Toss ROPEX RESISTRON RES-403 Operating Instructions Manual

RESISTRON
GB
RES-403
Operating
Instructions
Important features
Automatic zero calibration (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
Large current and voltage range
Set point selection with potentiometer
0…10VDC analog output for ACTUAL temperature
Activated with contact or 24VDC signal
Alarm function with fault diagnosis
Heatsealing band alloy and temperature range selectable
26.6.06
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 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 7
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Installation procedure . . . . . . . . . . . . 11
8.2 Installation steps . . . . . . . . . . . . . . . . 12
8.3 Power supply . . . . . . . . . . . . . . . . . . . 13
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 14
8.5 Current transformer PEX-W3 . . . . . . 14
8.6 Wiring diagram (Standard) . . . . . . . . 15
8.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 16
8.8 Wiring diagram with "Temp­erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46) . . . . 17
8.9 Startup and operation . . . . . . . . . . . . 18
8.10 View of the controller . . . . . . . . . . . . . 18
8.11 Controller configuration . . . . . . . . . . . 18
8.12 Replacing and "burning in" the heat-
sealing band . . . . . . . . . . . . . . . . . . . 20
8.13 Startup procedure . . . . . . . . . . . . . . . 21
9 Controller functions . . . . . . . . . . . . . . . . . 23
9.1 Indicators and controls . . . . . . . . . . . 23
9.2 Temperature setting
(set point selection) . . . . . . . . . . . . . . 24
9.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 25
9.4 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 26
9.5 "START" signal (HEAT) . . . . . . . . . . . 27
9.6 Measuring impulse duration
(as of October 2005) . . . . . . . . . . . . . 28
9.7 Automatic phase angle compensation (AUTOCOMP)
(as of October 2005) . . . . . . . . . . . . . 28
9.8 Temperature diagnosis
(as of October 2005) . . . . . . . . . . . . . 29
9.9 Heatup timeout
(as of October 2005) . . . . . . . . . . . . . 29
9.10 Diagnostic interface/visualization software
(as of October 2005) . . . . . . . . . . . . . 30
9.11 System monitoring/alarm output . . . . 30
9.12 Error messages . . . . . . . . . . . . . . . . . 31
9.13 Fault areas and causes . . . . . . . . . . . 36
10 Factory settings . . . . . . . . . . . . . . . . . . . . . 37
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 38
12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 39
13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Page 2 RES-403
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 a too low
!
temperature coefficient and incorrect coding of the RESISTRON temperature controller lead to uncontrolled heating and ultimately to burn-out of the heatsealing band!
The heatsealing bands that were originally supplied must be identified by detail specification, part number or some other means that will assure that 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 bobin. 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-403 Page 3

1.4 Current transformer PEX-W2/-W3

The current transformer supplied with the RESISTRON temperature controller is an integral part of the control system.
Only the original ROPEX PEX-W2 or PEX-W3
!
current transformer may be used. Other transformers may cause the equipment to malfunction.
The current transformer may only be operated if it is connected to the RESISTRON temperature controller correctly (see section 9, "Startup and operation"). The relevant safety instructions contained in section 8.3, "Power supply", must be obeyed. External monitoring modules can be used in order to additionally increase
Application
operating safety. They are not included in the scope of supply of the standard control system and are described in a separate document.

1.5 Line filter

The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions mentioned in section 1.7 "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.

1.6 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 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.

1.7 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
EN 50081-1 EMC interference emissions
EN 50082-2 EMC interference immunity:
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.
Safety provisions for electrical measuring, control and laboratory devices (low voltage directive). Overvoltage category III, pollution severity 2, safety class II.
(machinery directive)
according to EN 55011, group 1, class B
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.
Page 4 RES-403
The controller is most commonly used for impulse­heatsealing PE films in:
Vertical and horizontal f/f/s machines
Pouch, filling and sealing machines
Film wrapping machines
Pouch-making machines
Group packaging machines
•etc.
Principle of operation
The use of RESISTRON temperature controllers results in:
Repeatable quality of the heatseals under any con­ditions

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 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 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. 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
Increased machine capacity
Extended life of the heatsealing bands and teflon coatings
Simple operation and control of the sealing process
to the required dynamic range despite the exceptionally compact dimensions 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 and interrelated.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Heatsealing band R = f (T)
U
2
sec.
Impulse transformer
Current transformer
U
1
prim.
RESISTRON controller
URI
R
R=f(T)
LINE
_
+
Actual value
Start
Set point
RES-403 Page 5
Indicators
and
controls
or
bus interface

4 Description of the controller

Description of the controller
The microprocessor technology endows the RESIS­TRON temperature controller RES-403 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: The AUTORANGE function (as of October 2005) covers a secondary voltage range from 0.4V to 120V and a current range from 30 A to 500A.
Automatic adjustment to the line frequency in the range from 47 Hz…63Hz.
Increased protection against dangerous conditions, such as overheating of the heatsealing band.
The ACTUAL temperature of the heatsealing band is supplied to an analog 0…10VDC output. The real heat­sealing band temperature can thus be displayed on an external temperature indicator (e.g. ATR-x). The RESISTRON temperature controller RES-403 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. To increase operational safety and interference immu­nity, all 24 VDC logic signals are electrically isolated from the controller and the heating circuit. Coding switches on the temperature controller itself can be used to adapt to different heatsealing band alloys (Alloy-20, NOREX etc.) and set to the required temperature range (0…300°C, 0…500 °C etc.). The compact design of the RESISTRON temperature controller RES-403 and the plug-in connections make this controller easy to install.

5 Accessories and modifications

A wide range of compatible accessories and peripheral devices are available for the RESISTRON temperature controller RES-403. They allow it to be optimally adapted to your specific heatsealing application and to your plant's design and operating philosophy.
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail). Analog indication of the ACTUAL temperature of the heatsealing band in °C. The meter damping of the unit is optimized for the abrupt temperature changes that occur in impulse mode.
Digital temperature meter DTR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail). Digital indication of the ACTUAL temperature of the heatsealing band in °C, with HOLD function.
Set point potentiometer PD-x
Front panel mounting version for setting the required SET heatsealing temperature of the RESISTRON temperature controller. The number which appears on the dis­play corresponds to the SET heatsealing temperature in °C.

5.1 Accessories

The products described below are only a few of the wide range of accessories available for RESISTRON temperature controllers (ª"Accessories" leaflet).
Page 6 RES-403
Accessories and modifications
Line filter
Essential in order to ensure CE conformity. Optimized for the RESISTRON temperature controller.
Impulse transformer
Designed according to VDE 0570/EN 61558 with a one section bobbin. Optimized for impulse operation with RESISTRON temperature controllers. Specified according to the heatsealing application (ª ROPEX Application Report).
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter­face (DIAG) to the PC (USB port). Associated PC visualization software for dis­playing setting and configuration data, and for recording SET and ACTUAL tempe­ratures in real time.
Booster
External switching amplifier, necessary for high primary currents (continuous current > 5 A, pulsed current > 25 A).
Monitoring current transformer
For detecting frame short-circuits on the heatsealing band. Used as an alternative to the standard PEX-W2 current transformer.

5.2 Modifications (MODs)

Owing to its universal design, the RESISTRON tempe­rature controller RES-403 is suitable for a very wide range of heatsealing applications. Various modifications (MODs) are available for the RESISTRON temperature controller RES-403 for implementing special applications. The modifications described here are just a few of the large number available. Separate documents are sup­plied for all modifications.
MOD 01
Amplifier for low secondary voltages
= 0.25…16VAC). This modification is necessary,
(U
R
for example, for very short or low-resistance heat­sealing bands.
MOD 26
Additional terminal for connecting an external switching amplifier (booster). This modification is necessary for high primary currents (continuous current > 5 A, pulsed current > 25A).
RES-403 Page 7
Accessories and modifications
MOD 40
Additional terminal for "Temperature reached" signal. This output signal is activated when the ACTUAL temperature of the heatsealing band exceeds 95 % of the SET heatsealing temperature. It can be used to monitor the process, for example, or to control the closure of the heatsealing bars.
MOD 40 cannot be used in combination with
!
MOD 26 (booster connection) manufactured
prior to September 2005.
MOD 46 (as of October 2005)
Additional terminal for "Temperature OK" signal. If this modification is installed, the RES-403 checks whether the ACTUAL temperature is within a settable tolerance band ("OK" window) on either side of the SET temperature. The lower ( ) and upper
∆ϑ
( ) tolerance band limits are configured in the
upper
factory to -10 K and +10 K. These values can be set independently of one another in the ROPEX visualization software (ª section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30). 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):
∆ϑ
lower
If the actual temperature leaves the tolerance band, the output signal is deactivated again. The output signal then remains deactivated, even if the actual tempera­ture subsequently returns to the tolerance band. It is thus possible to check - as part of the monitoring concept, for instance - whether the output signal is still active at the end of the heatsealing process, in other words whether the actual temperature has remained within the defined tolerance band throughout the entire process. The output signal is not deactivated again until the next "START" signal is activated or until an alarm is signaled.
MOD 46 ("Temperature OK" signal) cannot be
!
used in combination with MOD 40
("Temperature reached" signal).
Set+∆ϑ
Set+∆ϑ
Signal „Temp. OK“
Not conduct.
upper
Set
lower
Conductive
Actual value
Time
Time
Page 8 RES-403
Technical data

6 Technical data

Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35 mm) acc. to DIN EN 50022 Dimensions: 90 x 75 mm; height: 135 mm (incl. terminals)
Line voltage All controllers manufactured as of October 2005:
115VAC version: 110VAC -15 %…120VAC +10% (equivalent to 94…132 VAC) 230VAC version: 220VAC -15 %…240VAC +10% (equivalent to 187…264VAC) 400VAC version: 380VAC -15 %…415VAC +10% (equivalent to 323…456VAC)
All controllers manufactured as of January 2004 up to September 2005: 115VAC version: 115VAC -15 %…120VAC +10% (equivalent to 98…132 VAC) 230VAC version: 230VAC -15 %…240VAC +10% (equivalent to 196…264VAC) 400VAC version: 400VAC -15 %…415VAC +10% (equivalent to 340…456VAC)
All controllers manufactured up to December 2003: 115VAC, 230 VAC or 400VAC, tolerance: +10% / -15 %
depending on version selected (ª section 12 "How to order" on page 39)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band type and temperature range
All controllers manufactured as of October 2005: The temperature range and temperature coefficient settings can also be specified by means of the ROPEX visualization software (ª section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30) in addition to the rotary coding switch (see below):
Temperature range: 200°C, 300 °C, 400 °C or 500°C Temperature coefficient: 400…4000 ppm (variable setting range)
Five different ranges can be set on the controller with a rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy-A20), default Temperature coefficient 780 ppm, 0…300°C (e.g. Alloy L) Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy-A20) Temperature coefficient 780 ppm, 0…500°C (e.g. Alloy L) Temperature coefficient 3500ppm, 0…300 °C (e.g. NOREX)
The settings for a temperature coefficient of 780 ppm are only available on control­lers manufactured as of October 2003.
Set point selection
Terminals 16+17
With an external PD-3 or PD-5 precision potentiometer (R = 2kΩ) 0…2k, equivalent to 0…300°C or 0…500 °C
Analog output
(actual value) Terminals 14+15
Digital logic levels
Terminals 8, 12, 13
Digital logic levels „Temp. OK“ signal
(MOD 40)
0…10VDC, Imax = 5 mA Equivalent to 0…300 °C or 0…500°C Accuracy: ±1% add. 50mV
LOW (0V): 0…2 VDC HIGH (24VDC): 12…30 VDC (max. current input 6mA) Reverse polarity-protected
=30VDC
U
max
=50mA
I
max
U
< 2V (saturation voltage)
ON
RES-403 Page 9
Technical data
Alarm relay U
Maximum load
(primary current of
=50VDC, I
max
I
= 5A (duty cycle = 100%)
max
= 25A (duty cycle = 20 %)
I
max
max
= 0.2A, potential-free
impulse transformer)
Power dissipation max. 20W
Ambient
+5…+45°C
temperature
Degree of protection IP20
Installation If several controllers are installed on 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. 0.7 kg (incl. connector plug-in parts)
Housing material Plastic, polycarbonate, UL-90-V0
Connecting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12) Plug-in
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.
Page 10 RES-403
Dimensions

7 Dimensions

135.0
113.0
75.0 90.0

8 Installation

ª See also section 1 "Safety and warning notes" on page 3.
Installation and startup may only be per-
!
formed 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-403:
1. Switch off the line voltage and verify that the circuit
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…63 Hz.
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 6 "Technical data" on page 9 must be allowed between them.
4. Wire the system in accordance with the instructions in section 8.3 "Power supply" on page 13, section 8.6 "Wiring diagram (Standard)" on page 15 and the ROPEX Application Report. The information provided in section 8.2 "Installation steps" on page 12 must also be heeded additionally.
Check the tightness of all the system connec-
!
tions, including the terminals for the impulse
transformer windings.
5. Make sure that the wiring conforms to the relevant national and international installation regulations.
RES-403 Page 11

8.2 Installation steps

Installation
Heatseal element
with coppered ends
Sufficient wire
cross-section
Avoid long
cables
Dimension transformer correctly
- Secondary voltage
- Power
- Duty cycle
F
U (sec.)
2
Heatsealing band R= f (T)
No additional
resistance
in secondary
circuit
A
Impulse
transformer
Use heatseal bands with
suitable temperature coefficient
Note number of turns
Current transformer
U (prim.)
1
20mm clearance if several
controllers installed on
PEX-W2/-W3
Temperature
meter
ATR -x
Note
polarity
one top hat rail
Controller
No push-on connectors
Connect U measuring
heatsealing band ends
Twi sted
Current measuring
R
wires directly to
wires I
R
Line
Line filter
LF-xx480
Note
direction
of rotation
Digital potentiometer PD-x
Configure
DIP switches
correctly
(up to Sept. 2005)
Page 12 RES-403
Installation

8.3 Power supply

L1
(L1)
N(L2)
GND/ Earth
ON
OFF
Short wires
1
LINE
Ka
U
K1
I
2
R
R
I
>
3
LINE
FILTER
ROPEX
temperature
controller
U
1
PRIM.
U
2
SEC.
R
Line
115VAC, 230 VAC, 400VAC
Circuit breaker
Double-pole, C characteristic (ª ROPEX Application Report)
I
>
3
Kb
3
2
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 run the filter supply wires (line side) parallel
!
to the filter output wires (load side).
RESISTRON temperature controller belonging to the 4xx Series.
Relay Kb
Load break (all-pole), e.g. in combination with the alarm output of the temperature controller.
When using a series resistor RV-....-1 the relay Kb
!
shall be installed.
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 deter-
mined individually according to the application (ª ROPEX Application Report and "Accessories" leaflet for impulse transformers).
Wiring
The wire cross-sections depend on the application (ª ROPEX Application Report). Guide values:
Primary circuit: min. 1.5mm², max. 2.5 mm² Secondary circuit: min. 4.0 mm², max. 25 mm²
c These wires must always be twisted (>20/m) d These wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
e Twisting (>20/m) is recommended to improve EMC.
RES-403 Page 13
Installation

8.4 Line filter

To comply with EMC directives – corresponding to EN 50081-1 and EN 50082-2 – RESISTRON control loops must be operated with line filters. These filters damp the reaction of the phase-angle con­trol on the line and protect the controller against line disturbances.
The use of a suitable line filter is part of the
!
standards conformity and a prerequisite of
the CE mark.
ROPEX line filters are specially optimized for use in RESISTRON control loops. Providing that they are
Large cross-section wire to ground
PE
LINE
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. For more technical information: ª "Line filter" docu­mentation.
It is permissible to supply several RESIS-
!
TRON 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 8.3 "Power supply" on page 13 must be observed.
max. 1m
ROPEX
temperature
controller
Do not lay parallel
Large cross-section wire to ground
Large frame contact surface

8.5 Current transformer PEX-W3

The PEX-W3 current transformer supplied with the RESISTRON temperature controller is an integral part
24
23
terminal
wires
60
39
26
14
Mounting plate (galvanized)
of the control system. The current transformer may only be operated if it is connected to the temperature con­troller correctly (ª section 8.3 "Power supply" on page 13).
28
75
12
14
terminal
block
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
Page 14 RES-403
Installation

8.6 Wiring diagram (Standard)

NOTE:
AUTOCAL button also provided on controller
AUTOCAL
with 24VDC signal
ALARM
OUTPUT
max. 50V/0,2A
START (HEAT)
with
24VDC signal
GND 13
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
START (HEAT)
with contact
_
ATR
°C
+
ANALOG
OUTPUT
+0...10VDC
Cable shielded
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
(also with MOD 01)
8
6
5
Contact closed or opened by ALARM (see configuration)
12
18
15
14
16
0V
(Internnal ground)
17
No external
grounding allowed!
RES-403
(Internal ground)
No external
grounding allowed!
until
productions
date
09.05
(Internal ground)
No external
grounding allowed!
0V
0V
1
2
3
4
Impuls
transformer
7
U
R
9
10
11
twisted
I
R
Current transformer
PEX-W2/-W3
Line filter LF-xx480
LINE
U
1
prim.
U
2
sec.
Heat-
R
sealing
band
RES-403 Page 15
8.7 Wiring diagram with booster connection (MOD 26)
Installation
NOTE:
AUTOCAL button also provided on controller
AUTOCAL
with 24VDC signal
ALARM
OUTPUT
max. 50V/0,2A
START (HEAT)
with 24VDC signal
GND 13
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
START (HEAT)
with contact
_
ATR
°C
+
ANALOG
OUTPUT
+0...10VDC
Cable shielded
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
(also with MOD 01)
8
6
5
Contact closed or opened by ALARM (see configuration)
12
18
15
14
16
0V
(Internnal ground)
17
No external
grounding allowed!
RES-403
(Internal ground)
No external
grounding allowed!
until
productions
date
09.05
(Internal ground)
No external
grounding allowed!
0V
0V
1
2
Booster
20
IN OUT
19
NC
3
NC
4
7
U
R
9
10
I
R
11
Current transformer
13
24
Impuls
transformer
twisted
PEX-W2/-W3
Line filter LF-xx480
LINE
U
1
prim.
U
2
sec.
Heat-
R
sealing
band
Page 16 RES-403
Installation
A
1
2
3
4
Additional terminals in housing cover for MOD 26 (Booster connection)
ALARM
HEAT
OUTPUT
UTOCAL
BOOSTER
MOD 26 cannot be used in combination with
!
MOD 40 ("Temperature OK" signal)
manufactured up to September 2005.
19 20
8.8 Wiring diagram with "Temp­erature reached" signal (MOD 40) or „Temp. OK“ signal (MOD 46)
+24VDC
+24VDC
RES- 403
+
I
max. 50mA
GND
MOD 40 cannot be used in combination with
! !
MOD 26 (booster connection) manufactured
prior to September 2005.
GND
1
2
3
4
Additional terminals in housing cover for MOD 40 (”Temp. reached” signal) or MOD 46 (”Temp. OK” signal)
MOD 46 cannot be used in combination with MOD 40.
ALARM HEAT OUTPUT AUTOCAL
RES-403 Page 17

8.9 Startup and operation

8.10 View of the controller

Terminals
Wiring diagramm
Installation
LEDs
Button for AUTOCAL function
Nameplate

8.11 Controller configuration

The controller must be switched off in order
!
to configure the coding switches and plug-in
jumpers.
8.11.1 Configuration of the DIP switches
for secondary voltage and current
Automatic configuration (AUTORANGE) (as of October 2005)
The secondary voltage and current ranges are automatically configured by the automatic calibration function (AUTOCAL). The voltage is configured in the range from 0.4 VAC to 120VAC and the current in the
Coding switches and plug-in jumpers
range from 30 A to 500A. If the voltage and/or the current is outside the permissible range, a detailed error message appears on the controller (ª see section 9.12 "Error messages" on page 31).
Configuration with coding switches (up to September 2005)
Set the DIP switches for matching the secondary voltage U position for your application.
!
Report calculated for your particular application.
and the secondary current I2 to the correct
2
You can find the exact configuration of the DIP switches in the ROPEX Application
Page 18 RES-403
Installation
F
F
O
1-10
)
V
2
ON
U (
3 4
SWITCH
5 4 3 2 1
F F
O
N O
O
2
1
N
U
2
1...10V
3
6...60V
20...120V
If the secondary current I2 is less than 30A, the PEX-W2 or PEX-W3 current transformer must have two turns (ª ROPEX Application Report).
2x
Factory settings
4
5
DIP switch DIP switch
12
OFF
ON
OFF
OFF
ON
OFF
3
OFF
OFF
ON
I
2
30...100A
60...200A
120...400A
4
OFF
ON
ON
5
OFF
OFF
ON
8.11.2 Configuration of the rotary coding
switch for the temperature range and alloy
Switch
position
0 1 4 5 8
9 PC-CONFIGURATION
0 = Factory settings
The settings for a temperature coefficient of
!
780ppm (switch position 1 and 5) are only available on controllers manufactured as of October 2003.
Te mp .
range
300°C 300°C 500°C 500°C 300°C
Te mp .
coefficient
1100ppm/K 780ppm/K 1100ppm/K 780ppm/K 3500ppm/K
Band
alloy
e.g. Alloy-20 e.g. Alloy L e.g. Alloy-20 e.g. Alloy L e.g. NOREX
0
1
9
2
8
3
7
4
6
5
0 1 4 5 8
9
TEMP. RANGE
300°C 300°C 500°C 500°C 300°C
PC CONFIGURATION
SWITCH POS.
0
1
9
2
8
3
7
4
6
5
ALLOY
1100ppm/K
780ppm/K
1100ppm/K (A20)
780ppm/K
3500ppm/K
(A20)
(L)
(L)
(NOREX)
If the switch is set to "9" (as of October 2005), more temperature ranges and alloys can be selected by means of the ROPEX visualization software (ª see section 9.10 "Diagnostic interface/visualization soft­ware (as of October 2005)" on page 30).
RES-403 Page 19

8.11.3 Configuration of the alarm relay

Installation
Alarm relay contact opened by alarm/ PC-CONFIGURATION.
Alarm relay contact closed by alarm. (factory setting)
If the plug-jumper is not inserted - or if it is
!
incorrectly inserted - an error message appears when the controller is switched on (ªªªª section 9.12 "Error messages" on page 31).
If the "Alarm output opened by alarm/PC CONFIGURA­TION" position is selected (as of October 2005), the behavior of the alarm output can be configured in more detail by means of the ROPEX visualization software (ª see section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30).
8.12 Replacing and "burning in" the
heatsealing band

8.12.1 "Burning in" the heatsealing band

The heatsealing band is a key component in the control loop, since it is both a heating element and a sensor. The geometry of the heatsealing band is too complex to be discussed at length here. We shall therefore only refer to a few of the most important physical and elec­trical properties: The measuring principle applied for this system neces­sitates a heatsealing band alloy with a suitable tempe-
DE-ENERGIZED / PC AT ALARM ENERGIZED
0
1
9
2
8
3
7
4
6
5
CONFIGURATION ALARM OUTPUT
rature coefficient 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 first glance slight resistance change results in a zero point error of 20…30°C. The zero point must therefore be corrected after a few heating cycles, i.e. the AUTOCAL function must be repeated. The burn-in effect described here does not occur if the heatsealing band has already been thermally pret­reated by the manufacturer.
An overheated or burned-out heatsealing
!
band must no longer be used because the
TCR has been altered irreversibly.
One very important design feature is the copper or silver-plating of the heatsealing band ends. Cold ends allow the temperature to be controlled accurately and increase the life of the teflon coating and the heat­sealing band.
Page 20 RES-403
Installation

8.12.2 Replacing the heatsealing band

All power supply leads must be disconnected from the RESISTRON temperature controller in order to replace the heatsealing band.
The heatsealing band must be replaced in
!
accordance with the instructions provided by the manufacturer.
Each time the heatsealing band is replaced, the zero point must be calibrated with the AUTOCAL function while the band is still cold, in order to compensate pro­duction-related resistance tolerances. The burn-in pro­cedure described above should be performed for all new heatsealing bands.

8.13 Startup procedure

Please also refer to section 1 "Safety and warning notes" on page 3 and section 2 "Application" on page 4.
powered up correctly.
As of SW-Revision 106:
!
If the red "ALARM" LED lights up for 0.3s in addition to the yellow "AUTOCAL" LED when the voltage is switched on, the configuration of this controller has been changed in the visualization software (ªªªª section 9.10 "Diagnostic interface/ visualization software (as of October 2005)" on page 30). In order to avoid malfunctions, please check the controller configuration before continuing the startup procedure.
7. One of the following states then appears:
"ALARM"
LED
OFF Short pulses
BLINKS fast (4Hz)
"OUTPUT"
LED
every 1.2 s
OFF Go to 7
ACTION
Go to 7
Installation and startup may only be per-
!
formed by technically trained, skilled per­sons who are familiar with the associated risks and warranty provisions.

8.13.1 Initial startup

Prerequisites: The controller must be correctly installed and connected (ª section 8 "Installation" on page 11). Proceed as follows to start up the controller for the first time:
1. Switch off the line voltage and verify 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…63 Hz.
3. In the case of controllers manufactured up to Sep-
tember 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 8.11 "Controller configuration" on page 18).
4. Make sure that no START signal is activated.
5. Switch on the line voltage.
6. When the voltage is switched on, the yellow
"AUTOCAL" LED lights up for approximately 0.3 seconds to indicate that the controller is being
Lit Continuously
Activate the AUTOCAL function while the heat­sealing band is still cold (either with the manual button on the controller or by applying an external signal to terminals 8+13). The yellow "AUTOCAL" LED lights up the duration of the calibration process (approx. 10…15 s). A voltage of app. 0VDC appears at the same time at the actual value output (termi­nals 14+15). If an ATR-x is connected, it indicates 0…3°C. When the zero point has been calibrated, the "AUTOCAL" LED goes out and a voltage of
0.66VDC (300 °C range) or 0.4VDC (500 °C range) appears at the actual value output instead. If an ATR-x is connected, it must be set to "Z". If the zero point has not been calibrated suc­cessfully, the red "ALARM" LED blinks slowly (1Hz). In this case the controller configuration is incorrect (ª section 8.11 "Controller configuration" on page 18 and ROPEX Application Report). Repeat the calibration after the controller has been confi­gured correctly.
8. When the zero point has been calibrated suc­cessfully, set a defined temperature on the set point potentiometer and activate the "START" signal (HEAT). The "HEAT" LED then lights up. The hea­ting and control process can be observed at the
OFF Fault diagnosis
(ª sec. 9.12)
RES-403 Page 21
Installation
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 would indicate that the U have been wired incorrectly. If an error code is displayed, please proceed as des­cribed in section 9.12 "Error messages" on page 31.
9. Burn in the heatsealing band (ª section 8.12
"Replacing and "burning in" the heatsealing band" on page 20) and repeat the AUTOCAL function.
measuring wires
R
The controller is now
ready
8.13.2 Restart after replacing the heat-
sealing band
To replace the heatsealing band, proceed as described in section 8.12 "Replacing and "burning in" the heat­sealing band" on page 20.
Always use a heatsealing band with the cor-
!
rect alloy, dimensions and copper-plating in
order to avoid malfunctions and overheating.
Continue with section 8.13.1 steps 4 to 9.
Page 22 RES-403
Controller functions

9 Controller functions

See also section 8.6 "Wiring diagram (Standard)" on page 15.

9.1 Indicators and controls

Manufactured as of October 2005
1
2
3
ALARM
HEAT
OUTPUT AUTOCAL
4
RESISTRON
RES- 403
Temperature
controller
5 6
7
8
ROPEX
Tel:+49(0) 7142-7776-0
9
1 0
11
Made in Ge rmany
Manufactured up to September 2005
1
AUTOCAL
2
12 13 14 1516 17 18
Red LED, lights up or blinks to indicate ALARM.
Yellow LED, lit during heating phase.
Green LED, indicates pulses in measure-
ment mode. In control mode, luminous
intensity is proportional to heating current.
Yellow LED, remains lit for duration
of AUTOCAL process.
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.
3
4
!
RESISTRON
µP-Controller
ROPEX
INDUSTRIE - ELEKTRONIK
.
5 6
7
8 9
1 0
11
OUTPUT
HEAT
ALARM
12 13 14 1516 17 18
Yellow LED, remains lit for duration
of AUTOCAL process.
Green LED, indicates 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.
RES-403 Page 23
Controller functions
In addition to the functions shown in the diagram above, various controller operating states are indicated
LED Blinks slowly (1 Hz) Blinks fast (4Hz) Lit continuously
RESET active,
AUTOCAL
(yellow)
HEAT
(yellow)
OUTPUT
(green)
ALARM
(red)
START and AUTOCAL
functions are locked
(as of October 2005)
In control mode the luminous intensity is proportional to the heating current.
Configuration error,
AUTOCAL not possible

9.2 Temperature setting (set point selection)

The heatsealing temperature is set by means of a 2 k potentiometer at terminals 16+17. The connecting wires between the controller and the potentiometer must be shielded (ª section 8.6 "Wiring diagram (Standard)" on page 15).
RES-403
Set point selection input
0V
e.g.
Potentiometer P03
digital dial KD
PD-3
with
17
16
Cable shielded
3
1
3
cw
2K
2
1
2
by the LEDs. These states are described in detail in the table below:
AUTOCAL requested, but
function disabled
START requested,
but function disabled
Controller calibrated incor-
rectly, run AUTOCAL
Setting range: 0 Æ 0°C 2kÆ 300°C or 500 °C
(depending on the controller
configuration). The relationship 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. For the termi­nals of the external potentiometer touch voltage protection must be installed. External grounding is not allowed. If this warning is ignored, the con­troller will be damaged by frame currents.
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. 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!
AUTOCAL executing
START executing
Fault, ª section 9.12
Page 24 RES-403
Controller functions
e
V
e

9.3 Temperature indication (actual value output)

The RES-403 supplies an analog 0…10 VDC signal, which is proportional to the real ACTUAL temperature, at terminals 14+15.
RES-403
Actual value output
0...10VDC
Temperature
meter
e.g. ATR-3
R=33Ohm
0V
max. 5mA
14
15
0...10VDC
+
The relationship between the change in the output voltage and the ACTUAL temperature is linear.
°C
T
300
e r
u
270
t a
r
240
e p
210
m e T
180
150
120
20°C
°C
T
500
e r
u
450
t a
r
400
e p
350
m e T
300
90
60
0.66V
"ZERO"
0 - 300°C rang
12345678910
oltage U
VDC
0 - 500°C rang
Voltage values: 0VDC Æ 0°C 10VDC Æ 300°C or 500°C
(depending on the controller configuration)
250
200
150
100
20°C
12345678910
0.4V
"ZERO"
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 indicator (size, scaling, dynamic response) are ideally suited to this application and this instrument should the­refore always be used (ª section 5 "Accessories and modifications" on page 6). It not only facilitates SET-ACTUAL comparisons, but also enables other criteria such as the heating rate, set point reached within the specified time, cooling of the heatsealing band etc. to be evaluated.
Voltage U
VDC
RES-403 Page 25
This indicator moreover permits disturbances in the
A
control loop (loose connections, contacting or wiring problems) as well as any line disturbances to be observed extremely effectively and interpreted accor­dingly. The same applies if mutual interference occurs between several neighboring control loops.
This output is not potential-free and might
!
have the potential of the secondary voltage of the impulse transformer. External grounding is not allowed. If this warning is ignored, the con­troller will be damaged by frame currents. For the terminals of the external temperature meter touch voltage protection must be installed.
24VDC
UTOCAL
max. 6mA
GND
Controller functions
RES- 403
8
13
If an alarm is signaled, the analog output at terminals 14+15 is used to display a selective error message (ª section 9.12 "Error messages" on page 31).
9.4 Automatic zero calibration
(AUTOCAL)
Because of the automatic zero calibration (AUTOCAL) function, there is no need to adjust the zero point manu­ally on the controller. This function matches the con­troller to the current and voltage signals that are pre­sent in the system. The zero point is calibrated in the factory to the initial temperature (ambient temperature, 20°C).
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 (ª section 9.10 "Diagnostic interface/visualization soft­ware (as of October 2005)" on page 30). This setting is remembered if the controller is switched off and then on again. As of SW Revision 107, the "External calibration tem­perature" setting can also be selected in the visualiza­tion software. The initial temperature for this setting can be specified in the +3…+40°C range via the set point potentiometer (terminals 16+17; ª section 9.2 "Tem­perature setting (set point selection)" on page 24). The value selected at the set point potentiometer must be present when the "AUTOCAL" function is activated. If the specified value is too high (greater than 40 °C) or if the selected value varies, an error message appears (error codes 115 and 116; ª section 9.12 "Error mes­sages" on page 31).
HIGH: 12VDC
LOW: 2VDC
The AUTOCAL function is activated either by means of a 24VDC pulse at terminals 8+13 or by pressing the AUTOCAL button on the controller.
The automatic calibration process takes about 10…15 seconds. The heatsealing band is not heated during this process. The yellow LED on the front panel lights up when the AUTOCAL function is active. The actual value output (terminals 14+15) is 0…3°C (corresponds to app. 0 VDC) during this process. If the temperature of the heatsealing band varies on controllers manufactured as of October 2005, the "AUTOCAL" function is executed a maximum of three times. If the function still cannot be terminated successfully, an error message appears (ª section 9.12 "Error messages" on page 31).
AUTOCAL
0,1...5s
Page 26 RES-403
Controller functions
You should always wait for the heatsealing
!
band and the bar to cool down (to ambient temperature) before activating the AUTOCAL function.
Reasons for disabled AUTOCAL function:
1. The AUTOCAL function cannot be activated until
10 seconds after the controller is switched on. If you attempt to activate it sooner, it will not function.
2. The AUTOCAL function is not activated if the heat-
sealing 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. AUTOCAL cannot be activated if error codes
101…103, 201…203, 801 or 9xx (up to September 2005: error codes 1…3, 5…7) occur at start-up. AUTOCAL cannot be activated with error codes 201…203, 801 or 9xx (up to September 2005: error codes 5…7). If the controller has operated correctly, at least one time, after start-up (ª section 9.12 "Error messages" on page 31).
If the AUTOCAL function is disabled and if
!
you attempt to activate it then the "AUTOCAL" LED blinks.

9.5 "START" signal (HEAT)

By means of a 24 VDC signal at terminals 12+13
24VDC
START (HEAT)
max. 6mA
GND
12
RES- 403
13
HIGH: 12VDC
START
(HEAT)
LOW: 2VDC
or
By means of a control contact at terminals 15+18
max. 5mA
18
START (HEAT)
with
contact
15
RES- 403
0V
When the "START" signal is activated, the controller­internal set/actual comparison is enabled and the heat­sealing band is heated up to the SET temperature. It remains at this temperature until the signal is deacti­vated. The "HEAT" LED on the front panel of the RES-403 is lit continuously for the duration of the heating phase. The "START" signal can be activated in two ways:
RES-403 Page 27
The "START" signal is disabled as long as the
!
AUTOCAL function is executing
("AUTOCAL" LED lit, "HEAT" LED blinks).
The terminals 15+18 are not potenial-free and
!
might have the potential of the secondary voltage of the impulse transformer. For the termi­nals of the control contact touch voltage protection must be installed. 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).
Controller functions
The alarm output is switched if the "START" signal is activated while an alarm signal is indicating error codes 104…106, 111…114, 211, 302 or 303 (up to Sep­tember 2005: error codes 8…12) (ª section 9.12 "Error messages" on page 31). The heatsealing band is no longer heated up.

9.6 Measuring impulse duration (as of October 2005)

The length of the measuring impulses generated by the controller can be set with the parameter. It may be necessary to set a measuring impulse that is longer than the default 1.7 ms for certain applications (ª ROPEX Application Report).
This parameter can only be set by means of
!
the ROPEX visualization software
(ª section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30).

9.7 Automatic phase angle compensation (AUTOCOMP) (as of October 2005)

If the interval between the two "AUTOCAL" functions is longer than 2.0 s, "AUTOCAL" is executed normally again the second time.
AUTOCAL signal
24VDC
0
Function
AUTOCAL
0
"AUTOCAL" LED
lit
off
"HEAT" LED
lit
<2.0s
t
AUTOCOMP
t
t
It may be necessary to compensate the phase angle displacement between the U signals for special heatsealing applications (ª ROPEX Application Report). The "AUTOCOMP" function is provided for this purpose. It is executed whenever the "AUTOCAL" function (ª section 9.12 "Error messages" on page 31) is run twice in quick succession. The interval between the end of the first "AUTOCAL" function and the start of the second "AUTOCAL" must be shorter than 2.0 s. The second "AUTOCAL" function only takes around 2.0 s and incorporates the "AUTOCOMP" function.
and IR measuring
R
off
The "HEAT" LED blinks repeatedly when the "AUTO­COMP" function is executed and the actual value output (terminals 17+14) is set to 0…3°C (i.e. app. 0 VDC).
The "AUTOCOMP" function must be
!
activated in the ROPEX visualization
software (ª section 9.10 "Diagnostic interface/ visualization software (as of October 2005)" on page 30) (default setting: AUTOCOMP off).
t
Page 28 RES-403
Controller functions

9.8 Temperature diagnosis (as of October 2005)

An additional temperature diagnosis can be activated in the ROPEX visualization software (ª section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30). The RES-403 checks whether the ACTUAL temperature is within a settable tolerance band ("OK" window) on either side of the SET temperature. The lower ( ) and upper
∆ϑ
( ) tolerance band limits are configured in the
upper
factory to -10 K and +10 K. 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 temperature diagnosis is activated as well. If the ACTUAL temperature leaves the tolerance band, the corresponding error code (307 or 308) is indicated and the alarm relay is switched (ª section 9.12 "Error mes­sages" on page 31).
Set+∆ϑ
Set+∆ϑ
upper
Set
lower
∆ϑ
lower
Actual value
tolerance 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 deactivated, e.g. if the tempera­ture drops temporarily 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 and the delay time are iden­tical to those for the "Temperature OK" signal (MOD 46).
9.9 Heatup timeout
(as of October 2005)
An additional heatup timeout can be activated in the ROPEX visualization software (ª section 9.10 "Dia­gnostic interface/visualization software (as of October
2005)" on page 30). This timeout starts when the START signal is activated. The RES-403 then monitors the time required for the ACTUAL temperature to reach 95% of the SET tempe­rature. If this time is longer than the parameterized time, the corresponding error code (304) is indicated and the alarm relay is switched (ª section 9.12 "Error messages" on page 31).
Time
Alarm
307
If the temperature diagnosis is not activated by the time the "START" signal is deactivated (i.e. if the ACTUAL temperature does not exceed the upper or lower tolerance band limit), the corresponding error code (309, 310) is indicated and the alarm relay is switched. An additional delay time (0…9.9s) can be set in the ROPEX visualization software. The first time the lower
Actual value
Set
95% of Set
Timeout
Time
Heatup time Alarm
304
RES-403 Page 29
Controller functions

9.10 Diagnostic interface/visualization software (as of October 2005)

An interface with a 6-pole Western socket 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 com­munication interface CI-USB-1.
DIAG
0
1
9
2
8
3
7
4
6
5
Only a ROPEX comunication interface is
!
allowed to be connected to the diagnostic interface. Connecting another device (e.g. a telephone cable) could result in malfunctions or damage to the controller.
2. Blinks slowly (1 Hz) The system configuration is incorrect and the zero calibration (AUTOCAL function) was unsuccessful (ª section 8.11 "Controller configuration" on page 18). It corresponds to error codes 110…114 (up to September 2005: error codes 10…12).
3. Lit continuously: This indicates that a fault is preventing the controller from being started (error codes 101…103, 107, 108, 201…203, 307, 308, 801, 9xx; up to September 2005: error codes 1…7). As a rule, it refers to an external wiring fault.
B.) Alarm relay (relay contact terminals 5+6):
This contact is set in the factory as follows:
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 (ª section 8.11.3 "Configuration of the alarm relay" on page 20), these states are reversed.
The ROPEX visualization software is described in a separate document.

9.11 System monitoring/alarm output

To increase operating safety and to avoid faulty heat­sealing, this controller incorporates special hardware and software features that facilitate selective fault detection and diagnosis. Both the external wiring and the internal system are monitored. These features assist the operator in identifying the cause of abnormal operations. A system fault is reported or differentiated by means of the following indications.
A.) Red "ALARM" LED on the controller
three states:
1. Blinks fast (4Hz) The AUTOCAL function should be executed (error codes 104…106, 211, 302, 303; up to September 2005: error codes 8+9).
C.) Error code output via the 010 VDC analog
output (terminals 14+15):
Since a temperature indication is no longer necessary if a fault occurs, the analog output is used to display error messages in the event of an alarm. 13 voltage levels (up to September 2005: 12 voltage levels) are offered for this purpose in the 0…10VDC range, each of which is assigned an error code (ª section 9.12 "Error messages" on page 31). If a state that requires AUTOCAL occurs – or if the con­troller configuration is not correct – (error codes 104…106, 111…114, 211, 302, 303; up to September 2005: error codes 8…12), the signal at the analog output jumps back and forth at 1Hz between the voltage value which corresponds to this error and the end of the scale (10 VDC, i.e. 300°C or 500°C). If the "START" signal is activated in one of these states, the voltage value does not change any more. Selective fault detection and indication can thus be implemented simply and inexpensively using the analog input of a PLC with a corresponding error mes­sage (ª section 9.12 "Error messages" on page 31).
Page 30 RES-403
Controller functions
An alarm can only be reset by switching the
!
controller off and then on again.
Invalid alarm signals may appear when the
!
controller is switched off owing to the unde­fined operating state. This must be taken into account when they are evaluated by the higher­level controller (e.g. a PLC) in order to avoid false alarms.

9.12 Error messages

The table below shows how the analog voltage values correspond with the faults that have occurred. It also describes the fault and the required corrective action. The error messages are listed in two separate tables for controllers "up to September 2005" and "as of October 2005". The block diagram in section 9.13 "Fault areas
and causes" on page 36 permits each fault to be cleared quickly and efficiently. 13 voltage levels 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 (ª section 9.10 "Diagnostic interface/visualization software (as of October 2005)" on page 30) to facilitate troubleshooting.
If the actual value output is evaluated in order
!
to identify an error message - in the higher­level controller, for instance - the tolerance window must be adjusted to prevent it from being incor­rectly interpreted. Please note the tolerances of the actual value output (ªªªª section 6 "Technical data" on page 9).
RES-403 Page 31
Action if machine
already operating,
HS band not chang.
c
Fault area
Fault area e
Fault area dk
Fault area fgh
Controller functions
Check
(loose contact)
Check power supply
Run RESET
Replace controller
Replace controller
Replace controller
Replace controller
Replace controller
plug-in jumper
Action
STATUS
for first time
if machine started
Cause
(factory set.)
of alarm relay
c
Fault area
signal missing
R
I
e
Fault area
signal missing
R
U
d
Fault area
signals missing
R
and I
R
U
fgh
Fault area
Temperature step, down
(loose contact)
Temperature step, up
Temperature too low/high
Replace controller
Int. faut, contr. defective
Check
plug-in jumper
output wrong
Plug-in jumper for alarm
Check
power supply
(ª section 9.8)
Frequency fluctuation,
inadmissible line frequency
Closed
Run RESET
Replace controller
Replace controller
Replace controller
Replace controller
(ª section 9.9)
Heatup time too long
Triac defective
Int. faut, contr. defective
Int. faut, contr. defective
Int. faut, contr. defective
LED
Error messages as of October 2005
Part 1 of 3:
Page 32 RES-403
ALARM
Tem p .
Temp.
Act. value
Error
500°C
300°C
output;
[°C]
[°C]
Voltage [V]
code
33
20
0.66
(101)
1
66
40
1.33
(102)
2
100
60
2.00
(103)
3
(107)
(108)
133
80
2.66
(307)
4
(308)
(309)
Lit
uously
contin-
(310)
(201)
166
100
3.33
(202)
5
(203)
200
120
4.00
(304)
6
(901)
(913)
(914)
233
140
4.66
(915)
7
(916)
(917)
(918)
Controller functions
Action if machine
already operating,
HS band not chang.
fgh
Fault area
---
(loose contact)
Action
STATUS
if machine started
Cause
of alarm relay
ij
for first time
signals incorrect,
R
I
impulse-transformer
incorrect specification of
(factory set.)
of transformer,
Check specification
Fault area
signals
R
incorrect,
and/or I
R
impulse-transformer
incorrect specification of
U
Open
Warning:
impulse-transformer
Temperature too low,
(voltage value
AUTOCAL wasn’t per-
at actual
value output
incorrect specification of
Fault:
Closed
Run AUTOCAL,
signals incorrect,
R
U
Run AUTOCAL
formed, loose contact,
fgh
and/or
(loose contact)
fault area
temperature too high,
formed, loose contact,
ambient temp. fluctuates
then no longer
AUTOCAL wasn’t per-
changes)
Run AUTOCAL
Data error
ambient temp. fluctuates
LED
ALARM
[°C]
Tem p .
500°C
[°C]
Tem p .
300°C
alarm LED blinks; alarm relay is open). When the "START" signal is activated, the warning changes to a fault
output;
Volt. [V]
Act. value
(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is closed.
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
code
Error
¯266«
ª500®
¯160«
ª300®
¯5.33«
ª 10 ®
(104)
(105)
Part 2 of 3: Error messages as of October 2005
RES-403 Page 33
fast
(4Hz)
Blinks
Warning:
¯300«
ª500®
¯180«
ª300®
¯6.00«
ª 10 ®
(106)
8
Lit
Fault:
¯333«
¯200«
¯6.66«
uously
contin-
ª500®
ª300®
ª 10 ®
(302)
¯366«
¯220«
¯7.33«
ª500®
ª300®
ª 10 ®
(303)
¯400«
¯240«
¯8.00«
ª500®
ª300®
ª 10 ®
(211)
9
Controller functions
Action if machine
already operating,
Action
if machine started
Cause
HS band not chang.
for first time
---
j,
Fehlerbereich
signal incorrect,
R
I
Konfiguration prüfen
calibration not possible
---
i,
Fehlerbereich
signal incorrect,
R
U
Konfiguration prüfen
calibration not possible
---
ij,
Fehlerbereich
Konfiguration prüfen
signals incorrect,
R
and I
calibration not possible
R
U
Temperature fluctuates,
Ext. calibration
temperature too high,
calibration not possible
calibration not possible
Ext. calibration
temperature fluctuates
calibration not possible
Part 3 of 3: Error messages as of October 2005
¯366«
¯220«
¯7.33«
(112)
11
ª500®
ª300®
ª 10 ®
Warning:
Open
Warning:
¯400«
¯240«
¯8.00«
STATUS
(factory set.)
of alarm relay
LED
ALARM
[°C]
Temp.
500°C
Tem p .
300°C
alarm LED blinks; alarm relay is open). When the "START" signal is activated, the warning changes to a fault
Act. value
Error
output;
(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is closed).
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
[°C]
Volt. [V]
code
¯333«
¯200«
¯6.66«
ª500®
ª300®
ª 10 ®
(111)
10
Blinks
(113)
12
ª500®
ª300®
ª 10 ®
Fault:
Closed
at actual
(voltage value
Lit
Fault:
(1Hz)
slowly
(114)
value output
contin-
¯433«
¯260«
¯8.66«
(115)
changes)
then no longer
uously
ª500®
ª300®
ª 10 ®
(116)
13
Page 34 RES-403
Controller functions
c
e
dk
fgh
fgh
---
---
---
---
Fault area
Action if machine
already operating,
HS-band not chang.
c
Action
for first time
Fault area
if machine started
Cause
signal missing
R
I
Fault area
Fault area e Fault area
signal missing
R
U
Fault areas
(loose contact)
Fault areas
d
fgh
(loose contact)
Fault areas
signals missing
R
and I U
Temperature step
R
Frequency fluctuation,
Run RESET
Check power supply
Run RESET
Check power supply
Internal fault
inadmissible line frequency
Replace controller
Replace controller
Internal fault,
controller defective
signal
R
and/or I
R
U
Fault areas
j,
Run AUTOCAL
Run AUTOCAL
incorrect
Data error
Fault area
signal incorrect,
R
I
i,
Fault area
check configuration
signal incorrect,
R
U
calibration not possible
ij,
Fault areas
signals incorrect,
R
and I
R
U
check configuration
calibration not possible
check configuration
calibration not possible
signal
¯333«
¯200«
¯6.66«
at analog
(voltage value
Blinks
ª500®
ª300®
ª 10 ®
10
until "START"
does not close
ª500®
ª300®
ª 10 ®
output then
¯365«
¯220«
¯7.33«
slowly
11
no longer
ª500®
ª300®
ª 10 ®
(1Hz)
changes)
¯400«
ª500®
¯240«
ª300®
¯8.00«
ª 10 ®
12
133
80
2.66
4
Lit
Closed
Continuously
166
200
100
120
3.33
4.00
5
6
233
140
4.66
7
STATUS
(factory set.)
of alarm relay
LED
ALARM
Error messages up to September 2005
33
66
40
1.33
2
100
60
2.00
3
Tem p .
Tem p .
Act. value
Error
[°C]
500°C
[°C]
300°C
output ;
Voltage [V]
code
20
0.66
1
¯266«
¯160«
¯5.33«
Open,
fast
(4Hz)
Blinks
¯300«
ª500®
¯180«
ª300®
¯6.00«
ª 10 ®
8
9
RES-403 Page 35

9.13 Fault areas and causes

1229
5
Controller functions
6
3
Temperature
4
8
1
The table below explains the possible fault causes.
Fault area Explanation Possible causes
Load circuit interrupted after U
pickoff point
- Wire break, heatsealing band break
R
- Contact to heatsealing band defective
UR
IR
controller
HARDWARE
8
7
c
PEX-W2/-W3 current transformer signal interrupted
Primary circuit interrupted
measuring wires from current transformer interrupted
- I
R
- Wire break, triac in controller defective
- Primary winding of impulse transformer interrupted
d
Secondary circuit interrupted before U
pickoff point
R
- Wire break
- Secondary winding of impulse transformer interrupted
9
45
I2
8
32
U2
1
7
U
e
f
g
h
i
Page 36 RES-403
signal missing
R
Partial short-circuit (delta R)
Parallel circuit interrupted
Total short-circuit
U
signal incorrect
R
- Measuring wires interrupted
- Heatsealing band partially bypassed by conducting part (clamp, opposite heatsealing bar etc.)
- Wire break, heatsealing band break
- Contact to heatsealing band defective
- Heatsealing band installed incorrectly, insulation at heatsealing bar ends missing or incorrectly installed
- Conducting part bypasses heatsealing band completely
- Up to September 2005: DIP switches 1 - 3 configured incorrectly (U
- As of October 2005: U
from 0.4…120VAC
range)
2
outside permissible range
2
Factory settings
Fault area Explanation Possible causes
- Up to September 2005: DIP switches 4 + 5 configured
j
signal incorrect
I
R
incorrectly (I
- As of October 2005: I
from 30…500A
range)
2
outside permissible range
2
Turns through PEX-W2/-W3 current transformer incorrect
- Check number of turns (two or more turns required for currents < 30 A)
- Hardware fault (replace controller)
k
Internal controller fault
- Plug-in jumper for alarm output not connected or incorrectly connected

10 Factory settings

The RESISTRON temperature controller RES-403 is configured in the factory as follows:
DIP switches
F
O
for secondary voltage
and current I
U
2
2
(up to September
2005)
F
3
2
4
1
O
N
=6…60VAC
U
2
I
=30…100A
2
DIP switches: 2 ON
5
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
Plug-in jumper for alarm relay
Automatic phase angle compensation (AUTOCOMP) [X]
Heatsealing band alloy: Alloy A20 Temperature range: 300°C Maximum temperature: 300°C
SWITCH POS.
0 1
0
1
9
2
8
3
7
4
6
5
4 5 8
300°C
9
Rotary coding switch: "0" position
Cobtact closes by alarm
SWITCH POS.
0 1
0
1
9
2
8
3
7
4
6
5
4 5 8
300°C
9
AUTOCOMP: OFF
RES-403 Page 37
Maintenance
Measuring impuse duration
[X]
„Temp. OK“ signal (as of October 2005:
With MOD 46 only)
[X]
Temperature diagnosis
[X]
Heatup timeout
[X]
[X] As of October 2005: With ROPEX visualization software only.
Measuring impulse length: 1,7ms
Tolerance band: -10 K…+10K
Temperature diagnosis: OFF
Heatup timeout: OFF

11 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 controller can be removed with dry com­pressed air.
Page 38 RES-403
How to order

12 How to order

Contr. RES - 403 / . . . VAC
Modification MOD . . (optional, if required)
Please indicate the article numbers of the controller and the required modifications (optional) in all orders,
115: Power supply 115 VAC, Art. No. 740301 230: Power supply 230 VAC, Art. No. 740302 400: Power supply 400 VAC, Art. No. 740303
Scope of supply: Controller includes connector plug-in
parts (without current transformer)
e.g.
01: MOD 01, Art. No. 800001 (Amplifier for low voltage) 26: MOD 26, Art. No. 800026 (Booster connection) 40: MOD 40, Art. No. 800040 ("Temperature OK" signal)
e.g. RES-403/400 VAC + MOD 26
(controller for 400 VAC power supply with booster connection) Art. No. 740303 + 800026 must be ordered
Current transformer PEX-W3
Art. No. 885105
Line filter LF- . . 480
06: Continuous current 6 A, 480VAC, Art. No. 885500 35: Continuous current 35 A, 480VAC, Art. No. 885506
Impulse transformer
See ROPEX Application Report for design and ordering information
Communiction interface CI-USB-1
Art. No. 885650
Potentiometer PD- .
3: For 300°C range, Art. No. 881103 5: For 500°C range, Art. No. 881105
Scope of supply: Potentiometer with digital dial
Temp. meter ATR- .
3: 300°C range, Art. No. 882130 5: 500°C range, Art. No. 882150
RES-403 Page 39
Booster B- . . . 400
For more accessories: ª"Accessories" leaflet
How to order
075: Max. pulse load 75A, 400VAC, Art. No. 885301 100: Max. pulse load 100 A, 400VAC, Art. No. 885304
Page 40 RES-403
Index

13 Index

A
Accessories 6 Actual value output 25 Alarm output 30 Alarm relay 10 Alloy 19 Ambient temperature 10 Analog temperature meter 6 Application 4 Application Report 11 AUTOCAL 6 AUTOCOMP 28 Automatic phase angle compensation 28 Automatic zero calibration 6 AUTOTUNE 6
, 20
, 22
, 14, 18
, 21, 26
, 21, 26
B
Booster 7, 16, 40 Burning in the heatsealing band 20
, 22
C
Circuit breaker 13 CI-USB-1 7 Communication interface 7 Controller configuration 18 Controls 23 Current transformer 14
, 30, 39
, 30, 39
, 39
Impulse transformer 7 Installation 10 Installation procedure 11 Installation regulations 11
, 11
, 13, 39
L
Line filter 7, 13, 14, 39 Line frequency 6 Line voltage 9
, 9
M
Maintenance 38 Measuring impulse duration 28 Modifications 7 MODs 7
, 16, 17, 39
, 16, 17, 39
O
Overheating of heatsealing band 6
P
PEX-W2/-W3 3 PEX-W3 14 Phase angle compensation 28 Potentiometer 6 Power dissipation 10 Power supply 13 Principle of operation 5
, 39
, 24, 39
, 39
D
Degree of protection 10 Diagnostic interface 30 Digital temperature meter 6 Dimensions 11 DIP switches 18
E
Error messages 31 External switching amplifier 7
F
Factory settings 37 Fault areas 36 Fault diagnosis 6
H
HEAT 21, 27 Heatsealing band type 9 Heatup timeout 29 How to order 39
I
Impulse heatsealing method 4
, 16
R
Replacing the heatsealing band 21, 22
S
Secondary current I218 Secondary voltage U Set point potentiometer 6 Set point selection 9 Signal „Temperatur erreicht“ 8 "START" signal 21 Startup 18 System diagnostics 30 System monitoring 30
2
, 24
, 27
18
, 24
T
TCR 3, 20 Technical data 9 Temperature coefficient 3 Temperature control 4 Temperature diagnosis 29 Temperature indication 25 Temperature indicator 25 Temperature meter 6 Temperature OK signal 17
, 20
, 39
RES-403 Page 41
Index
Temperature range 9, 19 Temperature reached signal 8 Temperature setting 24 Transformer 3 Type of construction 9
, 7, 13, 39
, 17
V
View of the controller 18 Visualization software 30
W
Wiring 11, 13 Wiring diagram 15
, 16
Page 42 RES-403
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