Ropex RESISTRON RES-403 Operating Instructions Manual
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Ropex RESISTRON RES-403 Operating Instructions Manual

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RESISTRON
RES-403
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 phase angle compensation (AUTOCOMP, as of October 2005)
•
Automatic frequency adjustment
•
Set point selection with potentiometer
•
0...10VDC analog output for ACTUAL temperature
•
Activated with contact or 24VDC signal
•
Alarm function with fault diagnosis
•
Heatsealing band alloy and temperature range selectable
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
D-74321-Bietigheim-Bissingen
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-403

  • Page 1 0…10VDC analog output for ACTUAL temperature • Activated with contact or 24VDC signal • Alarm function with fault diagnosis • Heatsealing band alloy and temperature range selectable 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: www.ropex.de...

  • Page 2: Table Of Contents

    Contents General information ....3 ....18 Controller functions Intended use .

  • Page 3: General Information

    The use of suitable heatsealing bands is a basic Only the original ROPEX PEX-W2, PEX-W3 or prerequisite for reliable and safe operation of the PEX-W4 current transformer may be used. Other trans- system.

  • 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 • Pouch, filling and sealing machines • Group packaging machines • Film wrapping machines • etc. • Pouch-making machines Principle of operation The resistance of the heatsealing band, which is tem- The control loop is closed: ACTUAL temperature = SET perature-sensitive, is monitored 50x per second (60x at temperature.

  • Page 6: Installation Procedure

    5.3 "Power supply" on page 8, section 5.6 "Wiring diagram (Standard)" on page 10 and the 1. Switch off the line voltage and verify that the circuit ROPEX Application Report. The information pro- is de-energized. vided in section 5.2 "Installation steps" on page 7 2.

  • Page 7: 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 heatsealing band ends Note circuit number Sufficient wire of turns Twisted cross-section...

  • Page 8: Power Supply

    RESISTRON temperature controller 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 PRIM. Designed according to EN 61558 (isolating transformer with reinforced insulation).

  • Page 9: Line Filter

    Installation ROPEX line filters are specially optimized for use in Line filter RESISTRON control loops. Providing that they are installed and wired correctly, they guarantee comp- To comply with EMC directives – corresponding to liance with the EMC limit values.

  • Page 10: Wiring Diagram (Standard)

    Installation Wiring diagram (Standard) Line filter LF-xx480 NOTE: RES-403 AUTOCAL button LINE also provided on (also with MOD 01) controller AUTOCAL with 24VDC signal ALARM OUTPUT max. 30V/0,2A Contact closed or opened by ALARM (see configuration) START (HEAT) with 24VDC signal prim.

  • Page 11: Wiring Diagram With Booster Connection (Mod 26)

    Installation Wiring diagram with booster connection (MOD 26) Line filter LF-xx480 NOTE: RES-403 AUTOCAL button LINE also provided on (also with MOD 01) controller Booster AUTOCAL with 24VDC signal ALARM OUTPUT max. 30V/0,2A Contact closed or opened by ALARM (see configuration) START (HEAT) with 24VDC signal prim.

  • Page 12: Wiring Diagram With "Temp

    Installation MOD 26 cannot be used in combination with MOD 40 ("Temperature OK" signal) manufactured up to September 2005. ALARM HEAT OUTPUT AUTOCAL BOOSTER Additional terminals in housing cover for MOD 26 (Booster connection) Wiring diagram with "Temp- erature reached" signal (MOD 40) or „Temp.

  • Page 13: Startup And Operation

    Installation Startup and operation 5.10 View of the controller LEDs Terminals Button for AUTOCAL function Wiring diagramm Nameplate Coding switches and plug-in jumpers function (AUTOCAL). The voltage is configured in the 5.11 Controller configuration range from 0.4VAC to 120VAC and the current in the range from 30A to 500A.
  • Page 14 Installation You can find the exact configuration of the DIP swit- ches in the ROPEX Application Report calculated for your particular 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 sec-...

  • Page 15: Replacing And "Burning In" The Heatse

    ROPEX visualization software ximately 2…3%. However, this at first glance slight see section 6.10 "Diagnostic interface/visualization resistance change results in a zero point error of software (as of October 2005)"...

  • Page 16: Startup Procedure

    3. In the case of controllers manufactured up to Sep- cessfully, the red "ALARM" LED blinks slowly (1Hz). tember 2005, the settings of the DIP switches on the In this case the controller configuration is incorrect controller are indicated in the ROPEX Application section 5.11 "Controller configuration"...
  • Page 17 Installation actual value output: on page 15) and repeat the AUTOCAL function. The controller is functioning correctly if the tempera- ture (which corresponds to the signal change at the The controller is now analog output) has a harmonious motion, in other ready words it must not jump abruptly, fluctuate or deviate temporarily in the wrong direction.

  • Page 18: Controller Functions

    AUTOCAL process. RESISTRON RES- 403 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 Button for manual activation of AUTOCAL AUTOCAL function (zero calibration).

  • Page 19: Temperature Setting (Set Point Selection)

    If a ROPEX PD-x 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 Cable shielded number which appears on the display corresponds to the SET temperature in °C.

  • Page 20: Temperature Indication

    An indicating instrument can be connected to this output in order to visualize the temperature of the heat- sealing band. The characteristics of the ROPEX ATR-x temperature indicator (size, scaling, dynamic response) are ideally suited to this application and this instrument should therefore always be used ( section 10 "Modifications...

  • Page 21: Automatic Zero Calibration (Autocal)

    Controller functions This indicator moreover permits disturbances in the perature setting (set point selection)" on page 19). The control loop (loose connections, contacting or wiring value selected at the set point potentiometer must be problems) as well as any line disturbances to be present when the "AUTOCAL"...

  • Page 22: Start" Signal (Heat)

    Controller functions (terminals 14+15) is 0…3°C (corresponds to app. • By means of a 24VDC signal at terminals 12+13 0 VDC) during this process. 24VDC If the temperature of the heatsealing band varies on RES- 403 START controllers manufactured as of October 2005, the (HEAT) "AUTOCAL"...

  • Page 23: Measuring Impulse Duration (As Of October 2005)

    "AUTOCAL" than the default 1.7ms for certain applications ROPEX Application Report). This parameter can only be set by means of the ROPEX visualization software ( section 6.10 "Dia- gnostic interface/visualization software (as of October 2005)" on page 25). "OUTPUT"...

  • Page 24: Temperature Diagnosis (As Of October 2005)

    6.10 sealing jaws. "Diagnostic interface/visualization software (as of The values that can be set in the ROPEX visualization October 2005)" on page 25). The RES-403 checks software for the upper and lower tolerance band and whether the ACTUAL temperature is within a settable tolerance band ("OK"...

  • Page 25: Heatup Timeout (As Of October 2005)

    ROPEX visualization software ( section 6.10 "Dia- damage to the controller. gnostic interface/visualization software (as of October The ROPEX visualization software is described in a 2005)" on page 25). separate document. This timeout starts when the START signal is activated.

  • Page 26: Error Messages

    104…106, 111…114, 211, 302, 303; up to September even more finely in the controller. The error codes 2005: error codes 8…12), the signal at the analog described below can be displayed with the ROPEX output jumps back and forth at 1Hz between the visualization software ( section 6.10 "Diagnostic...
  • Page 27 Controller functions Part 1 of 3: Error messages as of October 2005 (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...
  • Page 28 Controller functions Part 2 of 3: Error messages as of October 2005 (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 29 Controller functions Part 3 of 3: Error messages as of October 2005 (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 30 Controller functions Page 30 RES-403...

  • Page 31: Fault Areas And Causes

    Controller functions 6.13 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 Current transformer signal measuring wires from current transformer interrupted...

  • Page 32: 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 33 Measuring impulse length: 1,7ms duration „Temp. OK“ signal Tolerance band: -10K…+10K (as of October 2005: With MOD 46 only) Temperature Temperature diagnosis: OFF diagnosis Heatup timeout Heatup timeout: OFF [X] As of October 2005: With ROPEX visualization software only. RES-403 Page 33...

  • Page 34: Technical Data

    Heatsealing band The temperature range and temperature coefficient settings can also be specified type and temperature by means of the ROPEX visualization software ( section 6.10 "Diagnostic range interface/visualization software (as of October 2005)" on page 25) in addition to...
  • Page 35 Technical data = 30VDC Digital logic levels = 50mA „Temp. reached“ < 2V (saturation voltage) signal (MOD 40) or "Temp. OK" signal (MOD 46) = 30V (DC/AC), I = 0.2A, potential-free Alarm relay = 5A (duty cycle = 100%) Maximum load (primary current of = 25A (duty cycle = 20%) impulse...

  • Page 36: Dimensions

    Dimensions Dimensions 75.0 90.0 Modifications (MODs) Owing to its universal design, the RESISTRON tempe- MOD 01 rature controller RES-403 is suitable for a very wide Amplifier secondary voltages range of heatsealing applications. = 0.25…16VAC). This modification is necessary, Various modifications (MODs) are available for the for example, for very short or low-resistance heatse- RESISTRON temperature controller RES-403 for aling bands.
  • Page 37 ) tolerance band limits are configured in the upper factory to -10K and +10K. These values can be set independently another ROPEX visualization software ( section 6.10 "Diagnostic interface/visualization software (as of October 2005)" on page 25). If the actual temperature is inside the specified tolerance band when the "START"...

  • Page 38: How To Order

    P/N 885106 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- .
  • Page 39 How to order Booster B- . . . 400 075: Max. pulse load 75A, 400VAC, P/N 885301 100: Max. pulse load 100A, 400VAC, P/N 885304 For more accessories: "Accessories" leaflet RES-403 Page 39...

  • Page 40: Index

    Index Index Installation Installation procedure Actual value output Installation regulations Alarm output Alarm relay Alloy Ambient temperature Line filter Application Line frequency Application Report Line voltage AUTOCAL AUTOCOMP Automatic phase angle compensation Maintenance Automatic zero calibration Measuring impulse duration AUTOTUNE Modifications MODs Booster...
  • Page 41 Index Temperature reached signal Visualization software Temperature setting Transformer Type of construction Wiring Wiring diagram View of the controller RES-403 Page 41...

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