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RESISTRON
RES-401
Operating
Instructions
Important features
•
Automatic zero calibration (AUTOCAL)
•
Automatic optimization (AUTOTUNE)
•
Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of October 2005)
•
Automatic frequency adjustment
•
Set point selection with potentiometer
•
Temperature range: 300°C
•
0...10VDC analog output for ACTUAL temperature
•
Activated with contact or 24VDC signal
•
Alarm function
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)
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-401
- Page 1 Set point selection with potentiometer • Temperature range: 300°C • 0…10VDC analog output for ACTUAL temperature • Activated with contact or 24VDC signal • Alarm function 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 74321 Bietigheim-Bissingen (Germany)
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Page 2: Table Of Contents
Contents General information ....3 Controller functions ....18 Copyright . -
Page 3: General Information
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 4: Impulse Transformer
The use of an original ROPEX line filter is mandatory in order to comply with the directives mentioned in section "DECLARATION OF CONFORMITY" on page 6. This device must be installed and connected according to the instructions contained in section "Power supply"... -
Page 5: Disposal
General information Disposal This device is subject to Directive 2012/19/EU concerning the reduction of the increasing amount of waste electrical and 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. - Page 6 We also wish to point out that the transformer which is used must be designed in accordance with VDE 0551/EN 61558 or UL 5058 for safety reasons. July 12, 2020 J. Kühner (CEO) ROPEX Industrie-Elektronik GmbH Adolf-Heim-Str. 4 74321 Bietigheim-Bissingen (Germany) Page 6...
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Page 7: Application
Application Application ® This RESISTRON temperature controller is an integral part of the "Series 400", the outstanding feature of which is its microprocessor technology. All RESISTRON temperature controllers are used to control the temperature of heating elements (heatsealing bands, beaded bands, cutting wires, heatsealing blades, solder elements etc.), as required in a variety of heatsealing processes. -
Page 8: Installation
4. Wire the system in accordance with the instructions in section 5.3 "Power supply" on page 10, section 5.6 "Wiring diagram" on page 13 and the ROPEX Application Report. The information provided in section 5.2 "Installation steps" on page 9 must also be heeded additionally. -
Page 9: 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 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 Installation 5.5.1 PEX-W4 terminal wires terminal block Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022) 5.5.2 PEX-W5 Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022). Page 12 RES-401 Version 1...
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Page 13: Wiring Diagram
Installation Wiring diagram Line filter LF-xx480 NOTE: AUTOCAL button RES-401 LINE also provided on controller START (HEAT) with 24VDC signal prim. Impuls GND 13 transformer Ground for 24VDC signals. sec. Must be grounded externally to prevent electrostatic Heat- charging! sealing band (Internal ground) twisted... -
Page 14: View Of The Controller
Installation View of the controller Button for LEDs AUTOCAL function Terminals Typenschild Wiring diagramm Controller configuration The controller must be switched off in order to configure the coding switches. 5.9.1 Configuration of the DIP switches for secondary voltage and current Automatic configuration (AUTORANGE) (as of October 2005) The secondary voltage and current ranges are automatically configured by the automatic calibration function... -
Page 15: Replacing And "Burning In" The Heat
Installation You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your par- ticular application. Factory settings DIP switch DIP switch 1...10V 30...100A 6...60V 60...200A 20...120V 120...400A If the secondary current I is less than 30A, the secondary high-current wire must be laid twice (or several times) through the PEX-W3 or PEX-W4 current transformer (... -
Page 16: Startup Procedure
3. In the case of controllers manufactured up to September 2005, the settings of the DIP switches on the controller are indicated in the ROPEX Application Report and depend on the heatsealing band that is used (section 5.9 "Controller configuration" on page 14). - Page 17 If the zero point has not been calibrated successfully, the red "ALARM" LED blinks slowly (1Hz) (up to Sep- tember 2005: Twin-color LED blinks red slowly). In this case the controller configuration is incorrect ( section 5.9 "Controller configuration" on page 14 and ROPEX Application Report). Repeat the calibration after the controller has been configured correctly.
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Page 18: Controller Functions
AUTOCAL process. RESISTRON RES- 401 Temperature Button for manual activation of AUTOCAL controller function (zero calibration). Do not press ROPEX unless heatsealing band is cold. Tel:+49(0)7142-7776-0 Made in Germany Manufactured up to September 2005 AUTOCAL AUTOCAL Button for manual activation of AUTOCAL function (zero calibration). - Page 19 Controller functions In addition to the functions shown in the diagram above, various controller operating states are indicated by the LEDs. These states are described in detail in the table below: As of October 2005: Blinks slowly (1Hz) Blinks fast (4Hz) Lit continuously RESET active, AUTOCAL requested, but...
- Page 20 If a ROPEX PD-3 precision potentiometer is used, the SET temperature can be adjusted exactly with the help of the digital display in the window of the dial. The number which appears on the display corresponds to the SET temperature in °C.
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Page 21: Output
Controller functions Temperature indication (actual value output) The RES-401 supplies an analog 0…10VDC signal, which is proportional to the real ACTUAL temperature, at terminals 14+15. RES-401 max. 5mA Actual value R=33Ohm output 0...10VDC 0...10VDC Temperature meter ATR-3 Voltage values: 0VDC ... -
Page 22: Automatic Zero Calibration (Autocal)
An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing band. The characteristics of the ROPEX ATR-3 temperature indicator (size, scaling, dynamic response) are ideally suited to this application and this instrument should therefore always be used ( section 10 "Modifications (MODs)"... -
Page 23: Start" Signal (Heat)
Controller functions You should always wait for the heatsealing band and the bar to cool down (to ambient temperature) before activating the AUTOCAL function. Reasons for disabled AUTOCAL function: 1. The AUTOCAL function cannot be activated until 10 seconds after the controller is switched on. If you attempt to activate it sooner, it will not function. -
Page 24: Diagnostic Interface/Visualization Software (As Of October 2005)
Diagnostic interface/visualization software (as of October 2005) An interface with a 6-pole Modular Jack (RJ-12) is provided for system diagnostics and process visualization. This interface allows a data connection to be set up to the ROPEX visualization software using the ROPEX communi- cation interface CI-USB-1. -
Page 25: System Monitoring/Alarm Output
Controller functions System monitoring/alarm output To increase operating safety and to avoid faulty heatsealing, this controller incorporates special hardware and software features that facilitate selective fault detection and diagnosis. Both the external wiring and the internal system are monitored. A system fault is reported or differentiated by means of the following indications. Red "ALARM"... -
Page 26: Fault Areas And Causes
Controller functions 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 defective pickoff point ... -
Page 27: Factory Settings
Factory settings Fault area Explanation Possible causes - Up to September 2005: DIP switches 4 + 5 configured incorrectly (I range) signal incorrect - As of October 2005: I outside permissible range from 30…500A Turns through current transformer - Check number of turns (two or more turns required for incorrect currents <... -
Page 28: Technical Data
Technical data Technical data Type of construction Housing for installation in the electrical cabinet Snaps onto a standard top hat rail (DIN TS35 rail, 35 mm) acc. to DIN EN 50022 Dimensions: 90 x 75mm; height: 135mm (incl. terminals) Line voltage All controllers manufactured as of October 2005: 115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC) 230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC) -
Page 29: Dimensions
Dimensions Installation If several controllers are installed on one top hat 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 30: How To Order
Line filter LF- . . 480 06: Continuous current 6A, 480VAC, P/N 885500 35: Continuous current 35A, 480VAC, P/N 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communiction interface CI-USB-1 P/N 885650 Potentiometer PD- 3: For 300°C range, P/N 881103 Scope of supply: Potentiometer with digital dial Temp. -
Page 31: Index
Index Index Line frequency Line voltage Actual value output Alarm output Alloy Ambient temperature Maintenance Application Modifications Application Report MODs AUTOCAL Automatic zero calibration AUTOTUNE Over-current protection Overheating of heatsealing band Burning in the heatsealing band PEX-W4 PEX-W4/-W5 Circuit-breaker Potentiometer CI-USB-1 Power dissipation Communication interface... - Page 32 Index Wiring diagram Page 32 RES-401 Version 1...
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