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85 - Res 408 Eng
85 - Res 408 Eng
85 - Res 408 Eng
GB
RES-408
Operating
Instructions
Important features
• Microprocessor technology
• Separate terminal for operation and display
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of May 2006)
• Automatic phase angle compensation (AUTOCOMP, as of June 2006)
• Automatic frequency adjustment
• Wide current and voltage range
• 0…10VDC analog output for ACTUAL temperature
• 24VDC control signals for START and PREHEAT with electrical isolation
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable as standard (as of June 2006)
26.6.06
Page 2 RES-408
Safety and warning notes
A basic prerequisite for reliable and safe operation of The current transformer supplied with the RESISTRON
the system is the use of suitable heatsealing bands. temperature controller is an integral part of the control
system.
The resistance of the heatsealing band which
! is used must have a positive minimum tem- Only the original ROPEX PEX-W2 or PEX-W3
perature coefficient in order to guarantee trouble- ! current transformer may be used. Other
free operation of the RESISTRON-Temperatur- transformers may cause the equipment to mal-
regler. function.
The temperature coefficient must be specified as fol- The current transformer may only be operated if it is
lows: connected to the RESISTRON-Temperaturregler cor-
–4
TCR ≥ 10 ×10 K
–1 rectly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
e.g. Alloy-20: TCR = 1100 ppm/K "Power supply", must be obeyed. External monitoring
NOREX: TCR = 3500 ppm/K
modules can be used in order to additionally increase
operating safety. They are not included in the scope of
RES-408 Page 3
Application
supply of the standard control system and are des- 1.7 Standards / CE marking
cribed in a separate document.
The controller described here complies with the follo-
wing standards, provisions and directives:
1.5 Line filter
DIN EN 61010-1 Safety provisions for electrical
The use of an original ROPEX line filter is mandatory in (VDE 0411-1) measuring, control and laboratory
order to comply with the standards and provisions men- devices (low voltage directive).
tioned in section 1.7 "Standards / CE marking" on Overvoltage category III, pollution
page 4. This device must be installed and connected severity 2, safety class II.
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation DIN EN 60204-1 Electrical equipment of machines
enclosed with the line filter. (machinery directive)
2 Application
This RESISTRON temperature controller is an integral • Pouch, filling and sealing machines
part of the "series 400", the outstanding feature of
• Film wrapping machines
which is its microprocessor technology. All RESIS-
TRON temperature controllers are used to control the • Pouch-making machines
temperature of heating elements (heatsealing bands, • Group packaging machines
beaded bands, cutting wires, heatsealing blades,
• L-sealers
solder elements etc.), as required in a variety of heat-
sealing processes. • etc.
The controller is most commonly used for impulse-
heatsealing PE and PP films in:
• Vertical and horizontal f/f/s machines
Page 4 RES-408
Principle of operation
3 Principle of operation
The resistance of the heatsealing band, which is tem- transformer. This allows optimum adaptation to the
perature-sensitive, is monitored 50x per second (60x at load and to the required dynamic range despite the
60Hz) by measuring the current and voltage. The tem- exceptionally compact dimensions of the controller.
perature calculated with the help of these measure-
ments is displayed and compared with the set point. PLEASE NOTE!
The primary voltage of the impulse transformer is adju-
sted by phase-angle control if the measured values RESISTRON temperature controllers play a significant
deviate from the set point. The resulting change in the role in enhancing the performance of modern
current through the heatsealing band leads to a change machines. However, the full benefit can only be
in the band temperature and thus also its resistance. obtained from the advanced technology offered by this
This change is measured and evaluated by the RESIS- control system if all the system components, in other
TRON temperature controller. words the heatsealing band, the impulse transformer,
The control loop is closed: ACTUAL temperature = SET the wiring, the timing signals and the controller itself,
temperature. Even minute thermal loads on the heat- are compatible with one another.
sealing band are detected and can be corrected quickly
and precisely.
The thermoelectric control loop which is formed has a
We will be pleased to
highly dynamic response because purely electrical contribute our many
variables are measured at a high sampling rate. A very years of experience
wide secondary current range can be controlled with towards optimizing your
only minimal power loss - a considerable advantage - heatsealing system.
because power is controlled on the primary side of the
RESISTRON controller
IR UR Actual value
Current
transformer R=f(T)
Indicators
U2 and
sec. Start
U1 controls
_
prim. or
+ Set point bus interface
Impulse transformer
LINE
RES-408 Page 5
Description of the controller
Line filter
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Page 6 RES-408
Accessories and modifications
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).
Booster
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/W3 current transformer.
RES-408 Page 7
Accessories and modifications
5
1
789
0 = Factory settings
6
Page 8 RES-408
Technical data
6 Technical data
Type of construction Controller: Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm)
acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Five different ranges can be set on the controller with the rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20), default
Temperature coefficient 780ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780ppm, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm, 0…300°C (e.g. NOREX)
RES-408 Page 9
Technical data
Ambient +5…+45°C
temperature
End holders to mechanically fix the controller must be fitted at both ends for moun-
ting on a vertical top hat rail.
Page 10 RES-408
Controller/terminal compatibility
7 Controller/terminal compatibility
All RES-408 RESISTRON temperature controllers This has no effect on temperature control or on the
manufactured as of June 2006 are supplied as an external PLC control signals.
upgraded version.
Among other things, the data transfer between the con- RES-408 controllers manufactured as of
troller and the terminal has been modified. These ! June 2006 are fully electrically compatible
changes were necessitated by the new European with the old version (as far as the PLC control
RoHS/WEEE Directives. Lead has now been banned signals are concerned).
from some of the electronic components used in our
products. Please pay attention to the controller and terminal ver-
sions when ordering spare parts. The controller may
As a result, all RES-408 controllers manufac- have to be exchanged together with the terminal. Refer
! tured up to May 2006 can only be operated to the compatibility table below:
with a T-400 terminal. Controllers manufactured as
of June 2006 can only be operated with a T-408-1.
Malfunctions or damage may otherwise occur.
RES-408/115VAC 740841
Terminal T-408-1
RES-408/230VAC 740842
Art. No. 885441
RES-408/400VAC 740843
RES-408 Page 11
Dimensions
8 Dimensions
RES-408 controller
135.0
113.0
75.0 90.0
90.0
96.0
front panel
panel cutout
o 5mm
48.0
42.0
+0.8 +0.6
92 -0
x 45 -0
Page 12 RES-408
Installation
9 Installation
ª See also section 1 "Safety and warning notes" on minimum clearance specified in section 6 "Technical
page 3. data" on page 9 must be allowed between them.
4. Install the terminal in the front panel cutout. It is
Installation and startup may only be per- fastened by means of four clips which snap onto the
! formed by technically trained, skilled per- side of the terminal housing.
sons who are familiar with the associated risks and
5. Connect the controller and terminal together with
warranty provisions.
the cable provided for this purpose.
RES-408 Page 13
Installation
Impulse Terminal
transformer Note
Dimension polarity Controller
transformer correctly
- Secondary voltage
- Power
- Duty cycle Configure
20mm clearance if several DIP switches
controllers installed on correctly
one top hat rail (up to May 2006)
Page 14 RES-408
Installation
LINE Line
L1 (L1)
N (L2) 115VAC, 230VAC, 400VAC
GND/
Earth
Circuit breaker
Double-pole, C characteristic
ON K1
(ª ROPEX Application Report)
Short-circuit protection only.
I> I> ! RESISTRON-Temperaturreglers not protected.
OFF
3
Ka Relay Ka
For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".
Line filter
LINE The filter type and size must be determined according to
FILTER the load, the transformer and the machine wiring
(ª ROPEX Application Report).
Short wires Do not run the filter supply wires (line side) parallel
3 ! to the filter output wires (load side).
UR ROPEX
temperature RESISTRON-Temperaturregler belonging to the 4xx
IR controller Series.
Relay Kb
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.
U1 3
Impulse Transformer
PRIM.
Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.
Use transformers with a one section bobbin. The
2
U2 ! power, duty cycle and voltage values must be deter-
SEC.
mined individually according to the application (ª ROPEX
1
Application Report and "Accessories" leaflet for impulse
2
transformers).
Wiring
The wire cross-sections depend on the application
(ª ROPEX Application Report).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
R Secondary circuit: min. 4.0mm², max. 25mm²
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-408 Page 15
Installation
9.4 Line filter installed and wired correctly, they guarantee com-
pliance with the EMC limit values.
To comply with EMC directives – corresponding to You can find the exact specification of the line filter in
EN 50081-1 and EN 50082-2 – RESISTRON control the ROPEX Application Report calculated for your par-
loops must be operated with line filters. ticular heatsealing application.
These filters damp the reaction of the phase-angle con- For more technical information: ª "Line filter" docu-
trol on the line and protect the controller against line mentation.
disturbances.
It is permissible to supply several RESIS-
The use of a suitable line filter is part of the ! TRON control loops with a single line filter,
! standards conformity and a prerequisite of providing the total current does not exceed the
the CE mark. maximum current of the filter.
ROPEX line filters are specially optimized for use in The wiring instructions contained in section 9.3 "Power
RESISTRON control loops. Providing that they are supply" on page 15 must be observed.
Large cross-section
wire to ground
max. 1m
PE
LINE ROPEX
temperature
controller
9.5 Current transformer PEX-W3 of the control system. The current transformer may only
be operated if it is connected to the temperature con-
The PEX-W3 current transformer supplied with the troller correctly (ª section 9.3 "Power supply" on
RESISTRON temperature controller is an integral part page 15).
24 75 14
23 28
terminal
wires
60
12
39
26
14
terminal
block
Page 16 RES-408
Installation
START (HEAT) 5
with 24VDC-Signal
PREHEAT 7 4
with 24VDC-Signal U1
prim.
GND 6 Impulse
transformer
Ground
for 24VDC signals. U2
Must be grounded sec.
externally to prevent
electrostatic
charging! 8 Heat-
UR R sealing
14 0V 9 band
(Internal ground) twisted
ALARM No external
OUTPUT 12
grounding allowed!
max. 50V/0,2A 10
IR
13 up to 11
production Current transformer
17 date PEX-W2/-W3
+ May 2006
ATR
°C 0V
18 (Internal ground)
ANALOG No external
OUTPUT grounding allowed!
+0...10VDC
ROPEX T-408
SEALHEAT
PREHEAT
HOLD
ENTER
HAND
RESET
Display- and
operation panel
RES-408 Page 17
Installation
3 NC
PREHEAT 7 4 NC
with 24VDC-Signal U1
prim.
GND 6 Impulse
transformer
Ground
for 24VDC signals. U2
Must be grounded sec.
externally to prevent
electrostatic
charging! 8 Heat-
UR R sealing
14 0V 9 band
(Internal ground) twisted
ALARM No external
OUTPUT 12
grounding allowed!
max. 50V/0,2A 10
IR
13 up to 11
production Current transformer
17 date PEX-W2/-W3
+ May 2006
ATR
°C 0V
18 (Internal ground)
ANALOG No external
OUTPUT grounding allowed!
+0...10VDC
ROPEX T-408
SEALHEAT
PREHEAT
HOLD
ENTER
HAND
RESET
Display- and
operation panel
Page 18 RES-408
Startup and operation
RES-408 controller
Terminals LEDs
Connection for
terminal
Wiring diagram
Nameplate
Nameplate
Cable connection
Display
Fixing
clips (4x)
Operator keys
RES-408 Page 19
Startup and operation
10.2 Controller configuration side the permissible range, a detailed error message
appears on the controller (ª see section 11.18 "Error
The controller must be switched off in order messages" on page 38).
! to configure the coding switches and plug-in
jumpers. Configuration with coding switches
(up to May 2006)
10.2.1 Configuration for secondary
voltage and current Set the DIP switches for matching the secondary
voltage U2 and the secondary current I2 to the correct
Automatic configuration (AUTORANGE) position for your application.
(as of June 2006)
You can find the exact configuration of the
The secondary voltage and current ranges are automa- ! DIP switches in the ROPEX Application
tically configured by the automatic calibration function Report calculated for your particular application.
(AUTOCAL). The voltage is configured in the range
from 0.4VAC to 120VAC and the current in the range
from 30A to 500A. If the voltage and/or current are out-
OFF
1-10
Factory settings
ON 1 2 3 4 5
SWITCH
U2 ( V )
ON
3
U2 DIP switch I2 DIP switch
12345
4
1 2 3 4 5
1...10V ON OFF OFF 30...100A OFF OFF
OFF
ON
2x
Page 20 RES-408
Startup and operation
67 9
1
8
2 34
8 300°C 3500ppm/K (NOREX)
9 PC CONFIGURATION
5
0
1
789
2 34
0 = Factory settings
6
This configuration is set as standard on all If the switch is set to "9" (as of June 2006), other tem-
! controllers manufactured as of June 2006. perature ranges and alloys can be selected in the
The settings are only possible on older controllers ROPEX visualization software (ª see section 11.16
in conjunction with MOD 37 (ª ª section "MOD 37 "Diagnostic interface / visualization software (as of
(up to May 2006)" on page 8). June 2006)" on page 37).
(factory setting)
6
If the plug-in jumper is not inserted on con- section 11.16 "Diagnostic interface / visualization soft-
! trollers manufactured up to May 2006, the ware (as of June 2006)" on page 37).
alarm relay is permanently energized (alarm con-
tact between terminals 13 and 14 closed). The
other functions of the controller (e.g. heating the 10.3 Heatsealing band
heatsealing band, AUTOCAL etc.) are not affected.
If the plug-in jumper is not inserted on controllers 10.3.1 General
manufactured as of June 2006 - or if it is incorrectly
inserted - an error message appears when the con- The heatsealing band is a key component in the control
troller is switched on (ªª section 11.18 "Error mes- loop, since it is both a heating element and a sensor.
sages" on page 38). The geometry of the heatsealing band is too complex to
be discussed at length here. We shall therefore only
If the "Alarm relay de-energized by alarm/PC CONFI- refer to a few of the most important physical and elec-
GURATION" position is selected (as of June 2006), the trical properties.
behavior of the alarm output can be configured more The measuring principle applied for this system neces-
finely in the ROPEX visualization software (ª see sitates a heatsealing band alloy with a suitable tempe-
RES-408 Page 21
Startup and operation
rature coefficient TCR, i.e. one whose resistance The heatsealing band must be replaced in
increases as the temperature rises. ! accordance with the instructions provided by
Too low a TCR leads to oscillation or uncontrolled hea- the manufacturer.
ting.
If a heatsealing band with a higher TCR is used, the Each time the heatsealing band is replaced, the zero
controller must be specially calibrated. point must be calibrated with the AUTOCAL function
The first time the heatsealing band is heated to appro- while the band is still cold, in order to compensate pro-
ximately 200…250°C, the standard alloy undergoes a duction-related resistance tolerances. The burn-in pro-
once-only resistance change (burn-in effect). The cold cedure described above must be performed for all new
resistance of the heatsealing band is reduced by appro- heatsealing bands.
ximately 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 10.4 Startup procedure
after a few heating cycles (ª section 10.3.2 "Burning in
the heatsealing band" on page 22). Please also refer to section 1 "Safety and warning
One very important design feature is the copper or notes" on page 3 and section 2 "Application" on
silver-plating of the heatsealing band ends. Cold ends page 4.
allow the temperature to be controlled precisely and
increase the life of the teflon coating and the heat- Installation and startup may only be per-
sealing band. ! formed by technically trained, skilled per-
sons who are familiar with the associated risks and
An overheated or burned-out heatsealing warranty provisions.
! band must no longer be used because the
TCR has been altered irreversibly. 10.4.1 Initial startup
Prerequisites: The controller must be correctly installed
10.3.2 Burning in the heatsealing band
and connected (ª section 9 "Installation" on page 13).
If a new heatsealing band has been used, the zero Proceed as follows to start up the controller for the first
point is first of all calibrated while the band is still cold time:
by activating the "AUTOCAL" function on the controller. 1. Switch off the line voltage and verify that all circuits
When the "AUTOCAL" function has finished, the con- are deenergized.
troller outputs a voltage equivalent to a temperature of
2. The supply voltage specified on the nameplate of
20°C at the actual value output. Adjust the set point to
the controller must be identical to the line voltage
approximately 250°C and activate the "START" signal
that is present in the plant or machine. The line fre-
to heat for approximately 1 second. After recooling, the
quency is automatically detected by the tempera-
controller usually outputs an actual value of less than
ture controller in the range from 47 to 63Hz.
20°C. Repeat the "AUTOCAL" function. The heat-
sealing band has now been burned in and the change 3. In the case of controllers manufactured up to
in the alloying properties stabilized. May 2006, the DIP switches on the controller must
The burn-in effect described here does not occur if the be set according to the ROPEX Application Report
heatsealing band has already been thermally pret- and depend on the heatsealing band that is used
reated by the manufacturer. (section 10.2 "Controller configuration" on page 20).
4. Make sure that a START signal is not present.
10.3.3 Replacing the heatsealing band 5. Switch on the line voltage.
All power supply leads must be disconnected from the 6. When the voltage is switched on, the yellow
RESISTRON temperature controller in order to replace "AUTOCAL" LED lights up for approximately
the heatsealing band. 0.3 seconds on all controllers manufactured as of
June 2006 to indicate that the controller is being
powered up correctly.
Page 22 RES-408
Startup and operation
Controllers manufactured as of June 2006: minal display returns to the home position and a
! If the red "ALARM" LED lights up for 0.3s in voltage of 0.66V (300°C range) or 0.4V (500°C
addition to the yellow "AUTOCAL" LED when the range) appears at the actual value output instead. If
voltage is switched on, the configuration of this an ATR-x is connected, it must be set to "Z". The
controller has been changed in the visualization "AUTOCAL" LED goes out again on controllers
software (ª ª section 11.16 "Diagnostic interface / manufactured as of June 2006.
visualization software (as of June 2006)" on If the zero point has not been calibrated suc-
page 37). In order to avoid malfunctions, please cessfully, an alarm is indicated on the terminal dis-
check the controller configuration before conti- play. In addition, the red "ALARM" LED blinks slowly
nuing the startup procedure. (1Hz) on all controllers manufactured as of
June 2006. In this case the controller configuration
7. One of the following states then appears: is incorrect (ª section 10.2 "Controller configura-
tion" on page 20 and ROPEX Application Report).
Controllers manufactured as of June 2006: Repeat the calibration after the controller has been
configured correctly.
"ALARM" "OUTPUT" 9. When the zero point has been calibrated suc-
ACTION
LED LED cessfully, select a defined SET temperature and
activate the "START" signal (HEAT). The "SEAL-
OFF Short pulses Go to 8
HEAT" LED on the terminal then lights up. The
every 1.2s ACTUAL temperature appears on the display. The
BLINKS fast OFF Go to 8 heating and control process can now be observed
(4Hz) The controller is functioning correctly if the tempera-
ture has a continuous curve, in other words it must
Lit conti- OFF Fault diagnosis not jump abruptly, fluctuate or deviate temporarily in
nuously (ª section 11.18) the wrong direction. This kind of behavior would
indicate that the UR measuring wire has been laid
incorrectly.
Controllers manufactured up to May 2006:
If an error code is displayed, please proceed as des-
cribed in section 11.18 "Error messages" on
"OUTPUT" page 38.
Alarm no. ACTION
LED
10.Burn in the heatsealing band (ª section 10.3.2
--- Short pulses Go to 8 "Burning in the heatsealing band" on page 22) and
every 1.2s repeat the AUTOCAL function.
RES-408 Page 23
Controller functions
11 Controller functions
HEAT
OUTPUT
AUTOCAL Yellow LED, lit during heating phase.
2
TERMINAL T- 408
3
RES- 408
Temperature
controller
ROPEX
Tel:+49(0)7142-7776-0
Made in Germany
In addition to the functions shown in the diagram controller LEDs. These states are described in detail in
above, various operating states are indicated by the the table below:
OUTPUT
In control mode, luminous intensity is proportional to heating current
(green)
Page 24 RES-408
Controller functions
T-408-1 terminal
2 PREHEAT
1 Green LED: Heatung up/temp. control
3 HOLD
to set temperature active
ENTER
2 Yellow LED: PREHEAT active
HAND 3 Green LED: Hold mode active
RESET
“ENTER” key
ENTER function: Save values
HAND function: Manual mode
RESET function: Reset after alarm
RES-408 Page 25
Controller functions
ROPEX TERMINAL
1
2
RESISTRON
µP-Controller
ROPEX
INDUSTRIE - ELEKTRONIK
.
T-400 terminal
2 PREHEAT
1 Red/Green LED: Red, during heating up
3 HOLD
Green, set temp. achieved
ENTER
2 Yellow LED: PREHEAT active
HAND 3 Green LED: Hold mode active
RESET
“ENTER” key
ENTER function: Save values
HAND function: Manual mode
RESET function: Reset after alarm
Page 26 RES-408
Controller functions
HOLD
ENTER
ROPEX T-408 HAND
SEALHEAT
RESET
PREHEAT
HOLD
ENTER
HAND
RESET
11.2.2 Display in home position A "MENU" key is provided for navigating through the
various menu steps. By pressing this key briefly (<2s)
If no settings are entered on the controller and no alarm at any time, you can jump to the next menu step. By
signal is indicated, the display is in the home position, pressing the key for longer (>2s), you can return to the
in other words it shows the ACTUAL temperature. home position from anywhere in the menu structure,
providing a controller alarm is not active. In this case,
ROPEX T-408
SEALHEAT
the Alarm menu is opened.
PREHEAT In addition, you always return to the home position if
HOLD
you do not press any keys for a period of 30s. There is
no automatic return after 30s from "AC" [AutoCal] or
ENTER
HAND
RESET
"AL" [ALarm].
HOLD
If the fault can be rectified by executing the AUTOCAL
ENTER
function, you can select the "AC" [AutoCal] menu step
HAND directly by briefly pressing the "MENU" key (<2s). You
RESET
can then activate the "AUTOCAL" function by pressing
the "ENTER" key (ª section 11.8 "Automatic zero cali-
bration (AUTOCAL)" on page 32).
RES-408 Page 27
Controller functions
1) AUTOCOMP: OFF
Power-up message
2) AUTOCOMP: ON
°C Home position
SH Heatsealing temp.
PH Preheat temp.
AC Autocal?
Autocal
1) 2)
AP Autocomp?
Autocomp
Fault
AL Alarm
AC Autocal?
Autocal
Page 28 RES-408
Controller functions
RES-408 Page 29
Controller functions
HO [HOld] If Hold mode ("On") is activated, the last measured Controllers manufactured
Hold mode value at the end of the heating phase is stored and up to May 2006:
displayed on the terminal. On
The "HOLD" LED lights up on the terminal when OFF
hold mode is active. This procedure is repeated in
every cycle and the displayed value is updated. Controllers manufactured
Controllers manufactured as of June 2006: as of June 2006:
If you select the "On2" function, the display swit- On
ches back from hold mode to the actual value in real On2
time after 2 seconds. The hold function is activated OFF
again for 2 seconds at the end of the next cycle.
Page 30 RES-408
Controller functions
11.6 Temperature setting The heating and control process can thus be observed
(set point selection) at any time.
In addition, the RES-408 controller outputs an analog
The heatsealing temperature can be set on the 0…10VDC signal, which is proportional to the real
RES-408 controller with the setting in the "SH" [Seal- ACTUAL temperature, at terminals 17+18.
Heat] menu step.
The set point selected for the heatsealing temperature
must be greater than 40°C. If not, the heatsealing band RES-408
is not heated when the "START" signal is activated or
the "HAND" key is pressed. The 1…39°C setting range Actual value R=33ohm max. 5mA
is not available on controllers manufactured as of output 17
June 2006. 0…10VDC
0V 18
PREHEAT
HOLD
ENTER
HAND
RESET
RES-408 Page 31
Controller functions
°C 0 - 500°C range
Temperature T
Page 32 RES-408
Controller functions
times. If the function still cannot be terminated suc- The "START" signal is activated by applying a 24VDC
cessfully, an error message appears (ª section 11.18 signal at terminals 5+6.
"Error messages" on page 38).
24VDC
You should always wait for the heatsealing
! band and the bar to cool down (to ambient
START
(HEAT)
RES-408
+ 5
temperature) before activating the "AUTOCAL" max. 6mA
function.
RES-408 Page 33
Controller functions
0
24VDC t
PREHEAT RES-408 T1 = Preheat temperature (PREHEAT)
T2 = Heatsealing temperature
+ 7
max. 6mA
The heatsealing band is heated to the set preheat tem-
perature if the "HAND" key is pressed and the "PRE-
HEAT" signal is activated when the terminal display is
GND
- 6 in the home position. The "PREHEAT" LED then lights
up. On controllers manufactured up to December 2000,
the same effect can be achieved by pressing the
"HAND" key in the "HA" [HAnd] step.
HIGH: ≥ 12VDC
PREHEAT
11.11 Hold mode
LOW: ≤ 2VDC
The behavior of the ACTUAL temperature display in the
home position can be changed with the "HO" [HOld]
The heatsealing band is heated to the preheat step. The following settings are possible:
! temperature if the "START" and "PREHEAT" 1. "OFF" 1
signals are active. In this case, the "PREHEAT" If the home position is visible on the display, the real
LED on the T-400 or T-408-1 terminal lights up. ACTUAL temperature is always indicated.
2. "On"
If the display is in the home position, the ACTUAL
temperature that was valid at the end of the last
heatsealing phase is always indicated as a digital
value. When the controller is powered up, the real
ACTUAL temperature is shown until the end of the
first heating phase.
1. Factory setting
Page 34 RES-408
Controller functions
Hold mode only affects the value on the dis- This parameter can only be set in the ROPEX
! play. The ACTUAL temperature is always ! visualization software (ª
ª section 11.16 "Dia-
indicated in real time, regardless of the setting, at gnostic interface / visualization software (as of
the actual value output. June 2006)" on page 37).
0
t
Hold On2 Hold Hold
T
0
t
2s 2s
End of
Heatsealing phase
RES-408 Page 35
Controller functions
"ENTER" key June 2006)" on page 37). The RES-408 checks whe-
<2.0s
pressed ther the ACTUAL temperature is within a settable tole-
"AC" "AP" rance band ("OK" window) on either side of the SET
temperature. The lower ( ∆ϑ lower ) and upper
( ∆ϑ upper ) tolerance band limits are configured in the
0 factory to -10K and +10K. These values can be set
t
independently of one another in the ROPEX visualiza-
tion software.
Function
AUTOCOMP If the ACTUAL temperature is inside the specified tole-
rance band when the "START" signal is activated, the
AUTOCAL temperature diagnosis is activated as well. If the
0 ACTUAL temperature leaves the tolerance band, the
t corresponding error code (307 or 308) is indicated and
the alarm relay is switched (ª section 11.18 "Error
"AUTOCAL"
LED messages" on page 38).
lit
ACTUAL temp.
Set+ ∆ϑ upper
OFF
t Set
"HEAT" Set+ ∆ϑ lower
LED
lit
OFF
t
Page 36 RES-408
Controller functions
PREHEAT
HOLD
ENTER
Time HAND
304
The cause of a fault can be localized quickly and easily
with the help of the error code that appears on the dis-
11.16 Diagnostic interface / visualization play. Please refer to section 11.18 "Error messages" on
software (as of June 2006) page 38 for a list of possible error codes.
An interface with a 6-pole Western socket is provided B.) Controllers manufactured as of June 2006:
for system diagnostics and process visualization. This Red "ALARM" LED on the controller with
interface allows a data connection to be set up to the three states:
ROPEX visualization software using the ROPEX
CI-USB-1 communication interface. 1. Blinking fast (4Hz)
The "AUTOCAL" function should be executed (error
codes 104…106, 211, 302, 303).
2. Blinking slowly (1Hz)
DIAG
111…114.
2 34
6
RES-408 Page 37
Controller functions
HOLD
Page 38 RES-408
Part 1 of 3: Error messages as of June 2006
3 (103) 2.00 60 100 UR and IR signals missing Fault area d Fault area dk
(107) Temperature step, down Fault area fgh Fault area fgh
(108) Temperature step, up (loose contact) (loose contact)
RES-408
(310)
contin- Energized
(201) uously
Frequency fluctuation, Check
5 (202) 3.33 100 166 Check power supply
inadmissible line frequency power supply
(203)
Heatup time too long
6 (304) 4.00 120 200 Run RESET Run RESET
(ª section 11.15)
Page 39
Part 2 of 3: Error messages as of June 2006
Page 40
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
alarm LED blinks; alarm relay is de-energized). When the "START" signal is activated, the warning changes to a fault
(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is energized.
IR signals incorrect,
(104) incorrect specification of
impulse-transformer
¯5.33« ¯160« ¯266«
ª 10 ® ª300® ª500® Run AUTOCAL,
UR signals incorrect,
Check specification
(105) incorrect specification of
Warning: of transformer,
impulse-transformer
Warning: De-Energized Fault area ij
Blinks UR and/or IR signals
¯6.00« ¯180« ¯300« fast incorrect, Fault area fgh
RES-408
8 (106) (4Hz) Fault:
ª 10 ® ª300® ª500® incorrect specification of (loose contact)
Energized impulse-transformer
Fault: (voltage value
Lit at actual Temperature too low,
¯6.66« ¯200« ¯333« contin- value output AUTOCAL wasn’t per-
(302)
ª 10 ® ª300® ª500® uously then no longer formed, loose contact, Run AUTOCAL
changes) ambient temp. fluctuates and/or
temperature too high, fault area fgh
¯7.33« ¯220« ¯366« AUTOCAL wasn’t per- (loose contact)
(303)
ª 10 ® ª300® ª500® formed, loose contact,
ambient temp. fluctuates
¯8.00« ¯240« ¯400«
9 (211) Data error Run AUTOCAL ---
ª 10 ® ª300® ª500®
Controller functions
Part 3 of 3: Error messages as of June 2006
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
alarm LED blinks; alarm relay is de-energized). When the "START" signal is activated, the warning changes to a fault
(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is energized).
Controller functions
RES-408
Page 41
Error codes up to May 2006
Page 42
Error STATUS Action Action if machine
of alarm relay Cause if machine started already operating,
code
(factory setting) for first time HS band not chang.
101 IR signal missing Fault area c Fault area c
Internal fault,
RES-408
9xx Replace controller Replace controller
controller defective
104
105 UR and/or IR signal
Run AUTOCAL Fault areas fgh
106 incorrect
AC
De-energized,
5 1 2 2 9
6 3
Temperaturregler
4
HARDWARE
9
123 45
8 I2 8
UR
8
1 U2 7
IR
7
RES-408 Page 43
Factory settings
Turns through PEX-W2/-W3 cur- - Check number of turns (two or more turns required for
rent transformer incorrect currents < 30A)
12 Factory settings
The RES-408 RESISTRON temperature controller is
configured in the factory as follows:
8 300°C
6
9
5
8 300°C
6
9
5
Page 44 RES-408
Maintenance
[X]
[X]
[X]
13 Maintenance
The controller requires no special maintenance. the impulse transformer – is recommended. Dust depo-
Regular inspection and/or tightening of the terminals – sits on the controller can be removed with dry com-
including the terminals for the winding connections on pressed air.
RES-408 Page 45
How to order
14 How to order
Controller RES - 408 / . . . V AC
115: Line voltage 115VAC, Art. No. 740841
230: Line voltage 230VAC, Art. No. 740842
400: Line voltage 400VAC, Art. No. 740843
Scope of supply: Controller includes connector plug-in parts
(without terminal and current transformer)
Terminal T-408-1
Art. No. 885441
Please indicate the article numbers of the controller and the required
modifications in all orders,
e.g. RES-408/400VAC + MOD 26
(controller for 400VAC power supply with booster connection)
Art. Nos. 740843 + 800026 must be ordered
Impulse transformer
See ROPEX Application Report
for design and ordering information
Page 46 RES-408
How to order
Booster B- . . . 400
075: Max. pulse load 75A, 400VAC, Art. No. 885301
100: Max. pulse load 100A, 400VAC, Art. No. 885304
RES-408 Page 47
Index
15 Index
A I
Accessories 6 Impulse heatsealing method 4
Actual value output 31 Impulse transformer 7, 15, 46
Alarm output 37 Installation 10, 13
Alarm relay 10, 21 Installation procedure 13
Alloy 21, 23 Installation regulations 13
Ambient temperature 10
Analog input 9 L
Analog output 9 Line filter 6, 15, 16, 46
Analog temperature meter 6 Line frequency 6, 9
Application 4 Line voltage 9, 46
Application Report 13, 16, 20
AUTOCAL 6, 23, 32
AUTOCOMP 35 M
Automatic phase compensation 35 Maintenance 45
Automatic zero calibration 6, 23, 32 Manual mode 31, 34
AUTOTUNE 6 Measuring impulse duration 35
Modifications 8, 18, 46
MODs 8, 18, 46
B Monitoring current transformer 7
Booster 7, 8, 47
Burning in heatsealing band 22, 23
O
Overheating of heatsealing band 6
C
Circuit breaker 15
CI-USB-1 7, 37, 46 P
Communication interface 7, 37, 46 PEX-W2/-W3 3
Controller configuration 20 PEX-W3 16, 46
Controls 24 Phase compensation 35
Current transformer 7, 16, 46 Power loss 10
Power supply 15
"PREHEAT" signal 34
D Preheating 34
Degree of protection 10 Principle of operation 5
Diagnostic interface 37
Digital temperature meter 6
Dimensions 12 R
DIP switches 20 Replacing heatsealing band 22, 23
Display 27
S
E Secondary current I2 20
Error messages 38 Secondary voltage U2 20
External switching amplifier 7 Set point selection 31
"START" signal 23, 33
Startup 19
F System diagnostics 37
Factory settings 44 System monitoring 37
Fault areas 43
Fault diagnosis 6
T
TCR 3, 22
H Technical data 9
HEAT 23, 33 Temperature coefficient 3, 21
Heatsealing band type 9 Temperature control 4
Heatsealing temperature 33 Temperature diagnosis 36, 37
Heatup timeout 37 Temperature indication 6, 31
How to order 46
Page 48 RES-408
Index
RES-408 Page 49