Ropex 740301, Operating Instructions Manual

Page 1: ...ation 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 Heat...

Page 2: ...ation 16 5 10 View of the controller 16 5 11 Controller configuration 16 5 12 Replacing and burning in the heat sealing band 18 5 13 Startup procedure 19 6 Controller functions 20 6 1 Indicators and controls 21 6 2 Temperature setting set point selection 22 6 3 Temperature indication actual value output 23 6 4 Automatic zero calibration AUTOCAL 25 6 5 START signal HEAT 26 6 6 Measuring impulse dur...

Page 3: ...g bands which are expressly approved for them and providing the regulations notes and warnings contained in these instructions are observed In case of non observance or use contrary to the intended purpose there is a risk that safety will be impaired or that the heatsealing band electrical wiring transformer etc will overheat This is the personal responsibility of the user 1 3 Heatsealing band The...

Page 4: ... instructions contained in section Power supply must be observed External monitoring modules can be used in order to additionally increase operating safety They are not included in the scope of supply of the standard control system and are described in a separate document 1 6 Line filter ROPEX provides line filters in different power classes The ROPEX application report lists the suitable line fil...

Page 5: ...ally 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 Careless uncontrolled disposal can cause damage to the environment and human health By ensuring that your product is disposed of or recycled in a responsible way you can help protect the environment and human health This...

Page 6: ...ry significantly in terms of performance and physical dimensions All information provided by us in connection with the line filter is merely intended as a guide and is based on a typical measuring setup It serves to demonstrate that compliance with the EMC directive can be achieved by using a line filter that is suitable for the overall system The line filter and current transformer must however b...

Page 7: ... sealing band are detected and can be corrected quickly and precisely A highly high response thermo electric control loop is formed which is highly accurate because purely electrical variables are measured at a high sampling rate A high secondary current can be controlled because power is controlled on the primary side of the transformer This allows optimum adaptation to the load and to the requir...

Page 8: ...rcuit is de energized 2 The supply voltage specified on the nameplate of the RESISTRON temperature controller must be identical to the line voltage that is present in the plant or machine The line frequency is automatically detected by the RESISTRON temperature controller in the range from 47Hz 63Hz 3 Install the RESISTRON temperature controller in the electrical cabinet on a standard top hat rail...

Page 9: ...ith suitable temperature coefficient 20mm clearance if several controllers installed on one top hat rail Note polarity No additional resistance in secondary circuit Dimension transformer correctly Secondary voltage Power Duty cycle Configure DIP switches correctly Sufficient wire cross section No push on connectors Twisted Current measuring wires IR R Connect U measuring wires directly to heatseal...

Page 10: ... side RESISTRON temperature 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 Designed according to EN 61558 isolating transformer with reinforced insulation Connect core to ground Use transformers with a one section bobbin The power duty ...

Page 11: ...rt calculated for your particular heatsealing application For more technical information Line filter documentation It is permissible to supply several RESISTRON control loops with a single line filter providing the total current does not exceed the maximum current of the filter The wiring instructions contained in section 5 3 Power supply on page 10 must be observed Example drawing for LF 06480 5 ...

Page 12: ...RES 403 Version 1 5 5 1 PEX W4 5 5 2 PEX W5 Mounting on DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 Snap on for DIN rail 35 x 7 5 mm or 35 x 15 mm DIN EN 50022 terminal block terminal wires 14 60 24 75 14 23 28 26 39 12 ...

Page 13: ...MOD 01 GND 13 12 5 6 8 Contact closed or opened by ALARM see configuration 11 9 10 7 START HEAT with contact 14 15 18 17 16 cw 2K SET POINT POTENTIOMETER PD 3 or PD 5 Cable shielded C ATR _ ANALOG OUTPUT 0 10VDC 2 1 4 3 Current transformer twisted Impuls transformer Heat sealing band LINE Line filter LF xx480 sec U2 prim U1 0V Internnal ground No external grounding allowed 0V Internal ground No ex...

Page 14: ...12 5 6 8 Contact closed or opened by ALARM see configuration 0V Internnal ground No external grounding allowed R Current transformer Impuls transformer 11 9 10 7 IR UR Heat sealing band START HEAT with contact 14 15 18 17 16 cw 2K SET POINT POTENTIOMETER PD 3 or PD 5 Cable shielded C ATR _ ANALOG OUTPUT 0 10VDC LINE Booster NC NC 2 2 4 IN OUT 1 1 3 Line filter LF xx480 4 3 sec U2 prim U1 twisted 2...

Page 15: ... 40 cannot be used in combination with MOD 26 booster connection manufactured prior to September 2005 MOD 46 cannot be used in combination with MOD 40 Additional terminals in housing cover for MOD 26 Booster connection BOOSTER 19 20 4 3 2 1 AUTOCAL OUTPUT HEAT ALARM RES 403 Imax 50mA 24VDC GND GND 24VDC 4 3 2 1 Additional terminals in housing cover for MOD 40 Temp reached signal or MOD 46 Temp OK ...

Page 16: ...ured by the automatic calibration function AUTOCAL The voltage is configured in the range from 0 4VAC to 120VAC and the current in the range from 30A to 500A If the voltage and or the current is outside the permissible range an detailed error message appears on the controller see section 6 12 Error messages on page 34 Configuration with coding switches up to September 2005 Set the DIP switches for...

Page 17: ...s of October 2005 more temperature ranges and alloys can be selected by means of the ROPEX visualization software see section 6 10 Diagnostic interface visualization software as of October 2005 on page 32 3 2 1 4 5 ON OFF 1 10V 6 60V 20 120V ON OFF OFF OFF ON OFF OFF OFF ON 30 100A 60 200A 120 400A OFF ON ON OFF OFF ON DIP switch DIP switch 1 2 U2 I2 3 4 5 3 2 1 4 5 4 3 ON OFF U V 2 1 10 SWITCH ON...

Page 18: ...t TCR Too low a TCR leads to oscillation or uncontrolled heating When heatsealing bands with a higher TCR are used the controller must be calibrated for this The first time the heatsealing band is heated to approximately 200 250 C the standard alloy undergoes a once only resistance change burn in effect The cold resistance of the heatsealing band is reduced by approximately 2 3 However this at fir...

Page 19: ...fy that all circuits are de energized 2 The supply voltage specified on the nameplate of the controller must be identical to the line voltage that is present in the plant or machine The line frequency is automatically detected by the temperature controller in the range from 47 63Hz 3 In the case of controllers manufactured up to September 2005 the settings of the DIP switches on the controller are...

Page 20: ...nd activate the START signal HEAT The HEAT LED then lights up The heating and control process can be observed at the actual value output The controller is functioning correctly if the temperature which corresponds to the signal change at the analog output has a harmonious motion in other words it must not jump abruptly fluctuate or deviate temporarily in the wrong direction This kind of behavior w...

Page 21: ...dicates pulses in measure ment mode In control mode luminous intensity is proportional to heating current Yellow LED lit during heating phase Red LED lights up or blinks to indicate ALARM 4 3 2 1 9 8 6 5 10 11 7 12 13 14 15 16 17 18 Button for manual activation of AUTOCAL function zero calibration Do not press unless heatsealing band is cold Yellow LED remains lit for duration of AUTOCAL process G...

Page 22: ...p between the potentiometer setting and the SET temperature is linear The terminals 16 17 are not potenial free and might have the potential of the secondary voltage of the impulse transformer LED Blinks slowly 1Hz Blinks fast 4Hz Lit continuously AUTOCAL yellow RESET active START and AUTOCAL functions are locked as of October 2005 AUTOCAL requested but function disabled AUTOCAL executing HEAT yel...

Page 23: ... C The set point that is selected for the heatsealing temperature must be greater than 40 C If not the heatsealing band will not be heated up when the START signal is activated If a potentiometer is not connected the set point is assumed to be zero When you connect the potentiometer please note the direction of rotation 6 3 Temperature indication actual value output The RES 403 supplies an analog ...

Page 24: ...uch as the heating rate set point reached within the specified time cooling of the heatsealing band etc to be evaluated This indicator moreover permits disturbances in the control loop loose connections contacting or wiring prob lems as well as any line disturbances to be observed extremely effectively and interpreted accordingly The same applies if mutual interference occurs between several neigh...

Page 25: ...ature before activating the AUTOCAL function Variable initial temperature On controllers manufactured as of April 2005 the initial temperature for the AUTOCAL function can be set in the 0 40 C range in the visualization software section 6 10 Diagnostic interface visualization software as of October 2005 on page 32 This setting is remembered if the controller is switched off and then on again As of...

Page 26: ...attempt to activate it sooner it will not function 2 The AUTOCAL function is not activated if the heatsealing band is cooling down at a rate of more than 0 1K sec If the control signal is activated the function is activated automatically providing the cooling rate has fallen below the above mentioned value 3 If the START signal 24VDC is active the AUTOCAL function is not executed HEAT LED lit 4 AU...

Page 27: ...led External grounding is not allowed If this warning is ignored the controller will be damaged by frame currents The set point that is selected for the heatsealing temperature must be greater than 40 C If not the heatsealing band will not be heated up HEAT LED blinks The alarm output is switched if the START signal is activated while an error message is indicating error codes 104 106 111 114 211 ...

Page 28: ...ling applications ROPEX Application Report The AUTOCOMP function is provided for this purpose The AUTOCOMP function must be activated in the ROPEX visualization software section 6 10 Diagnostic interface visualization software as of October 2005 on page 32 The following settings are possible 1 OFF Factory settings The AUTOCOMP function is deactivated 2 ON The AUTOCOMP function is executed whenever...

Page 29: ...al value output terminals 17 14 is set to 0 3 C i e approx 0VDC 3 AUTO as of software revision 108 With this setting the AUTOCOMP function is activated automatically after the AUTOCAL function has been successfully executed Function AUTOCAL signal AC t t 0 0 AUTOCAL lit t OFF 2 0s AUTOCOMP AUTOCAL t OFF LED lit OUTPUT LED AP 24VDC ...

Page 30: ...able tolerance band OK window on either side of the SET temperature The lower and upper tolerance band limits are configured in the factory to 10K and 10K These values can be set independently of one another in the ROPEX visualization software If the actual temperature is inside the specified tolerance band when the START signal is activated the temper ature diagnosis is activated as well If the A...

Page 31: ... visualization software The first time the lower toler ance band limit is exceeded the temperature diagnosis is not activated until the parameterized delay time has elapsed The temperature diagnosis function can thus be explicitly suppressed 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 uppe...

Page 32: ...rm relay is switched section 6 12 Error messages on page 34 6 10 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 Only a ROPEX comunication ...

Page 33: ...s OPEN in operating states A 1 and A 2 but closed if a START signal is activated in one of these states CLOSED in operating state A 3 If the alarm relay is configured opposite to the factory setting section 5 11 3 Configuration of the alarm relay on page 18 these states are reversed C Error code output via the 0 10VDC analog output terminals 14 15 Since a temperature indication is no longer necess...

Page 34: ... for fault diagnostics appear at the actual value output of all controllers manufactured as of October 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 6 10 Diagnostic interface visualization software as of October 2005 on page 32 to facilitate troubleshooting If the actual v...

Page 35: ...rrent voltage signals Fault area Fault areas 107 2 66 Temperature step down Fault areas loose contact Fault areas loose contact 108 Temperature step up 307 Temperature too high low section 6 8 308 309 310 201 3 33 No line frequency line fre quency fluctuates Check power supply Check power supply 202 Line frequency too high fluctuates 203 Line frequency too low fluctuates 304 4 00 Heatup time too l...

Page 36: ...Action if machine started for first time Action if machine already operated HS band not changed 104 5 33 10 Current signal incorrect incorrect impulse transformer specification Perform AUTOCAL check transformer specifi cation fault areas Fault areas loose contact 105 Voltage signal incorrect incorrect impulse transformer specification 106 Current and voltage signals incorrect incorrect impulse tra...

Page 37: ...rrect no calibration possible Fault area check configuration Fault areas loose contact 112 7 33 10 Voltage signal incorrect no calibration possible Fault area check configuration Fault areas loose contact 113 8 00 10 Current voltage signals incor rect no calibration possible Fault area check configuration Fault areas loose contact 114 8 66 10 Temperature fluctuates no calibration possible Perform ...

Page 38: ...emperature step Frequency fluctuation inadmissible line frequency Internal fault Internal fault controller defective U R and or I R signal incorrect Data error I R signal incorrect calibration not possible U R signal incorrect calibration not possible U R and I R signals incorrect calibration not possible STATUS of alarm relay factory set Closed Open does not close until START signal voltage value...

Page 39: ...int Wire break Secondary winding of impulse transformer interrupted UR signal missing Measuring wires interrupted Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heatsealing band break Contact to heatsealing band defective Total short circuit Heatsealing band installed incorrectly insula...

Page 40: ...r incorrectly connected DIP switches for secondary voltage U2 and current I2 up to September 2005 U2 6 60VAC I2 30 100A DIP switches 2 ON 1 3 4 5 OFF These switches are automatically set by the AUTORANGE function on all controllers manufactured as of October 2005 Rotary coding switch for heatsealing band alloy and temperature range Heatsealing band alloy Alloy A20 Temperature range 300 C Maximum t...

Page 41: ...05 With ROPEX visualization software only Measuring impuse duration X Measuring impulse length 1 7ms Temp OK signal as of October 2005 With MOD 46 only X Tolerance band 10K 10K Temperature diagnosis X Temperature diagnosis OFF Heatup timeout X Heatup timeout OFF ...

Page 42: ...ufactured as of October 2005 The temperature range and temperature coefficient settings can also be specified by means of the ROPEX visualization software section 6 10 Diagnostic interface visualization software as of October 2005 on page 32 in addition to the rotary coding switch see below Temperature range 200 C 300 C 400 C or 500 C Temperature coefficient 400 4000ppm variable setting range Five...

Page 43: ...n 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 End holders to mechanical fix the controller must be fitted at both ends for mounting on a vertical top hat rail Weight Approx 0 7kg incl connector plug in parts Housing material Plastic polycarbonate UL 94...

Page 44: ...ions The modifications described here are just a few of the large number available Separate documents are supplied for all modifications The modifications must be ordered separately MOD 01 Amplifier for low secondary voltages UR 0 25 16VAC This modification is necessary for example for very short or low resistance heatsealing bands MOD 26 Additional terminal for connecting an external switching am...

Page 45: ...ware section 6 10 Diagnostic interface visualization software as of October 2005 on page 32 If the actual temperature is inside the specified tolerance band when the START signal is activated the output signal is activated as well see graph below If the actual temperature leaves the tolerance band the output signal is deactivated again The output signal then remains deactivated even if the actual ...

Page 46: ...al Please indicate the article numbers of the controller and the required modifications optional in all orders e g RES 403 400VAC MOD 26 controller for 400VAC power supply with booster connection P N 740303 800026 must be ordered Current transformer PEX W4 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 RO...

Page 47: ...How to order Version 1 RES 403 Page 47 For more accessories Accessories leaflet Booster B 075415 Max pulse load 75A 415VAC P N 885302 100400 Max pulse load 100A 400VAC P N 885304 ...

Page 48: ...w to order 46 I Impulse heatsealing method 7 Impulse transformer 10 46 Installation 8 43 Installation procedure 8 Installation regulations 8 L Line filter 4 10 11 46 Line frequency 7 42 Line voltage 42 M Maintenance 4 Measuring impulse duration 28 Modifications 14 15 44 46 MODs 14 15 44 46 O Over current protection 10 Overheating of heatsealing band 7 P PEX W4 46 PEX W4 W5 4 11 Phase angle compens...

Page 49: ...S 403 Page 49 Temperature reached signal 15 45 Temperature setting 22 Transformer 4 10 46 Transportation 4 Type of construction 42 V View of the controller 16 Visualization software 32 W Wiring 8 10 Wiring diagram 13 14 ...