Ropex Resistron RES-407 Operating Instructions Manual
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Ropex Resistron RES-407 Operating Instructions Manual

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RESISTRON
RES-407
Operating
Instructions
Important features
•
Automatic zero calibration (AUTOCAL)
•
Automatic optimization (AUTOTUNE)
•
Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of April 2005)
•
Automatic phase angle compensation (AUTOCOMP, as of April 2005)
•
Automatic frequency adjustment
•
Electrically isolated analog input for set point selection with potentiometer or 0...10VDC
•
Electrically isolated 0...10VDC analog output for ACTUAL temperature
•
24VDC control signals for START, AUTOCAL and RESET with electrical isolation
•
Alarm function with fault diagnosis
•
Heatsealing band alloy and temperature range selectable as standard (as of June 2003)
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-407

  • Page 1 24VDC control signals for START, AUTOCAL and RESET with electrical isolation • Alarm function with fault diagnosis • Heatsealing band alloy and temperature range selectable as standard (as of June 2003) ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: info@ropex.de Adolf-Heim-Str. 4...

  • Page 2: Table Of Contents

    Contents General information ....3 Controller functions ....22 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...

  • 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 "Aux- iliary voltage" on page 13 and the ROPEX Application Report. The information provided in section 5.2 "Instal- lation steps" on page 9 must 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-407 Version 1...

  • Page 13: Auxiliary Voltage

    Installation Auxiliary voltage Since the inputs and outputs of the RES-407 are electrically isolated, a 24VDC auxiliary voltage must be applied to terminals 12+13. The auxiliary voltage has a maximum current input of 1,0A and it is also protected against reverse polarity.

  • Page 14: Wiring Diagram (Standard)

    Installation Wiring diagram (standard) Line filter LF-xx480 RES-407 LINE (also with MOD 01) AUTOCAL with 24VDC signal START (HEAT) with 24VDC signal RESET with 24VDC signal prim. Impulse transformer Ground for 24VDC signals. sec. Must be grounded externally to prevent electrostatic Heat- charging!

  • Page 15: Wiring Diagram With Booster Connection (Mod 26)

    Installation Wiring diagram with booster connection (MOD 26) Line filter LF-xx480 RES-407 LINE (also with MOD 01) AUTOCAL Booster with 24VDC signal START (HEAT) with 24VDC signal RESET with 24VDC signal prim. Impulse transformer Ground for 24VDC signals. sec. Must be grounded externally to prevent electrostatic Heat-...

  • Page 16: Wiring Diagram With "Temperature Reached" Signal (Mod 40) Or „Temp. Ok" Signal (Mod 46)

    Installation ALARM HEAT OUTPUT AUTOCAL BOOSTER Additional terminals in housing cover for MOD 26 (booster connection) MOD 26 cannot be used in combination with MOD 40 ("Temperature reached" signal) manufactured up to March 2005. Wiring diagram with "Temperature reached" signal (MOD 40) or „Temp. OK“ signal (MOD 46) +24VDC +24VDC...

  • Page 17: Startup And Operation

    Set the DIP switches for matching the secondary voltage U and the secondary current I to the correct position for your application. You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your par- ticular application. Version 1 RES-407...
  • Page 18 If the switch is set to "9" (as of April 2005), more temperature ranges and alloys can be selected by means of the ROPEX visualization software ( see section 7.11 "Diagnostic interface/visualization software (as of April 2005)" on page 33).

  • Page 19: Replacing And "Burning In" The Heatsealing Band

    If the "Alarm output opened by alarm/PC CONFIGURATION" position is selected (as of April 2005), the behavior of the alarm output can be configured in more detail by means of the ROPEX visualization software ( see section 7.11 "Diagnostic interface/visualization software (as of April 2005)" on page 33).

  • Page 20: Startup Procedure

    3. In the case of controllers manufactured up to March 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 6.2 "Con- troller configuration" on page 17).
  • Page 21 If the zero point has not been calibrated successfully, the red "ALARM" LED blinks slowly (1Hz). In this case the controller configuration is incorrect ( section 6.2 "Controller configuration" on page 17 and ROPEX Appli- cation Report). Repeat the calibration after the controller has been configured correctly.

  • Page 22: Controller Functions

    Yellow LED, remains lit for duration of AUTOCAL process. RESISTRON RES- 407 Temperature controller ROPEX Tel:+49(0)7142-7776-0 Made in Germany Manufactured up to March 2005 Green LED, lit continuously when power supply is on. POWER ON...

  • Page 23: Temperature Setting (Set Point Selection)

    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: Blinks slowly (1Hz) Blinks fast (4Hz) Lit continuously RESET active, AUTOCAL requested, but START and AUTOCAL AUTOCAL...
  • Page 24 The connecting wires between the controller and the potentiometer must be shielded. 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 number which appears on the display corresponds to the SET temperature in °C.

  • Page 25: Output)

    Controller functions Temperature indication (actual value output) The RES-407 supplies an analog 0…10VDC signal, which is proportional to the real ACTUAL temperature, at ter- minals 17+14. RES-407 Actual value max. 5mA 33ohms output 0…10VDC 0…10VDC Temperature meter e.g. ATR-x Voltage values: 0VDC ...

  • Page 26: 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-x temperature meter (size, scaling, dynamic response) are ideally suited to this application and this instrument should therefore always be used ( section 12 "How to order" on page 47).

  • Page 27: Start" Signal (Heat)

    Controller functions The "AUTOCAL" function is activated by means of a 24VDC pulse at terminals 5+14. 24VDC RES-407 AUTOCAL max. 6mA ≥ HIGH: 12VDC AUTOCAL ≤ LOW: 2VDC 0.1…5s The automatic calibration process takes around 10…15seconds. The heatsealing band is not heated during this process.

  • Page 28: Reset" Signal

    Controller functions The "START" signal is activated by means of a 24VDC signal at terminals 6+14. 24VDC RES-407 START (HEAT) max. 6mA ≥ HIGH: 12VDC START (HEAT) ≤ LOW: 2VDC The "START" signal is disabled as long as the "AUTOCAL" function is executing or the „RESET“ signal is active. The set point that is selected for the heatsealing temperature must be greater than 40°C.

  • Page 29: Measuring Impulse Duration (As Of April 2005)

    The length of the measuring impulses generated by the controller can be set with the parameter. It may be nec- essary to set a measuring impulse that is longer than the default 1.7ms for certain applications ( ROPEX Appli- cation Report).
  • Page 30 Controller functions The "AUTOCOMP" function must be activated in the ROPEX visualization software ( section 7.11 "Diagnostic interface/visualization software (as of April 2005)" on page 33) (default setting: AUTOCOMP off). The following settings are possible: 1. „OFF" (Factory settings) The „AUTOCOMP“ function is deactivated.

  • Page 31: Temperature Diagnosis (As Of April 2005)

    (terminals 17+14) is set to 0…3°C (i.e. app. 0 VDC). Temperature diagnosis (as of April 2005) An additional temperature diagnosis can be activated in the ROPEX visualization software ( section 7.11 "Diag- nostic interface/visualization software (as of April 2005)" on page 33). The RES-407 checks whether the ACTUAL temperature is within a settable tolerance band ("OK"...

  • Page 32: Heatup Timeout (As Of April 2005)

    The temperature diagnosis function can thus be explicitly deactivated, e.g. if the temperature drops tem- porarily owing to the closure of the sealing jaws. The values that can be set in the ROPEX visualization software for the upper and lower tolerance band are iden- tical to those for the "Temperature OK" signal (MOD 46).

  • Page 33: Diagnostic Interface/Visualization Software

    Diagnostic interface/visualization software (as of April 2005) An interface with a 6-pole Modular socket (RJ-12) is provided for systemdiagnostics and process visualization. This interface allows a data connection to be set up to the ROPEX visualization software using the ROPEX com- munication interface CI-USB-1.

  • Page 34: Error Messages

    2005. The error messages are differentiated even more finely in the controller. The error codes described below can be displayed with the ROPEX visualization software ( section 7.11 "Diagnostic interface/visualization soft- ware (as of April 2005)" on page 33) to facilitate troubleshooting.
  • Page 35 Controller functions Part 1 of 3: Error messages as of April 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 36 Controller functions Part 2 of 3: Error messages as of April 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 37 Controller functions Part 3 of 3: Error messages as of April 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 38 Controller functions Page 38 RES-407 Version 1...

  • Page 39: Fault Areas And Causes

    Controller functions 7.14 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 40: Factory Settings

    Factory settings Fault area Explanation Possible causes - Up to March 2005: DIP switches 4 + 5 configured incor- rectly range) signal incorrect - As of April 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 41 „Temp. OK“ signal Tolerance band: -10K…+10K (as of April 2005: With MOD 46 only Temperature Temperature diagnosis: OFF diagnosis Heatup timeout Heatup timeout: OFF [X] As of April 2005: With ROPEX visualization software only. Version 1 RES-407 Page 41...

  • Page 42: Technical Data

    The temperature range and temperature coefficient settings can also be specified range by means of the ROPEX visualization software ( section 7.11 "Diagnostic inter- face/visualization software (as of April 2005)" on page 33) in addition to the rotary coding switch (see below): Temperature range: 200°C, 300°C, 400°C or 500°C...
  • Page 43 Technical data Reference voltage +10VDC / ±5%, I = 5mA Digital logic levels LOW (0V): 0…2VDC, electrically isolated Terminals 5, 6, 7 HIGH (24VDC): 12…30VDC (max. current input 6mA) Reverse polarity-protected Switching output for = 30VDC "Temp. reached" = 50mA signal <...

  • Page 44: Dimensions

    Dimensions Dimensions 75.0 90.0 Modifications (MODs) ® Owing to its universal design, the RESISTRON temperature controller RES-407 is suitable for a very wide range of heatsealing applications. ® Various modifications (MODs) are offered for the RESISTRON temperature controller RES-407 for implementing special applications.
  • Page 45 Modifications (MODs) MOD 37 (until May 2003) Additional rotary coding switch for the heatsealing band alloy and the temperature range. Various heatsealing band alloys (e.g. Alloy A20, LEX3500) and temperature ranges (e.g. 300°C, 500°C) can be selected. This modification is supplied as standard with all controllers manufactured as of June 2003 (...
  • Page 46 These values can be set independently of one another in the ROPEX visualization software ( section 7.11 "Dia- gnostic interface/visualization software (as of April 2005)" on page 33). If the actual temperature is inside the specified tolerance band when the "START" signal is activated, the output...

  • Page 47: 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 48 How to order Booster B- . . . 075415: Max. pulse load 75A, 415VAC, P/N 885302 100400: Max. pulse load 100A, 400VAC, P/N 885304 For more accessories: "Accessories" leaflet Page 48 RES-407 Version 1...

  • Page 49: Index

    Index Index Actual value output Impulse heatsealing method Alarm output Impulse transformer Alarm relay Installation Alloy Installation procedure Ambient temperature Installation regulations Analog input Analog output Application Line filter Application Report Line frequency AUTOCAL Line voltage AUTOCOMP Automatic phase angle compensation Automatic zero calibration Maintenance AUTOTUNE...
  • Page 50 Index Temperature control Temperature diagnosis View of the controller Temperature meter Visualization software Temperature OK signal Temperature range Temperature reached signal Wiring Temperature setting Wiring diagram Transformer Transportation Type of construction Page 50 RES-407 Version 1...

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