Ropex RESISTRON RES-402 Manuale utente

ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: [email protected]

Adolf-Heim-Str. 4 Fax: +49 (0)7142-7776-211 Internet: https://ropex.de

74321 Bietigheim-Bissingen (Germany) Data subject to change

24.7.20 Version 1

RESISTRON

RES-402

Important features

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)

• Automatic configuration of the secondary voltage and current ranges

(AUTORANGE, as of January 2006)

• Automatic frequency adjustment

• Temperature range: 300°C

• 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

Operating

Instructions

Page 2 RES-402 Version 1

Contents

1 General information . . . . . . . . . . . . . . . . . . 3

1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Intended use . . . . . . . . . . . . . . . . . . . . 3

1.3 Heatsealing band . . . . . . . . . . . . . . . . 3

1.4 Impulse transformer . . . . . . . . . . . . . . 4

1.5 Current transformer PEX-W4/-W5 . . . . 4

1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4

1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4

1.8 Transportation . . . . . . . . . . . . . . . . . . . 4

1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Principle of operation . . . . . . . . . . . . . . . . . 7

4 Traits of the controller . . . . . . . . . . . . . . . . 7

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Installation procedure . . . . . . . . . . . . . 8

5.2 Installation steps . . . . . . . . . . . . . . . . . 9

5.3 Power supply . . . . . . . . . . . . . . . . . . . 10

5.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 11

5.5 Current transformer PEX-W4/-W5 . . . 11

5.6 Auxiliary voltage . . . . . . . . . . . . . . . . 13

5.7 Wiring diagram . . . . . . . . . . . . . . . . . 14

6 Startup and operation . . . . . . . . . . . . . . . . 14

6.1 View of the controller . . . . . . . . . . . . . 15

6.2 Controller configuration . . . . . . . . . . . 15

6.3 Replacing and "burning in" the heat-

sealing band . . . . . . . . . . . . . . . . . . . 16

6.4 Startup procedure . . . . . . . . . . . . . . . 17

7 Controller functions . . . . . . . . . . . . . . . . . 19

7.1 Indicators and controls . . . . . . . . . . . 19

7.2 Temperature setting (set point selection)

7.3 Temperature indication (actual value

output) . . . . . . . . . . . . . . . . . . . . . . . . 22

7.4 Automatic zero calibration (AUTOCAL) .

7.5 "START" signal (HEAT) . . . . . . . . . . . 24

7.6 "RESET" signal . . . . . . . . . . . . . . . . . 25

7.7 Diagnostic interface/visualization software

(as of January 2006) . . . . . . . . . . . . . 26

7.8 System monitoring/alarm output . . . . 26

7.9 Error messages . . . . . . . . . . . . . . . . . 27

7.10 Fault areas and causes . . . . . . . . . . . 27

8Factory settings. . . . . . . . . . . . . . . . . . . . . 28

9 Technical data . . . . . . . . . . . . . . . . . . . . . . 29

10 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 30

11 Modifications (MODs) . . . . . . . . . . . . . . . . 30

12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 31

13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

General information

Version 1 RES-402 Page 3

1 General information

This RESISTRON® temperature controller is manufactured according to EN 61010-1. In the course of its manu-

facture it passed through quality assurance, whereby it was subjected to extensive inspections and tests. As a

result of this, the product left our factory in perfect condition.

Please carefully read through the operating manual before using the RESISTRON® temperature controller. Keep

the operating manual for later reference and make sure that information and functions important for the user are

available.

The recommendations and warning notes contained in these operating instructions must be complied with, in

order to guarantee safe operation.

The device can be operated within the limits indicated in the "Technical Data" without impairing its operational

safety. Installation and maintenance may only be performed by technically trained, skilled persons who are familiar

with the associated risks and warranty provisions.

1.1 Copyright

All contents, in particular texts, photographs and graphics, are protected by copyright. All rights, including to rep-

lication, publication, editing and translation, are reserved.

1.2 Intended use

RESISTRON® temperature controllers may only be used for heating and temperature control of heatsealing 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 use of suitable heatsealing bands is a basic prerequisite for reliable and safe operation of the system.

The resistance of the heatsealing band which is used must have a positive minimum temperature coefficient in

order to guarantee trouble-free operation of the RESISTRON® temperature controller.

The temperature coefficient must be specified as follows:

e.g. Alloy A20: TCR = 1100 ppm/K

LEX3500: TCR = 3500 ppm/K

Vacodil: TCR = 1100 ppm/K

The RESISTRON® temperature controller must be set and coded according to the temperature coefficient of the

heatsealing band.

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

RESISTRON® temperature controller leads to uncontrolled heating of the heatsealing band, which

will ultimately burn out!

The original heatsealing bands must be clearly identified by means of suitable markings as well as the connector

geometry, length, or other means to ensure that replacement bands are identical.

TCR 10x10 4– K1– or K 1– or ppm/K=

General information

Page 4 RES-402 Version 1

1.4 Impulse transformer

A suitable impulse transformer is necessary in order to guarantee trouble-free operation of the control loop. This

transformer must be designed according to EN 61558 or UL 5058 (isolating transformer with reinforced insulation)

and have a one section bobbin. When the impulse transformer is installed, suitable touch protection must be

provided in accordance with the national installation regulations for electrical equipment. In addition to this, water,

cleaning solutions and conductive fluids must be prevented from seeping into the transformer.

Incorrect installation of the impulse transformer impairs electrical safety.

1.5 Current transformer PEX-W4/-W5

The current transformer supplied with the RESISTRON® temperature controller is an integral part of the control

system.

Only the original ROPEX PEX-W4 or PEX-W5 current transformer may be used. Other transformers may cause

the equipment to malfunction.

The current transformer may only be operated if it is correctly connected to the RESISTRON® temperature

controller (see section "Startup and operation"). The relevant safety 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 filter

which can be ordered accordingly.

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" as well as the separate documentation enclosed with the line

filter.

1.7 Maintenance

The controller requires no special maintenance. Regular inspection and / or tightening of the terminals – including

the terminals for the winding connections on the impulse transformer – is recommended. Dust deposits on the con-

troller can be removed with dry compressed air.

Dust deposits and dirt from liquids result in a loss of function. Accordingly, installation in a switch

cabinet or terminal cabined with IP54 is recommended.

1.8 Transportation

Store and transport the device in its original carton.

After transport, perform a visual inspection for possible damage.

General information

Version 1 RES-402 Page 5

1.9 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.

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 device must not be disposed of as residual waste!

General information

Page 6 RES-402 Version 1

DECLARATION OF CONFORMITY

We hereby declare that the following device has been developed and manufactured in conformance with the direc-

tives cited below:

Compliant with following standards and directives:

Note:

This declaration of conformity certifies that the device/electronic itself complies with the above-mentioned direc-

tives. The CE mark on the device/electronic does not relieve the machinery manufacturer of his duty to verify the

conformity of the completely installed, wired and operationally ready system in the machine with the EMC directive.

Comments:

RESISTRON/CIRUS temperature controllers are not independently operable devices. They are used by the

machinery manufacturer to form a sealing system by adding EMC-relevant components such as filters, transfor-

mers, heatsealing bands and wiring. The final configuration may vary 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, be determined on the basis of the respective application. 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.

ROPEX Industrie-Elektronik GmbH

Adolf-Heim-Str. 4

74321 Bietigheim-Bissingen (Germany)

Designation: RESISTRON temperature controller with accessories

Type: RES-402 with line filter and current transformer

Operating principle: Impulse sealing of films and plastics

EN 61010-1 Safety requirements for electrical equipment, control, and laboratory use

2014/35/EU low voltage directive

2014/30/EU electromagnetic compatibility directive

2011/65/EU RoHS directive

July 12, 2020

J. Kühner (CEO)

Application

Version 1 RES-402 Page 7

2 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.

The controller is most commonly used for impulse-heatsealing PE and PP films in:

• Vertical and horizontal f/f/s machines

• Pouch, filling and sealing machines

• Film wrapping machines

• Pouch-making machines

• Group packaging machines

•L-sealers

•etc.

3 Principle of operation

The resistance of the heatsealing band, which is temperature-sensitive, is monitored 50x per second (60x at 60Hz)

by measuring the current and voltage. The temperature calculated with the help of these measurements is dis-

played and compared with the set point.

The primary voltage of the impulse transformer is adjusted by phase-angle control if the measured values deviate

from the set point. The resulting change in the current through the heatsealing band leads to a change in the band

temperature and thus also its resistance. This change is measured and evaluated by the RESISTRON® temper-

ature controller.

The control loop is closed: ACTUAL temperature = SET temperature. Even minute thermal loads on the heat-

sealing band are detected and can be corrected quickly and precisely.

The thermoelectric control loop which is formed has a highly dynamic response because purely electrical variables

are measured at a high sampling rate. A very wide secondary current range can be controlled with only minimal

power loss - a considerable advantage - because power is controlled on the primary side of the transformer. This

allows optimum adaptation to the load and to the required dynamic range despite the exceptionally compact

dimensions of the controller.

4 Traits of the controller

• Very simple operation thanks to AUTOCAL, the automatic zero calibration function.

• Good dynamic response of the control system thanks to AUTOTUNE, which adapts automatically to the con-

trolled system.

• High precision thanks to further improved control accuracy and linearization of the heatsealing band character-

istic.

• High flexibility: The AUTORANGE function (as of January 2006) covers a secondary voltage range from 0.4V

to 80V and a current range from 30A to 500A.

• Automatic adjustment to the line frequency in the range from 47Hz to 63Hz.

• Increased protection against dangerous conditions, such as overheating of the heatsealing band.

Installation

Page 8 RES-402 Version 1

The electrically isolated analog interfaces for the temperature set point and the actual temperature (0-10VDC)

allow the temperature to be set either directly on the machine PLC or by means of an external potentiometer

(PD-3).

Similarly, the real heatsealing band temperature can be visualized either on the display of the machine PLC or on

an external temperature meter (ATR-3).

To increase operational safety and interference immunity, all 24VDC logic signals are electrically isolated from the

controller and the heating circuit.

An external 24VDC auxiliary voltage is required to supply the isolating amplifiers and optocouplers. The compact

design of the RESISTRON® temperature controller RES-402 and the plug-in connections make this controller

easy to install.

5Installation

See also section 1 "General information" on page 3.

Installation and startup may only be performed by technically trained, skilled persons who are

familiar with the associated risks and warranty provisions.

5.1 Installation procedure

Proceed as follows to install the RESISTRON® temperature controller RES-402:

1. Switch off the line voltage and verify that all circuits are deenergized.

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

temperature controller in the range from 47Hz to 63Hz.

3. Install the RESISTRON® temperature controller in the electrical cabinet on a standard top hat rail (DIN TS35

rail, according to DIN EN 50022). If several controllers are installed on one top hat rail, the minimum clearance

specified in section 9 "Technical data" on page 29 must be allowed between them.

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.

Check the tightness of all the system connections, including the terminals for the impulse trans-

former windings.

5. Make sure that the wiring conforms to the relevant national and international installation regulations.

Installation

Version 1 RES-402 Page 9

5.2 Installation steps

Line

Impulse

transformer

Current transformer

PEX-W2/-W3

U (prim.)

Heatsealing band R= f (T)

U (sec.)

Controller

Temperature

meter

ATR-x

Digital

potentiometer

PD-x

Avoid long

cables

Heatseal element

with coppered ends

Use heatseal bands with

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

push-on

connectors

Twisted

Current measuring

wires IR

Connect U measuring

wires directly to

heatsealing band ends

Line filter

LF-xx480

Note

direction

of rotation

Note

number

of turns

(up to Dec. 2005)

Installation

Page 10 RES-402 Version 1

5.3 Power supply

ROPEX

temperature

controller

PRIM.

SEC.

LINE

GND/

Earth

N (L2)

L1 (L1)

LINE

FILTER

OFF

Short wires

Line

Over-current protection

Double-pole circuit-breaker or fuses,

(ROPEX Application Report)

Short-circuit protection only. RESISTRON® temper-

ature controller not protected.

Relay Ka

For "HEAT ON - OFF" function (all-pole) or

"EMERGENCY STOP".

Line filter

The filter type and size must be determined according to

the load, the transformer and the machine wiring

(ROPEX Application Report).

Do not run the filter supply wires (line side) parallel

to the filter output wires (load 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 cycle and voltage values must be deter-

mined individually according to the application (ROPEX

Application Report and "Accessories" leaflet for impulse

transformers).

Wiring

The wire cross-sections depend on the application

(ROPEX Application Report).

Wires must always be twisted (min. 20 turns/meter).

These wires must be twisted (min. 20 turns/meter)

if several control loops are laid together ("crosstalk").

Twisting (min. 20 turns/meter) is recommended to

improve EMC.

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