Ropex Resistron RES-242, Resistron RES-241 User Manual

09.02

RESISTRONRESISTRON

RES-241RES-241

without Alarm

ROPE X

ROPE X

INDUSTRIE

TEMPERATURE CONTROLLER
FOR HEATSEAL BANDS
TO SEAL PLASTIC FILMS

-

ELEKTRONIK

FEATURES

Designed for Easy Mounting on the Control Panel
Analog Temperature Meter
Integrated Heat Sealing and Cooling Programs
Numerous Programming Functions
Easy Installation and Operation
Built in Timers
Preferred for General Applications

TABLE OF CONTENTS

1. APPLICATION AND SHORT DESCRIPTION

2. FUNCTIONS OF THE RES-241/242

2.1 Control Function

RES-242RES-242

with Alarm

4. PROGRAMMING OF THE TIMING FUNCTIONS

5. EXAMPLE

6. WIRING DIAGRAM

2.2 Zero Calibration

2.3 Start-Function

2.4 Cycle Timing

2.5 Alarm Function

2.5.1 Alarm Signal

2.5.2 Reset

3. CONTROLS AND INDICATORS

Industrie - Elektronik GmbH.Gansäcker 21.D-74321 Bietigheim-Bissingen

ROPE X

ROPE X

Telefon [phone].Telefax (07142) 7776-19

7. OPERATING INSTRUCTIONS

8. HEATSEAL ELEMENT

9. HEATING IMPULSE, TIMING

10. OUTLINE DIMENSIONS

11. SPECIFICATIONS

12. GENERAL INSTALLATION INSTRUCTIONS

.

ROPE X

ROPE X

1. APPLICATION AND SHORT DESCRIPTION

Page 2

As all other , this unit is used to control
the temperature of heating elements (heatseal bands,
beaded bands, cutting wires, etc.) by monitoring the
resistivity of the heating elements. Precision
measurement together with high response produces
perfect temperature control during the film sealing
processes. With a correctly installed system, the
temperature is controlledwithan accuracy of±3%.
By changing settings, this controller can be used to
control heating elements with a range ofresistances from
a few milliohmsto several ohms. Therefore, this universal
controller may be used in a variety ofgeneral applications
for controlling theheatseal elements in:

vertical and horizontalf/f/s machines
pouch filling andsealing machines
film wrapping machines
pouch making machines
group packaging machines,etc.

The controller, have all the known
functions of the RES-200 series, plus two digital timers,
sealing time and cooling time. This eliminates additional
external usage of timers to control heat impulse timing
and jaw action.
This additional feature makes the controller very suitable
for use in:

RES controllers

RES-241 / 242,

As shown in Section 5, a complete sealing station can be
controlled with this controller without using additional
electrical components.
All parameters related to the sealing phase, like time and
temperature, can easily be selected by use of the digital
switches on thefront panel of theunit.
The desired values are entered according to the
appropriate units, i.e. and/or .
Numerous functional sequences can be programmed
with the dip switches mounted on side of the controller.
This allows the user to select the best program for any
specific heatsealing process.

Processes that are primarily temperature dependent can
be programmed, e.g. closing of the jaw only after full
sealing temperature has been reached; or opening of the
jaws only after the cooling to a pre-determined
temperature has beenreached.
(see Section 4:Timing Functions Programming).

The cycle sequence can beobserved during operation by
means of the analog temperature meter and the LED´s
for heating andcooling.

°C sec

hand operated andtable top machines
heatsealing sealing presses
L-sealers

2. FUNCTIONS OF THE RES-241 / 242

2.1

The controller operates in two different modes: monito­ring or controlling.
If there is , the controller will only
monitor the resistance of the heating element without
raising the temperature. Resistance monitoring is
accomplished by means of short low power pulses every
10 cycles of the line frequency. It is in this mode that the
"Z" calibration is performed. In the monitoring mode, the
"ON" LED blinks red. When a START signal is applied,
LED "ON" becomessteady state red.

no START signal

CONTROL FUNCTIONS

Both the and controllers are identical
with the exception ofthe "alarmfunction" that is contained
only in theModel RES-242.

The controller then goes into the regulating mode and
increases the temperature of the heating element to the
desired set point as rapidlyas possible.
The maximum secondary voltage is initially supplied to
the heating element and then subsequently reduced by
the phase control as the preset maximum temperature is
approached.
A high sampling rate together with virtually instant
feedback gives the controller an instantaneous response
capability.

RES-241 RES-242

ROPE X

ROPE X

INDUSTRIE - ELEKTRONIK GmbH

ROPE X

ROPE X

Page 3

Control Function (Continuation)

Current

Temp.

Start

full

heat current

20°C

OFF

sampling sampling

regulating mode

set point

reduced

heat current

ON

OFF

temperature display

controller

actual

temperature

sampling

pulses

Start

2.2

ZERO calibration is the adjustmentof thecontroller tothe
resistance of thecold heatseal element.
This calibration must be performed with the heatseal
band at room temperature. The hand of the analog
temperature meter is set to "Z" by turning the "ZERO"
adjustment trimmer with the heatseal element at ambient
temperature and the controller in the monitoring mode.
("Z" = 20°C/68°F). After calibration the hand should rest
quietly at "Z".

2.3

A heating cycle is initiated with the start function. The
controller then switches from the monitoring mode to the
regulating mode, and concurrently starts the timing
cycles. The START signal can be given in three different
ways:

by pressing "HAND"on the front panel
by closing thecircuit between terminals 2 and 7,
with potential freecontact.
by supplying 24VDCto Terminals 3 and 4

A feature prevents the overheating of the

"START-Lock"

heating element when the controller is improperly
calibrated, set belowthe "Z" point.
Should this occur, the RES-241 controller will not accept
the START signal, while the RES-242 will go into "ALARM"
and shut down.

ZERO CALIBRATION

START-FUNCTION

Proper operation depends upon the accurate calibra-tion
of the system. Because the resistance of the heatseal
element may very depending upon its precise length and
cross-section, the calibration ("Z" point) must be checked
and reset after each change or replacement of the
heatseal element.
(see Sect. 8, "Heatseal Element" and Sect. 7, "Operating
Instructions")

NOTE - When using new heating elements:

After a few temperature cycles the resistance of the
element will be reduced, the calibration may no longer be
correct. When this occurs, allow the heating element to
return to ambient temperature and reset the meter to "Z"
by using theZero Trimmer.

START ENABLE

when needle is
below zero

Mechanical zero adjustment. Do not move!

Z

0

100 200

300

°C

ROPE X

ROPE X

INDUSTRIE - ELEKTRONIK GmbH

ROPE X

ROPE X

Page 4

Functions of the RES-241/242 (Continuation)

2.4

Heating and cooling cycle time follow each other.
Depending upon the program selected by use of the DIP
switch, the either starts with the "START"
signal or when the heating element reaches the pre-set
temperature.
(see Section 4"Timing Functions Programming").
The always starts at the end of the
heating cycle. The maximum time duration for heating or
cooling is 9.9 seconds. Depending upon the program
selected, the duration of the cooling cycle may be set to

heating time

cooling cycle time

2.5

2.5.1

To increase the reliability of operation and to assure
adequate seals, the RES-242 controller contains a
comprehensive monitoring system that will send an
alarm signal (LED "ALARM" will turn red) and activate the
alarm relay when:

CYCLING TIMING

ALARM FUNCTION (RES-242 only)

ALARM SIGNAL

be a funtionof time or temperature.The cooling cycle may
be setto end when a pre-set temperature is reached, that
means that the relayK1 will drop out when the temperatu­re drops below the pre-select level. The selection is done
by means of the 2 position digital selector switch in °C x 10
in increments of10 degrees.

EXAMPLE:

To assure a trouble free "ZERO" calibration, functions e)
and f) willonly activate after thestart signal is given.

Other reasons foran ALARM signal are:

Selection 08 = 80 °C
Selection 12 = 120 °C

a) the heatseal elementbreaks, or any discontinuityin

the secondary circuitoccurs.

b) ONE of theheatseal elements breaks whentwo

bands are mountedparallel.

c) A short circuitoccurs at the heatsealelement

d) Any discontinuity occursin the monitoring wiringof

the heatseal elementor the current transformer.

e) Any overheating ofthe heatseal element by20%

above the controller´soperating temperature range

f) "Z" point isincorrectly set.

(see "START Function" and "StartBlock")

2.5.2

The controller can be reset - after the cause of the alarm
has beencorrected - by pushing the "RESET" button or
by turning offthe main power byat least 1 second.

RESET

incorrect programming of DIP switchesin the
for U voltage selection.

2

improper position ofthe frequency jumper.

improper power supplyvoltage.

internal malfunction.

In the case of an alarm, the LED "ALARM" will turn red, the
controller output will be disabled, and the ALARM relay
will close betweenterminals 5 and 6.

Taste "RESET" oder Abschalten der Netzspannung
für mind. 1 sec und Wiedereinschalten.

ROPE X

ROPE X

INDUSTRIE - ELEKTRONIK GmbH

ROPE X

ROPE X

3. CONTROLS AND INDICATORS

Page 5

Preset Temperature

Digital Switch in °C

max.299°C

DIP Switches

ON

12345 678910

for Programming of

Sealing Process

14

DIP Switch

to select U

3

2

15

Temperature Meter

in °C

"Z" pt. is at 20 °C

1

LED RED for

Sealing Time

8

Select Sealing

Time

in sec x 0,1

9

11

LED GREEN for

Cooling Time

10

Select Cooling

Time

in Sec. x 0,1.

max.9,9sec

or depending upon

the DIP switch

programming

Select Cooling

13

Jumper for

Frequency Selection

2

7

6

4

5

12

10 Turn "ZERO" Trimmer

for

setting Calibration to "Z"

LED is RED when

on RES-242 only

START "HAND" BUTTON
will start controller with a

full timing cycle

ROPE X

ROPE X

LED RED, blinks in

monitoring mode,

remains when

controller starts

(heating cycle)

LED YELLOW

Indicates status of

K1 Output Relay;
ON when relay is

closed

INDUSTRIE - ELEKTRONIK GmbH