THERMOSALD ISC
Contents
1. 3 INSTALLATION 3 1 ANALYSIS OF APPLICATION BEFORE BEGINNING THE FIRST INSTALLATION READ CAREFULLY THE WARNINGS AT CHAPTER 0 AND PARTICULARLY THE SAFETY PRECUTIONS AT CHAPTER 0 1 AND COMPLIANCE WITH ELECTRO MAGNETICS STANDARDS AT CHAPTER 0 2 IT IS ENOUGH FOLLOW STEP TO STEP THE FOLLOWING INSTRUCTIONS TO START UP THERMOREGULATOR WELL FOR ANY QUESTIONS DON T EXITATE TO CONTACT OUR TECHNICAL OFFICE WHICH BAND CAN USE TO HAVE THE MAXIMUM If You like You can contact our technical office to choise band Cutting wire seeee4 4 IH Endless steel bands Other C r r aed Material e Original bands by in special alloy Good e NiCr80 20 No good e Altro Contact our technical office Profile e Chamfered tapered edge 2222525566666 7 AERIS IIS e Concave grooved 1 e lt vDJI IIII eeeessc ee e Double vate date ERROR e Beaded T Shap amp e e e Geometrical Dimensions e Width LARG 2 essen mm Thicknes SP O eesesesn mm e Length L TOT 42542 eee mm e Copper Silver Ends L RAM 2 2 x mm e Copper Silver in the cente L RAMC aza 2222562626666 mm e Teflon in the center L TEFL 4 mm Othet 00200002000 Rattle THERMOSALD ISC MAINTENANCE amp OP2. PROTECTION OF THE OUTPUTS WIRES class electric strength 4 KV OUTPUTS TERMINALS IP20 5 406 INSULANCE TREATMENT Impregnating by insulance paint auto extinguishing type BC359 D green Class F DRYING oven drying of the insulance paints after treatment THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Includes all models Manuale cod 3 5080 Vx MU EN Page Nr 45 Rev 2010 03 Tot Nr 47 ANNEX START UP CARD PAG 1 COMMERCIAL NOTE MODEL OF MACHINE CUSTOMER BAND POSITION KIND OF FILM TO SEAL THICKNESS OF FILM TO SEAL APPLICATION NOTE Band material Band form profile Width of the band mm Thickness of the band mm Length overall mm Copper Silver ends 2 x mm Copper Silver in the centre mm Teflon coat in the centre mm Type of connections Parallel Serial P S TECNICHAL NOTE SECTION OF THE SEALING BAND square mm RESISTANCE OF THE SEALING BAND HEATING CURRENT CALCULATED 60 90 120 A SECONDARY VOLTAGE OF THE TRANSFORMER V MODEL OF THE THERMOSALD ISC PRIMARY SECONDARY LOW VOLT RATED CURRENT 60 9 1200 PRE HEAT TEMPERATURE SEALING TEMPERATURE m SEALING TIME SET INTO THE PLC _ THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page N
3. 4 THE MACHINE IS READY TO WORK THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 32 Tot Nr 47 5 3 TROUBLESHOOTING PROBLEM Allarm Fxxx appears on the display VERIFY alarm list in this book ANNEX D PROBLEM In Balancing the band is hot VERIFY that logic and power supply are in the same phase PROBLEM On the display You can see oscillating temperature VERIFY that contacts of bands are good Verify that connections are not linked together verify machine data and if they are not regular do a master reset and a following calibration with machine cold 5 4 THERMOREGULATOR MAINTENANCE Depend on the working environment in every way not more then every 180 days 1 Verify that all the thermoregulator terminals are screw tight 2 Verify the right function of the emergency output floating contact press the key mode as requested at power on periodically the output relay must open power circuit 5 5 GRIPPER JAWS MAINTENANCE Depend on the working environment in every way not more then every 20 days 1 Verify that the reference and power terminals are screw tight 2 Verify that the connections of the bands are good without oxidation 3 Verify the teflon and the isolation of gripper jaws THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx
4. SECONDARY 90 AMPERE ICC 90 x 2 5 225 AMPERE PRIMARY 120A 120 x 2 5 300 AMPERE STANDARD OR LOW VOLTAGE It depends from the HEATING CURRENT as following calculate the section of the band if serial or parallel in the case of parallel the section is twice If we think a current of 30 Ampere mmq from experience for more informations contact our technical office we have the following I HEATING BAND SECTION S square mm x 30 Amp squaremm The thermoregulator must have a nominal current more then I HEATING SAMPLES CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD 4 x 0 25 1 30 Amp 60 5x02 1 30 Amp 60 6x02 1 2 36 Amp 60 8 x 0 15 1 2 36 Amp 60 CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD 4x025 x2 2 60 Amp 60 5x02 x2 2 60 Amp 60 6x02 x2 2 4 72 Amp 60 90 8 0 15 x2 2 4 72 60 90 CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD 8x02x2 3 2 96 Amp 90 120 THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 14 Tot Nr 47 3 4 POWER TRANSFORMER CHOISE WHICH TRANSFORMER IS TO CHOOSE The choise depends on I heating current and resistance At the first start up it s better to use transformers multivoltage original by 3E specific for the thermoregulators 60 Ampere 90 Ampere with control of the secondary with control of the primary for the following applications it s possible to m
5. TEMPERATURE CONTROLLER FOR IMPULSE SEALING THERMOSALD ISC MODULAR SYSTEM AUTOMATIC CALIBRATION ANALISYS ON LINE OF BAND CHARACTERISTICS DIAGNOSTIC PANEL WITH 6 LANGUAGES CAN BUS INTERFACE OPTIONAL PROFIBUS INTERFACE OPTIONAL RS 485 INTERFACE OPTIONAL WORKING WITH POTENTIOMETER BURN IN OF SEALING BAND MAINTENANCE amp OPERATIONS MANUAL 3E S r l via del Maccabreccia 37 a 40012 LIPPO DI CALDERARA BOLOGNA Tel 39 051 6466225 228 e Mail mail 3e3e3e com Fax 4439 051 6426252 web site www 3e3e3e com CONTENTS 0 WARNINGS 0 1 SAFETY PRECAUTIONS 0 2 COMPLIANCE WITH ELECTRO MAGNETIC STANDARD 1 DESCRIPTION 1 1 DESCRIPTION OF MANUALS 1 2 GENERAL DESCRIPTION 2 WIRING DIAGRAM AND DIMENSIONS 2 1 LIST OF CHANGE OVER SIGNALS 2 2 WIRING DIAGRAMS 3 INSTALLATION 3 1 ANALYSIS OF APPLICATION 3 2 CALCULATION OF SEALING BAND RESISTANCE 3 3 THERMOREGULATOR CHOISE 3 4 POWER TRANSFORMER CHOISE 3 5 PROTECTIVE DEVICE CHOISE 3 6 ADVICES TO DEVELOP ELECTRIC CONNECTIONS 4 START UP 4 1 START UP GENERAL OPERATIONS 4 2 START UP BASE CONFIGURATION 4 3 START UP BASE MULTILANGUAGE PANEL 4 4 START UP BASE BASE MULTILANGUAGE PANEL POTENTIOMETER 4 5 START UP BASE CAN BUS 4 6 START UP BASE PROFIBUS 4 7 INSTRUCTION TO USE MULTILANGUAGE PANEL 4 8 THEORETICAL CALCULATIONS AND DIAGNOSTIC PROCEDURES WITH THE AID OF THE DATA IMPUT PANEL 4 9 SETUP PROCEDURES WITH THE AID OF THE CONTROL PANEL 4 10 SETUP PROCE
6. 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 10 Tot Nr 47 22 ELECTRIC DRAW POWER CONNECTIONS CONTROL OF THE PRIMARY 230V 50Hz POTENTIONETERS RS4B5 CN2 CN CN5 32 FLER d EMC IS uw 9 ruse 2 4 z ent I 1 c 1 3 hi dry 2 cw 1 3 KO 2 31415 6 2 4 CONTROLS CNS 112131451617 PANEL gt gt i4 X X z z GROUN 21314 PE 1 TEES 10004A ov 230V OV I dup SEALING BAND PANEL oy 40V 50V NOTE Power supply CN1 1 e 1 4 must be with the same phase as control supply CN2 3 CN2 2 Ground screw must be connected to the ground of machine with the cable jellow green section gt power cable section Twist power cable twist TA cable Twist and screen sealing reference cable THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 11 Tot Nr 47
7. industrial environment e CEI EN 61000 6 2 02 2000 Electromagnetic compatibility Generic immunity standard industrial environment EMISSION Requisites Test Normative References Test Result e Electromagnetic Emission CEI EN 55011 S IMMUNITY Requisites e Immunity elecricity static discharge ESD CEI IEC 1000 4 2 S e Immunity radiated electromagnetic field AM EN 61000 4 3 S e Immunity fast transient oscillation BURST CEI IEC 1000 4 4 5 e Immunity high energy pulse SURGE CEI EN61000 4 5 S e Immunity conduit RF CEI EN61000 4 6 S e Immunity electromagnetic field 50Hz CEI EN61000 4 8 S e Immunity micro interruption of main CEI EN61000 4 11 S S Prova Superata THE PRODUCT IS COMPLIANCE TO ABOVE MENTIONED NORMES EMC in accord to DIRECTIVE 89 336 CEE and DLg N 476 92 e N 615 96 EMC Test Report n 029 03 RP on 03 02 03 THE PRODUCT IS COMPLIANCE TO LOW VOLTAGE NORME in accord to DIRECTIVE 73 23 CEE 93 68CEE THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 4 Tot Nr 47 1 DESCRIPTION 1 1 DESCRIPTION OF MANUALS In Italian Language IT and in English Language EN the following manuals are avaliable MANUAL COD 3ES080x Vx CO IT COMMERCIAL CATALOGUE IT DESCRIBES THE PRODUCT AND ITS FOUNDAMENTAL CARACTERISTICS MANUAL COD 3ES080x Vx QS IT QUICK START MANUAL IT S SUPPLIED WITH THE THERMOREGULATOR
8. AND DESCRIBES THE ELETTRICAL CONNECTIONS THE START UP OPERATIONS THE USE OPERATIONS THE MAINTENANCE OPERATIONS THE TROUBLE SHOOTING DIAGNOSTIC MANUAL COD 3ES080x Vx MU IT MAINTENANCE amp OPERATIONS MANUAL IT CONTAINS ALL THE INFORMATIONS ABOUT THE PRODUCT AND MUST BE KNOWN BEFORE DOING AN INSTALLATION IT S SUPPLIED TO INSTALLATOR AND DESCRIBES THE NORMES USED FOR DESIGN THE INSTAL CONDITIONS FOR SAFETY THE ELETTRICAL CONNECTIONS THE START UP OPERATIONS THE USE OPERATIONS THE MAINTENANCE OPERATIONS THE TROUBLE SHOOTING DIAGNOSTIC MANUAL COD 3ES080x Vx CO COMMERCIAL CATALOGUE MANUAL COD 3ES080x Vx QS EN QUICK START MANUAL MANUAL COD 3ES080x Vx MU EN MAINTENANCE amp OPERATIONS MANUAL In French Language FR German DE Spanish SP the following manuals are avaliable MANUALE COD 3ES080x Vx QS FR QUICK START MANUAL MANUALE COD 3ES080x Vx QS DE QUICK START MANUAL MANUALE COD 3ES080x Vx QS SP QUICK START MANUAL If requested It will be possible to edit specific language ALL MANUALS ARE AVALIABLE ON OUR INTERNET WEB SITE www 3e3e3e com THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 5 Tot Nr 47 1 2 GENERAL PRODUCT DESCRIPTION APPLICATION Impulse heat seal technology is used to seal rapidly and with great accuracy polyethylen films polyprophilene films sing
9. CHECKSUM ERROR Verify checksum selection on the Master or Slave F20 RS485 SLAVE CHECKSUM ERROR Verify checksum selection on the Master or Slave F21 RS485 SLAVE OE ERROR OVERRUN Following data arrived before reading the previous 22 RS485 SLAVE FE ERROR FRAME ERROR Data stop bit not arrived F23 RS485 MASTER NO ANSWER FROM SLAVE After a Master calling no answer received from the slave F24 RS485 SLAVE TOO DATA REQUESTED FROM MASTER OR WRONG ADDRESS Master ha s requested to the slave too many data or a wrong address F25 RS485 SLAVE BUFFER FULL Slave Buffer is full because of too many data trasmitted or too frequently trasmitted F26 RS485 MASTER OE ERROR OVERRUN Following data arrived before reading the previous F27 RS485 MASTER FE ERROR FRAME ERROR Data stop bit not arrived F28 RS485 MASTER TOO DATA REQUESTED FROM SLAVE OR WRONG ADDRESS Slave ha s requested to the master too many data or a wrong address F29 RS485 MASTER BUFFER FULL Master Buffer is full because of too many data trasmitted from the slave F33 NO VOLTAGE ON POWER TRASFORMER Verify power on CN1 L1 L2 verify power trasformer circuit F34 DON T USE F35 CALIBRATION REQUEST THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 40 Tot Nr 47 Used in distance control RS485 F36 CALIBRATING IN PROGRESS Used in distance control RS485 to know when calibrating end 8 THE MACHINE IS WA
10. HEAT SEALING POTENTIOMETER CLEAR FAULTS RESET BUTTON CALIBRATION BUTTON Step 1 Calibrate the system after performing the steps indicated in paragraph 4 1 Step 2 The machine should be at ambient temperature Step 3 The pre heat and heat sealing controls should be inactivated Step 4 Power up the temperature controller Step 5 In the event of faults the Red ALARM Led lights up follow the instructions given on the temperature regulator and put the faults right as required the id number of the fault can be found by multiplying the pulses emitted by the green Balance Led by 10 e g 9 pulses 90 the pulses of the red Balance Led by the units e g 10 pulses 20 Step 6 Calibrate the system Keep the external CALIBRATION button pressed for 3 seconds and wait the four LEDS on the system go on flashing as long as the the instrument is being calibrated Step 7 The system is ready to start cycling as soon as the calibration procedure has been completed Set the Heat Sealing and Pre Heat temperature by using the respective potentiometers 30 degrees turn WARNING If calibration problems arise perform a MASTER RESET procedure starting from stage 5 to perform the MASTER RESET procedure keep the external RESET CALIBRATION buttons pressed for 6 seconds the 4 Leds on the equipment stay on for 3 seconds THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx
11. by 3E in special alloy For the first start up this is indispensable For the following start up we advise to continue to use the original bands to don t loose stability In the market You can find other good bands don t use bands of any materials for informations contact our commercial office Execute wiring as advised in the WIRING NOTE and in the FOLLOWING PICTURES SEE FOLLOWING PAGES Pay much attention to the connections on the machine of the reference wire and of the power cables to have no problems at starting up and in the future contact our technical office for more informations Connect in phase the supply of logic 230 Volts with the primary of power transformer 230Vac o 380 Vac The 230V of logic must be 1 The same of the primary of the power transformer if the primary of the power transformer is 230V 2 In phase or out of phase 180 degree originated by a little transformer es 30VA 0 400 0 230 if the primary of the power transformer is 400V Read diagnostic warning and act accordingly If it happens to have some problems during start up or later read and pay attention at the alarm number that appears on the display panel read the cause and the remedy in this book see append D and act accordingly if the problems persist don t exitate to contact our technical office the diagnostic permit to us to help You to solve problems also at distance It s better to position the panel cable far from cables supplyi
12. in contact with our technical office the necessity to change some machine data may be in specific applications TO ENTER from secondary menu SETTING DATA press key MODE TO OUTPUT press key RES and follow guide LANGUAGE SELECTION ITALIAN It possible select up to 6 language ITALIAN ENGLISH FRENCH GERMAN SPANISH FREE DEGREES SELECTION CELSIUS Select the temperature display in Celsius or Farheneit degrees CALIBRATING TEMPERATURE 30 DEGREE Set the calibrating temperature it inform the thermoregulator of the sealing band temperature at the time of calibrating if machine is cold the calibrating temperature is equal to the ambient temperature MAXIMUM SEALING TEMPERATURE 220 DEGREE Limit of the temperature set in pre heat and seal MAXIMUM SEALING TIME 0 0 SECONDS Set the maximum sealing time if sealing time is longer than this value thermoregulator sends fault signal F085 000 means that control is not active and it is possible to do continuos sealing BURN IN TEMPERATURE 160 DEGREES Hot temperature in a burn in cycle Note the burn in cycle is used to stabilize bands in temperature it executes 3 cycles of heating and cooling BURN IN TIME 30 SECONDS Heating time in seconds of the Burn_in cycle Nota the Burn in cycle is used to stabilize bands in temperature it executes 3 cycles of heating and cooling BURN IN CYCLE NUMBER 3 U M Numbers of heating and cooling phases in a burn in cy
13. with PLC or PC with or without digital panel in this way it s possible to exchange RUN TIME data SETTING data and MACHINE data with an external temperature probe connected to PLC it s possible read temperature of the bar and calibrating the machine with a very high precision EASY TO USE At start up a calibrating command automatically calibrate for sealing bands from 10 cm length to 400 IMPORTANT START UP SUPPORT The thermoregulator has a special software to dimension the plant the user introduces bands characteristics and the thermoregulator display the optimum voltage and power of transformer see field diagnostic FIELD DIAGNOSTIC The thermoregulator has a potent diagnostic to compare easily and immediately the current voltage resistance power read in real time with the same memorized during start up and the same calculated theorically see start up support in this way the thermoregulator can enhance the differences which can causes the trouble ALARM DIAGNOSTICS The temperature controller comes with an efficient diagnostics system capable of identifying faults which have occured during the production process indicating the cause and suggesting the remedies required to restore normal operating conditions THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 6 Tot Nr 47 2 WIRING DIAGRAM AND DIMENSIONS 2 1 LIST OF CHANG
14. ANSFORMER TECHNICAL FEATURES TRANSFORMER 1400VA 70V 30A CODE 3ESD0063 Impulsive Transformer for thermoregulator 30A 0 230 400 SCH GND 0 30 40 50 60 70 DESCRIPTION REFERENCE NORM CEI 96 2 EN60742 Insulation and safety transformers TRASFORMER IN CLASS I MONOPHASE PROTECTION RATIO IP20 COOLING Natural air FEATURES RATED POWER 1400 VA FREQUENCY 50 60 Hz MAINS SUPPLY 230 400 Monophase ACTIVE MAINS CURRENT 6 1 3 5 A OUTPUT VOLTAGE 30 40 50 60 70 V Monophase ACTIVE OUTPUT CURRENT 30A OUTPUT UNLOAD VOLTAGE 31 41 3 51 6 64 8 76 8 V c d t at rated power 5 4 ISTANTANEUS APPARENT POWER 2 1 the rated power Supplied for a short time with c d t 5 e cos 0 5 PRIMARY PROTECTION D type circuit braker with In active supply current THERMIC CLASS F INSULANCE CLASS MATERIALS F MAXIMUM AMBIENT TEMPERATURE 40 C VACUUM TEST 0 0 11 P0218W 10 0 4 30 a230 V SHORT CIRCUIT TEST 0 94 Pcc 75 Vcc 5 796 ADDITIONAL LEAKAGE Padd 10 W TOTAL LEAKAGE Pp Pcc PO Padd 103 W EFFICENCY cosg 1 n 92 5 MATERIAL CHARACTERISTIC SUPPORT BY INSULANCE MATERIAL Class F COILS IN COPPER GRADE 2 Classe PROTECTION OF THE OUTPUTS WIRES class electric strength 4 KV OUTPUTS TERMINALS IP20 INSULANCE TREATMENT Impregnating by insulance paint auto extinguishing type BC359 D
15. CAL 10 Iz PAGE 4 V THEORETICAL V0 V PAGE 5 P THEORETICAL 0 P 4 Particularlty useful information on the system conditions can be obtained by comparing the three variables so that any malfunctioning and diagnostic problems can be dealt with remotely THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 29 Tot Nr 47 4 9 SETUP PROCEDURES WITH THE AID OF THE CONTROL PANEL 1 Enter the theoretical values see paragraph 4 8 above 2 Access the DIAGNOSTIC ANALYSIS submenu see paragraph 4 8 above 3 Read the effective pulsed voltage of the strip THEORETICAL 4 Setthe transformer secondary voltage allowing for a multiplication coefficient of 1 5 2 for pulsed operation and a coefficient of 1 5 for continuous operation transformer V strip V x multiplication coefficient 1 5 2 select the nearest one 4 10 SETUP PROCEDURES WITHOUT USING THE CONTROL PANEL MANUAL MODE Calculating total resistance R strip specific resistance Ohm m x strip length m Calculating the strip cross section S Strip cross section S mm strip length mm x strip thickness mm Calculating the theoretical pulsed heating currents I I heating strip cross section S mm x 30 Amp Calculating the effective pulsed voltage applied to the strip V strip R strip x I heating Calculating the transformer secondary voltag
16. DURES WITHOUT USING THE CONTROL PANEL MANUAL MODE 5 MAINTENANCE 5 1 CHANGING THE SEALING BAND WITH MACHINE COLD 5 2 CHANGING THE SEALING BAND WITH MACHINE HOT 5 3 TROUBLESHOOTING 5 4 THERMOREGULATOR MAINTENANCE 5 5 GRIPPER JAWS MAINTENANCE 6 SPECIFICATIONS 6 1 SPECIFICATIONS 7 DETAILS FOR ORDER FORM 7 1 DETAILS FOR ORDER FORM App A TYPICAL SEALING CYCLE App B MACHINE DATA LIST App C SETTING DATA LIST App D FAULT AND WARNING LIST CAUSES REMEDIES App E DIMENSIONS App F TRANSFORMER TECHNICAL FEATURES App G START UP CARD THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 2 Tot Nr 47 0 WARNINGS THIS BOOK IS SUPPLIED WITH OUR PRODUCT AND DESCRIBES THE FUNDAMENTAL FUNCTIONS EMPLOY QUALIFIED AND WELL TRAINED PERSONNEL FAMILIAR WITH THE TECHNOLOGY USED TO INSTALL OR MAINTENANCE THE EQUIPMENT CONSULTING MAINTENANCE amp OPERATIONS MANUAL 0 1 SAFETY PRECAUTIONS Never use the equipment in explosive atmospheres or with explosive materials Never use the equipment with flammable material without first taking the required safety precautions Operate the equipment by following the instructions contained in this MAINTENANCE amp OPERATIONS MANUAL before doing an installation Never turn on the temperature controller power circuit when the safety guards are open Do not use the temperature controller for
17. E OVER SIGNALS CN1 POWER TERMINAL BLOCK SWITCH ON SECONDARY PINI ALTERNATING CURRENT SUPPLY 4 10 sq mm PIN2 ALTERNATING CURRENT SUPPLY 4 10 sq mm PIN BAND 4 10 sq mm PIN4 BAND 4 10 sq mm NOTE 1 Power supply and control circuit supply with the same phase NOTE 2 Twist power cable POWER TERMINAL BLOCK SWITCH ON PRIMARY PINI ALTERNATING CURRENT SUPPLY 230Vac 4 10 sq mm PIN2 4 10 sq mm PIN3 CONNECT TO 0 VOLTS ON THE SECONDARY OF THE POWER TRANSFORMER 4 10 sq mm TO CONTROL LEAKAGE CURRENT TO GROUND PIN4 ALTERNATING CURRENT SUPPLY 230Vac 4 10 sq mm NOTE 1 Power supply and control circuit supply with the same phase NOTE 2 Twist power cable CN2 CONTROL CIRCUIT SUPPLY TERMINAL BLOCK PIN1 400 Vac 0 1 absorption max 1sq mm PIN2 230 Vac 0 1A absorption max 1sq mm PIN3 O absorption max 1sq mm NOTE 1 Power supply and control circuit supply with the same phase CN3 CONTROLS TERMINAL BLOCK PINI COMMON 0 V PLC 24V DC 1 sq mm PIN2 IN PRE HEAT SIGNAL FROM PLC 24V DC OV DC 12 mA absorption max 1 sq mm PIN3 IN SEALING SIGNAL FROM 24V DC OV DC 12 mA absorption max 1 sq mm PIN4 IN RESET SIGNAL FROM PLC 24V DC OV DC 12 mA absorption max 1 sq mm PINS IN CALIBRATING SIGNAL FROM PLC 24V DC 0V DC 12 mA absorption max 1 sq mm PIN6 OUT SEALING FAULT CONTACT N C cosP 1 250 8A 1
18. ENTS RESISTANCES CHART Band width Band thickness Specific resistance RO M P mm Q mt THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 21 Tot Nr 47 e CONCAVE SPECIAL ALLOY ELEMENTS RESISTANCES CHART Band width Band thickness Specific resistance RO mm mm Se mt THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 22 Tot Nr 47 4 STURT UP 4 4 STURT UP PROCEDURES INSPECTING THE SYSTEM AND THE PARTS USED Stage 1 In order to properly set up the system read the instructions given in paragraph 4 8 THEORETIC CALCULATIONS AND DIAGNOSTIC PROCEDURES and 4 9 SETUP PROCEDURES WITH THE AID OF THE MULTI LINGUAL CONTROL PANEL Stage 2 Switch over to Low Voltage mode for power transformer outputs up to 10 Volt Select Standard mode for power transformer outputs from 11 to 99 V Switch to High Voltage mode for power transformer outputs from 100 to 140 V Select Primary or Secondary mode for pulsed currents up to 100 Amps Select Primary mode for pulsed currents from 100 A to 300 A Stage 3 Make the system has been contructed in an workmanshiplike manner Stage 4 For any further information call 3E ENGINEERING DEPARTMENT 4 2 PUTTING THE SYSTEM INTO SERVICE BASIC SETUP RS485 OPTION PRE HEAT POTENTIOMETER
19. ERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 12 Tot Nr 47 e CALCULATION OF THE USABLE BAND LENGTH It s the length of the part not coppered it s calculated by the following formula L UTIL LTOT x 2 LRAMC Usable length LLUTIL HIR mm e CALCULATION OF THE BAND SECTION The band section is calculated by the following formula SEZ LARG x SP in mmq Section SEZ mmq 32 CALCULATION OF SEALING BAND RESISTANCE If You USE AN ORIGINAL band 3E included in the underlying tables You can calculate band resistance using the tables and applying the following formula 1 single band R BAND R0 x L UTIL mt 2 2 bands in series R BAND R0 x L UTIL x 2 mt 3 2bandsin parallel R BAND RO x L UTIL 2 mt RO Specific resistance of the band mt L UTIL Usable length of the band mt If You DON T USE AN ORIGINAL band 3E included in the underlying tables You must measure the band resistance directly on te contact with a precision instrument Resistance THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 13 Tot Nr 47 3 3 THERMOREGULATOR CHOISE WHAT TYPE OF THERMOREGULATOR IS TO CHOOSE SECONDARY 60 AMPERE ICC 60 x 2 5 150 AMPERE
20. ETUP CAN BUS PRELIMINARY STAGES CAN BUS 4 6 BASIC SETUP PROFIBUS PRELIMINARY STAGES PROFIBUS THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 26 Tot Nr 47 4 7 OPERATING THE MULTI LINGUAL CONTROL PANEL NOTe The user can go back to the initial display from any video pages by pressing the RES button several times INITIAL DISPLAY LEVEL 1 NOTe To scroll the sub menus press buttons MODE ARROW DOWN or ARROW UP in the order given TEMPERATURE SUBMENU LEVEL 2 DIAGNOSTIC SUBMENU LEVEL 2 EMERGENCY TEST SUBMENU LEVEL 2 BURN IN SUBMENU LEVEL 2 DATA SETTING SUBMENU LEVEL 2 MACHINE DATA SUBMENU LEVEL 2 INFORMATION SUBMENU LEVEL 2 NOTE Press buttons MODE ARROW DOWN or ARROW UP to access any submenu or parameter NOTE To alter any parameter displayed proceed as follow Press the MODE button to switch over to modification mode 080 Press the ARROW UP button to alter any data item 081 Press the MODE button to quit the modification mode 081 THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 27 Tot Nr 47 NOTE Before saving any changes made the system prompts the user to confirm the entry 2 2ENTER YES MODE NO RES Select YES to c
21. ITING COOLING DOWN DURING CALIBRATION PROCEDURE Wait please F46 NO CURRENT SIGNAL Verify sealing band connection TA connection F47 TA SIGNAL WRONG TURNED TurnTA connection F48 PRE HEATING POTENZIOMETER NO CONNECTED OR CABLES BROKEN Verify pre heating potenziometer connections and cables F49 SEALING POTENZIOMETER NO CONNECTED OR CABLES BROKEN Verify sealing potenziometer connections and cables F51 WIPER I Switch off and switch on the thermoregulator if problem persist call the supplying 52 WIPER V Switch off and switch on the thermoregulator if problem persist call the supplying F53 WIPER VGROSS Switch off and switch on the thermoregulator if problem persist call the supplying 54 WIPER VFINE Switch off and switch on the thermoregulator if problem persist call the supplying F60 RESET WITH CALIBRATING IN PROCESS Repeat the calibrating F61 BALANCE UNSUCCESSFULL Repeat the calibrating F62 BALANCE V UNSUCCESSFULL Repeat the calibrating F63 BALANCE VGROSS UNSUCCESSFULL Repeat the calibrating F64 BALANCE VFINE UNSUCCESSFULL Repeat the calibrating F65 BALANCE UNSUCCESSFULL Repeat the calibrating F66 MAIN PHASE SYNCHRONISM Reset the thermoregulator if problem persist call the supplying F69 CURRENT TO GROUND Verify sealing bands in the machine touch ground F71 FAULT HARDWARE 15V INTERNAL Reset the thermoregulator if problem persist call the supplying F72 FAULT HARDWARE 15V INTERNAL Reset the thermoregulator if probl
22. LATION ON THE PRIMARY On the 220 Vac supply voltage of the logic 2 fuses inside the thermoregulator protect the internal transformer It s necessary protect only the 220 Vac supply cables from short circuit in compliance with the normes IEC204 1 On the power supply the transformer must be protect on the primary on the secondary it s possible to connect directly the transformer to the band without protections because of an active protection inside the termoregulator by the T A circuit protective devices depends on the HEATING CURRENT on the secondary rated to the primary Use the D curve protections or delay fuses The protections suggested must be verified by the designer in compliance with the application THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 16 Tot Nr 47 3 6 ADVICES TO DEVELOP ELECTRIC CONNECTIONS WHICH ACTIONS ARE TO DO TO HAVN T PROBLEMS DURING STARTING UP Use original power transformers by 3E For the first start up we recommend to use the original multi voltage power transformers by 3E specific for the thermoregolators 3E For the following start up we can supply original single voltage power transformers by 3E lower cost If You prefer to use a different transformer from above refer to technical characteristic on this book see ANNEX F MULTIVLTAGE TRANSFORMER TECHNICAL FEATURES Use original bands
23. MU EN Page Nr 23 Tot Nr 47 STURT UP THE SYSTEM INTO SERVICE BASIC SETUP MULTI LINGUAL CONTROL PANEL RS485 OPTION Step 1 Carry out the calibration procedure after performing the steps indicated in paragraph 4 1 Step 2 Make sure the machine is at ambient temperature Step 3 The Pre Heat and Heat Sealing controls should be inactivated Step 4 Power up the temperature controller Step 5 In the event of faults the Red ALARM LED on the temperature controller comes on follow the instructions given on the control panel and put the faults right as required the number of the fault occured is displayed on the control panel along with the relevant description in one of the 6 languages provided Step 6 Calibration keep the CAL button on the multi lingual control panel pressed for 3 seconds as indicated in the illustration below Figure 3 the four LEDS on the equipment go on flashing as long as calibration is being performed NOTE For further calibration procedures press buttons CAL MODE CAL on the multi lingual panel in the order given Also refer to the illustration below Figures 1 2 3 Figure 1 Figure 2 Figure 3 NOTE Calibration can be carried out from the outside as described in paragraph 4 2 with the basic setup Step 7 The system is ready to cycle once the calibration procedure has been carried out Set the Pre Heat and Heat Sealing temperatures press the MODE MODE button in the sequence
24. MU EN Page Nr 33 Tot Nr 47 6 SPECIFICATIONS 6 1 SPECIFICATIONS MODELS WITH CONTROL OF THE SECONDARY LOGIC CIRCUIT SUPPLY CN2 230Vac 10 0 1 A absorption POWER CIRCUIT SUPPLY MODEL SECONDARY 10 100V MAXIMUM SHORT CIRCUIT CURRENT MOD 60 A 150 AMP MAXIMUM SHORT CIRCUIT CURRENT MOD 90 A 260 AMP 10 MAINS FREQUENCY 50 60 Hz automatic changing DIGITAL CONTROLS 24 VDC 12 mA max absorption OUTPUT SEALING FAULT CONTACT 250 V 8A 1 250V 5A cos 0 4 ACCURACY H 1 C PRE HEATING TEMPERATURE be set from display console O 250 C SEALING TEMPERATURE can be set from display console O 250 SEALING TIME determined by PLC or precision timer COOLING TIME determined by PLC or precision timer AMBIENT TEMPERATURE 0 C 50 LEVEL OF BOARD PROTECTION IPOO LEVEL OF DISPLAY CONSOLE PROTECTION IP65 POWER ASSEMBLY WEIGHT 1 6 Kg PANEL WEIGHT 0 2 Kg PANEL POWER ASSEMBLY EXTENSION WEIGHT 0 2 Kg 6 2 SPECIFICATIONS MODELS WITH CONTROL OF THE PRIMARY LOGIC CIRCUIT SUPPLY CN2 POWER CIRCUIT SUPPLY MODEL PRIMARY MAXIMUM SHORT CIRCUIT CURRENT MOD PRIMARY MAINS FREQUENCY DIGITAL CONTROLS OUTPUT SEALING FAULT CONTACT ACCURACY PRE HEATING TEMPERATURE SEALING TEMPERATURE SEALING TIME COOLING TIME AMBIENT TEMPERATURE LEVEL OF BOARD PROTECTION LEVEL OF DISPLAY CONSOLE PROTECTION POWER ASSEMBLY WEIGHT PANEL WEIGHT PANEL POWER ASSEMBLY EX
25. N3 PRE HEAT POTENTIOMETER Screened 0 25 PIN4 Connect PIN3 to PIN4 Screened 0 25mmq PINS PIN6 SEAL POTENTIOMETER 4 58V Screened 0 25mmq PIN7 SEAL POTENTIOMETER RIF Screened 0 25mmq PIN8 SEAL POTENTIOMETER 0V Screened 0 25 PIN9 Connect PIN 8 to PIN9 Screened 0 25 NOTE 1 If conneted to PLC analog output use PIN2 PIN3 PIN7 PIN8 and leave free PIN4 PIN9 NOTE 2 Twist cables or better use cable TWINAX IBM Ns cod 3esd0066 THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Includes all models Manuale cod 3 5080 Vx MU EN Page Nr 8 Rev 2010 03 Tot Nr 47 22 ELECTRIC DRAW DIGITAL CONNECTIONS POTENTIDMETERS RS485 CONTROL SUPPLY CN2 CNS alada m z c Fuse BAND PADE 0 4 0 24VDC REFERENCE CNB 1 2 3141 81 6 SB KMO 5 POWER z BUTTON DD s gt Lil Pg aen guste ue zzz z x d CN3 6 b sapone pe PANEL 4 7 EMERGENCY BUTTON POWER SUPPLY GROUND 1 12 3 4 KAD imma 0WDCO l 24 vDC KAD Al KAQ KMQ 2 2 TERMOREGULATOR 4 4 ALARM TERMOREGULATOR EMERGENCY PLC PLC ALARM OUTPUT INPUT THERMOSALD ISC MAINTENANCE am
26. NG CYCLE NOTE The sealing cycle showed bottom is only for example and not a standard cycle to follow everytime From experience we have learnt that it s necessary modify the cycle depending on materials dimensions speeds and else For other informations don t exitate to contact our technical office SEALING CYCLE PRE HEATING SIGNAL IN THERMOSALD SEALING SIGNAL IN THERMOSALD closed FILM GRIPPER JAWS open closed BAND SEALERS 1 i open i 1 i COOLING FILM FEED THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 36 Tot Nr 47 ANNEX B MACHINE DATA LIST NOTE The machine data must be changed only by skilled workers with experience after getting in contact with our technical office the necessity to change some machine data may be in specific applications TO ENTER from secondary menu MACCHINE DATA press key MODE TO OUTPUT press key RES and follow guide CURRENT 60 90 120 AMPERE Not changeable it shows the nominal current of the model used conseguently the short circuit current will be I short circuitzInominal x 2 5 e HEATING INCREASE DEGREE 10 MS 2 4 U M Itis the speed of temperature increase following a pre heat or a sail comand Units degree 10 ms Increase this parameter means decrease time necessary to hot the sealing band to pre hea
27. TENSION WEIGHT 230Vac 1096 0 1 A absorption 230Vac 1096 300 AMP 50 60 Hz automatic changing 24 VDC 12 mA max absorption 250 V 8A cos 1 250V 5A cos 0 4 19 be set from display console O 250 C be set from display console O 250 C determined by PLC or precision timer determined by PLC or precision timer 0 C 50 IPOO IP65 1 6 Kg 0 2 Kg 0 2 Kg THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Manuale cod 3ES080x Vx MU EN Includes all models Page Nr Rev 2010 03 Tot Nr 47 DETAILS FOR ORDER FORM DETAILS FOR ORDER FORM MODEL Description THERMOSALD ISC Impulse Thermoregulator 100V 60A THERMOSALD ISC Impulse Thermoregulator 100V 90A obsolete THERMOSALD ISC Impulse Thermoregulator 100V 60A on PRIMARY THERMOSALD ISC Impulse Thermoregulator 100V 90A PANEL Multilanguage Panel data input PANEL RS485 Multilanguage Panel data input connection RS485 CAVO Cable panel Thermoregulator TA Amperometric Transformer CORNICE ADATT Aluminum molding for mounting ISC panel on old machines with old UPSCR panel OPTIONS RS485 Option serial interface RS485 INAN Option analog input LOWVOLT Opzione low volts OPTIONAL EQUIPMENT TRANSFORMER 2100VA 70V 30A Impulsive transformer for Thermoregulator 60 Ampere 0 230 400 SCH GND 0 30 40 50 60 70 TRANSFORMER 3000VA 50V 60A Impul
28. anufacture specific transformers lower cost by 3E or to supply electric features see append F WHICH VALUE OF SECONDARY VOLTAGE It s calculate from I heatin current and band s resistance VOLT SECONDARY R BAND x I HEATING Sample It s to connect a band with 0 4 Ohm of resistance section 2 sqmm heating current will be 60 Ampere 30Ampere x 2sqmm and the voltage of secondary will be 24 Volts 0 4 ohm x 60 Ampere Transforer POWERS 565 5 54 5 VA PRIMARY 7 7 V SECONDARY sea L V THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 15 Tot Nr 47 3 5 PROTECTION DEVICE CHOISE WHICH PROTECTIVE DEVICES ARE TO CHOOSE MODULATION ON THE SECONDARY On the 220 Vac supply voltage of the logic 2 fuses inside the thermoregulator protect the internal transformer It s necessary protect only the 220 Vac supply cables from short circuit in compliance with the normes IEC204 1 On the power supply the transformer must be protect on the primary and secondary protective devices depends on the HEATING CURRENT on the secondary and the same rated to the primary Use the D curve protections or delay fuses The protections suggested must be verified by the designer in compliance with the application e WHICH PROTECTIVE DEVICES ARE CHOOSE MODU
29. ay warning 66 without to stop the production this parameter indicates the seconds that the message is displayed THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 39 Tot Nr 47 ANNEX D FAULT AND WARNINGS LIST CAUSES REMEDIES NOTE To reset every alarm give external reset command or press reset button RES on the panel NOTE when an alarm happens on the thermoregulator the led red of alarm light it s possible to know the number of alarm reading the multilanguage panel or reading the number of lightening of led red and green ALARM NUMBER NR IMPULSES OF LED GREEN x 10 NR IMPULSES LED RED WARNING ALARM CAUSES Remedies ALARMA TERMOREGULATOR OFF AND DISPLAY OFF Verify power Logic supply fault call the supplying builder ALARMB TERMOREGULATOR WITH LED OFF AND DISPLAY ON Circuit of synchronisme fault call the supplying builder ALARM C TERMOREGULATOR WITH LED ON AND DISPLAY ON AND INDICATION SRL THERMOSALD Verify cable connection display F06 DISPLAY EEPROM FLASH WRITE Switch off and switch on the equipment and call the supplier F07 A D CONVERTER Switch off and switch on the equipment and call the supplier F08 INTERNAL TRASMISSION DC X Switch off and switch on the equipment F09 INTERNAL TRASMISSION I2C EEPR Switch off and switch on the equipment and verify parameters F19 RS485 MASTER
30. cle a standard burn in cycle includes 3 phases of heating at burn in temperature and 3 phases of cooling at 100 degrees TEMPERATURE GRADIENT FOR CALIBRATING START DEGREES 10SECONDS Indica la massima velocit di raffreddamento della temperatura in gradi 10secondi sopra la quale il bilanciamento non abilitato e compare warning 38 Se aumentiamo questo parametro si pu perdere precisione Set the maximum speed of cooling in degrees 10seconds upper this value the calibrating is disabled and a warning 38 is displayed Increasing this parameter can loose precision of calibrating ENABLE COMPENSATION WITH SYSTEM COLD SCC 2 0 U M Not developed enable the special function of a different initial seal temperature For more informations do not Exitate to contact our technical office SEAL TEMPERATURE WITH SYSTEM COLD WITH SCC 1 220 GRADI Not developed it s the seal temperature of the first seals when temperature of the band is less then structure temperature For more informations do not exitate to contact our technical office STRUCTURE TEMPERATURE WITH SYSTEM COLD WITH SCC 1 80 GRADI Not developed if sealing band temperature is less then structure temperature the seal temperature will be equal to SEAL TEMPERATURE WITH SYSTEM COLD For more informations do not exitate to contact our technical office TIME WARN66 3 SECONDS In the case of frequency instability caused by power factor correction the thermoregulator displ
31. e allowing for a multiplication coefficient of 1 5 2 to increase the sealing speed under pulsed operating conditions and coefficient 1 for continuous operation V transformer V strip x multiplication coefficient 1 5 2 select the nearest one THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 30 Tot Nr 47 5 MAINTENANCE 5 1 CHANGING THE SEALING BANDS WITH MACHINE COLD i e gripper jaws at ambient temperature e HAVE YOU TO CHANGE THE SEALING BANDS WITH THE MACHINE AT AMBIENT TEMPERATURE BECAUSE OF A PROGRAMMED MAINTENANCE Pre heat and seal comands are off the machine is at ambient temperature The sealing bands have little differences in measure for optimum accuracy it is possible to do an automatic cold balance to compensate the differences it is possible doing a burn in cycle after to become stable electric characteristics 1 Switch off power release pre heat and seal commands let the gripper jaws getting cold down 2 Install the new sealing bands switch on power 3 Make the CALIBRATING Normally is not necessary change ambient temperature gripper jaws temperature in the SETTING DATA and doing a burn in cycle at the end of calibrating 4 THE MACHINE IS READY TO WORK THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page N
32. ector verify breaking of power cables verify breaking of bands REFERENCE SIGNAL CABLE FROM BANDS IS INTERRUPTED Verify the connection of reference signal cable from band CN6 1 CN6 2 MAIN SUPPLY SYNCRONISM DOES NOT MUCH MACHINE REQUIREMENTS Internal hardware problem call the supplying builder FAULT V I TOO HIGH Saturation of the voltage circuit verify connection probable break of one seal if seals in parallel PARTIAL SHORT CIRCUIT BETWEEN THE BANDS Verify bands into machine probably not perfectly isolated If the problem persist repeat burn in procedure or do calibrating To reduce the problems increase machine data partial short circuit FAULT GENERIC call the builder THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 42 Tot Nr 47 ANNEX E DIMENSIONS PANEL BORING DIGITAL PANEL 96x48 BACK DIMENSION 86x40 5 H 55 CONNECTION mm TOP VIEW TERMOREGULATOR 60 AMPERE 90 AMPERE AND HOLES FOR PANEL MOUNTING Nr 3 HOLES D 4 5 mn 120 mm 95 mm H 145 mm T 20 mm 100 mm TOP VIEW TERMOREGULATOR 90 AMPERE OBSOLETE AND HOLES FOR PANEL MOUNTING Nr 2 HOLES D 4 5 mn 180 mm 168 mm H 145 mm THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 43 Tot Nr 47 ANNEX F MULTIVOLTAGE TR
33. em persist call the supplying F73 FAULT HARDWARE 5V INTERNAL REFERENCE Reset the thermoregulator if problem persist call the supplying F76 TREAD TOO HIGH Verify if short circuit on the seals F78 THERMOREGULATOR NOT CALIBRATED Do a calibrating 79 FAULT OF EMERGENCY CIRCUIT Verify contactor power verify emergency chain THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 41 Tot Nr 47 F081 F082 F083 F085 F089 F090 F092 F093 F094 F095 F096 F097 F099 FAULT HARDWARE CHECK SUM Data in the eeprom wrong pay much attention please Press button RES verify TEMPERATURE SETTING MACHINE DATA call the builder LOGIC SUPPLY CN2 AND POWER SUPPLY CN1 HAVE DIFFERENT PHASES Verify that the supplies have the same fase REFERENCE CABLE WRONG TURNED Turn reference cable CN1 3 WITH CN6 1 CN1 4 WITH CN6 2 SEALING TIME HIGHER THEN MACHINE DATA SEALING TIME Increase machine data sealing time If O the controll is off BAND BROKEN IF THE BANDS ARE PARALLEL CONNECTED Verify the bands SHORT CIRCUIT BETWEEN THE BANDS OR BETWEEN A BAND AND GROUND IN THE CASE OF HIGH CURRENT Verify bands verify power connection between thermoregulator and bands POWER PART FAILURE Reset the thermoregulator if problem persist call the supplying BAND BROKEN DURING A SEAL Verify power on the transformer Verify voltage on CN 1 CN 2 conn
34. given to access the TEMPERATURE submenu refer to paragraph 4 7 Step 8 To go back to the initial display press the RES button and follow the instructions given THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 24 Tot Nr 47 NOTE If calibration problems arise perform a MASTER RESET procedure starting from stage 5 To perform a MASTER RESET procedure use either of the two modes below mode 1 Keep the ARROW DOWN ARROW UP buttons pressed for 6 seconds mode 2 Keep the external RESET CALIBRATION buttons pressed for 6 seconds The four LEDS on the equipment stay on for 3 seconds 4 4 PUTTING THE SYSTEM INTO SERVICE BASIC SETUP MULTI LINGUAL PANEL POTENTIOMETERS RS485 OPTION PRE HEAT POTENT HEAT SEAL POTENT CLEAR FAULTS RESET BUTTON CALIBRATION BUTTON NOTE 1 Perforn the same operations as those described in paragraph 4 3 above NOTE 2 To enable the potentiometers change the MACHINE DATA items 1 Potentiometers display NOTE 3 Set the maximum pre heat and heat seal temperatures by using the control panel To step them down adjust the analog inputs potentiometer setting 30 degrees turn analog input settings 13 mV degree THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 25 Tot Nr 47 4 5 BASIC S
35. green Class F DRYING oven drying of the insulance paints after treatment THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 44 Tot Nr 47 TRANSFORMER 3000VA 50V 60A SERV 40 Impulsive Transformer for thermoregulator 60A 0 230 400 SCH GND 0 30 40 50 CODE 3ESD0064 DESCRIPTION REFERENCE NORM CEI 96 2 EN60742 Insulation and safety transformers TRASFORMER IN CLASS I MONOPHASE PROTECTION RATIO IP20 COOLING Natural air FEATURES RATED POWER 3000 VA Serv 40 FREQUENCY 50 60 Hz MAINS SUPPLY 230 400 Monophase ACTIVE MAINS CURRENT 6 1 3 5 A OUTPUT VOLTAGE 30 40 50 V Monophase ACTIVE OUTPUT CURRENT 60A OUTPUT UNLOAD VOLTAGE 31 41 3 51 6 64 8 76 8 c d t at rated power ISTANTANEUS APPARENT POWER 2 1 the rated power Supplied for a short time with c d t 5 e 0 5 PRIMARY PROTECTION D type circuit braker with In active supply current THERMIC CLASS F INSULANCE CLASS MATERIALS F MAXIMUM AMBIENT TEMPERATURE 40 C VACUUM TEST 0 0 11 PO 18W 10 0 4 30 a230 V SHORT CIRCUIT TEST cosgcc 0 94 Pec 75 Vcc 5 796 ADDITIONAL LEAKAGE Padd 10 W TOTAL LEAKAGE Pp Pcc PO Padd 103 W EFFICENCY 1 n 92 5 MATERIAL CHARACTERISTIC SUPPORT BY INSULANCE MATERIAL Class F COILS IN COPPER GRADE 2 Classe
36. le component plastic films multilayer plastic films in general that must reach their melting temperature and a cool down immediately to avoid deformations OPERATING PRINCIPLES To execute impulse sealing use a sealing bar with a sealing band o wire electrically insulated from earth supplied by an equipment specific for impulse sealing i e an impulse thermoregulator This equipment must supply the power required to heat the band at the desired sealing temperature in an extremely short time and maintain the desired temperature with high precision during all the sealing operations No additional probe are required the equipment simpy reads the feedback signals from the bands and controls the heating current with a closed loop circuit The termoregulator first receives a pre heat signal from the outside so that the sealing bar can reach a required pre heat temperature not far from sealing temperature before starting works The thermoregulator further receive a sealing signal from the outside so that the sealing bars can reach the correct sealing temperature when brought together MAIN FEATURES The thermoregulator THERMOSALD ISC is manufactured in 3 versions switch of the power transformer on the secondary up to 60 or 90 ampere switch on the primary up to 300 Ampere it s interchangable with all the previous thermoregulator by our company it s very easy to use RS485 SERIAL INTERFACE The low cost option RS485 let user to interface thermoregulator
37. ng high currents or other electrical noise sources In any case the panel cable is screened and protected from electrical noise Mount the thermoregulator leaving a rigth space around for cooling 8 cmabout for model 60 Ampere 10 cm about for model 90 Ampere THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 17 Tot Nr 47 CONNECTIONS TO SINGLE BAND THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 18 Tot Nr 47 CONNECTIONS IN PARALLEL SUGGESTED THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU EN Page Nr 19 Tot Nr 47 CONNECTION IN PARALLEL HIGH PRECISIOUS CONTACT OUR TECHNICAL OFFICE FOR 2 o 4 REFERENCE CABLE if 2 reference cables use the couple 3 6 or 4 5 OBSOLETE THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Includes all models Manuale cod 3 5080 Vx MU EN Page Nr 20 Rev 2010 03 Tot Nr 47 CHAMFERED SPECIAL ALLOY ELEMENTS RESISTANCES CHART Band width Band thickness Specific resistance RO mm mm Q mt e T SHAPE SPECIAL ALLOY ELEMENTS RESISTANCES CHART Band width Band thickness Specific resistance RO mm mm mt E BEADED SPECIAL ALLOY ELEM
38. onfirm NO to restore the earlier data THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3 5080 Vx MU Page Nr 28 Tot Nr 47 4 8 THEORETICAL CALCULATIONS AND DIAGNOSTIC PROCEDURES WITH THE AID OF THE DATA INPUT PANEL 1 Access the DIAGNOSTIC THEORETICAL CALCULATION submenu 2 Enter the data that concern the shape of the strip length width cross section number of strips in series number of strips in parallel 3 Enter the data and quit DIAGNOSTIC 1 Select the DIAGNOSTIC ANALISYS submenu 2 Scroll the diagnostic video pages by using the ARROW UP DOWN buttons These pages contain the electrical specifications that concern the sealing strip maximum effective currents resistance full wave effective currents full wave effective power 3 Each video page indicates 3 values that relate to the same variable under different conditions i e THEORETICAL VALUES CALIBRATION SETTINGS REAL TIME VALUE in particular PAGE 1 IMAX 10 Where IMAX stands for the maximum pulsed effective currents of the temperature controller IO represents the full wave effective current for calibration and I is the actual full wave effective current PAGE 2 R THEORETICAL R0 R Where R THEORETICAL stands for the theoretical resistance of the temperature controller RO is the calibration resistance and R represents the actual resistance PAGE 3 I THEORETI
39. p OPERATIONS MANUAL Includes all models Manuale cod 3ESO80x Vx MU EN Page Nr 9 Rev 2010 03 Tot Nr 47 22 ELECTRIC DRAW POWER CONNECTIONS CONTROL OF THE SECONDARY 230v 400V 50Hz Imma POTENTIOMETERS R3485 CN CN CNS 71 2 FILTER u 12 lt EMC i ie 12 8 FUSE 1 meo a H LoL E 1 3 c z z 2 ox A B d om cue 1 3 KMO 2 314515 2 4 2 1000 0 2304 CONTROLS m Z EC e PANEL v 50 lt CN4 zz 2 4 d OF n s 3 3 314 GROUN 1 CN1 2 1 3 4 10mmq PE 1 d SEALING BAND aspen PANEL NOTE Power supply CN1 1 e CN1 2 must be with the same phase as control supply CN2 3 CN2 2 Ground screw must be connected to the ground of machine with the cable jellow green section gt power cable section Twist power cable twist TA cable Twist and screen sealing reference cable THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010
40. r 31 Tot Nr 47 5 2 CHANGING THE SEALING BANDS WITH MACHINE HOT ie gripper jaws cooling down but hot too because of inertia HAVE YOU TO CHANGE THE SEALING BANDS WITH THE MACHINE HOT WITH THE PRODUCTION IN PROGRESS WITHOUT WAITING THAT GRIPPER JAWS TEMPERATURE FALLS DOWN AT AMBIENT TEMPERATURE A sealing bands change with the machine hot with the production in progress is less accurate then a change with the machine cold in a programmed maintenance because the automatic cold balancing must not be done an automatic cold balance is done to compensate the differences in measure of the sealing bands If the application needs a very high precision it is possible doing a quick change of the all gripper jaws with sealing bands and go on with the preceding procedure of CHANGING THE SEALING BANDS WITH MACHINE COLD see par 5 1 Another less expensive way to work but easier to make a mistake is to set the parameter of ambient temperature at the gripper jaws temperature and doing an automatic cold balancing do not exitate to contact our technical office 1 Switch off power release pre heat and seal commands let the gripper jaws cooling down 2 Install the new sealing bands switch on power If the machine is hot must not do the automatic cold balancing 3 Only if necessary do the BURN IN CYCLE Verify if burn in is necessary in the specific application looking at the quality of the first seal
41. r 46 Tot Nr 47 ANNEX G START UP CARD PAG 2 MACHINE DATA TABLE RATED CURRENT HEATING INCREASE DEGREE PROPORZION GAIN KV INTEGRAL GAIN KI OPERATING LIMIT KI DERIVATTIV GAIN KD HEATING FACTOR INITIAL TEMPERATURE PARTIAL SHORT CIRC FACT ALLARM DISABLE CONFIG IMPULSE SEAL CONFIG PANEL CONFIG SER RS485 1 9600 ADDRESS SERIAL 5485 SETTING DATA TABLE LANGUAGE SELECTION DEGREES SELECTION CALIBRATING TEMPERAT MAX SEALING TEMPER AT MAX SSEALING TIME BURN IN DEGREES BURN IN SECONDS BURN IN NR CYCLES TEMPERATURE GRADIENT ENABLE COMP WITH COLD SEAL TEMPER WITH COLD STRUCTURE TEMPERATURE TIME WARN66 PAR 1 ODD 2 EVEN NR STOP BIT PROTOCOL TIME OUT IDLE CHAR BEFORE TX CHECK 1 CRC 2 XOR 0 NO Default xxx 4 100 100 60 40 1 9 0 1 2 0 Default ITAL IAN CELSIUS 30 250 0 0 180 5 5 4 0 220 80 3 0 2 0 1 0 1 THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 47 Un RU Rev 2010 03 Tot Nr 47
42. rmoregulator sends fault signal F097 e FAULT DISABLE 0 U M Disable any alarm use much caution sometime it can help to continue the production alarm disable must be considered temporary and it s necessary understand immediately the cause of the trouble e CONFIGURATION MODE 0 The thermoregulator is designed to develope 2 type of functions 0 standard function IMPULSE SEALING 1 function HOT BAR THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 37 Tot Nr 47 e CONFIGURATION PANEL 2 The thermoregulator is designed for 5 type of functions 0 function only with potentiometers at first start up 1 function with potentiometers and display the temperature set on display in pre heat and seal is the maximum value with potentiometers can decrease also with analog input 2 function only with display 3 predisposed for CAN BUS 4 predisposed for PROFIBUS e CONFIGURATION SERIAL INTERFACE SERIAL 485 OFF Thermoregulator can exchange data with supervisor by RS485 interface e SERIAL ADDRESS RS485 0 Unit address for serial interface RS485 value admitted 0 15 THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 38 Tot Nr 47 ANNEX C SETTING DATA LIST NOTE The setting data must be changed only by skilled workers with experience after getting
43. sive transformer for Thermoregulator 60 Ampere 0 230 400 SCH GND 0 30 40 50 TRANSFORMER 3000VA 30V 90A Impulsive transformer for Thermoregulator 90 Ampere 0 230 400 SCH GND 0 20 30 TRANSFORMER 3000VA 15V 200A PER PRIMARIO Impulsive transformer for Thermoregulator 120 Ampere on PRIMARY 0 230 400 500 900 SCH GND 0 15 SEALING BANDS WIRES ENDLESS BELT Bands wires and endless belts with many profiles selled in meters on specific draw Copper Silver ended teflon coated THERMOSALD 485 Supervisor simulator for RS485 CD Box 5232 5485 MANUALS ITALIAN COMMERCIAL CATALOGUE ITALIAN QUICK START MANUAL ITALIAN MAINTENANCE amp OPERATOR MANUAL ENGLISH COMMERCIAL CATALOGUE ENGLISH QUICK START MANUAL ENGLISH MAINTENANCE amp OPERATOR MANUAL FRENCH MANUAL QUICK START MANUAL GERMAN MANUAL QUICK START MANUAL SPANISH MANUAL QUICK START MANUAL THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Manuale cod 3ES080x Vx MU EN Includes all models Page Nr 35 CODE 3ES080DH 3ES081DH 3ES082DH 3ES083DH 3ES080DL 3ES080DM 3ES080A001 3ES080A002 3ES080A003 3ES080DZ 485 3ES080DZ INAN 3ES080DZ LOVL 3ESD0063 3ESD0064 3ESD0065 3ES082A001 3ESD0075 3ES080x_Vx_CO_IT 3ES080x_Vx_QS_IT 3ES080x_Vx_MU_IT 3ES080x_Vx_CO_EN 3ES080x_Vx_QS_EN 3ES080x_Vx_MU_EN 3ES080x Vx QS FR 3ES080x Vx QS DE 3ES080x Vx QS SP Rev 2010 03 Tot Nr 47 ANNEX A TYPICAL SEALI
44. sq mm OUT SEALING FAULT CONTACT N C 0 4 250V 5A 1 sq mm THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 7 Tot Nr 47 CN4 DISPLAY PANEL CONNECTOR 15 PIN FEMALE PINI S5Vcc Screened 0 25 PIN2 OV Screened 0 25mmq PIN3 SPI SDO Screened 0 25mmq PIN SPI SCK Screened 0 25mmq PINS SPI SDI Screened 0 25mmq PIN6 PIN7 PIN8 PIN 5 55 Screened 0 25mmq PINIO RESERVED Screened 0 25mmq PINI1 RESERVED Screened 0 25 PINI2 RESERVED Screened 0 25mmq PINI3 RESERVED PIN14 PIN15 NOTE 1 The cable termoregulator panel must be screened pin to pin connected Max Mt 15 CN5 5 485 SERIAL INTERFACE CONNECTOR 9 PIN FEMALE PIN3 Channel B Screened 0 25 PIN8 Channel A Screened 0 25mmq NOTE 1 Twist the cables CN6 REFERENCE TERMINAL BLOCK PINI SEALING BAND REFERENCE REF 0 5mmq PIN2 SEALING BAND REFERENCE REF 0 5mmq PIN3 SCREEN REFERENCE CABLE REF 0 Don t connect on machine side 1mmq PIN4 REFERENCE TA 0 5mmq PINS REFERENCE TA 0 5mmq PIN6 SCREEN TA CABLE TAO Don t connect on machine side 1mmq NOTE 1 Twist cables or better use cable TWINAX IBM Ns cod 3esd0066 CN7 POTENTIOMETER CONNECTOR 9 PIN MALE PINI POTENTIOMETER 4 58V Screened 0 25 PIN2 POTENTIOMETER RIF Screened 0 25 PI
45. t temperature i e increase speedy increase overshoot increase bands wear and tear PROPORTIONAL GAIN KV 100 U M Loop integral gain Increase this parameter means to increase the precision of the target temperature increase the speedy increase the stability of the system Increase too much means to introduce a temperature overshoot following a pre heat or sealing command INTEGRAL GAIN KI 100 U M Loop integral gain Increase this parameter means to increase the precision of the target temperature increase the speedy increase the stability of the system Increase too much means to introduce a temperature overshoot following a pre heat or sealing command KI OPERATING LIMIT 60 40 Limits the maximum value of the integral gain KI increasing this value overshoot with the machine cold increases DERIVATIVE GAIN KD 40 U M Loop derivative gain Increase this parameter means increase speed of the loop and then increase speed of the system Increase too much means to do the system and temperature less stable HEATING FACTOR 1 9 U M This parameter modify the temperature characteristic of the thermoregulator Increase this parameter means increase the temperature of the band INITIAL TEMPERATURE 0 DEGREE Degree Value relating to 0 of AD converter PARTIAL SHORT CIRCUIT FACTOR 1 1 U M This parameter is used to set an istantaneous current threshold above which a partial short circuit occurs and the the
46. tasks other than those it is designed for i e to control the temperature of bands or wires for industrial grade sealing Contact our engineering department for information regarding specific applications Do not deliver electrical power to the temperature controller if the protective cover has been removed for special servicing on the electronic system Employ qualified and well trained personnel familiar with the technology used to install and use the equipment Grounding the thermoregulator by yellow green cable connected to the predisposed screw and by 4 fixing screw Use bands or wires having an adequate positive temperature coefficient gt 1 x 10E 3 When the machine is running under normal conditions make sure the heat sink of the controller does not exceed 60 C If this happens increase heat sink ventilation or contact our engineering department THERMOSALD ISC MAINTENANCE amp OPERATIONS MANUAL Rev 2010 03 Includes all models Manuale cod 3ES080x Vx MU EN Page Nr 3 Tot Nr 47 0 2 COMPLIANCE WITH ELECTRO MAGNETIC STANDARDS CE KITE MARKS TESTS AND RESULTS Test conditions e Mains supply filter Mod Siemens B84112 B B60 115 250 V 6A 50 60 Hz e Connecting cable thermoregulator panel mt 5 e Input power cables length mt 5 e Output power cables length mt 5 Normative References e CEI EN 50081 2 06 1997 Electromagnetic compatibility Generic emission standard Part 2
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