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Ropex RESISTRON RES-5027, Operating Instructions Manual, Page: 1 / 48

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Ropex RESISTRON RES-5027 Operating Instructions Manual Download Page 1

ROPEX Industrie-Elektronik GmbH

Tel.: +49 (0)7142-7776-0

E-Mail:

[email protected]

Adolf-Heim-Str. 4

Fax: +49 (0)7142-7776-211

Internet:

https://ropex.de

74321 Bietigheim-Bissingen (Germany)

Data subject to change

28.7.20

Version 1

RESISTRON

RES-5027

Important features

• Automatic zeroing (AUTOCAL)

• Automatic optimisation (AUTOTUNE)

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

• Automatic phase correction (AUTOCOMP)

• Automatic frequency adaptation

• Booster output

• Temperature OK output

• 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, RESET and CH-1, e.g. constant setting degree

• Alarm function with error diagnosis

• Heating element alloy and temperature range can be selected

• Micro-USB interface for ROPEXvisual

®

• cULus approval

Operating

Instructions

Summary of Contents for RESISTRON RES-5027

Page 1: ...n of the secondary voltage and current range AUTORANGE Automatic phase correction AUTOCOMP Automatic frequency adaptation Booster output Temperature OK output 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 RESET and CH 1 e g constant setting degree Alarm function with error diagnosis ...

Page 2: ...he heating element 17 7 4 Commissioning rules 18 8 Device functions 20 8 1 Display and operating elements 20 8 2 Temperature setting setpoint specification 21 8 3 Temperature display actual value output 22 8 4 Autom zeroing AUTOCAL 23 8 5 START signal HEAT 24 8 6 RESET signal 25 8 7 CH 1 signal 26 8 8 Measurement impulse duration 26 8 9 Automatic phase correction AUTOCOMP 27 8 10 Temperature diagn...

Page 3: ...raphics 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 observa...

Page 4: ...rt 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 supply must be observed External mon...

Page 5: ...electronic equipment and the disposal of such waste in an environmentally 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 respo...

Page 6: ...ry significantly in terms of performance and physical dimensions All information provided by us in connection with the line filter is merely intended as a guide and is based on a typical measuring setup It serves to demonstrate that compliance with the EMC directive can be achieved by using a line filter that is suitable for the overall system The line filter and current transformer must however b...

Page 7: ... network 60 times per second in a 60 Hz network The primary voltage of the impulse transformer is adjusted following the leading edge principle if the measured values deviate from the setpoint value The related current change in the heating element results in a rise in tem perature and change of resistance The change in resistance is measured and evaluated by the RES 5027 The temperature controlle...

Page 8: ...ge for flexible use from 110 VAC to 415 VAC Easy and convenient system diagnosis and process visualisation through the free downloadable software ROPEXvisual Error diagnosis Booster output available for connecting a switching amplifier 6 Mounting and Installation See also section 2 General information on page 3 Mounting installation and commissioning may only be performed by qualified and trained ...

Page 9: ...ication 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 used e g cable impulse transformer etc must be adjusted accordingly 5 A disconnect device which must be marked as belonging to the system and attached in an easily...

Page 10: ...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 11: ...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 12: ...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 11 must be observed Example drawing for LF 0...

Page 13: ...rsion 1 RES 5027 Page 13 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 14: ...S 5027 also with MOD 01 4 3 2 1 U1 22 21 BOOSTER 14 12 7 6 5 16 17 15 13 18 20 19 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 INPUT setpoint 0 10 VDC 24 VDC POWER SUPPLY GND TEMP OK OUTPUT 24 VDC CH 1 24 signal VDC R Current transform...

Page 15: ...ART HEAT 24 signal VDC Protective con ductor connection AUTOCAL 24 signal VDC ALARM OUTPUT 24 VDC RES 5027 also with 01 MOD PE 24 VDC 14 12 7 6 5 9 8 4 3 2 1 REFERENCE VOLTAGE OUTPUT UREF 10 VDC 16 17 15 13 18 ANALOG OUTPUT actual value 0 10 VDC ANALOG INPUT setpoint 0 10 VDC 11 10 24 VDC POWER SUPPLY 22 21 GND 20 19 TEMP OK OUTPUT 24 VDC CH 1 24 signal VDC Heat sealing band LINE Line filter twist...

Page 16: ... 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 19 Error messages on page 34 For secondary currents I2 less than 30 A the secondary high current line must be guided 2 times or several times...

Page 17: ... The measurement 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...

Page 18: ...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 7 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 19: ...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 20: ...ating current ALARM red Configuration error AUTOCAL not possible Controller incorrectly cali brated carry out AUTOCAL Error chap 8 19 12 13 14 15 16 17 18 9 8 6 5 10 11 7 4 3 2 1 Visual AC HEAT OUTPUT ALARM CH 1 TEMP OK µC POWER 24 V POWER www de ROPEX Made in Germany RES 5027 PROCESS CONTROL EQUIPMENT E464680 CH 1 TEMP OK Yellow LED Green LED µC POWER 24 V POWER Green LED Green LED Lit if the inp...

Page 21: ...or 500 C Depending on the device configuration A corresponding diagram is depicted in section 8 3 Temperature display actual value output on page 22 CH 1 yellow CH 1 function requested but function is blocked CH 1 function is carried out TEMP OK green Temperature lies in the temperature monitoring band or Actual value has achieved 95 of the setpoint value µC POWER green Voltage supply to the micro...

Page 22: ...NT temperature in C The setpoint specification for the welding temperature must be greater than 40 C If it is less no heating process takes place when the START signal is activated Setpoint value zero applies if the potentiometer is not connected or 0 VDC is applied at the setpoint value input Pay attention to the direction of rotation when connecting the potentiometer 8 3 Temperature display actu...

Page 23: ... AUTOCAL function the controller adapts to the current and voltage symbols present in the system In the factory setting zeroing is carried out at the basic temperature of 20 C Perform the AUTOCAL function only when heating element and support rail have cooled off basic temperature Variable basic temperature The basic temperature for the AUTOCAL function can be set in the range of 0 40 C with the v...

Page 24: ...e heating element is more than 0 1 K s With an activated control signal the function is automatically carried out if the cooling speed has fallen below the above named value 3 The AUTOCAL is not executed LED HEAT lights up in case of an activated START signal 24 VDC 4 The AUTOCAL is not executed in case of an activated RESET signal 24 VDC 5 Directly after the controller is switched on the AUTOCAL ...

Page 25: ...ntroller RES 5027 can be reset through the external RESET signal terminal 7 13 Here An ongoing welding cycle is interrupted No additional measurement impulses are generated Any error message displayed is reset Note The error message is not reset until the RESET signal is switched off During activation of the RESET signal the actual value output goes to 0 3 C i e approx 0 VDC This can be evaluated ...

Page 26: ...gnal to the terminals 20 13 Activation of the CH 1 signal is not accepted during performance of the AUTOCAL function or with an active RESET signal The setpoint specification for the power setting degree must be greater than 5 If this is smaller the heat up process is not started LED CH 1 flashes During a warning message with error no 104 106 111 114 211 302 or 303 the alarm output is switched on ...

Page 27: ... function section 8 4 Autom zeroing AUTOCAL on page 23 has been called up quickly twice in sequence The pause between the end of the first and start of the second execution of AUTOCAL must be less than 2 0 seconds The second execution of AUTOCAL lasts only about 2 0 seconds and contains the AUTOCOMP function If the pause between the two executions is longer than 2 0 seconds the normal AUTOCAL func...

Page 28: ...od 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 ...

Page 29: ...PEX visualisation software are identical to the values for the Temperature OK signal section 8 11 Temperature reached or Temperature OK signal on page 29 8 11 Temperature reached or Temperature OK signal In addition to the temperature diagnosis the RES 5027 provides a digital switch output for the Temperature reached or Temperature OK signal at its connection terminal 19 This signal switches throu...

Page 30: ...e output signal is switched on This can be used for process monitoring for example or for control of the closing process of the welding tools The output signal is switched off with the deactivation of the START signal or when an alarm occurs 8 11 3 ACTUAL SETPOINT operating mode After activation of the START signal if the actual temperature lies within the specified tolerance band the output signa...

Page 31: ...ithin the defined tolerance band during the entire welding procedure The output signal is not switched off until the next activation of the START signal or when an alarm occurs 8 12 Heat up time monitoring An additional heat up time monitoring can be activated with the ROPEX visualisation software section 8 14 USB interface for visualisation software ROPEXvisual on page 32 This monitoring is activ...

Page 32: ... length of 1 m and must be twisted to avoid EMC interference 8 14 USB interface for visualisation software ROPEXvisual A USB interface type micro USB is available for system diagnosis and process visualisation A data connection can be built up with the ROPEX visualisation software ROPEXvisual over this USB interface There is a separate documentation available for the ROPEX visualisation software T...

Page 33: ...e controller must be switched on for at least 3 hours to charge the clock condenser completely When the con denser is switched off a fully charged condenser can operate the clock for approx 2 4 weeks If the controller is switched off longer the date and time must be set again This must be done with the ROPEX visualisation soft ware section 8 14 USB interface for visualisation software ROPEXvisual ...

Page 34: ... 8 19 Error messages on page 34 For statuses that require AUTOCAL or when the device configuration is not correct error no 104 106 111 114 211 302 303 the actual value output switches back and forth between the voltage value that corre sponds to the error and the end value 10 VDC i e 300 C or 500 C with 1 Hz If the START signal is output during these statuses the voltage value no longer changes Th...

Page 35: ...e 32 The error search can thus be performed even more effectively Evaluation of the actual value output for detection of an error message e g in the higher order controller must be done with an adapted tolerance window to avoid incorrect evaluations The tol erances of the actual value output must be observed section 10 Technical data on page 42 ...

Page 36: ...ls 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 10 308 309 310 201 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 37: ...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 38: ...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 39: ...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 40: ...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 OK signal X Tolerance band 10 K 10 K Temperature diagnosis X Temperature diagnosis...

Page 41: ...Factory settings Version 1 RES 5027 Page 41 X Only with ROPEX visualisation software Heat up time monitoring X Heat up time monitoring OFF ...

Page 42: ...AC 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 14 USB interface for visu...

Page 43: ... Umax 30 VDC Imax 200 mA UON 2 V saturation voltage galvanically separated from the heating circuit short circuit proof Can be inverted through slide switch Power loss Max 20 W Ambient conditions Maximum altitude 2000 m Ambient temperature 5 45 C Maximum relative humidity 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 M...

Page 44: ...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 Connecting cable Type cross sections Rigid or flexible 0 2 2 5 mm AWG 24 12 through pluggable terminals Pluggable terminals Tightening torque 0 5 0 6 Nm Screwdriver SZS 0 6x3 5 mm If ferrules are used they must be cr...

Page 45: ...no 885107 Monitoring current transformer MSW 2 Art no 885212 Line 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 spe...

Page 46: ...ies brochure Temperature display ATR 3 300 C range art no 882130 5 500 C range art no 882150 Booster B 075415 Impulse loaded 75 A 415 VAC art no 885302 100400 Impulse loaded 100 A 400 VAC art no 885304 Lines For design and order specifications see ROPEX applica tion report ...

Page 47: ... of protection 43 Design 42 Device configuration 16 Device view 16 Dimensions 44 Disposal 5 E Error diagnosis 8 Error messages 34 Error ranges 39 F Factory settings 40 Functional principle 7 Fuse 11 H HEAT 19 24 Heating element type 42 Heat up time monitoring 31 High altitude 43 How to order 45 Humidity 43 I Impulse transformer 11 45 Installation 8 Installation rules 8 L Line filter 4 11 12 M Main...

Page 48: ...cal data 42 Temperature coefficient 3 17 Temperature diagnosis 28 31 Temperature display 22 23 46 Temperature OK signal 29 Temperature range 17 42 Temperature reached signal 29 43 Temperature regulation 7 Temperature setting 21 Thermal impulse process 7 Time 33 Time stamp 33 Transformer 4 11 45 Transportation 5 U UL file 43 USB interface 32 Use 7 V Visualisation software 32 W Wiring 9 11 ...

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