 21: ...0VAC 1 5A GND GND 15 14 1 2 8 9 12 13 10 11 19 7 START HEAT with contact PREHEAT Vorwärme with contact Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging Contact closed or opened by ALARM see configuration 0V Internal ground Terminal 2 R Impulse transformer IR UR Current transformer twisted Heat sealing band LINE Line filter LF xx480 0V sec U2 prim U1 0V Intern ...

Page 22: ... 1 5A GND GND 15 14 1 2 8 9 12 13 10 11 19 7 START HEAT with contact PREHEAT Vorwärme with contact Ground for 24VDC signals Must be grounded externally to prevent electrostatic charging 0V Intern ground No external grounding allowed 0V Internnal ground No external grounding allowed 0V Intern ground No external grounding allowed Contact closed or opened by ALARM see configuration 0V Internal ground...

Page 23: ...or keys Clips Display 1 2 3 4 5 6 7 8 9 10 11 19 20 21 22 23 24 25 26 18 17 16 30V 0 2A ROPEX 19 20 21 22 23 24 25 26 1 16 17 18 K1 U1 4 5 6 7 8 9 10 11 12 13 14 15 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 AUTO RANGE R U 2 I 0 4 120V 30 500A RES 440 DIAG PREHEAT 24VDC TEMP OK GND TEMP OUT 0 10VDC PREHEAT CONTACT 0V Printed wirin...

Page 24: ...A If the voltage and or the current is outside the permissible range a detailed error message appears on the controller s section 10 26 Fault areas and causes on page 81 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 application You can find the exact configurati...

Page 25: ...ting with step 202 can still be changed even if the Con figuration menu is disabled 9 3 3 Restoring the factory settings The internal controller settings can be reset to the factory settings with step 202 21 in the Configuration menu Only the language setting step 201 20 in the Configuration menu remains unchanged Please refer to section 11 Factory settings on page 83 for more information about th...

Page 26: ...efficient 780ppm 0 500 C e g Alloy L software revision 011 or higher 11 Temperature coefficient 870ppm 0 300 C software revision 019 or higher 12 Temperature coefficient 980ppm 0 300 C software revision 019 or higher 13 Temperature coefficient 1100ppm 0 200 C e g Alloy A20 14 Temperature coefficient 1100ppm 0 300 C Factory settings e g Alloy A20 15 Temperature coefficient 1100ppm 0 400 C e g Alloy...

Page 27: ...Configuration of the timer function The necessary controller settings are explained in the detailed functional descriptions in section 10 6 Menu steps on page 42 and section 10 23 Time control timer function on page 64 They are only allowed to be entered by technically trained persons The timer function is activated with step 26 in the Configuration menu 9 3 8 Relay K1 without time control The fun...

Page 28: ...perature OK signal without time control On controllers up to software revision 027 the switching output at terminals 20 21 was called Temperature OK The more general name Output 1 is used as of software revision 100 because this output now also supports other functions The Output 1 signal is available at terminals 20 21 as a digital control signal Up to software revision 027 The RES 440 checks whe...

Page 29: ... 29 The ACTUAL temperature is evaluated and the output signal at terminals 20 21 activated in all operating states except when a fault is signaled Soll Output 1 Set Δϑlower Set Δϑupper Actual value Time Time Not conduct Conductive Terminals 20 21 ...

Page 30: ...9 3 10 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 440 then checks whether the ACTUAL temperature is inside a specifiable tolerance band OK window on either side of the SET temperature The lower and upper limits of the tolerance band can be changed independently of one another by means ...

Page 31: ... General 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 te...

Page 32: ...nd press the HAND key display in home position to heat for approximately 1 second After recooling the con troller usually indicates a value less than 20 C Repeat the AUTOCAL function The heatsealing band has now been burned in and the change in the alloy properties stabilized The burn in effect described here does not occur if the heatsealing band has already been thermally pretreated by the manuf...

Page 33: ... controllers up to software revision 027 the setting of the DIP switches on the controller are indicated in the ROPEX Application report and depend on the heatsealing band section 9 3 Controller configuration on page 24 4 Make sure that a START signal is not present 5 Switch on the line voltage 6 A power up message appears on the display for approximately 2 seconds when the controller is switched ...

Page 34: ...T signal HEAT Alternatively a heatsealing process can be started by pressing the HAND key dis play in home position The indication of the ACTUAL temperature on the display digital value and dynamic bar permits the heating and control process to be monitored The controller is functioning correctly if the temperature indicated on the display has a continuous curve in other words it must not jump abr...

Page 35: ... key for advancing to next menu step or switching menu 1 sec Press Next menu step 1 2 sec Press Return to previous position as of SW Revision 100 2 sec Press Hold Return to home position ENTER key ENTER function HAND function RESET function Save values Manual mode Reset after alarm UP and DOWN keys for setting values Press 2 sec Slow change Hold 2 sec Fast change LC display 4 lines multilingual op...

Page 36: ...on 10 4 Menu structure on page 39 10 2 4 Error messages The fault diagnosis function of the controller is always active If a fault is detected it is indicated on the display immediately in the form of an error message section 10 24 System monitoring alarm output on page 76 Icon indicates that NO contact of additional Specified heatsealing temperature SET temperature relay K1 is closed Measured ACT...

Page 37: ...om 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 indicated 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 always return to the home position if you do not press any keys for a period ...

Page 38: ... briefly pressing the MENU key 2s You can then activate the AUTOCAL function by pressing the ENTER key section 10 9 Automatic zero calibration AUTOCAL on page 53 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 pressing the MENU key for long...

Page 39: ... Relay K1 function 213 Lock HAND key 207 Set point reached 205 Temperature range Settings Configuration 1 Time control ON 2 Time control OFF 3 AUTOCOMP OFF 4 AUTOCOMP ON 5 TCR variable 6 TCR not variable 7 Cooling mode abso lute relative time 8 Cooling mode none 211 Start of sealing time Fault 215 Alarm relay 204 Temp coefficient 214 Cycles 107 Autocal 102 Preheating temp Autocal 5 6 209 Time cont...

Page 40: ...Controller functions Page 40 RES 440 Version 1 221 Autocomp 220 Meas imp length 219 Heatup timeout Configuration 222 Output 1 Continued from previous page Back to home position 225 Temperature unit ...

Page 41: ...The new three digit menu step numbers are described first in all relevant sections of this document The older two digit numbers are indicated afterwards in square brackets e g step 201 20 Menu Menu steps Numbering up to software revision 027 Numbering as of software revision 100 Settings menu Heatsealing temperature 1 101 Preheating temp PREHEAT 2 102 Starting delay 3 103 Heatsealing time 4 104 Co...

Page 42: ...etting of step 205 22 0 40 C maximum tem perature step 206 23 102 2 Preheating temper ature The required preheating temperature can be set with the UP and DOWN keys The maximum temperature step 206 23 applies to both the heatsealing temperature and the preheating tem perature The preheating function can be deactivated by entering 0 C Depends on setting of step 205 22 0 40 C maximum tem perature st...

Page 43: ...ed 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 next cycle ON OFF 2 s 107 7 Autocal The AUTOCAL function matches the control...

Page 44: ...an Software 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 83 In addition as of software revision 100 The UP and DOWN keys can be used to select whether The controller should ...

Page 45: ...ppm 200 C TCR 3500ppm 300 C 203 Alloy Various heatsealing band alloys can be selected here The corresponding characteristic for the controller parameters is calculated 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...

Page 46: ...ulate the switching threshold 5K 99K 208 25 Set point exceeded upper limit As of software revision 100 If the actual value is less than the switching threshold specified here and greater than the threshold set with step 207 Output 1 and or relay K1 can be activated depending on the configuration step 212 or 222 Up to software revision 027 If the actual value is less than the switching threshold sp...

Page 47: ...me control step 209 26 is active Time in s 211 28 Start of heatsealing time This menu step specifies whether the heatsealing time step 104 4 should begin as soon as the start signal is applied or when 95 of the set point is reached This function can only be selected if time control step 209 26 is active Heatsealing time starts when heating starts Heatsealing time starts when temperature reached 21...

Page 48: ...nergized for up to 0 5 seconds at the end of the cooling phase momentary impulse The length of the momentary impulse can be short ened by applying the start signal during the impulse Relay K1 generates end of cycle impulse In addition as of software revision 100 K1 is energized if the actual value is inside the specified temperature tolerance band steps 207 208 Relay K1 active if Tact Tset In addi...

Page 49: ...08 is output OFF ON 218 Temperature diagnosis delay time This delay time starts when 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 ba...

Page 50: ... start signal is present The relay is deenergized at the end of the cooling phase Output 1 active with START signal Output 1 is energized when the actual value reaches 95 of the set point The relay is deen ergized at the end of the cooling phase Output 1 active when temperature reached Output 1 is energized at the end of the heating phase and deenergized again at the end of the cooling phase This ...

Page 51: ...a dynamic bar The heating and control process can thus be monitored at any time In addition the RES 440 controller outputs an analog 0 10VDC signal which is proportional to the real ACTUAL temperature at terminals 23 24 Voltage values 0VDC 0 C 10VDC 300 C or 500 C depending on the controller configuration RES 440 24 max 5mA 23 0V R 33ohms Actual value output 0 10VDC 0 10VDC Temperature meter e g A...

Page 52: ...sponse are ideally suited to this application section 5 Accessories and modifications on page 10 It not only facilitates SET ACTUAL comparisons but also enables other criteria such as the heating rate set point reached within the specified time cooling of the heatsealing band etc to be evaluated This meter moreover permits disturbances in the control loop loose connections contacting or wiring pro...

Page 53: ...mperature of the heatsealing bar s which is currently valid for calibration can be set beforehand in the 0 40 C range using the UP and DOWN keys The zero point is calibrated in the factory to 20 C The automatic calibration process takes around 10 15 seconds The heatsealing band is not heated until the cali bration process has finished The message Calibration Please wait appears on the display whil...

Page 54: ...d the heatsealing band is heated up to the SET temperature 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 2 Time control on activated If time control timer function is on activating the START signal starts the internally parameterized timeout T...

Page 55: ...gnal is used it is deactivated internally during the heating and control process The heatsealing band is not returned to the set preheating temperature until the PREHEAT signal is activated again at the end of the control process for the main heat section 10 11 PREHEAT signal preheating on page 55 10 11 PREHEAT signal preheating The heatsealing band can be heated to a specified preheating temperat...

Page 56: ...le an error message is indicating error codes 104 105 111 113 or 211 section 10 26 Fault areas and causes on page 81 The heatsealing band is like wise not heated If a PREHEAT signal is active it is deactivated internally for the duration of a heating and control process that is activated either by means of the START signal or by pressing the HAND key The ACTUAL temperature shows whether the heatse...

Page 57: ...ting If the main menu is visible on the display the real ACTUAL temperature is always indicated 2 ON If the display is in the home position 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 Software revision 0...

Page 58: ...uring impulse duration as of software revision 026 The length of the measuring impulses generated by the controller can be set with this parameter by means of step 220 32 It may be necessary to set a measuring impulse that is longer than the default 1 7ms for certain applications ROPEX Application Report ACTUAL temp START signal 24VDC T t t 0 0 Hold OFF T t 0 ACTUAL indication Hold ON T t 0 Hold 2...

Page 59: ...interval after the end of the AUTOCAL function must be less than 2 0s Start AUTOCOMP Start with ENTER appears on the display during this time The subsequent AUTOCOMP function is executed in approximately 2 0s AUTOCOMP Please wait appears on the display during this time If the interval following the successful execution of the AUTOCAL function is longer than 2 0s the display returns to the home pos...

Page 60: ...rameterized with step 225 as followed 1 Celsius Factory setting Temperature indication and value selection in Celsius C 2 Fahrenheit Temperature indication and value selection in Fahrenheit F Up to software revision 105 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...

Page 61: ...gain To do so repeat the above procedure press the MENU key for 2 0seconds while the power up message is displayed The display then shows a message confirming that the disable function has been canceled In the factory setting the Configuration menu is not disabled 10 19 Setting the display brightness VF display only Software revision 019 or higher If the display is in the home position the brightn...

Page 62: ...elay terminals 5 6 is only switched by an undervoltage condition in controllers up to and including software revision 008 The last valid temperature value continues to appear at the analog output terminals 23 24 The alarm relay in controllers with a higher software revision number is not switched if an undervoltage condition occurs The standby mode is indicated by 0 3 C corresponds to app 0V at th...

Page 63: ...gnostic 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 10 22 Booster connection The RES 440 controller has a connection for an external switching amplifier booster as standard This connec tion at terminals 1 2 is necessary for high primary currents continuous c...

Page 64: ...e timeout either ends with the parameterized cooling phase or is interrupted by activating the RESET signal 3 ON with START monitoring Software revision 021 or higher Time control timer function activated and START signal monitored Once again the internal timeout is started by activating the START signal In this setting however the START signal must remain activated until the end of the parameteri...

Page 65: ... time control ON with START monitoring is configured If the display is in the home position the individual timeouts can be monitored there The remaining heatsealing time is indicated on the display in the form of a countdown at the end of the heating phase A direction arrow indicates the active process The active cooling phase is subsequently marked with the direction arrow at the end of the heati...

Page 66: ...to bridge the closing time of the heatsealing bars When the START signal is activated the controller waits for the time specified with this menu step to elapse before commencing the heating process The starting delay can be set in the range from 0 to 9 9s A delay of 0s is defined as the factory setting In this case the heating process begins as soon as the START signal is activated 10 23 3 Setting...

Page 67: ...ling band falls below a specified tem perature value This cooling temperature can be set with step 105 5 in the Settings menu 2 Relative The cooling phase ends when the ACTUAL temperature falls to a value corresponding to X of the SET tem perature This percentage cooling value can be set with step 105 5 in the Settings menu Example SET temperature 180 C cooling value 60 Cooling phase ends when ACT...

Page 68: ...n if step 210 27 is changed subsequently The possible settings are as follows 1 Cooling temp in C if setting with menu step 210 27 Absolute The cooling phase of the internal timeout ends when the ACTUAL temperature of the heatsealing band falls below the set temperature The minimum settable temperature is 50 C This is also the factory setting The maximum value of the setting range is limited eithe...

Page 69: ...menu can be specified with step 211 28 in the Configuration menu The following settings are possible 1 When heating starts The parameterized heatsealing time starts as soon as the set starting delay elapses Settings menu step 103 3 If the starting delay 0s the heatsealing time begins as soon as the START signal is activated 2 When temperature reached Factory setting Once again the heating process ...

Page 70: ...3 When temperature reached Factory setting The normally open contact of relay K1 closes when the ACTUAL temperature reaches 95 of the SET tem perature and remains closed until the end of the parameterized timeout i e until the end of the cooling phase 4 While cooling Software revision 010 or higher The normally open contact of relay K1 closes at the end of the heating phase and opens again at the ...

Page 71: ...Page 71 The possible settings are shown below ACTUAL temperature START signal 24VDC T t t 0 0 95 of set point When start signal present t 0 Relay K1 When temperature t 0 reached end of cooling t 0 While cooling t 0 End of cycle impulse 500ms ...

Page 72: ...eaves the tolerance band once during the heatsealing phase relay K1 is opened The relay is not closed again until the next START signal is activated The switching state of relay K1 can thus also be interrogated by the higher level PLC after a heatsealing process latch function see graph below 10 23 8 Output 1 Temperature OK signal with time control On controllers up to software revision 027 the sw...

Page 73: ...tory setting For a detailed description of these functions see section 10 23 7 Relay K1 with time control on page 70 10 23 9 Preheating with time control If time control is active the preheating temperature section 10 11 PREHEAT signal preheating on page 55 is only deactivated during the heating phase Preheating is active during the starting delay and the cooling phase The ACTUAL temperature conse...

Page 74: ...st close The solenoid valve is then energized and the sealing jaws are closed The heatsealing time t2 1s begins simultaneously 4 The heatsealing bands are not heated any further at the end of the heatsealing phase i e at the end of the heatsealing time The cooling phase begins 5 The cooling phase must end when the ACTUAL temperature of the heatsealing bands falls to T 80 C The sealing jaws are sti...

Page 75: ...settings should be undertaken in the specified order Then Step in Configuration menu Setting 26 Time control ON 27 Cooling mode Absolute 28 Start of heatsealing time When temp reached 29 Relay K1 function When temp reached Step in Settings menu Setting 101 1 Heatsealing temp 180 C 103 3 Starting delay 0 0 s 104 4 Heatsealing time 1 0 s 105 5 Cooling value Cooling temp 80 C ACT temperature START si...

Page 76: ...differently from the factory setting section 9 3 12 Configuration of the alarm relay on page 31 these states are inverted C Error code output via the 0 to 10VDC actual value output terminals 23 24 Since a temperature indication is no longer necessary if a fault occurs the actual value output is used to display error codes in the event of a fault 13 voltage levels up to software revision 027 12 vol...

Page 77: ... to be cleared quickly and efficiently The error codes described below can also be displayed in the ROPEX visualization software section 10 21 Diagnostic interface visualization software as of software revision 100 on page 63 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 the tolerance window ...

Page 78: ...oller Replace controller Replace controller 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 10 Frequency fluctuation inadmissible line frequency Heatup time too long section 9 3 11 Int faut contr defective Triac defective Int faut contr defective Int faut contr defective Int faut contr defective ...

Page 79: ...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 too high AUTO...

Page 80: ... 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 Warnin...

Page 81: ... 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 incorrectly insulat...

Page 82: ...igured 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 83: ...07 7 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 22 Alloy range Alloy A20 max 300 C No 206 23 Maximum temperature 300 C No 207 24 Set point reached 10K No 208 25 Set point exceeded 10K No 209 26 Time control OFF No 210 27 Cooling mode Absolute No 211 28 Start ...

Page 84: ...tep 21 in the Configuration menu The factory settings are restored if the ENTER key is pressed An acknowledgment message is displayed for approximately 2s The language which is selected with step 20 in the Configuration menu remains set even if the fac tory settings are restored ...

Page 85: ...n the controller in this way 3 Restore customer settings Selecting this option restores the customer settings 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...

Page 86: ...ation 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 440 L 400VAC MOD 01 controller with LC display for 400VAC line voltage and amplifier for low voltage Art Nos 744013 800001 must be ordered Current transformer PEX W3 Art No 885105 Line filter LF 480 ...

Page 87: ...How to order Version 1 RES 440 Page 87 For more accessories Accessories leaflet Booster B 400 075 Max pulse load 75A 400VAC Art No 885301 100 Max pulse load 100A 400VAC Art No 885304 ...

Page 88: ...4 Disabling Configuration menu 60 Display 35 Display brightness 61 Disposal 6 E Error messages 77 External switching amplifier 11 22 F Factory settings 25 83 Fahrenheit F 60 Fault areas 81 Fault diagnosis 10 76 Front cover 11 Fuse 18 H HEAT 34 54 Heatsealing band type 13 Heatsealing time 66 Heatup timeout 31 Hold mode 57 I Impulse heatsealing method 8 Impulse transformer 10 18 86 Installation 14 1...

Page 89: ...t 4 26 31 Temperature control 8 Temperature diagnosis 30 Temperature indication 51 Temperature meter 10 52 86 Temperature OK 14 Temperature OK signal 14 Temperature range 13 25 27 Temperature setting 50 Temperature unit 60 Time control 27 Timer function 27 54 Transformer 5 10 18 86 Transportation 5 Type of construction 13 U Undervoltage detection 61 V View of controller 23 Visualization software 6...

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