Ropex RESISTRON RES-420 Operating Instructions Manual
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Ropex RESISTRON RES-420 Operating Instructions Manual

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RESISTRON
RES-420
Operating
Instructions
Important features
•
Microprocessor technology
•
LC display (green), 4 lines, 20 characters, (multilingual)
Alternatively:
VF display (blue), 4 lines, 20 characters, (multilingual)
•
Automatic zero calibration (AUTOCAL)
•
Automatic optimization (AUTOTUNE)
•
Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of software revision 100)
•
Automatic phase angle compensation (AUTOCOMP, as of software revision 100)
•
Automatic frequency adjustment
•
Large current and voltage range
•
Booster connection as standard
•
Heatsealing band alloy and temperature range selectable
•
Alarm function with fault diagnosis
Identical design to and compatible with RES-210, -211, -220, -221
GB

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Summary of Contents for Ropex RESISTRON RES-420

  • Page 1 RESISTRON RES-420 Operating Instructions Important features • Microprocessor technology • LC display (green), 4 lines, 20 characters, (multilingual) Alternatively: VF display (blue), 4 lines, 20 characters, (multilingual) • Automatic zero calibration (AUTOCAL) • Automatic optimization (AUTOTUNE) • Automatic configuration of the secondary voltage and current ranges (AUTORANGE, as of software revision 100) •...

  • Page 2: Table Of Contents

    Contents Safety and warning notes ....3 Controller functions ....24 Use .

  • Page 3: Safety And Warning Notes

    The resistance of the heatsealing band which is used must have a positive minimum Only the original ROPEX PEX-W2 or PEX-W3 temperature coefficient in order to guarantee current transformer may be used. Other trouble-free...

  • Page 4: Line Filter

    DIN EN 61010-1 Safety provisions for electrical (VDE 0411-1) measuring, control and laboratory The use of an original ROPEX line filter is mandatory in devices (low voltage directive). order to comply with the standards and provisions Overvoltage category III, pollution mentioned in section 1.7 "Standards / CE marking"...

  • Page 5: Principle Of Operation

    Principle of operation • etc. • Increased machine capacity The use of RESISTRON temperature controllers • Extended life of the heatsealing bands and teflon coatings results in: • Simple operation and control of the sealing process • Repeatable quality of the heatseals under any con- ditions Principle of operation The resistance of the heatsealing band, which is tem-...

  • Page 6: Description Of The Controller

    Description of the controller Description of the controller microprocessor technology endows are available as an option. Various display languages RESISTRON temperature controller RES-420 with pre- can be selected. viously unattainable capabilities: The real heatsealing band temperature is visualized on the display both as a digital number in °C and in the •...

  • Page 7: Accessories And Modifications

    Designed according to VDE 0570/EN 61558 with a one-section bobbin. Optimized for impulse operation with RESISTRON temperature controllers. Specified according to the heatsealing application ( ROPEX Application Report). Communication interface CI-USB-1 Interface for connecting a RESISTRON temperature controller with diagnostic inter- face (DIAG) to the PC (USB port).

  • Page 8: Modifications (Mods)

    Accessories and modifications Adapter for top hat rail mounting, HS-Adapter-01 For mounting the RESISTRON temperature controller RES-420 on a top hat rail (DIN TS35). Allows the controller to be installed in the electrical cabinet, for instance, where it is only accessible to authorized persons. Lockable door TUER-S/K-1 Transparent door (with lock) for mounting on the bezel of the controller.

  • Page 9: Technical Data

    Technical data Technical data Type of construction Housing for front panel mounting Dimensions (W x H): 144 x 72mm; depth: 161mm (incl. terminals) Line voltage All controller manufactured as of December 2005 (as of software revision 100): 115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC) 230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC) 400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC) All controllers manufactured as of January 2004 up to November 2005...
  • Page 10 Technical data START with contact Switching threshold: 3.5VDC, U = 5VDC, I = 5mA Terminals 2+7 Alarm relay Contact, potential-free, U = 50V (DC/AC), I = 0.2A Terminals 5+6 Maximum load = 5A (duty cycle = 100%) (primary current of = 25A (duty cycle = 20%) impulse transformer) Power dissipation...

  • Page 11: Dimensions/Front Panel Cutout

    Dimensions/front panel cutout Dimensions/front panel cutout panel cutout outline dimensions front frame ±0.2 ±0.2 x 68 rubber seal mounting clamp terminal blocks front panel terminal wires front frame DIP-switch to select U , I RES-420 Page 11...

  • Page 12: Installation

    Kap. 8.3 „Power supply“ auf Seite 14, Kap. 8.6 „Wiring diagram (standard)“ auf Seite 16 and the Installation procedure ROPEX Application Report. The information pro- vided in Kap. 8.2 „Installation steps“ auf Seite 13 Proceed as follows to install the RESISTRON tempera- must be heeded additionally.

  • Page 13: Installation Steps

    Installation Installation steps Use heatseal bands with suitable temperature coefficient Heatseal element push-on with coppered ends connectors Heatsealing band R= f (T) No additional Connect U measuring resistance wires directly to in secondary Note heatsealing band ends circuit number Sufficient wire of turns Twisted cross-section...

  • Page 14: Power Supply

    Use transformers with a one section bobbin. The power, duty cycle and voltage values must be deter- SEC. mined individually according to the application ( ROPEX Application Report and "Accessories" leaflet for impulse transformers). Wiring The wire cross-sections depend on the application (...

  • Page 15: Line Filter

    CE mark. The wiring instructions contained in section 8.3 "Power ROPEX line filters are specially optimized for use in supply" on page 14 must be observed. RESISTRON control loops. Providing that they are...

  • Page 16: Wiring Diagram (Standard)

    Installation Wiring diagram (standard) Line filter LF-xx480 RES-420 LINE (also with MOD 01) ALARM OUTPUT max. 50V/0.2A Contact closed or prim. opened by ALARM (see configuration) Impulse transformer sec. Heat- sealing band (Internnal ground) twisted START (HEAT) No external with 24VDC signal grounding allowed! Current transformer Ground...

  • Page 17: Wiring Diagram With Booster

    Installation Wiring diagram with booster connection Line filter LF-xx480 RES-420 LINE (also with MOD 01) Booster ALARM OUTPUT max. 50V/0.2A Contact closed or prim. opened by ALARM (see configuration) Impulse transformer sec. Heat- sealing band (Internnal ground) twisted START (HEAT) No external with 24VDC signal grounding allowed!

  • Page 18: Startup And Operation

    Operator keys Wiring diagram Diagnostic interface (on rear of controller) Nameplate Clips Display Rear view of the controller As of software revision 100: Printed wiring diagram ROPEX RES- 420 SEC. PRIM. (L1) FILTER L1 (L2) 0,4 - 120V AUTO (PE)

  • Page 19: Controller Configuration

    Automatic configuration (AUTORANGE) You can find the exact configuration of the (as of software revision 100) DIP switches in the ROPEX Application Report calculated for your particular application. The secondary voltage and current ranges are auto- matically configured by the automatic calibration func-...
  • Page 20 If the controller settings are unknown when it PEX-W2/W3 current transformer must have two turns is started up for the first time, the factory set- ( ROPEX Application Report). tings must be restored in order to prevent malfunc- tions. 9.3.4...
  • Page 21 (e.g. Alloy-L) Set+  2. Temperature coefficient 1100ppm lower (Factory setting) (e.g. Alloy-20) 3. Temperature coefficient 1400ppm (e.g. ROPEX CIRUS system) 4. Temperature coefficient 1700ppm (e.g. ROPEX CIRUS system) Time 5. Temperature coefficient 3500ppm Error code (e.g. NOREX) 6. Temperature coefficient „variable“...

  • Page 22: Heatsealing Band

    Startup and operation 9.3.8 Heatup timeout Too low a TCR leads to oscillation or uncontrolled hea- ting. (as of software revision 100) When heatsealing bands with a higher TCR are used, The heatup timeout can be parameterized with the controller must be calibrated for this. step 219 in the Configuration menu ("0"...

  • Page 23: Startup Procedure

    20°C is indi- the setting of the DIP switches on the controller are cated as the actual value. indicated in the ROPEX Application report and If the zero has not been calibrated successfully, an depend on the heatsealing band (section 9.3 "Con- erro message indicates error codes 104…106, 211.

  • Page 24: Controller Functions

    Return to home position ENTER HAND RESET "ENTER" key Save values ENTER function: ROPEX Manual mode HAND function: RESET function: Reset after alarm "UP" and "DOWN" keys for setting values Press (< 2 sec.): Slow change Hold (> 2 sec.): Fast change...

  • Page 25: Display

    Controller functions 10.2 Display This message also includes details of the software ver- sion. 10.2.1 Power-up message A power-up message appears on the display for appro- ximately 2 seconds when the controller is switched on. Company name (optional: customer-specific) Software ID number Controller type (RES-420) 10.2.2 Display in home position tion, in other words it indicates the SET temperature as...

  • Page 26: Navigation In The Menus

    Controller functions 10.2.4 Error messages immediately in the form of an error message ( Kap. 10.22 „System monitoring/alarm output“ auf The fault diagnosis function of the controller is always Seite 40). active. If a fault is detected, it is indicated on the display Alarm indication Fault description and error code...
  • Page 27 Controller functions 10.3.2 Navigation in menus with a fault can then activate the "AUTOCAL" function by pressing the "ENTER" key ( section 10.9 "Automatic zero cali- If an alarm is signaled, the controller switches to the bration (AUTOCAL)" on page 35). Alarm menu.

  • Page 28: Menu Structure

    Controller functions 10.4 Menu structure Settings Configuration Power-up message Home position Language 3) AUTOCOMP: OFF 4) AUTOCOMP: ON Factory settings 101 Heatsealing temp. 5) TCR variable 6) TCR not variable Alloy 102 Preheating temp. 204 Temp. coefficient Starting delay 205 Temperature range Sealing time 206 Max.
  • Page 29 Controller functions Configuration Continued from previous page Heatup timeout 220 Meas. imp. length Autocomp "Output 1" 225 Temperature unit Back to home position RES-420 Page 29...

  • Page 30: Two-Digit Numbering System Up To Software Revision 027

    Controller functions 10.5 Two-digit numbering system revision 027. Three-digit numbers were introduced in software revision 100 to improve the clarity of the menu up to software revision 027 structure. The table below compares the two numbering systems: A system of one and two-digit numbers was used for the Settings and Configuration menus up to software Numbering Numbering...

  • Page 31: Menu Steps

    Controller functions 10.6 Menu steps Name Description Setting range Home position The specified set value and the current actual value are displayed in digital form. The actual value is also represented as a dynamic bar. If time control (step 209 [26]) is active, the heatse- aling time and the cooling value are also displayed.
  • Page 32 In addition, as of software revision 100: The "UP" and "DOWN" keys can be used to select whether • The controller should be reset to the ROPEX fac- tory settings • The current configuration should be specified as the default setting •...
  • Page 33 Controller functions Name Description Setting range Alloy/range This step in the Configuration menu is (Availability depends on available up to software revision 027 only. software revision) TCR 410ppm, 300°C Various heatsealing band alloys and temperature TCR 460ppm, 300°C ranges can be selected here. TCR 510ppm, 300°C The corresponding characteristic for the controller TCR 570ppm, 300°C...
  • Page 34 Controller functions Name Description Setting range Alarm relay This menu step permits the switching characteri- [25] stics of the alarm relay to be configured. • Normal: The alarm relay output (terminals 5+6) Normal operates as an NO contact in the event of a fault. •...

  • Page 35: Temperature Setting

    Controller functions 10.7 Temperature setting (set point The automatic calibration process takes around 10…15 seconds. The heatsealing band is not heated selection) until the calibration process has finished. The message "- Calibration - Please wait..." appears The heatsealing temperature can be set on the on the display while the "AUTOCAL"...

  • Page 36: Cycle Counter

    Controller functions independently of the "START" signal by pressing the codes 104…105, 111…113 or 211 ( section 10.24 "ENTER" key ("HAND" function) while the main menu "Fault areas and causes" on page 44). The heatsealing is displayed. band is likewise not heated. The "START"...

  • Page 37: Measuring Impulse Duration (As Of Software Revision 026)

    It may be necessary to compensate the phase angle displacement between the U and I measuring signals in certain heatsealing applications ( ROPEX Application Report). The "AUTOCOMP" function is pro- vided for this purpose. It can be parameterized with ACTUAL indication...

  • Page 38: Locking The "Hand" Key (As Of Software Revision 100)

    Controller functions 3. „AUTO“ 2. „Fahrenheit“ (as of software revision 105) Temperature indication and value selection in With this setting the „AUTOCOMP“ function is acti- Fahrenheit (°F) vated automatically after the "AUTOCAL" function Up to software revision 105 only Celsius (°C) can be has been successfully executed.

  • Page 39: Setting The Display Brightness (Vf Display Only)

    No more heatsealing processes take phone cable) could result in malfunctions or place and no more measuring impulses are generated. damage to the controller. The display changes to indicate this. The ROPEX visualization software is described in a separate document. RES-420 Page 39...

  • Page 40: Booster Connection

    The error codes described below can also be displayed in the ROPEX visualization software ( section 10.20 Alarm relay (relay contact, terminals 5+6): "Diagnostic interface/visualization software (as of soft- ware revision 100)" on page 39) to facilitate troubles- hooting.
  • Page 41 Controller functions RES-420 Page 41...
  • Page 42 Controller functions Page 42 RES-420...
  • Page 43 Controller functions RES-420 Page 43...

  • Page 44: Fault Areas And Causes

    Controller functions 10.24 Fault areas and causes Temperature controller HARDWARE The table below explains the possible fault causes. Fault area Explanation Possible causes Load circuit interrupted after U - Wire break, heatsealing band break - Contacting to heatsealing band defective pickoff point ...
  • Page 45 Controller functions Fault area Explanation Possible causes - Up to software revision 027: DIP switches 4+5 configured incorrectly (I range) signal incorrect - As of software revision 100: I outside permissible range  from 30…500A Turns through PEX-W2/W3 cur- - Check number of turns (two or more turns required for rent transformer incorrect currents <...

  • Page 46: Factory Settings

    Factory settings Factory settings The RESISTRON temperature controller RES-420 is configured in the factory as follows: DIP switches = 6…60VAC = 30…100A secondary voltage and current I DIP switches: 2 ON (Up to software 1, 3, 4, 5 OFF revision 027) These switches are automatically set by the AUT- ORANGE function on all controllers as of software revision 100.

  • Page 47: Customer Settings (As Of Software Revision 100)

    Settings and Configura- Step 203 then appears on the display. tion menus as "customer settings". These "cus- tomer settings" are independent of the Ropex The language which is selected with step 201 settings. Machine-specific settings can be stored in in the Configuration menu remains set even if the controller in this way.

  • Page 48: How To Order

    Line filter LF- . . 480 06: Continuous current 6A, 480VAC, Art. No. 885500 35: Continuous current 35A, 480VAC, Art. No. 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communication interface CI-USB-1 Art. No. 885650 Booster B- . . . 400 075: Max.

  • Page 49: Index

    Index Index Heatsealing band type Heatup timeout Accessories Hold mode Adapter for top hat rail mounting Alarm output Alarm relay Alloy Impulse heatsealing method Ambient temperature Impulse transformer Application Installation Application Report Installation procedure AUTOCAL Installation regulations AUTOCOMP Automatic phase angle compensation Automatic zero calibration Line filter AUTOTUNE...
  • Page 50 Index Temperature control Temperature diagnosis Undervoltage detection Temperature indication Temperature range Temperature setting View of controller Temperature unit Visualization software Transformer Type of construction Wiring Wiring diagram Page 50 RES-420...

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