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Ropex RESISTRON RES-5010, Operating Instructions Manual, Page: 1 / 47

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Ropex RESISTRON RES-5010 Operating Instructions Manual Download Page 1

RESISTRON

Industrie-Elektronik GmbH

Tel.: +49 7142 7776-0

E-Mail: 

[email protected]

Adolf-Heim-Str. 4

Fax: +49 7142 7776-211

Internet: 

www.ropex.de

74321-Bietigheim-Bissingen (Germany)

Data subject to change

29.7.20

RES-5010

Important features

• Microprocessor technology

• OLED display (yellow / green), 4 lines, 20 characters (multilingual)

• Automatic zero calibration (AUTOCAL)

• Automatic configuration of the secondary voltage and current ranges (AUTORANGE)

• Diagnostic interface for the PC visualization software

• Automatic frequency adjustment

• Heatsealing band alloy and temperature range selectable

• Configurable alarm output

• Configurable RESET input

• 0…10VDC analog output for ACTUAL temperature, electrically isolated

• 24VDC control inputs for AUTOCAL and ALARM-IN/RESET, electrically isolated

• Alarm function with error diagnosis

Functionally compatible with the RESM-4

Operating 

Instructions

Summary of Contents for RESISTRON RES-5010

Page 1: ...o calibration AUTOCAL Automatic configuration of the secondary voltage and current ranges AUTORANGE Diagnostic interface for the PC visualization software Automatic frequency adjustment Heatsealing band alloy and temperature range selectable Configurable alarm output Configurable RESET input 0 10VDC analog output for ACTUAL temperature electrically isolated 24VDC control inputs for AUTOCAL and ALA...

Page 2: ...the unit 18 8 2 Unit configuration 18 8 3 Heatsealing band 20 8 4 Startup procedure 20 8 5 Basic functional test on the RESM 5 22 9 Unit functions 22 9 1 LEDs and controls 22 9 2 Display 23 9 3 Navigation in the menus 24 9 4 Menu structure 26 9 5 Menu steps 28 9 6 Monitoring temperature setting maximum temperature set point 31 9 7 Temperature indication actual value output 31 9 8 Automatic zero ca...

Page 3: ...ied as follows e g Alloy A20 TCR 1100 ppm K LEX3500 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 T...

Page 4: ... devices are tested and calibrated in the factory Devices that have been damaged due to faulty connections dropping electrical overloading natural wear incorrect or negligent handling chemical influences or mechanical overloading as well as devices that have been modified relabeled or otherwise altered by the customer for example in an attempt to repair them or install additional components are ex...

Page 5: ...s indicated at the alarm output of the RESM 5 if the limit value is exceeded To prevent dangerous situations refer to the risk analysis for the machine or plant 3 Basics of temperature control measurement The following section starts by outlining the possible causes of unwanted overheating when the temperature of a heatsealing band is controlled according to the resistance principle 3 1 Problem Wh...

Page 6: ...and sections which are still active to rise significantly Dangerous levels involving a risk of fire or explosion can then occur very quickly Depending on the design execution and wiring of the heatsealing tools and the interconnection of the heatsealing bands numerous potential fault causes can thus be identified 3 2 Basics The diagram below is an electrical schematic of a sealing bar showing the ...

Page 7: ...s If all of the components belonging to the control loop are analyzed with respect to possible faults that could lead to dangerous overheating several potential causes can be identified e g Contact between two heatsealing bands wired in series Ground fault Partial short circuit Non coppered heatsealing band ends Unsuitable heatsealing band alloy or too low Defect in the measuring circuit of the co...

Page 8: ...re is a risk of corrosion Bar end blocks the heatsealing band s expansion joints Electrically insulated at both ends Tightened at both ends Sufficient spring force unrestricted movement Heatsealing band tightly clamped Power connection tightly clamped No current flowing through moving parts pivot pins etc Carefully executed insulation Bars Flat bars not warped Carefully executed insulation of the ...

Page 9: ... measurement cables break or short circuit Yes No Yes Contact between two heatsealing bands wired in series Possibly 1 Yes No Heatsealing band partially short circuited Possibly 1 No No Ground fault No Yes No Zero point suppression due to incorrect calibration Yes No Yes Controller hardware defect No No Yes Triac conductive or bypassed Yes No Yes Current transformer defect No No Yes Heatsealing ba...

Page 10: ...contact loose contact contact resistance The sealing tool is open the heatsealing band is cold and the controller is calibrated using the AUTOCAL function The tool closes and the controller heats up The contact with the heatsealing band improves under the closing pressure the resistance is reduced and the controller heats to a higher temperature In other words The zero point is calibrated when the...

Page 11: ...necessary for example for very short or low resistance heat sealing bands Analog temperature meter ATR x For front panel mounting or mounting on a top hat rail DIN TS35 rail Analog indication of the ACTUAL 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 Line filter LF xx480 Essential to ensure CE conf...

Page 12: ...4VDC 20 10 protected against reverse polarity Max current input 1 0A Measuring range Secondary voltage UR 0 4 120VAC Secondary current IR 30 500A with PEX W2 W3 current transformer ROPEX Application report Heatsealing band type and temperature range The temperature range and temperature coefficient settings can also be specified independently of one another in the Configuration menu Temperature ra...

Page 13: ...on a horizontal top hat rail End holders to mechanically fix the controller must be fitted at both ends for mounting on a vertical top hat rail Weight Approx 0 7kg incl connector plug in parts Housing material Plastic polycarbonate UL 94 V0 Connecting cables Type cross sections Rigid or flexible 0 2 2 5mm AWG 24 12 Plug in connectors Screw terminals Clamping torque 0 5 0 6Nm Screw driver size SZS ...

Page 14: ...uency is automatically detected by the temperature controller in the range from 47Hz to 63Hz 3 Install the RESISTRON monitoring device 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 7 3 Wiring diagram on page 17 section 7 3 Wiring diagram on page 17 and the ROPEX Appl...

Page 15: ...l signals The alarm outputs of the RESM 5 and the main RESISTRON controller can be separately evaluated and tested in this way The additional control signals to the PLC machine control system enable both the status and the sequence of the alarms to be evaluated e g an alarm indicated by the main RESISTRON controller results in an RESM 5 alarm This wiring principle is shown in the diagram below To ...

Page 16: ...M 5 and the main RESISTRON controller is simpler than when the alarms are separately evaluated section 7 2 1 RESM 5 and RESISTRON controllers with separate evaluation of alarms recommended by ROPEX on page 15 On the other hand it is very difficult to reconstruct the alarm sequence Servicing and troubleshooting are likewise more complicated To prevent dangerous situations refer to the risk analysis...

Page 17: ...g band 16 17 15 13 18 sec U2 prim U1 Twisted Auxiliary power supply ANALOG OUTPUT actual value 0 10VDC 0V Internal ground NO EXTERNAL GROUNDING ALLOWED Current transformer PEX W2 W3 11 10 IR NC NC NC NC Ground Must be grounded externally to pre vent electrostatic charging LINE Line filter LF xx480 Note If error code 118 appears when you switch on the RESM 5 these cables should be reversed intercha...

Page 18: ...s are explained in the following sections Proceed as described in section 8 4 1 Initial startup on page 20 to start up the unit for the first time 8 2 1 Configuration of the secondary voltage and current ranges The secondary voltage and current ranges are automatically configured by the automatic calibration function AUTOCAL The voltage is configured in the range from 0 4VAC to 120VAC and the curr...

Page 19: ...k analysis for the machine or plant 8 2 5 Configuration of the temperature range The temperature range for the RESISTRON monitoring device can be set with step 205 in the Configuration menu You can choose between 200 C 300 C factory setting 400 C and 500 C 8 2 6 Configuration the maximum temperature alarm threshold You set the maximum temperature with step 206 in the Configuration menu If the meas...

Page 20: ...t be disconnected from the RESISTRON monitoring device in order to replace the heatsealing band The heatsealing band must be replaced in accordance with the instructions provided by the manufacturer To prevent dangerous situations refer to the risk analysis for the machine or plant Each time the heatsealing band is replaced the zero point must be calibrated with the AUTOCAL function while the band...

Page 21: ...means the heating and control process can be observed The unit is functioning correctly if the temperature indicated on the display has a harmonious motion in other words it must not jump abruptly fluctuate or deviate temporarily in the wrong direction This kind of behavior would indicate that the UR measurement cable has been laid incorrectly If an error message is displayed please proceed as des...

Page 22: ...the Settings menu on the RESM 5 refer to the risk analysis for the machine or plant 5 Activate the START signal on the temperature cont roller 6 If the maximum temperature set on the RESM 5 is exceeded an alarm must appear on the display and the alarm output must be energized switched The complete functional test must be carried out in accordance with the risk analysis for the machine or plant 9 U...

Page 23: ...digital value and the ACTUAL temperature as a digital value and a progress bar The main controller s measuring impulses are represented as flashing asterisks 9 2 3 Settings Configuration menus You specify the various parameters on two menu levels the Settings control menu and the Configura tion menu section 9 4 Menu structure on page 26 Company name Software ID number Unit type RESM 5 Specified ma...

Page 24: ...or longer 2s you can return to the home position from anywhere in the menu system provided no alarms are indicated on the RESISTRON monitoring device In this case you see the Alarm menu If the display is in the home position or an alarm is indicated and you press the MENU key for longer than 2s the Configuration level is selected directly step 201 appears first In addition to this you always retur...

Page 25: ...ly by briefly pressing the MENU key 2s You can then run the AUTOCAL function by pressing ENTER section 9 8 Automatic zero calibration AUTOCAL on page 32 If you press the MENU key for longer than 2s in the Alarm menu the Configuration level is selected directly step 201 appears first You can return from the Configuration menu to the Alarm menu either by pressing the MENU key for longer than 2s or b...

Page 26: ...wer up message 208 Set point exceeded 206 Max temperature 210 Cooling mode 212 Relay K1 function 213 Key lock 207 Set point reached 205 Temperature range Settings Configuration 211 Heatslg time start Error 215 Alarm output 204 Temp coefficient 214 Cycles 107 Autocal 102 Preheat temp Autocal 5 6 209 Time control 1 2 216 Analog output 1 2 217 Temp diagnosis 218 Temp diag delay Continued on next page...

Page 27: ...Page 27 221 Autocomp 220 Meas imp length 219 Heatup timeout Configuration 222 Output 1 Continued from previous page Back to home position 225 Temperature unit 226 System time 227 Visualization 228 Screensaver 229 RESET input ...

Page 28: ...e Calibration appears on the display while the AUTOCAL function is executing and a counter counts down from 15 to 0 When the unit has been calibrated successfully the display returns directly to the home position If the unit cannot be calibrated the AUTOCAL function is canceled and an error message is displayed instead 0 40 C 201 Language This menu step selects the desired display language English...

Page 29: ...is energized at alarm inverse The alarm output terminal 18 is de energized at alarm normal w RESET The alarm output terminal 18 is energized at alarm or when the ALARM IN RESET input is energized inverse w RESET The alarm output terminal 18 is de energized at alarm or when the ALARM IN RESET input is energized 30sec inactive The alarm output terminal 18 is de energized for a period of 30 seconds T...

Page 30: ...the ALARM IN RESET input terminal 7 is energized The RESM 5 generates error message 120 STANDBY not observed if the main controller controls the heatsealing band measuring impulses or control mode while the ALARM IN RESET input is energized inverse An active alarm is reset if the ALARM IN RESET input terminal 7 is de energized inverse w STANDBY survey An active alarm is reset if the ALARM IN RESET...

Page 31: ...cation actual value output If the display is in the home position the ACTUAL tem perature is indicated there both as a digital value and as a progress bar The heating and control process can thus be observed at any time The RESISTRON monitoring device RESM 5 addition ally supplies an electrically isolated analog 0 10VDC signal which is proportional to the real ACTUAL tem perature at terminals 17 1...

Page 32: ...n page 37 9 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 RESISTRON monitoring device This function adjusts the RESM 5 to the current and voltage signals that are present in the system This function can be activated in two ways By means of a 24VDC signal at terminals 5 14 By selecting step 107...

Page 33: ...et by means of an external ALARM IN RESET signal terminals 7 14 As a result of this A message appears on the display if no alarm is indicated by the RESM 5 The standby monitoring function for the main controller to be monitored is activated provided this function has been activated with step 229 in the Configuration menu An error message is reset if one is present Note The error message is not res...

Page 34: ...or parameters in the Configuration menu This prevents the unit configuration from being tampered with by unauthorized persons In the factory setting the Configuration menu is not disabled You can still display all steps values and parameters even if the Configuration menu is disabled However you are no longer allowed to enter or change any values The language selected with step 201 can still be ch...

Page 35: ...med brightness level 9 14 Undervoltage detection Trouble free operation of the RESISTRON monitoring device is guaranteed within the line voltage and 24 VDC supply voltage tolerances specified in section 5 Technical data on page 12 If the line voltage drops below the permitted lower limit the RESISTRON monitoring device is switched to standby mode No more measurements take place and the temperature...

Page 36: ... The ROPEX visualization software is described in a separate document 9 17 System monitoring alarm output To increase operational safety and avoid faulty heatsealing the RESISTRON monitoring device incorporates special hardware and software features that facilitate selective error detection and diagnosis Both the external wiring and the internal system are monitored These features assist the opera...

Page 37: ...rature controller is set in one of these states the voltage value does not change any more An error message can only be reset by pressing the RESET key activating the ALARM IN RESET signal at terminals 7 14 section 9 9 ALARM IN RESET signal on page 33 or switching the RESM 5 off and then on again Invalid error messages may appear when the RESM 5 is switched off owing to the undefined operating sta...

Page 38: ...ng polarity section 7 3 Wiring diagram on page 17 Reconnect Interchange UR measuring wire to terminals 8 9 Reconnect Interchange UR measuring wire to terminals 8 9 3 103 2 00 No current voltage signals Fault area Fault areas 120 STANDBY test failed 4 107 2 66 Temperature step down Fault areas loose contact Fault areas loose contact 108 Temperature step up 109 Maximum temperature exceeded Check app...

Page 39: ...t Replace unit Replace unit 920 Internal fault Replace unit Replace unit 936 Main controller indicates alarm Part 1 of 3 Error messages faults NOTE The error messages shown here are output as faults a constant error voltage appears at the actual value output the alarm output is energized Error code Act val output voltage V Cause Action if machine started for first time Action if machine already op...

Page 40: ...y operating HS band not changed 8 104 5 33 10 Current signal incorrect incorrect specification of impulse transformer Run AUTOCAL check specification of transformer fault areas Fault areas loose contact 105 Voltage signal incorrect incorrect specification of impulse transformer 106 Voltage and current signals incorrect incorrect specification of impulse transformer 119 Measurement pause too short ...

Page 41: ...or code Act val output voltage V Cause Action if machine started for first time Action if machine already operating HS band not changed 10 111 6 66 10 Current signal incorrect calibration not possible Fault area check configuration Fault areas loose contact 11 112 7 33 10 Voltage signal incorrect calibration not possible Fault area check configuration Fault areas loose contact 12 113 8 00 10 Curre...

Page 42: ...easurement cable interrupted Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heatsealing band break Contact to heatsealing band is defective Total short circuit Heatsealing band installed incorrectly no insulation at heatsealing bar ends or insulation incorrectly installed Heatsealing ba...

Page 43: ...tored with step 202 in the Configuration menu Step 204 Temp coefficient TCR 400ppm K Step 205 Temperature range 300 C Step 206 Max temperature 40 C Step 213 Key lock No key Step 215 Alarm output Normal energized at alarm Step 225 Temperature unit Celsius Step 228 Screensaver 5min Step 229 ALARM IN RESET input Normal Rotary coding switch for locking the Configuration menu as of August 2014 Configur...

Page 44: ...estore customer settings By choosing this option you restore the customer settings that were defined as described in 2 When the unit is shipped the customer settings are identical to the Ropex settings After pressing the ENTER key in this menu you are asked to confirm the new settings safety query If you confirm these settings by pressing the ENTER key for approximately 2seconds you then see anoth...

Page 45: ...ed e g 01 MOD 01 Art No 800001 booster for low voltage Please indicate the article numbers of the unit and the required modifications optional in all orders e g RESM 5 400VAC MOD 01 unit for 400VAC power supply with booster for low voltage Art Nos 885243 800001 must be ordered Current transformer PEX W3 Art No 885105 Line filter LF 480 06 Continuous current 6A 480VAC Art No 885500 35 Continuous cu...

Page 46: ...eit F 34 Fault areas 41 H Heatsealing band type 12 I Installation 13 14 Installation procedure 14 Installation regulations 14 L Line filter 11 45 Line frequency 12 Line voltage 12 M Maintenance 44 MAN key locked 33 Maximum temperature set point 31 Measurement cable 11 Measuring range 12 Modifications 11 45 MODs 11 45 Monitoring current transformer 11 Monitoring temperature 31 P PEX W2 W3 3 PEX W3 ...

Page 47: ...Index RESM 5 Page 47 W Wiring 14 Wiring diagram 17 ...

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