Table of Contents
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RESISTRON
RES-5010
Operating
instructions
Important features
•
Microprocessor technology
•
Complete control via PROFINET interface ("Conformance Class B", IO / RT acc. to IEC 61784-2)
(2 x RJ-45)
•
Automatic zero calibration (AUTOCAL)
•
Automatic optimization (AUTOTUNE)
•
Automatic configuration of the secondary voltage and current ranges (AUTORANGE)
•
Automatic phase angle compensation (AUTOCOMP)
•
Automatic frequency adjustment
•
Large current and voltage range
•
Booster connection as standard
•
0...10VDC analog output for ACTUAL temperature
•
Alarm function with error diagnosis
•
Heatsealing band alloy and temperature range selectable
Industrie-Elektronik GmbH
Gansäcker 21
D-74321-Bietigheim-Bissingen (Germany)
GB
Tel: +49/(0)7142/7776-0
Fax: +49/(0)7142/7776-211
E-Mail:
info@ropex.de
Internet:
www.ropex.de
Data subject to change
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Summary of Contents for Ropex RESISTRON RES-5010
- Page 1 Booster connection as standard • 0…10VDC analog output for ACTUAL temperature • Alarm function with error diagnosis • Heatsealing band alloy and temperature range selectable Industrie-Elektronik GmbH Tel: +49/(0)7142/7776-0 E-Mail: info@ropex.de Gansäcker 21 Fax: +49/(0)7142/7776-211 Internet: www.ropex.de D-74321-Bietigheim-Bissingen (Germany) Data subject to change...
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Page 2: Table Of Contents
Contents Safety and warning notes ....3 ....21 Controller functions 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
Line filter device itself complies with the above-mentioned standards. The use of an original ROPEX line filter is mandatory in It does not imply, however, that the overall system also order to comply with the standards and provisions fulfils these standards. -
Page 5: Principle Of Operation
Principle of operation • Film wrapping machines The use of RESISTRON temperature controllers results in: • Pouch making machines • Repeatable quality of the heatseals under any • Group packaging machines conditions • L-sealers • Increased machine capacity • etc. •... -
Page 6: Description Of The Controller
Description of the controller Description of the controller microprocessor technology enriches interfaces can be used to control all of the controller RES-5010 RESISTRON temperature controller with functions and query controller information. previously unattainable capabilities: The ACTUAL temperature of the heatsealing band is supplied to the PROFINET interface and to an analog 0 •... -
Page 7: Modifications (Mods)
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 a diagnostic interface (DIAG) to the PC (USB port). -
Page 8: Technical Data
FSU (Fast Startup) support: Yes, but startup time approx. 1.5s. The temperature range and temperature coefficient settings can also be specified Heatsealing band by means of the ROPEX visualization software (section 10.11 "Diagnostic type and temperature interface / visualization software" on page 35) in addition to the rotary coding... -
Page 9: Dimensions
Dimensions IP20 Degree of protection If several controllers are installed on one top hat Installation rail (DIN TS35 rail), a clearance of at least 20mm should be allowed between them. The moving clip required for fastening must be facing down for mounting on a horizontal top hat rail. -
Page 10: Installation
Proceed follows install RES-5010 be entered in the ROPEX Application Report based RESISTRON temperature controller: on the calculated currents. If a larger overcurrent 1. Switch off the line voltage and verify that the circuit protective device is fitted, you must match the is de-energized. -
Page 11: 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 12: 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 13: 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 12 must be observed. RESISTRON control loops. Providing that they are... -
Page 14: Wiring Diagram (Standard)
Installation Wiring diagram (standard) Line filter LF-xx480 RES-5010 LINE Ethernet PORT 1 (RJ45) Ethernet module electrically isolated 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 electrostatic... -
Page 15: Wiring Diagram With Booster Connection
Installation Wiring diagram with booster connection Line filter LF-xx480 RES-5010 LINE Ethernet PORT 1 (RJ45) Booster Ethernet twisted module Max. length 1m electrically isolated prim. Shield Impulse Ethernet transformer PORT 2 (RJ45) (for assignment sec. see PORT 1) Ground Heat- Must be grounded sealing externally to... -
Page 16: Startup And Operation
30A, the 9.2.1 Configuration of the secondary PEX-W2 or PEX-W3 current transformer must have voltage and current ranges two turns ( ROPEX Application Report). The secondary voltage and current ranges are automatically configured by the automatic calibration Page 16 RES-5010... - Page 17 "Parameter data" on page 28). switches: If the switch is set to "9", more temperature ranges and alloys can be selected by means of the ROPEX Rotary coding Station name visualization software (...
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Page 18: Replacing And Burning In The Heatsealing Band
URATION" position is selected, the behavior of the incorrectly inserted – an error message alarm output can be configured in more detail by means appears when the controller is switched on ROPEX visualization software ( see ( section 10.17 "Error messages" on page 37). -
Page 19: Startup Procedure
"ALARM" LED blinks slowly (1Hz). In this case communication is active. It does not go out again controller configuration incorrect ( until it detects an active communication. section 9.2 "Controller configuration" on page 16 and ROPEX Application Report). Repeat the RES-5010 Page 19... - Page 20 Startup and operation calibration after the controller has been configured 11. Burn in the heatsealing band ( section 9.3 correctly. "Replacing and burning in the heatsealing band" on page 18) and repeat the AUTOCAL function. 10.When the zero point has been successfully calibrated, specify a defined temperature by means of the PROFINET protocol (set point) and set the The controller is now ready...
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Page 21: Controller Functions
Lit during heating phase. (yellow LED) ALARM Lit or blinking to indicate fault. www.ROPEX.de (Red LED) In addition to the functions shown in the diagram by the LEDs. These states are described in detail in the above, various controller operating states are indicated... - Page 22 Controller functions BLINKS slowly (1Hz) BLINKS fast (4Hz) Lit continuously AUTOCAL requested but "RS" bit is set (reset) function disabled (e.g. AUTOCAL executing AUTOCAL START active) (yellow) LED blinks with a different frequency: Supply voltages incorrect (too low) START requested but function is locked (e.g.
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Page 23: Profinet Communication
The device master files and the associated image files (.BMP) (for visualization in the configuring tool) However, if the line voltage is not present can be requested by e-mail (support@ropex.de) or (e.g. if it is switched off in order to open a downloaded from our website (www.ropex.de). -
Page 24: Communication Protocol
Controller functions information and the control functions, to enable it to be 10.4 Communication protocol decoded more easily by the PROFINET controller. The communication protocol consists of 2x16 bit input words and 3x16 bit output words (from the point of view Bits 0…7 form the low byte and bits 8…15 the of the controller). - Page 25 Controller functions 10.5.1 Automatic zero calibration Reasons for disabled AUTOCAL function: "AUTOCAL" (AC) 1. An "AUTOCAL" request cannot be processed until 10 seconds after the controller is switched on. Owing to the automatic zero calibration (AUTOCAL) During this time the controller reports "AUTOCAL function, there is no need to adjust the zero point disabled"...
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Page 26: Output Data
Controller functions output. As soon as the bit is reset, new measuring 10.5.3 Reset (RS) impulses are generated, all error messages are This bit resets the controller if the controller reports a evaluated, and the actual value is updated again. fault. - Page 27 Controller functions 10.6.2 AUTOCAL disabled (AG) Actual value Set+ Δϑ If the "AG" bit is set, the AUTOCAL function is upper temporarily disabled. This is the case if "START" is active or if the heatsealing band is still in the cooling phase.
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Page 28: Parameter Data
Controller functions b.) Temperature OK 10.7 Parameter data Actual value Set+ Δϑ The parameter data contains values for selecting the upper heatsealing band alloy, the temperature range, the upper and lower tolerance band limits for temperature monitoring, the calibration temperature, and the Set+ Δϑ... - Page 29 Index Function range value 300°C TCR = 3500 ppm/K, e.g. NOREX 16/17 Maximum 300°C 200…500° temperature PC configuration PC configuration (ROPEX (ROPEX Temperature Off, on visualization visualization diagnosis software) software) Temperature 0…99 Rotary coding Rotary coding switch diagnosis delay (0…9.9s)
- Page 30 It may be necessary to compensate the phase angle calibration "AUTOCAL" (AC)" on page 25). displacement between the U and I measuring signals for special heatsealing applications ( ROPEX You do not need to execute the AUTOCAL Application Report). The "AUTOCOMP" function is function after changing the calibration provided for this purpose.
- Page 31 The lower and upper tolerance band limits ( section 10.7 "Parameter data" on page 28) cannot be set using the ROPEX visualization (default setting: AUTOCOMP off). software. The same limits apply as for the "TO" bit.
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Page 32: Undervoltage Detection
ROPEX visualization software. It has no parameterized time, the corresponding error code effect on the ACTUAL temperature that appears at (304) is indicated and the fault relay is switched the controller's analog output or is recorded in the (... -
Page 33: Temperature Indication
ATR-3 output in order to visualize the temperature of the heatsealing band. The characteristics of the ROPEX ATR-x temperature meter (size, scaling, dynamic response) are ideally suited to this application and this instrument should therefore always be used ( section 5 "Accessories Voltage values: and modifications"... -
Page 34: Booster Connection
Controller functions temperature meter additionally permits 10.10 Booster connection disturbances in the control loop (loose connections, contacting or wiring problems) as well as any line The RES-5010 controller has a connection for an disturbances to be observed extremely effectively and external switching amplifier (booster) as standard. -
Page 35: Diagnostic Interface / Visualization
"Diagnostic interface / visualization software" on bit = 1). This counter can only be displayed and not page 35). reset. It can only be displayed using the ROPEX visualization software ( section 10.11 "Diagnostic The clock is operated by means of a interface / visualization software"... -
Page 36: System Monitoring / Alarm Output
( section 10.17 "Error messages" on calibration (AUTOCAL function) was unsuccessful page 37). ( section 9.2 "Controller configuration" If there is a ROPEX analog temperature meter (i.e page 16). This corresponds error codes ATR-x) connected to the analog output of the controller, 111…114). -
Page 37: Error Messages
The 3-digit error numbers described below can be displayed via the PROFINET interface and An error message can only be reset by using ROPEX visualization software setting the "RS" bit or by momentarily ( section 10.11 "Diagnostic interface / visualization interrupting the power to the controller (24VDC software"... - Page 38 Controller functions Teil 1 von 3: Error messages (faults) NOTE: The specified error messages are initially output as faults (stable error voltage level at the actual value output; alarm LED lit continuously; alarm relay is energized). Act. value Action Action if machine Error output;...
- Page 39 Controller functions Teil 2 von 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 is 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;...
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Page 40: Fault Areas And Causes
Controller functions Teil 3 von 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 is 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;... - Page 41 Controller functions 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 PEX-W2/-W3 current transformer measurement cable from current transformer interrupted signal interrupted - Wire break, triac in controller defective Primary circuit interrupted...
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Page 42: Factory Settings
Factory settings Factory settings The RES-5010 RESISTRON temperature controller is configured at the factory as follows: Rotary coding switch Heatsealing band alloy: Alloy A20 Temperature range: 300°C heatsealing band alloy Rotary coding switch: „0“ position SWITCH POS. temperature range 300°C Jumper Fault relay is energized at alarm fault relay... -
Page 43: 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 Temp. meter ATR - . -
Page 44: Index
Index Index Extended controller diagnosis Nummern External switching amplifier 24VDC supply voltage Factory settings "AA" bit Fault "AC" bit Fault relay Actual value Fehlerbereiche Actual value output Fuse "AG" bit "AL" bit Alarm output Alloy GSDML file Ambient temperature Analog temperature meter Anschlussbild Heatsealing band type Application... - Page 45 Index Temperature control Temperature diagnosis "RA" bit Temperature meter Replacing the heatsealing band Temperature OK Reset Temperature range "RS" bit Temperature reached Time Time stamp Set point "TO" bit Standby mode Total cycle counter Start Transformer "START" bit Type of construction Startup System diagnosis System monitoring...
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