Ropex Resistron RES-5011 Operating Instructions Manual
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Ropex Resistron RES-5011 Operating Instructions Manual

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RESISTRON
RES-5011
Operating
instructions
Important features
•
Complete control via EtherNet/IP
•
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
•
Analogue output 0...10 VDC for ACTUAL temperature
•
Alarm function with error diagnosis
•
Heating element alloy and temperature range can be selected
•
Wide voltage range for the use of 110...415 V
•
Eight channels for administration of various calibration values
•
Micro-USB interface for ROPEXvisual
•
cULus approval
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)
TM
interface (2 x RJ-45)
®
Tel.: +49 (0)7142-7776-0
Fax: +49 (0)7142-7776-211
E-Mail:
info@ropex.de
Internet:
https://ropex.de
Data subject to change

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Summary of Contents for Ropex Resistron RES-5011

  • Page 1 Wide voltage range for the use of 110…415 V • Eight channels for administration of various calibration values ® • Micro-USB interface for ROPEXvisual • cULus approval ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: info@ropex.de Adolf-Heim-Str. 4 Fax: +49 (0)7142-7776-211 Internet: https://ropex.de...

  • Page 2: Table Of Contents

    Contents Revision list ......3 Device functions ....20 LEDs and controls .

  • Page 3: Revision List

    Version Change • Creation of documentation • Change to one column layout • ROPEX logo changed • Covering page with important features • Additions in general information  section 2 "General information" on page 3 • Addition in Communication protocol: Status bit measurement interruption ...

  • Page 4: Heatsealing Band

    The temperature coefficient must be taken from the ROPEX application report and must be set accordingly. The use of incorrect alloys with a too low temperature coefficient and incorrect coding of the ®...

  • Page 5: Line Filter

    The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions mentioned in section 2.7 "Standards / CE marking" on page 5. This device must be installed and connected according to the instructions contained in section "Power supply"...

  • Page 6: Transportation

    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. 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 2012/19/EU concerning the reduction of the increasing amount of...

  • Page 7: Functional Principle

    Functional principle 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 edge principle if the measured values deviate from the setpoint value.

  • Page 8: Mounting And Installation

    If one such device is not adequate for the heatsealing application, two separate overcurrent protective devices should be provided – one for the controller and one for the application ( ROPEX Application Report). The overcurrent protective device must be located directly adjacent to the controller.

  • Page 9: Installation Steps

    Mounting and installation Installation steps Sample depiction 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 heatsealing band ends Note circuit number...

  • Page 10: Power Supply

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

  • Page 11: Line Filter

    ROPEX line filters are specially optimized for use in RESISTRON control loops. Providing that they are installed and wired correctly, they guarantee compliance with the EMC limit values. You can find the exact specification of the line filter in the ROPEX Application Report calculated for your particular heatsealing application.
  • Page 12 Mounting and installation 6.5.1 PEX-W4 terminal wires terminal block Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022) 6.5.2 PEX-W5 Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022). Page 12 RES-5011 Version 2...

  • Page 13: Wiring Diagram (Standard)

    Mounting and installation Wiring diagram (standard) Line filter RES-5011 LINE Ethernet PORT 1 (RJ45) BOOSTER OUTPUT Ethernet module prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Heat- Must be grounded sealing externally to band prevent twisted...

  • Page 14: Wiring Diagram With Booster Connection

    Mounting and installation Wiring diagram with booster connection Line filter RES-5011 LINE Ethernet PORT 1 (RJ45) Booster twisted Ethernet Max. length 1 m module prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Heat- Must be grounded sealing externally to...

  • Page 15: Startup And Operation

    ( section 8.19 "Error messages" on page 63). If the secondary current I is less than 30 A, the secondary high-current wire must be laid twice (or several times) through the PEX-W4, or PEX-W5 current transformer ( ROPEX Application Report). Version 2 RES-5011...

  • Page 16: Band

    The setting of the rotary coding switch for the temperature range and alloy can be overwritten with the parameter data ( section 8.7 "Parameter object (class: 0x0F)" on page 28). If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization software ®...
  • Page 17 (factory setting) If the switch is set to "Alarm relay de-energized at alarm / PC CONFIGURATION", you can select more alarm output configurations in the ROPEX visualization software ( section 8.12 "USB interface for visualization soft- ® ware ROPEXvisual "...

  • Page 18: Startup Procedure

    Startup and operation Each time the heatsealing band is replaced, you must calibrate the zero point with the AUTOCAL function while the band (and the environment, i.e. silicone, PTFE cover, sealing bar etc.) is still cold in order to compensate pro- duction-related resistance tolerances.
  • Page 19 (1 Hz). In this case the controller configuration is incorrect ( section 7.2 "Device configuration" on page 15, ROPEX Application Report). Repeat the calibration after correcting the controller configuration. 9. After the zero point has been successfully calibrated, specify a defined temperature by means of the EtherNet/ protocol (set point) and set the ST bit.

  • Page 20: Device Functions

    24V POWER Lit if external 24VDC power EQUIPMENT E464680 www.ROPEX.de (green LED) supply is present. In addition to the functions shown above, the LEDs also indicate various controller operating states. These states are described in detail in the table below:...
  • Page 21 Device functions Blinks slowly (1 Hz) Blinks fast (4 Hz) Lit continuously START requested but func- tion blocked (e.g. HEAT — START executing (yellow) AUTOCAL active, set tem- perature < 40 °C) OUTPUT In control mode, luminous intensity is proportional to heating current. (green) Configuration error, no Controller calibrated incor-...

  • Page 22: Ethernet/Ip Tm Communication

    ROPEX_RES-5011_V2_4.eds file of the RES-5011 contains all essential controller information for the configura- tion, e.g. the I/O data description, parameter descriptions etc. The device description files and the associated image files (.BMP and .ICO) can be requested by e-mail (support@ropex.de) or downloaded from our website (https://ropex.de).

  • Page 23: Communication Protocol

    Device functions Communication protocol The communication protocol consists of 2x16 bit input words and 3x16 bit output words (from the point of view of the controller). This protocol separates the set point and the actual value of the RES-5011 from the status infor- mation and the control functions, to simplify decoding by the EtherNet/IP scanner.
  • Page 24 Device functions Some EtherNet/IP scanners do not allow the parameter data to be changed during operation. In this case, the calibration temperature cannot be adapted to the actual ambient conditions in the machines. The calibration temperature can thus be specified by means of the "Set point / AC temperature" input data when- ever the zero point is calibrated, provided this is permitted in the parameter data (...
  • Page 25 Device functions this state and no measuring impulses are generated. As a result of this, the actual value is no longer updated. The reset request is not accepted until the RS bit is reset. EtherNet/IP communications are not interrupted by a con- troller reset.

  • Page 26: Output Data

    Device functions It is possible to switch to another channel during the AUTOCAL function; however, the controller continues working with the original channel until the AUTOCAL function has finished. The channel currently being used by the con- troller is shown in the status information. 8.5.7 Set point A set point of up to 300 °C or 500 °C is allowed, depending on the selected temperature range (...
  • Page 27 Device functions Actual value Set+ Δϑ high Set+ Δϑ Time TO bit Time Unlike the "Temperature achieved" status bit (TE bit), the actual temperature is evaluated independently of the control mode. 3. "Active when Tact = Tset" with latch function A heatsealing cycle starts when the ST bit is set.

  • Page 28: Parameter Object (Class: 0X0F)

    Device functions 8.6.9 Standby active (SA) This bit is active if the RS bit is set. It shows the PLC when the controller has accepted the RS bit or the MP bit, so that these bits can be reset again (handshake). 8.6.10 Measurement interruption (MU) This bit is available as from firmware version 303.
  • Page 29 Device functions Data Attri- Default Instance Name Value range bute ID value type USINT Temperature range / alloy 0, 1, 4, 5, 8, 9, 10, 11 ( 8.7.1) USINT Link path length EPATH Link path 20 0F 24 01 30 01 WORD Descriptor 0x0000...
  • Page 30 Device functions Data Attri- Default Instance Name Value range bute ID value type UINT Heating time limit (100 ms steps) 0…999 (0…99.9 s) USINT Link path length EPATH Link path 20 0F 24 05 30 01 WORD Descriptor 0x0004 (scaling supported) USINT Data type 0xC7...
  • Page 31 Device functions Data Attri- Default Instance Name Value range bute ID value type UINT Temperature coefficient 1100 ppm/K 400…4000 ppm/K USINT Link path length EPATH Link path 20 0F 24 08 30 01 WORD Descriptor 0x0000 USINT Data type 0xC7 USINT Data length USINT...
  • Page 32 Device functions Data Attri- Default Instance Name Value range bute ID value type USINT Temperature diagnosis delay 0…99 (100 ms steps) (0…9.9 s) USINT Link path length EPATH Link path 20 0F 24 0C 30 01 WORD Descriptor 0x0004 (scaling supported) USINT Data type 0xC6...
  • Page 33 Device functions Data Attri- Default Instance Name Value range bute ID value type USINT Temperature OK bit Active when Off (0), Tact=Tset active when Tact=Tset (1), active when Tact=Tset with latch (2) USINT Link path length EPATH Link path 20 0F 24 0F 30 01 WORD Descriptor 0x0000...
  • Page 34 Device functions Data Attri- Default Instance Name Value range bute ID value type SINT Calibration temperature, channel 2 20 °C -1 (= variable), 0…40 °C USINT Link path length EPATH Link path 20 0F 24 12 30 01 WORD Descriptor 0x0000 USINT Data type...
  • Page 35 Device functions Data Attri- Default Instance Name Value range bute ID value type UINT Temperature coefficient, channel 4 1100 ppm/K 400…4000 ppm/K USINT Link path length EPATH Link path 20 0F 24 17 30 01 WORD Descriptor 0x0000 USINT Data type 0xC7 USINT Data length...
  • Page 36 Device functions Data Attri- Default Instance Name Value range bute ID value type SINT Calibration temperature, channel 7 20 °C -1 (= variable), 0…40 °C USINT Link path length EPATH Link path 20 0F 24 1D 30 01 WORD Descriptor 0x0000 USINT Data type...
  • Page 37 Device functions Data Attri- Default Instance Name Value range bute ID value type UDINT Operating hours 0…9999999.9 h USINT Link path length EPATH Link path 20 0F 24 21 30 01 WORD Descriptor 0x0014 (scaling supported) USINT Data type 0xC8 USINT Data length USINT...
  • Page 38 Device functions Data Attri- Default Instance Name Value range bute ID value type UDINT Cycle counter, channel 1 0…99999999 USINT Link path length EPATH Link path 20 0F 24 25 30 01 WORD Descriptor 0x0000 USINT Data type 0xC8 USINT Data length UDINT Cycle counter, channel 2...
  • Page 39 Device functions Data Attri- Default Instance Name Value range bute ID value type UDINT Cycle counter, channel 6 0…99999999 USINT Link path length EPATH Link path 20 0F 24 2A 30 01 WORD Descriptor 0x0000 USINT Data type 0xC8 USINT Data length UDINT Cycle counter, channel 7...
  • Page 40 Device functions Data Attri- Default Instance Name Value range bute ID value type Calibration deviation, channel 0 -100.00…100.00% USINT Link path length EPATH Link path 20 0F 24 2E 30 01 WORD Descriptor 0x0014 (scaling supported) USINT Data type 0xC3 USINT Factor USINT...
  • Page 41 Device functions Data Attri- Default Instance Name Value range bute ID value type Calibration deviation, channel 2 -100.00…100.00% USINT Link path length EPATH Link path 20 0F 24 31 30 01 WORD Descriptor 0x0014 (scaling supported) USINT Data type 0xC3 USINT Data length USINT...
  • Page 42 Device functions Data Attri- Default Instance Name Value range bute ID value type Calibration deviation, channel 6 -100.00…100.00% USINT Link path length EPATH Link path 20 0F 24 34 30 01 WORD Descriptor 0x0014 (scaling supported) USINT Data type 0xC3 USINT Data length USINT...
  • Page 43 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Calibration resistance, channel 0 (in 0…65535 Ω Ω 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 37 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 44 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Calibration resistance, channel 3 (in 0…65535 Ω Ω 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 3A 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 45 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Calibration resistance, channel 6 (in 0…65535 Ω Ω 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 3D 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 46 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Initial calibration resistance, 0…65535 Ω Ω channel 1 (in 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 40 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 47 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Initial calibration resistance, 0…65535 Ω Ω channel 4 (in 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 43 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 48 Device functions Data Attri- Default Instance Name Value range bute ID value type Ω UINT Initial calibration resistance, 0…65535 Ω Ω channel 7 (in 0.1 m (0…6553.5 m USINT Link path length EPATH Link path 20 0F 24 46 30 01 WORD Descriptor 0x0014 (scaling supported)
  • Page 49 Device functions When the controller is switched on, the last values saved in the retentive parameter object are auto- matically restored. If the controller needs to be replaced, you must load the old parameter data into the new controller using a suitable network configuration tool and then run the "Save" service. The parameter object is also reset to the default values if a type 1 reset is triggered on the identity object (class 1).
  • Page 50 It may be necessary to compensate the phase angle displacement between the U and I measuring signals for specific heatsealing applications ( ROPEX Application Report). The AUTOCOMP function is provided for this purpose. The following settings are possible: 1. "Off" (factory setting) The AUTOCOMP function is switched off.
  • Page 51 Device functions AC bit <2.0 s Function AUTOCOMP AUTOCAL "AUTOCAL" "OUTPUT" The "OUTPUT" LED blinks several times when the AUTOCOMP function is executed and the actual value output (terminals 17+18) changes to 0…3 °C (corresponds to approx. 0 VDC). 3. "AUTO" This setting causes the AUTOCOMP function to be automatically activated after the AUTOCAL function has been successfully executed.
  • Page 52 Device functions AC bit Function AUTOCOMP AUTOCAL "AUTOCAL" "OUTPUT" The "OUTPUT" LED blinks several times when the AUTOCOMP function is executed and the actual value output (terminals 17+18) changes to 0…3 °C (corresponds to approx. 0 VDC). The AUTOCOMP function must be activated in the parameter data ( section 8.7 "Parameter object (class: 0x0F)"...
  • Page 53 The high and low tolerance limits cannot be set in the ROPEX visualization software. The same limits apply as with the TO bit. They can only be set in the parameter data ( section 8.7 "Parameter object (class: 0x0F)" on page 28).
  • Page 54 ROPEX visualization software. It has no effect on the ACTUAL temperature that appears at the controller’s analog output or is plotted in the graphics window of the ROPEX visualization software. The various hold modes are shown below:...

  • Page 55: Integrated Web Server

    You can go direct to the official ROPEX website by clicking on the ROPEX logo in the top right-hand corner. The web server uses JavaScript and has been successfully tested with Internet Explorer 9, 10, and 11 as well as with Microsoft Edge.
  • Page 56 Device functions The inputs ( section 8.5 "Input data" on page 23) are shown in the left-hand column, the outputs ( section 8.6 "Output data" on page 26) in the middle column, and the current status of all device LEDs ( section 8.1 "LEDs and controls"...
  • Page 57 Device functions described in detail in section 8.19 "Error messages" on page 63. Each error code is explained in a tooltip when you hover over it briefly. The data can also be exported to a CSV file to enable further processing in another software program. By clicking on the appropriate button you can select a comma separated format or a semicolon separated format.

  • Page 58: Undervoltage Detection

    Device functions 8.8.6 Calibration page This page is first available as from firmware version 303. The temperature controller stores the absolute calibration resistance of each channel (Calibration resistance ch. 0…7) with an resolution of 0.1 mΩ. The calculation of the respective calibration resistance is done at the end of the AUTOCAL function (...

  • Page 59: Temperature Meter (Actual Value Output)

    Device functions Trouble-free operation of the controller is only guaranteed within the specified tolerance range of the input voltage. An external voltage monitor must be connected to prevent low line or 24 VDC supply voltage from resulting in defective heatseals. 8.10 Temperature meter (actual value output) The RES-5011 supplies an analog 0…10 VDC signal, which is proportional to the real ACTUAL temperature, at...

  • Page 60: Booster Connection

    An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing band. The ROPEX ATR-x temperature meter is optimally adapted to this application in every respect (size, scale, dynamic behavior) and can be used for this, if needed ( section 6 "Mounting and installation" on page 8).

  • Page 61: Usb Interface For Visualization Software Ropexvisual

    The number of heatsealing cycles executed since the controller was shipped is stored in the internal memory (ST bit = 1). This is a read-only counter which cannot be reset. It can be displayed in the ROPEX visualization soft- ®...

  • Page 62: Data Memory For Error Messages And Autocal

    AUTOCAL" on page 62) together with their date and time of occurrence (timestamp). Error messages can thus be interpreted more accurately whenever a problem needs to be analyzed. The built-in clock can be set and read out in the ROPEX visualization software ( section 8.12 "USB interface for ®...

  • Page 63: Error Messages

    If a ROPEX temperature meter (e.g. an ATR-x) is connected to the controller’s analog output, the temperature indication can be directly assigned to the error codes if an alarm is signaled.
  • Page 64 Device functions Part 1 of 3: Error messages (faults) NOTE: The error messages shown here are output as faults (constant error voltage at actual value output, alarm LED lit continuously, alarm relay energized). Act. val. Action if machine Error output Action if machine Cause already operated, HS...
  • Page 65 Device functions Part 2 of 3: Error messages (warnings) NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values, alarm LED blinks, alarm relay de-energized). When the START signal is activated, the warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm LED lit continuously, alarm relay energized).
  • Page 66 Device functions Part 3 of 3: Error messages (warnings) NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values, alarm LED blinks, alarm relay de-energized). When the START signal is activated, the warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm LED lit continuously, alarm relay energized).

  • Page 67: Fault Areas And Causes

    Device functions 8.20 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 - Contact to heatsealing band is defective pickoff point ...
  • Page 68 Device functions Fault area Explanation Possible causes - Hardware fault (replace controller) Internal device fault / no line - Jumper for alarm relay not connected or incorrectly con-  voltage nected - No line voltage Page 68 RES-5011 Version 2...

  • Page 69: Factory Settings

    Factory settings Factory settings ® The RESISTRON temperature controller RES-5011 is configured at the factory as follows: Rotary coding switch Heatsealing band alloy: Alloy 20 Temperature range: 300 °C heatsealing band alloy Rotary coding switch: "0" position temperature range Slide switch Alarm relay energized at alarm alarm relay Automatic phase...
  • Page 70 ACD and DLR support: Yes Heatsealing band The temperature range and temperature coefficient settings can also be specified type and temperature in the ROPEX visualization software ( section 8.12 "USB interface for visualiza- ® range tion software ROPEXvisual " on page 61) in addition to using the rotary coding...
  • Page 71 Technical data Analog output 0…10 VDC, I = 5 mA (actual value) Equivalent to 0…300 °C or 0…500 °C Terminals 17+18 Accuracy: ±1% plus 50 mV Alarm relay = 30 V (DC/AC), I = 0.2 A, changeover contact, potential-free Terminals 12, 13, 14 Power loss Max.

  • Page 72: Dimensions

    Dimensions Dimensions 75.0 90.0 Modifications 12.1 Modifications (MODs) ® Owing to its universal design, the RESISTRON temperature controller RES-5011 is suitable for a very wide range of heatsealing applications. ® One modification (MOD) is available for the RESISTRON temperature controller RES-5011 for implementing special applications.

  • Page 73: How To Order

    50520: Continuous curr. 50 A, 520 VAC, art. no. 885509 (with UL and CSA certification) Impulse transformer For design and order specifications, see ROPEX applica- tion report Design in accordance with EN 61558 Available with UL certifications and thermal switch, if nec- essary.
  • Page 74 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 74 RES-5011 Version 2...

  • Page 75: Index

    Index Index Numbers Ethernet/IP interface External switching amplifier 24VDC supply voltage Factory settings AA bit Fault Actual value Fault areas Actual value output Fuse AC bit AG bit Alarm output Alarm relay Heatsealing band type Alloy Heatup timeout Altitude AL bit Ambient conditions Impulse transformer Ambient temperature...
  • Page 76 Index Power supply system Temperature range Temperature regulation TE bit Thermal impulse process RA bit Time Relative humidity Timestamp Replacement (heatsealing band) TO bit Reset Transformer ROPEXvisual Transportation RS bit Type of construction Set point UL file Standby mode Undervoltage detection Start USB interface Startup...

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