RESISTRON
GB
RES-430
Operating
Instructions
Important features
• Microprocessor technology
• LC display (green), 4 lines, 20 characters (multilingual)
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic frequency adjustment
• Secondary control
• Heatsealing band alloy and temperature range selectable
• Time control, heatsealing time and cooling time settable
• Configurable relay output, e.g. "end of cycle"
• Time or temperature-controlled cooling phase
• 0…10VDC analog output for ACTUAL temperature
• Load cell interface for monitoring closing pressure
• Serial data interface (optional)
• Fault diagnosis
20.1.05
Industrie-Elektronik GmbH Tel: +49/(0)7142/7776-0 E-mail: info@ropex.de
Gansäcker 21 Fax: +49/(0)7142/7776-19 Internet: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Line filter . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Warranty provisions . . . . . . . . . . . . . . . 3
1.6 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 5
5 Modifications (MODs) /
optical data interface . . . . . . . . . . . . . . . . . . 6
5.1 Modifications . . . . . . . . . . . . . . . . . . . . 6
5.2 Optional data interface
(piggyback module) . . . . . . . . . . . . . . . 6
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
7 Dimensions / front panel cutout . . . . . . . . 10
7.1 Motherboard . . . . . . . . . . . . . . . . . . . 10
7.2 Display terminal . . . . . . . . . . . . . . . . . 11
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.1 Installation procedure . . . . . . . . . . . . 12
8.2 Installation steps . . . . . . . . . . . . . . . . 12
8.3 Power supply . . . . . . . . . . . . . . . . . . . 13
8.4 Wiring diagram with relay K1
(standard) . . . . . . . . . . . . . . . . . . . . . 14
8.5 Wiring diagram with solenoid drive
(optional) . . . . . . . . . . . . . . . . . . . . . . 15
9 Startup and operation . . . . . . . . . . . . . . . . 16
9.1 View of the controller . . . . . . . . . . . . . 16
9.2 General controller configuration . . . . 17
9.3 Time control (timer function) . . . . . . . 18
9.4 Temperaturediagnosis . . . . . . . . . . . . 22
9.5 Load cell interface /
temperature sensor . . . . . . . . . . . . . . 23
9.6 Heatsealing band . . . . . . . . . . . . . . . 24
9.7 Startup procedure . . . . . . . . . . . . . . . 25
10 Controller functions . . . . . . . . . . . . . . . . . 27
10.1 Indicators and controls . . . . . . . . . . . 27
10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 27
10.3 Navigation in the menus . . . . . . . . . . 29
10.4 Menu structure . . . . . . . . . . . . . . . . . . 31
10.5 Two-digit numbering system
up to SW revision 006 . . . . . . . . . . . . 33
10.6 Temperature setting
(set point selection) . . . . . . . . . . . . . . 34
10.7 Temperature indication /
actual value output . . . . . . . . . . . . . . 34
10.8 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 35
10.9 "FOOT SWITCH" signal . . . . . . . . . . 36
10.10 Hold time for "FOOT SWITCH"
signal . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.11 "START" signal (HEAT) . . . . . . . . . . . 36
10.12 Cycle counter . . . . . . . . . . . . . . . . . . . 37
10.13 Single/double sealing . . . . . . . . . . . . 37
10.14 Hold mode . . . . . . . . . . . . . . . . . . . . . 37
10.15 Locking the "HAND" key . . . . . . . . . . 38
10.16 Locking the Configuration menu . . . . 38
10.17 Undervoltage detection . . . . . . . . . . . 39
10.18 System monitoring / alarm output . . . 42
10.19 Error messages . . . . . . . . . . . . . . . . . 42
10.20 Fault areas and causes . . . . . . . . . . . 45
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 46
11.1 Ropex settings . . . . . . . . . . . . . . . . . . 46
11.2 Customer settings . . . . . . . . . . . . . . . 47
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 47
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 48
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Page 2 RES-430
Safety and warning notes
1 Safety and warning notes
This RESISTRON temperature controller is
manufactured according to DIN EN 61010-1. In the
course of its manufacture it passed through quality
assurance, whereby it was subjected to extensive
inspections and tests.
It left the factory in perfect condition.
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 Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance 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.
Ensuring such compliance is the personal
responsibility of the user.
The RESISTRON temperature controller must be set
and coded according to the temperature coefficient of
the heatsealing band.
The use of incorrect alloys with too low a
!
temperature coefficient and incorrect coding
of the RESISTRON temperature controller leads to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by their detailed specification, part
number or some other means to ensure that all
replacement bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one-section bobbin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.
Incorrect installation of the impulse
!
transformer impairs electrical safety.
1.2 Heatsealing band
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands.
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:
TCR 104–×10 K
≥
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
1–
RES-430 Page 3
1.4 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.6 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.5 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
Application
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
1.6 Standards / CE marking
The controller described here complies with the
following standards, provisions and directives:
DIN EN 61010-1
(VDE 0411-1)
DIN EN 60204-1 Electrical equipment of machines
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
(machinery directive)
Compliance with these standards and provisions is only
guaranteed if original accessories and/or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
EN 50081-1 EMC interference emissions
according to EN 55011, group 1,
class B
EN 50082-2 EMC interference immunity:
ESDs, RF radiation, bursts, surges.
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 impulseheatsealing PE and PP films in simple table welding
machines and welding presses:
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
•L-sealers
•etc.
The use of RESISTRON temperature controllers
results in:
• Repeatable quality of the heatseals under any
conditions
• Increased machine capacity
• Extended life of the heatsealing bands and teflon
coatings
• Simple operation and control of the sealing process
Page 4 RES-430
Principle of operation
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 displayed and compared with the set
point.
The secondary 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 temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the
heatsealing 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.
4 Description of the controller
PLEASE NOTE!
RESISTRON temperature controllers play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
The microprocessor technology endows the RES-430
RESISTRON temperature controller with previously
unattainable capabilities:
• 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 controlled system.
• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
• High flexibility: Secondary voltage range from 12 V
to 42V, current range from 20A to 90 A.
• Automatic adjustment to the line frequency in the
range from 47 Hz to 63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
A time control (timer) function integrated in the
controller enables the complete heatsealing process to
be controlled on simple machines, such as table
heatsealing tools. A configurable relay output can be
used to drive motors, energize magnets etc.
The process data is represented on an LC display with
4 lines and 20 characters. Various display languages
can be selected.
The real heatsealing band temperature is visualized on
the display both as a digital number in °C and in the
form of a dynamic bar.
In addition to the digital and bar indications on the
display, the ACTUAL temperature of the heatsealing
band is supplied to an analog 0…10VDC output. The
real heatsealing band temperature can thus be
visualized on an external temperature meter (e.g.
ATR-x).
The RESISTRON temperature controller RES-430 also
features an integrated fault diagnosis function, which
tests both the external system (heatsealing band,
wiring etc.) and the internal electronics and outputs a
selective error message in case of a fault.
The menu in the temperature controller itself can be
used to adapt to different heatsealing band alloys
(Alloy-20, NOREX etc.) and set the required
temperature range (0…300°C, 0…500 °C etc.).
The RESISTRON temperature controller RES-430
consists of two components: a motherboard with a
power section for installation in the machine frame and
a separate display terminal. The compact design and
RES-430 Page 5
the plug-in connections make this controller easy to
install.
5 Modifications (MODs) /
optical data interface
Modifications (MODs) / optical data interface
5.1 Modifications
No modifications are available for the RESISTRON
temperature controller RES-430.
5.2 Optional data interface (piggyback module)
A serial data interface (piggyback module) is optionally
available for the RES-430 controller.
This module can be ordered separately and retrofitted
onto the motherboard. It is connected to a PC by means
of a serial data cable (ª section 13 „How to order“ on
page 48).
Page 6 RES-430
Modifications (MODs) / optical data interface
5.2.1 Scope of supply / installation
The serial piggyback module is supplied with spacers
for installation on the motherboard of the RES-430.
Proceed as follows to install the module.
Sub-D connector, 9-pole
for serial
data cable
RES-430 motherboard
Snap-on end
Latching end
Schematic diagram:
4x spacer
Snap-on
Latching
Connect the of the 4 spacers to the
motherboard first. Then connect the piggyback module
to the with the solder side up.
The 5-pole male connector on the motherboard must
insert into the 5-pole female connector on the
piggyback module.
latching end
snap-on end
Piggyback module
Female connector, 5-pole
Male connector, 5-pole
RES-430 motherboardPiggyback module
5.2.2 Visualization software
A visualization software tool is provided for data
communication with a PC. This software shows all the
data for a heatsealing cycle (ACTUAL temperature,
closing force). You can also export the data as a CSV
file for further processing in another PC program.
RES-430 Page 7
In addition, the software permits the values in the
Configuration and Settings menus to be transferred to
the controller or read from it.
This visualization software is described in a separate
document.
6 Technical data
Type of construction RES-430 motherboard with power section:
Open design for installation in the machine frame
Dimensions (L x W): 210 x 110mm, height: 45mm (incl. terminals)
T-430 display terminal:
For installation in the machine frame
Dimensions (W x H): 144 x 72mm; depth: 66 mm (incl. connecting cables)
Line voltage 115VAC, 230 VAC, tolerance: +10% / -15 %
depending on device version (ª section 13 „How to order“ on page 48)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Technical data
Heatsealing band
type and temperature
range
Heatsealing band
Several different ranges can be selected on the controller in the
Configuration menu:
Default: Temperature coefficient 1100 ppm (Alloy 20), 0…300 °C
12…42VAC
voltage
(secondary voltage of
impulse transformer)
Max. load current
(max. secondary
Two heatsealing bands: I
One heatsealing band: I
sec max
sec max
current of impulse
transformer)
Terminals 5, 6, 7, 8
If only one heatsealing band is used, terminals 7+8
!
must be externally jumpered with a high current cable in order to
avoid malfunctions or damage to the controller.
Min. load current Up to SW revision 007: I
SW revision 008 or higher: I
Analog output
(actual value)
0…10V DC, Imax = 5 mA
Equivalent to 0…300 °C or 0…500°C
Terminals 10+11
START with contact
Switching threshold: 3.5VDC, U
max
Terminals 12+14
= 90A (per heatsealing band: I
=70A
sec min
sec min
= 5VDC, I
=30A
=20A
max
=5mA
max
=45A)
FOOT SWITCH
Switching threshold: 3.5VDC, U
with contact
Terminals 12+13
Relay K1
Terminals 19, 20, 21
Solenoid drive output
(optional, instead of
Changeover contact, potential-free, U
Interference suppression with 47nF / 560ohms for each terminal
U
= 30VAC (supply voltage at terminals 17+18)
max
=2A
I
max
K1)
Terminals 15, 16, 17,
18
Load cell interface
Terminals 22, 23, 24,
For load cells with 2 mV/V, R
min
Supply voltage (terminals 22+25): U
25
Page 8 RES-430
= 5VDC, I
max
= 240VAC/100 VDC, I
max
= 165ohms
=5VDC
VCC
max
=5mA
max
=1.5A
Technical data
Temperature sensor
Terminals 26+27
Display LC display (green), 4 lines, 20 characters
Ambient temperature +5…+45°C
Degree of protection Motherboard:
Installation Motherboard:
Weight Motherboard: Approx. 0.5 kg (incl. connector plug-in parts)
Housing material
Display terminal
Measuring range: 0…+80°C,
For connecting a Philips Type KTY-81-121 temperature sensor
IP00
Display terminal:
Front: IP42 (IP65 with transparent front cover, Art No. 887000)
Back: IP20
6 fixing holes (diameter: 3.2 mm) for screw mounting
Display terminal:
Installed in front panel cutout with (W x H) 138
Fastened with clamps
Display terminal: Approx. 0.4 kg
Black plastic, type Noryl SE1 GFN2
(+-0.2)
x68
(+-0.2)
mm
Connecting cables
Type / cross-sections
Terminals 4…9: Rigid or flexible; 0.2…4.0 mm² (AWG 24…10)
with screw terminals
Terminals 1…3, 10…27: Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
with plug-in connections
If ferrules are used, they must be crimped in accordance
!
with DIN 46228 and IEC/EN 60947-1.
This is essential for proper electrical contact in the terminals.
RES-430 Page 9
7 Dimensions / front panel cutout
7.1 Motherboard
210.0
Dimensions / front panel cutout
110.0
3.0 3.0
Diameter: 3.2mm
(optional data
interface)
ConnectorPiggyback module6 x fixing hole
for T-430 terminal
105.0
3.03.0
Specified component heights
for connectors, incl.
plug-in parts
Spacing bolts with a minimum length of 6mm
!
must be used to fasten the printed circuit
board on the underside. All national and
international regulations must be complied with.
Page 10 RES-430
Dimensions / front panel cutout
7.2 Display terminal
144
Panel cutout
72
138 x 68
Rubber seal Mounting clamp
Front frame
Front panel Connecting cable (length: 250mm)
9
58
±0.2 ±0.2
66
4
Outline dimensions
of front frame
Connector
144
136
RES-430 Page 11
8 Installation
Installation
ª See also section 2 „Application“ on page 4.
Installation and startup may only be
!
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON
temperature controller RES-430:
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 47 Hz to 63Hz.
3. Install the motherboard in the machine frame using
the fixing screws.
4. Install the display terminal in the front panel cutout.
It is fastened by means of two clamps which snap
onto the side of the controller housing.
5. Wire the system in accordance with the instructions
in section 6 „Technical data“ on page 8, section 8.4
„Wiring diagram with relay K1 (standard)“ on
page 14 and the ROPEX Application Report. The
information provided in section 8.2 „Installation
steps“ on page 12 must be heeded additionally.
8.2 Installation steps
The following points should be heeded in addition to the
information provided in the ROPEX Application Report
when installing the RES-430:
Wiring/cable cross-sections:
• Use the cable cross-sections indicated in the
ROPEX Application Report. The cables between
the RES-430 motherboard and the heatsealing
band must not be longer than 1m.
• Connect the heatsealing band directly to the RES-
430. Additional clamping points can cause contact
resistances, leading to temperature control errors.
The connecting cables between the
!
motherboard and the heatsealing band must
not be laid through closed steel sheets or pipes, in
order to avoid temperature control errors. The
permissible pipe and sheet materials are aluminum
and plastic.
Impulse transformer:
• Specification as indicated in the ROPEX Application
Report.
Heatsealing band/sealing bar:
• Use a heatsealing band with a suitable (positive)
temperature coefficient.
• Copper the ends of the heatsealing band to prevent
them from overheating.
Check the tightness of all the system
!
connections, including the terminals for the
impulse transformer windings.
6. Make sure that the wiring conforms to the relevant
national and international installation regulations.
Page 12 RES-430
• Push-on connectors on the sealing bar can lead to
loose contacts. Use cables with screw connections.
Installation
8.3 Power supply
L1
N (L2)
GND/
Earth
ON
OFF
(L1)
LINE
Ka
Short
wires
Short
wires
K1
I
>
3
LINE
FILTER
U
1
PRIM.
U
2
SEC.
ROPEX
temperature
controller
Line
115VAC, 230 VAC
Circuit breaker
Double-pole, Z characteristic,
Rated current: 16 A, e.g. ABB-STOTZ, Type S282-Z16 (for
I
>
1
2
all applications)
Short-circuit protection only. RESISTRON
!
temperature 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
(ª ROPEX Application Report).
Do not lay the filter supply wires (line side) parallel
!
to the filter output wires (load side).
Impulse transformer
Designed according to VDE 0570/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
determined individually according to the application
(ª ROPEX Application Report and "Accessories" leaflet
for impulse transformers).
RES-430 RESISTRON temperature controller
Short
wires
2
R
Wiring
The wire cross-sections depend on the application
(ª ROPEX Application Report).
Guide values:
Primary circuit: min. 1.0mm², max. 2.5 mm²
Secondary circuit: min. 2.5 mm², max. 4.0mm²
cde Twisting (>20/m) is recommended to
improve EMC.
RES-430 Page 13
8.4 Wiring diagram with relay K1 (standard)
Installation
GND/
Earth
LINE
A16F
Fuse
A16F
Main switch
START
FOOT SWITCH
ANALOG
OUTPUT
(ACTUAL
temperature
of heatsealing
band)
+0...10VDC
Impulse
transformer
1
2
3
12
14
13
10
11
21
19
20
2x 47nF/560R
15
16
RES-430
K1
17
18
22
23
Load cell
interface
and
24
25
temperature
sensor
26
27
IMPORTANT:
If only ONE heatsealing band is used,
output terminals 7+8 must be jumped
with a high current cable in order to
avoid malfunctions or damage of the
controller. Step 240 in the Configuration
menu must be set to “Double” for this
purpose.
44556677889
Band 1
Band 2
9
Heatsealing band
Page 14 RES-430
Installation
8.5 Wiring diagram with solenoid drive (optional)
GND/
Earth
LINE
A16F
Fuse
A16F
Main switch
START
FOOT SWITCH
ANALOG
OUTPUT
(ACTUAL
temperature
of heatsealing
band)
+0...10VDC
Impulse
transformer
Solenoid
Line
12
14
13
10
11
21
19
20
15
16
17
18
22
1
2
RES-430
3
~~+
-
23
Load cell
interface
and
24
25
temperature
sensor
26
27
IMPORTANT:
If only ONE heatsealing band is used,
output terminals 7+8 must be jumped
with a high current cable in order to
avoid malfunctions or damage of the
controller. Step 240 in the Configuration
menu must be set to “Double” for this
purpose.
44556677889
Band 1
Band 2
9
Heatsealing band
RES-430 Page 15
Loading...