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Ropex RESISTRON RES-5007, Operating Instructions Manual

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Ropex RESISTRON RES-5007 Operating Instructions Manual Download Page 30

Device functions

Page 30

RES-5007

Version 1

Part 1 of 3: Error messages (malfunctions)

NOTE:

 The specified error messages are output as malfunctions (actual value output emits constant error 

voltage; alarm LED is continuously lit; alarm relay is active).

Error 

no.

Actual 

value 

output 

Voltage 

[V]

Cause

Measure if initial start-

up

Measure of machine in 

operation, heating ele-

ment not changed

101

0.66

Current signal missing

Error range 

Error range 

102

1.33

Voltage signal missing

Error range 

Error range 

103

2.00

Voltage and current signals 
missing

Error range 

Error ranges 



107

2.66

Temperature jump downward

Error ranges 



(“Loose connection”)

Error ranges 



(“Loose connection”)

108

Temperature jump upward

307

Temperature too low/high
(

chap. 8.9)

-

-

308

309

310

201

3.33

Network frequency missing/
fluctuates

Check network

Check network

202

Network frequency too large/
fluctuates

203

Network frequency too small/
fluctuates

304

4.00

Heat-up time too long
(

chap. 8.10)

Perform 

RESET

Perform 

RESET

901

4.66

Network voltage/synchronising 
signal missing

Replace device

Replace device

913

Triac defective

Replace device

Replace device

914

Int. error, device defective

Replace device

Replace device

915

916

917

Slide switch for alarm output 
incorrect

Check slide switch

Check slide switch

918

Summary of Contents for RESISTRON RES-5007

Page 1: ...tion AUTOTUNE Automatic configuration of the secondary voltage and current range AUTORANGE Automatic phase correction AUTOCOMP Automatic frequency adaptation Analogue input for setpoint specification with potentiometer or 0 10 VDC Analogue output 0 10 VDC for ACTUAL temperature 24 VDC control signals for START AUTOCAL and RESET Alarm function with error diagnosis Heating element alloy and temperat...

Page 2: ...n 14 7 3 Changing and burning in the heating element 15 7 4 Commissioning rules 16 8 Device functions 18 8 1 Display and operating elements 18 8 2 Temperature setting setpoint specification 19 8 3 Temperature display actual value output 20 8 4 Autom zeroing AUTOCAL 21 8 5 START signal HEAT 22 8 6 RESET signal 22 8 7 Measurement impulse duration 23 8 8 Automatic phase correction AUTOCOMP 23 8 9 Tem...

Page 3: ... graphics are protected by copyright All rights including to rep lication publication editing and translation are reserved 2 2 Intended use RESISTRON temperature controllers may only be used for heating and temperature control of heatsealing bands which are expressly approved for them and providing the regulations notes and warnings contained in these instructions are observed In case of non obser...

Page 4: ...ture controller is an integral part of the control system Only the original ROPEX PEX W4 or PEX W5 current transformer may be used Other transformers may cause the equipment to malfunction The current transformer may only be operated if it is correctly connected to the RESISTRON temperature controller see section Startup and operation The relevant safety instructions contained in section Power sup...

Page 5: ...he con troller can be removed with dry compressed air Dust deposits and dirt from liquids result in a loss of function Accordingly installation in a switch cabinet or terminal cabined with IP54 is recommended 2 9 Transportation Store and transport the device in its original carton After transport perform a visual inspection for possible damage 2 10 Disposal This device is subject to Directive 2012...

Page 6: ... and much more 4 Functional principle The resistance of the heating element which changes with temperature is measured by means of current and voltage measurement displayed and compared with the specified setpoint value Measurements are made 50 times per second in a 50 Hz network 60 times per second in a 60 Hz network The primary voltage of the impulse transformer is adjusted following the leading...

Page 7: ...point setting High control dynamics through AUTOTUNE automatic adjustment to the controlled system High flexibility A secondary voltage range of 0 4V to 120V and a current range of 30A to 500A are covered through the AUTORANGE function Automatic adjustment to the network frequency in the range of 47 Hz to 63 Hz Wide voltage range for flexible use from 110 VAC to 415 VAC Easy and convenient system ...

Page 8: ...ler and the sealing application ROPEX application report The overcurrent protective device must be located in the immediate vicinity of the device In the ROPEX application report the smallest possible specification for this overcurrent protective device is specified based on the calculated currents If the protective device is dimensioned differently the current car rying capacity of the components...

Page 9: ...red ends Use heatseal bands with suitable temperature coefficient 20 mm clearance if several controllers installed on one top hat rail 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 Lin...

Page 10: ...es load 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 powe...

Page 11: ...on Report 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 6 3 Power supply on page 10 must be observed Example drawing for LF 0...

Page 12: ...ge 12 RES 5007 Version 1 6 5 1 PEX W4 6 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: ... 7 Connection diagram standard RES 5007 also with MOD 01 R Impulse transformer 9 8 4 3 2 1 UR Heat sealing band sec U2 prim U1 twisted Current transfomer 11 10 IR 14 12 7 6 5 16 17 15 13 18 RESET 24 signal VDC START HEAT 24 signal VDC Protective con ductor connection AUTOCAL 24 signal VDC ALARM OUTPUT 24 VDC PE 24 VDC REFERENCE VOLTAGE OUTPUT UREF 10 VDC ANALOG OUTPUT actual value 0 10 VDC ANALOG ...

Page 14: ... AUTOCAL is carried out Configuration takes place in the voltage range of 0 4 VAC to 120 VAC and in the current range from 30 A to 500 A If voltage and or current is outside the allowed range a detailed error message is output by the controller see section 8 16 Error messages on page 29 For secondary currents I2 less than 30 A the secondary high current line must be guided 2 times or several times...

Page 15: ...ement principle used here requires from the heating element alloy a suitable temperature coefficient TCR ie an increase in resistance with temperature A TCR that is too small results in vibrating or overheating of the heating element If the TCR is large the controller must be calibrated for it The RESISTRON temperature controller is suitable for temperature coefficients in the range 400 4000 ppm K...

Page 16: ...ance With a new heating element the above described procedure for burning in must be performed 7 4 Commissioning rules Observe here section 2 General information on page 3 and section 3 Use on page 6 Mounting installation and commissioning may only be performed by qualified and trained persons who are familiar with the related hazards and warranty stipulations 7 4 1 Initial startup Requirement Dev...

Page 17: ...t terminal 16 and apply the START signal HEAT HEAT LED then lights up The heat up and control procedure can be observed at the actual value output It is functioning correctly when the temperature i e signal change at the analogue output is steady that is does not jump oscillate or even go briefly in the wrong direction Such behaviour indicates an incorrect place ment of the UR measurement line Whe...

Page 18: ...EAT yellow HEAT requested But function is blocked START is carried out OUTPUT green In control operation the light intensity is proportional to the heating current ALARM red Configuration error AUTOCAL not possible Controller incorrectly cali brated carry out AUTOCAL Error chap 8 16 AUTOCAL Yellow LED HEAT Yellow LED Red LED OUTPUT ALARM Green LED Lit during heating phase Lit while AUTOCAL process...

Page 19: ...elation between potentiometer setting and the SETPOINT temperature is linear The connection line between controller and potentiometer must be screened When the ROPEX precision potentiometer PD x PD 03 for 300 C or PD 05 for 500 C is used the set SET POINT temperature can be set exactly with the help of the numbers in the viewing window of the fine drive button The set number equals the SETPOINT te...

Page 20: ...rature display ATR x in its overall characteristics size scaling dynamic behaviour is optimally suited for this use and can be used for this if needed section 13 How to order on page 38 With this display not only can TARGET ACTUAL comparisons be made but other criteria can be evaluated such as heat up speed reaching the setpoint in the specified time cooling of the heating element etc RES 5007 17 ...

Page 21: ...ough the visualisation software With this set ting the basic temperature is specified through the analogue input terminal 16 13 in the range 3 40 C section 8 2 Temperature setting setpoint specification on page 19 The specification value at the analogue input must be present when the AUTOCAL function is activated If too high of a temperature greater than 40 C or a fluctuating specification value i...

Page 22: ...ion of the START signal the device internal target actual comparison is enabled and the heating ele ment is heated up to the set SETPOINT temperature This takes place until the signal is switched off The HEAT LED on the front panel of the RES 5007 lights up permanently during this time The START signal is activated through a 24 VDC signal to the terminals 6 13 During execution of the AUTOCAL funct...

Page 23: ...pulse beyond the standard of 1 7 ms ROPEX application report This parameter can only be set with the ROPEX visualisation software section 8 11 USB interface for visual isation software ROPEXvisual on page 27 8 8 Automatic phase correction AUTOCOMP In special welding applications it may be necessary to compensate the phase displacement between the UR and IR measurement signals ROPEX application rep...

Page 24: ...imes and the actual value output terminal 17 13 goes to 0 3 C i e approx 0 VDC 3 AUTO With this setting the AUTOCOMP function is automatically started after a successful execution of the AUTOCAL function Function AUTOCAL Signal 24 VDC t t 0 0 AUTOCAL Lights up t Off 2 0 s AUTOCOMP AUTOCAL t Off LED Lights up OUTPUT LED ...

Page 25: ...d window tolerance band around the SETPOINT temperature The lower and upper tolerance band limit are set at the factory to 10 K and 10 K respectively These values can be set separately from each other with the ROPEX visualisation software After activation of the START signal if the ACTUAL temperature lies within the specified tolerance band the tem perature diagnosis is switched on If the ACTUAL t...

Page 26: ...is can be intentionally suppressed such as during a temperature drop caused by closing the welding jaws 8 10 is activeHeat up time monitoring An additional heat up time monitoring can be activated with the ROPEX visualisation software section 8 11 USB interface for visualisation software ROPEXvisual on page 27 This monitoring is activated when the START signal is switched on The RES 5007 then moni...

Page 27: ...ller RES 5007 has data storage for error messages and executed AUTOCAL processes The last 400 messages are stored These can be read and displayed with the ROPEX visualisation software The RES 5007 also has an integrated clock section 8 14 Integrated clock date and time on page 27 The messages are then stored with the date and time specified time stamp The stored messages can be exported as a csv f...

Page 28: ...D ALARM at the controller with three statuses 1 Flashes quickly 4 Hz Means that the AUTOCAL function should be performed error no 104 106 211 302 303 2 Flashes slowly 1 Hz Means that the system configuration is incorrect and therefore the executed zeroing AUTOCAL function was not successful section 7 2 Device configuration on page 14 This corresponds to the error numbers 111 114 3 Lights up contin...

Page 29: ...lues at the actual value output to the errors that occur In addition the cause of the errors and the necessary measures to remedy them are described The simplified circuit diagram in section 8 17 Error ranges and causes on page 33 permits fast and efficient error remedy The controller outputs at the actual value output 13 voltage levels for error diagnosis Internally in the controller the error me...

Page 30: ...als missing Error range Error ranges 107 2 66 Temperature jump downward Error ranges Loose connection Error ranges Loose connection 108 Temperature jump upward 307 Temperature too low high chap 8 9 308 309 310 201 3 33 Network frequency missing fluctuates Check network Check network 202 Network frequency too large fluctuates 203 Network frequency too small fluctuates 304 4 00 Heat up time too long...

Page 31: ...t up Measure of machine in operation heating ele ment not changed 104 5 33 10 Current signal incorrect Impulse transformer incorrectly sized Perform AUTOCAL Check transformer speci fication Error ranges Error ranges Loose connection 105 Voltage signal incorrect Impulse transformer incorrectly sized 106 Voltage and current signal incorrect Impulse transformer incorrectly sized 302 Temperature too l...

Page 32: ...eck configuration Error ranges Loose connection 112 7 33 10 Voltage signal incorrect Calibration not possible Error range Check configuration Error ranges Loose connection 113 8 00 10 Voltage current signal incor rect Calibration not possible Error ranges Check configuration Error ranges Loose connection 114 8 66 10 Temperature fluctuates Calibration not possible Perform AUTOCAL and or Error range...

Page 33: ...int Wire break Primary coil of the impulse transformer interrupted UR signal missing Measurement line interrupted Partial short circuit Delta R Heating element is partially bridged through a conducting part hold down device safety rail etc Interruption of the parallel circuit Wire break heating element break Contacting at the heating element defective Complete short circuit Heating element incorre...

Page 34: ...nge June 2003 and later Heating element alloy Alloy A20 Temperature range 300 C Maximum temperature 300 C Rotary encoder switch Position 0 Slide switch for Alarm output Alarm output active in case of alarm Automatic Phase correction AUTOCOMP X AUTOCOMP OFF Measurement impulse duration X Measurement impulse duration 1 7 ms Temperature diagnosis X Temperature diagnosis OFF Heat up time monitoring X ...

Page 35: ...VAC Cat II Measurement range Secondary voltage UR 0 4 120 VAC Secondary current IR 30 500 A transformer PEX W4 W5 ROPEX application report Heating element type and temperature range Besides setting through the rotary encoder switch see below the setting for the temperature range and temperature coefficient can be performed through the ROPEX visualisation software section 8 11 USB interface for vis...

Page 36: ...umidity 80 at temperatures up to 31 C decreasing line arly to 50 relative humidity at 45 C Degree of protection IP 20 UL file E464680 Mounting When mounting the device a surrounding safety dis tance of 20 mm e g To other devices and wiring must be maintained When mounting on a horizontal top hat rail the mov able latch which is necessary for fastening must face downward When mounting on a vertical...

Page 37: ...its uni versal design A device modification MOD is available for the RESISTRON temperature controller RES 5007 to implement special applications The modifications must be ordered separately MOD 01 Supplemental booster for small secondary voltages UR 0 25 16 VAC This modification is necessary for very short or low resistance heating elements for example 75 0 90 0 113 0 135 0 ...

Page 38: ...o 885107 Monitoring current transformer MSW 2 Art no 885212 Network filter LF 06480 Continuous current 6 A 480 VAC art no 885500 with UL certification 10520 Continuous curr 10 A 520 VAC art no 885504 with UL and CSA certification 35480 Continuous curr 35 A 480 VAC art no 885506 50520 Continuous curr 50 A 520 VAC art no 885509 with UL and CSA certification Impulse transformer For design and order s...

Page 39: ...ion 1 RES 5007 Page 39 Additional accessories Accessories brochure Temperature display ATR 3 300 C range art no 882130 5 500 C range art no 882150 Lines For design and order specifications see ROPEX applica tion report ...

Page 40: ... 36 Design 35 Device configuration 14 Device view 14 Dimensions 37 Disposal 5 E Error diagnosis 7 Error messages 29 Error ranges 33 F Factory settings 34 Functional principle 6 Fuse 10 H HEAT 17 22 Heating element type 35 Heat up time monitoring 26 High altitude 36 How to order 38 Humidity 36 I Impulse transformer 10 38 Installation 7 Installation rules 7 L Line filter 4 10 11 M Maintenance 5 Meas...

Page 41: ...onitoring 28 T TCR 3 15 Technical data 35 Temperature coefficient 3 15 Temperature diagnosis 25 26 Temperature display 20 39 Temperature range 15 35 Temperature regulation 6 Temperature setting 19 Thermal impulse process 6 Time 27 Time stamp 27 Transformer 4 10 38 Transportation 5 U UL file 36 USB interface 27 Use 6 V Visualisation software 27 W Wiring 8 10 ...

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