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Operating instructions RES-406 - About

1. x Controller functions 10 4 1 Compact protocol with 4 Bit error code The 16 bit input data from the PROFIBUS master to the RES 406 contains the set point and the control functions and has the following structure Control function Set point AC temperature 75 65 P P L U 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit no 15 14 The 16 bit output data from the RES 406 to the error code and the status information and has the PROFIBUS master contains the actual value or the following structure Error code if AL 1 Status information Actual value compact if AL 0 pasta e oja T T T l T 4 13 12 11 10 9 8 7 5 4 3 2 1 0 Bit no 15 1 6 10 4 2 Compact protocol vvith 10 Bit codes must be activated in the parameter data error code section 10 7 9 Error code format on page 31 The 10 Bit error codes are available on all The 16 bit input data from the PROFIBUS master to controllers manufactured as of duly 24 2006 the RES 406 contains the set point and the control and supplied with GSD Version v1 6 These error functions and has the following structure Control function Set point AC temperature s b 5 s p P P Pt P OP 1 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit no 15 14 The 16 bit output data from the RES 406 to the error code and the status information and has the PROFIBUS master contains the actual value or the following structure Error code if AL 1 Statu
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3. Startup and operation switches A new setting does not take effect until the next time the controller is switched on PROFIBUS STATION ADDRESS Top of housing DE ENERGIZED PC D ENERGIZED 9 3 Replacing and burning in the heatsealing band 9 3 1 Burning in the heatsealing band The heatsealing band is a key component in the control loop since it is both a heating element and a sensor The geometry of the heatsealing band is too complex to be discussed at length here We shall therefore only refer to a few of the most important physical and electrical properties The measuring principle applied for this system necessitates a heatsealing band alloy with a suitable temperature coefficient TCR Too low a TCR leads to oscillation or uncontrolled heating When heatsealing bands with a higher TCR are used the controller must be calibrated for this The first time the heatsealing band is heated to approximately 200 250 C the standard alloy undergoes a once only resistance change burn in effect The cold resistance of the heatsealing band is reduced by approximately 2 3 However this at first glance slight resistance change results in a zero point error of 20 30 C The zero point must therefore be RES 406 Startup and operation corrected after a few heating cycles i e the AUTOCAL function must be repeated The burn in effect described here does not occur if the heatsealing band has alr
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5. Since a temperature indication is no longer necessary if a fault occurs the analog output is used to display error messages in the event of an alarm 13 voltage levels up to January 2006 12 voltage levels are offered for this purpose in the 0 10VDC range each of which is assigned an error code section 10 15 Error messages on page 35 If a state that requires AUTOCAL occurs or if the con troller configuration is not correct error codes 8 12 as of February 2006 also 104 106 111 114 211 302 303 the signal at the analog output jumps back and forth at 1Hz between the voltage value which corresponds to this error and the end of the scale 10VDC i e 300 C or 500 C If the ST bit is acti vated in one of these states the voltage value does not change any more Selective fault detection and indication can thus be implemented simply and inexpensively using the analog input of a PLC with a corresponding error mes sage section 10 15 Error messages on page 35 RES 406 LR O P E An alarm can only be reset by activating the RS bit or by switching the controller off and then on again If an error message is reset using the RS bit the RS bit must be deactivated first Invalid error messages may appear when the controller is switched off owing to the undefined operating state This must be taken into account when they are evaluated by the higher level controller e g a PLC in or
6. As of February 2006 With ROPEX visualization software only 12 Maintenance The controller requires no special maintenan Regular inspection and or tightening of the terminal including the terminals for the winding connections Page 42 Maintenance Station address 01 Jec AUTOCOMP OFF Temperature diagnosis OFF Heatup timeout OFF ce the impulse transformer is recommended Dust 5 deposits on the controller can be removed with dry on compressed air RES 406 How to order R 0 D E x 13 How to order Contr RES 406 VAC 115 Power supply 115VAC Art No 740601 230 Power supply 230VAC Art No 740602 400 Power supply 400VAC Art No 740603 Scope of supply Controller includes connector plug in parts without current transformer Modification MOD optional if required e g L 01 MOD 01 Art No 800001 Amplifier for low voltage Please indicate the article numbers of the controller and the required modifications optional in all orders e g RES 406 400VAC MOD 01 controller for 400VAC power supply with amplifier for low voltage Art No 740603 800001 must be ordered Current transformer PEX W3 Art No 885105 Line filter LF 480 06 Continuous current 6A 480VAC Art No 885500 35 Continuous current 35A 480VAC Art No 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communiction interface CI USB 1 Art No
7. green In control mode the luminous intensity is proportional to the heating current ALARM red Configuration error AUTOCAL not possible incorrectly run AUTOCAL Controller calibrated Fault section 10 15 DATA EXCHANGE green The following sections describe only controller specific functions For general information about PROFIBUS and the system configuration please refer to the description of your PLC 10 2 PROFIBUS communication up to Jan 2006 as of Feb 2006 On controllers manufactured up to January 2006 PROFIBUS communication is only assured if the Page 22 Communication vvith PROFIBUS master active 24VDC power supply terminals 5 7 and PROFIBUS connector pins 7 2 and the line voltage are present If the line voltage is svvitched off e g for safety reasons in order to open a door the PROFIBUS master indi cates a bus fault because PROFIBUS communication is not possible on the RES 406 This problem has been rectified on controllers manu factured as of February 2006 PROFIBUS communica tion is alvvays possible on these controllers as long as the 24VDC power supply is present i e svvitching off the line voltage no longer results in a bus fault RES 406 Controller functions If the line voltage is not present however e g if it is switched off in order to open a door error code 901 error group 7 no line voltage sync signal appears on controllers m
8. 34 mpulse heatsealing method 4 mpulse transformer 7 12 43 nput data 26 nstallation 9 10 nstallation procedure 10 Installation regulations 10 L Line filter 6 12 13 43 Line frequency 8 Line voltage 8 M Maintenance 42 Measurement cable 7 Measurement pause 27 Measuring impulse duration 30 Modifications MODs 7 43 MODs 7 43 MP bit 27 o Output data 28 Overheating of heatsealing band 6 P PEX W2 W3 3 PEX VV3 13 43 Phase angle compensation 32 Power dissipation 9 Power supply 12 43 Principle of operation 5 PROFIBUS DP interface 8 Protocol Compact 10 Bit error code 24 Compact 4 Bit error code 24 RES 406 Index Extended 10 Bit error code 25 Extended 4 Bit error code 25 R RA bit 20 28 Replacing the heatsealing band 19 20 Reset 27 RS bit 27 s Secondary current 12 16 Secondary voltage Up 16 Set point 28 Start 27 START bit 20 Startup 16 System diagnostics 34 System monitoring 34 T TCR 3 18 nol 54 TE bit 28 Temperature coefficient 3 18 Temperature control 4 Temperature diagnosis 33 Temperature indication 31 Temperature meter 32 43 Temperature OK 28 Temperature range 17 Temperature reached 28 TO bit 28 Transformer 3 7 12 43 Type of construction 8 V View of the controller 16 Visualization software 34 Ww Wiring 10 12 VViring diagram 14 15 RES 406 Page 45
9. AUTOCAL function should be executed error codes 8 9 as of February 2006 also 104 106 211 302 303 2 Blinks slowly 1Hz The system configuration is incorrect and the zero calibration AUTOCAL function was unsuccessful 5 section 9 2 Controller configuration on page 16 It corresponds to error codes 10 12 as of February 2006 also 111 114 3 Lit continuously This indicates that a fault is preventing the controller from being started error codes 1 7 as of February 2006 also 101 103 107 108 201 203 307 308 801 9xx As a rule it refers to an external wiring fault RES 406 Controller functions B Alarm relay relay contact terminals 12 13 14 This relay is set in the factory as follows DE ENERGIZED in operating states A 1 and 2 but energized if the ST bit is activated in one of these states e ENERGIZED in operating state If the alarm relay is configured opposite to the factory setting 5 section 9 2 4 Configuration of the alarm relay on page 18 these states are reversed C Error code indication via the PROFIBUS protocol If a fault occures the AL bit is set and in the compact protocol the error code appears instead of the actual value in bits 0 3 while in the extended protocol it is contained at bit positions 8 11 in the second word section 10 6 9 Error codes on page 29 D Error code output via the 0 10VDC analog output terminals 17 18
10. Controller functions AUTOCAL bit 2 05 1 t Function 11 AUTOCOMP AUTOCAL AUTOCAL LED lit off HEAT LED The HEAT LED blinks AUTOCOMP function is executed and the actual value output terminals 17414 is set to 0 3 C i e app 0 VDC repeatedly when the The AUTOCOMP function must be activated in the ROPEX visualization software 5 section 10 13 Diagnostic interface visualization softvvare as of February 2006 on page 34 default setting AUTOCOMP off 10 11 Temperature diagnosis as of February 2006 An additional temperature diagnosis can be activated in the ROPEX visualization software section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 The RES 406 checks whether the ACTUAL temperature is within a settable tolerance band OK vvindovv on either side of the SET RES 406 4 0 42 92 temperature lower Qe wer and upper Av Upper tolerance band limits are the same like in the Temperature OK function section 10 6 5 Temperature OK TO on page 28 The limits are configured in the factory to 10K and 10K f the actual temperature is inside the specified tolerance band when the START signal is activated the temperature diagnosis is activated as well If the ACTUAL temperature leaves the tolerance band the corresponding error code 307 or 308 is indicated and the alarm relay is
11. machinery directive EN 50081 1 EMC interference emissions according to EN 55011 group 1 class B EN 50082 2 EMC interference immunity ESDs RF radiation bursts surges Compliance with these standards and provisions is only guaranteed if original accessories and or peripheral components approved by ROPEX are used If not then the equipment is operated on the user s own responsibility The CE marking on the controller confirms that the device itself complies with the above mentioned standards It does not imply however that the overall system also fulfils these standards t is the responsibility of the machine manufacturer and of the user to verify the completely installed wired and operationally ready system in the machine with regard to its conformity with the safety provisions and the EMC directive see also section 8 3 Power supply If peripheral components e g the transformer or the line filter from other manufacturers are used no functional guarantee can be provided by ROPEX The controller is most commonly used for impulse heatsealing PE films in Vertical and horizontal f f s machines e Pouch filling and sealing machines Film wrapping machines e Pouch making machines e Group packaging machines etc RES 406 Principle of operation The use of RESISTRON temperature controllers results in e Repeatable quality of the heatseals under any conditions 3 Principle of operation The
12. maximum current of the filter The wiring instructions contained in section 8 3 Power supply on page 12 must be observed ROPEX temperature controller Mounting plate galvanized Large frame contact surface of the control system The current transformer may only be operated if it is connected to the temperature controller correctly 5 section 8 3 Power supply on page 12 14 gt 28 terminal block Snap on for DIN rail 35 x 7 5mm or 35 x 15mm DIN EN 50022 RES 406 Page 13 D E x Installation 8 6 Wiring diagram standard PROFIBUS PLUG SUB D 9 POLE Line filter LF xx480 PROFIBUS controller electrically 5V VP isolated Impulse transformer 24VDC POWER SUPPLY GND Heat sealing band ALARM OUTPUT max 50V 0 2A up to production date I o danuary Current transformer aa Ni PEX W2 W3 Internnal ground Must be grounded No external externally to prevent electrostatic charging grounding allowed 0V Internnal ground No external grounding allowed ANALOG OUTPUT 0 10VDC Page 14 RES 406 Installation R 0 E nx 8 7 VViring diagram vvith booster connection PROFIBUS PLUG SUB D 9 POLE Line filter LF xx480 PROFIBUS controller electrically 65V VP isolated Impulse transformer 24VDC
13. remains set for longer than the time specified by this limit The start bit must be reset before the controller can be started up again The heating time limit is deactivated as default 0 but can be set to any value between 05 and 25 05 and 250 10 7 6 Extended controller diagnosis The extended controller diagnosis uses the diagnostic function of the PROFIBUS protocol to display several faults of the RES 406 on the PROFIBUS master directly For each fault there is a text message stored in the device master file so the error codes appear on the PROFIBUS master in plain text if the master has the capability to display text messages With the help of parameter No 9 the extended con troller diagnosis can be activated or deactivated The default setting is activated Although the extended controller diagnosis ist deacti vated there is the fault diagnosis which is coded in the protocol This paramter is available on all controllers manufactured as of June 17 2002 and supp lied with GSD Version v1 2 10 7 7 Measuring impulse duration The length of the measuring impulses generated by the controller can be set with parameter no 10 It may be necessary to set a measuring impulse that is longer than the default 1 7ms for certain applications This parameter is available on all controllers manufactured as of July 14 2003 and supplied with GSD Version v1 3 RES 406 Controller functions 10 7 8 Data format This para
14. the case if START is active or if the heatsealing band is still in the cooling down phase 10 6 3 Alarm active AL If the AL bit is set an alarm has been triggered but not yet reset The error code provides information about the exact cause of the fault section 10 15 Error messages on page 35 10 6 4 Temperature reached TE The TE bit is set if the actual temperature exceeds 95 of the set temperature As soon as the control mode is exited ST bit 0 or an alarm is signaled AL bit 1 this status bit is reset again 10 6 5 Temperature OK TO The RES 406 checks whether the actual temperature is within a settable tolerance band OK window on either side of the set temperature The lower A yer and upper AB oper limits of the Page 28 Controller functions tolerance band can be changed independently of one another by means of the parameter data section 10 7 Parameter data on page 29 If the actual temperature is inside the specified tolerance band the TO bit is set see graph below A Actual value Set A pper Set Sett AD wer gt TO bit A Time 1 0 gt Time Unlike the Temperature reached status bit TE bit the actual temperature is evaluated independently of the control mode The limits of the tolerance band are adjustable to max 99K on controllers manufactured as of February 2006 and supplied with GSD Version v1 5 On older controllers t
15. word at bit positions 8 11 error code format 4 bit or 6 15 error code format 10 bit section 10 15 Error messages on page 35 10 bit error codes are available on all control lers manufactured as of July 24 2006 and supplied with GSD Version v1 6 Older controllers only show 4 bit error codes In addition to the error codes the PROFIBUS diagno stics function also sends error messages to the PROFIBUS master The error messages correspon ding to each error code are already stored in the device master file GSD so that they automatically appear in plain text on the PROFIBUS master whenever the device diagnosis for the RES 406 is interrogated there The language in which the error messages are dis played depends on the selected device master file The PROFIBUS diagnostics function always transfers 4 bit error codes regardless of the setting of the Error code format parameter section 10 7 9 Error code format on page 31 10 7 Parameter data The parameter data contains values for selecting the heatsealing band alloy the temperature range the upper and lower tolerance band limits for temperature monitoring the calibration temperature and the optional RES 406 RO P E heating time limit It is transferred from the PROFIBUS master to the RES 406 each time the system is started up If the parameter data is changed during operation the RES 406 performs a reset The PROFIBUS communication is not inter
16. 132VAC 230VAC version 220VAC 15 240VAC 10 equivalent to 187 264VAC 400VAC version 380 VAC 15 415VAC 10 equivalent to 323 456VAC All controllers manufactured as of January 2004 up to January 2006 115VAC version 115VAC 15 120VAC 10 equivalent to 98 132VAC 230VAC version 230 VAC 15 240VAC 10 equivalent to 196 264VAC 400VAC version 400 VAC 15 415VAC 10 equivalent to 340 456VAC All controllers manufactured up to December 2003 115VAC 230VAC or 400VAC tolerance 10 15 depending on version selected section 13 How to order on page 43 47 63Hz automatic adjustment to frequencies in this range 24VDC Imax 100mA Tolerance 10 10 The 24VDC Supply voltage can be fed either via terminals 5 and 7 or via the PROFIBUS plug at pins 2 and 7 9 6kbaud 19 2kbaud 45 45kbaud 93 75kbaud 187 5kbaud 500kbaud 1 5Mbaud 3Mbaud 6Mbaud 12Mbaud Plug acc to IEC 61158 Baud rates All controllers manufactured as of February 2006 The temperature range and temperature coefficient settings can also be specified by means of the ROPEX visualization software section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 in addition to the rotary coding switch see below Temperature range 200 C 300 C 400 C or 500 C Temperature coefficient 400 4000ppm variable setting range All controllers manufactured as of start of production
17. 16 bit output data contains the actual value in word Q and the error code and status information in word Q Bit no 15 Error code Bit no 15 14 10 5 Input data The term input data refers to the data that is transferred from the PROFIBUS master to the RES 406 It contains the set point and the control functions such as START or AUTOCAL for the RES 406 These functions are explained in the following 10 5 1 Automatic zero calibration AUTOCAL AC Because of the automatic zero calibration AUTOCAL function there is no need to adjust the zero point manually on the controller This function matches the controller to the resistance of the system and calibrates it to the value which is predefined in the parameter data section 10 7 4 Variable calibration temperature on page 30 If no parameter data is transferred by the PROFIBUS master the default value is 20 C Some PROFIBUS masters do not allow the parameter data to be changed during operation t is therefore not possible to adapt the calibration temperature to the pre vailing ambient conditions in the machine As of GSD Version v1 6 the calibration temperature can be specified by means of the Set point AC tempe rature input data whenever the zero point is calibrated providing this setting is selected in the parameter data section 10 7 4 Variable calibration temperature on page 30 It can be specified in the 0 40 C range The va
18. 20VAC RES 406 Factory settings Fault area Explanation LR 54 Possible causes R signal incorrect Up to Jan 2006 DIP switches 4 5 configured incorrectly lp range As of Feb 2006 15 outside permissible range from 30 500A Turns through PEX W2 W3 current transformer incorrect Check number of turns two or more turns required for currents lt 30A Internal controller fault 11 Factory settings Hardware fault replace controller Plug in jumper for alarm output not connected or incorrectly connected The RESISTRON temperature controller RES 406 is configured in the factory as follows DIP switches for OFF ON 12345 secondary voltage U gt and current Ip up to January 2006 Rotary coding switch for heatsealing band alloy and temperature range Plug in jumper for alarm relay SWITCH POS DN RES 406 Uz 6 60 VAC l2 30 100A DIP switches 2 ON 1 3 4 5 OFF These svvitches are automatically set by the AUTORANGE function on all controllers manufactured as of February 2006 Heatsealing band alloy Alloy 20 Temperature range 300 C Rotary coding switch 0 position Alarm relay is energized at alarm Page 41 l 53 Rotary coding svvitches for station address Automatic phase angle compensation AUTOCOMP X Temperature diagnosis w X Heatup timeout X X
19. 27 7 06 RESISTRON RES 406 Operating instructions Important features e Microprocessor technology Complete control via PROFIBUS DP interface e Automatic zero calibration AUTOCAL e Automatic optimization AUTOTUNE Automatic configuration of the secondary voltage and current ranges as of February 2006 e Automatic phase angle compensation AUTOCOMP as of February 2006 Automatic frequency adjustment Large current and voltage range Booster connection as standard 0 10VDC analog output for ACTUAL temperature Alarm function with fault diagnosis e Heatsealing band alloy and temperature range selectable Industrie Elektronik GmbH Tel 49 0 7142 7776 0 E y Gansacker 21 Fax 49 0 7142 7776 19 D 74321 Bietigheim Bissingen Germany E Mail info ropex de Internet www ropex de Data subject to change l 53 Contents 1 Safety and vvarning notes 3 10 11 WSS ayasa 7 3 1 2 Heatsealing band 3 1 3 Impulse transformer 3 1 4 Current transformer PEX VV2 VV3 3 1 5 Line filter 4 1 6 Warranty provisions 4 1 7 Standards CE marking 4 2 Application 4 3 Principle of operation 5 4 Description of the controller 6 5 Accessories and modifications 6 5 1 Accessories 6 5 2 Mo
20. 885650 Temp meter ATR Z 3 300 C range Art No 882130 5 500 C range Art No 882150 Booster 400 075 Max pulse load 75A 400VAC Art No 885301 100 Max pulse load 100A 400 VAC Art No 885304 For more accessories Accessories leaflet RES 406 Page 43 l 5 14 Index Nummern 24VDC Supply voltage 8 A AA bit 28 AC bit 26 Actual value 28 Actual value output 31 AG bit 28 AL bit 20 28 Alarm 28 Alarm output 34 Alarm relay 9 18 Alloy 17 20 Ambient temperature 9 Analog temperature meter 6 Application 4 Application Report 10 13 16 AUTOCAL 6 20 Active 28 Disabled 26 28 Starting 26 AUTOCOMP 32 Automatic phase angle compensation 32 Automatic zero calibration 6 20 26 AUTOTUNE 6 B Booster 7 15 43 Booster connection 32 Burning in the heatsealing band 18 20 C Circuit breaker 12 CI USB 1 7 34 43 Communication interface 7 34 43 Controller active 28 Controller configuration 16 Controller diagnosis 30 Current transformer 13 43 D Data format 31 Degree of protection 9 Device master file GSD 23 Diagnostic interface 34 Digital temperature meter 6 Dimensions 10 DIP switches 16 E Error code format 31 Error messages 35 Page 44 ndex Extended controller diagnosis 30 External svvitching amplifier 7 15 F Factory settings 41 Fault areas 40 Fault diagnosis 6 G GSD 23 H Heatsealing band type 8 Heatup timeout
21. CAL function 1 The AUTOCAL function cannot be activated until 10 seconds after the controller is svvitched on During this time the controller reports AUTOCAL disabled AG bit 1 in the output data 2 The AUTOCAL function is not activated if the heatsealing band is cooling dovvn at a rate of more than 0 1K sec If the AC bit is activated the function is executed automatically providing the cooling rate has fallen belovv the above mentioned value 3 If the START bit ST bit 1 is activated the AUTOCAL function is not executed HEAT LED lit RES 406 Controller functions 4 If the RESET bit RS bit 1 is activated the AUTOCAL function is not executed 5 AUTOCAL cannot be activated if error codes 1 3 5 7 As of February 2006 also 101 103 201 203 801 9xx occur at start up AUTOCAL cannot be activated vvith error codes 5 7 As of February 2006 also 201 203 801 9xx if the controller has operated correctly at least one time after start up 5 section 10 15 Error messages on page 35 If the AUTOCAL function is disabled AG bit 1 and if you attempt to activate it AC bit 1 then the AUTOCAL LED blinks fast 4Hz 10 5 2 Start ST When the START bit is activated ST bit 1 the controller internal set actual comparison is enabled and the heatsealing band is heated up to the SET temperature t remains at this temperature either until the ST bit is reset
22. Five different ranges can be set with the rotary coding switch or via the PROFIBUS interface Temperature coefficient 1100 ppm 0 300 C e g Alloy 20 Temperature coefficient 780ppm 0 300 C e g Alloy L Temperature coefficient 1100 ppm 0 500 C e g Alloy 20 Temperature coefficient 780ppm 0 500 C e g Alloy L Temperature coefficient 3500 ppm 0 300 C e g NOREX The settings for a temperature coefficient of 780 ppm are only available on controllers manufactured as of October 2003 RES 406 Technical data R 0 p E Analog output 0 10V DC Imax 5mA actual value Equivalent to 0 300 C or 0 500 C Terminals 17 18 Accuracy 1 add 50mV Alarm relay Umax 50VDC Imax 0 2A changeover contact potential free Terminals 12 13 14 Maximum load Imax SA duty cycle 100 primary current of Imax 25A duty cycle 20 impulse transformer Power dissipation max 20W Ambient 5 45 C temperature Degree of protection IP 20 Installation If several controllers are installed on one top hat rail DIN TS35 rail a clearance of at least 20mm should be allowed between them The moving clip required for fastening must be facing down for mounting on a horizontal top hat rail End holders to mechanical fix the controller must be fitted at both ends for mounting on a vertical top hat rail Weight Approx 0 7kg incl connector plug in parts Housing material Plastic polycarbon
23. POWER SUPPLY GND 7 Heat sealing band ALARM OUTPUT max 50V 0 2A up to ir zz production 1 date I o danuary Current transformer 2 oV PEX W2 W3 Internnal ground Must be grounded No external externally to prevent electrostatic charging grounding allowed OV Internnal ground ANALOG No external OUTPUT grounding allowed 0 10VDC RES 406 Page 15 l 53 9 Startup and operation 9 1 Vievv of the controller Terminals lt Wiring diagram 9 2 Controller configuration The controller must be switched off in order to configure the coding switches and plug in jumpers 9 2 1 Configuration of the DIP switches for secondary voltage and current Automatic configuration AUTORANGE as of February 2006 The secondary voltage and current ranges are automatically configured by the automatic calibration function AUTOCAL The voltage is configured in the range from 0 4VAC to 120VAC and the current in the Page 16 Startup and operation q Nameplate i Coding switches and plug in jumpers range from 30A to 500A If the voltage and or the current is outside the permissible range a detailed error message appears on the controller see section 10 15 Error messages on page 35 Configuration with coding switches up to January 2006 Set the DIP switches for matching the secondary voltage U gt and the secondary current l gt to the correct pos
24. addition to the yellow AUTOCAL LED when the voltage is switched on the configuration of this controller has been changed in the visualization software W section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 In order to avoid malfunctions please check the controller configuration before continuing the startup procedure 8 The green DATA EXCHANGE LED lights up to indicate an active PROFIBUS communication Page 19 l 53 9 One of the follovving states then appears Up to production date January 2006 ALARM LED OUTPUT LED ACTION OFF Shortpulses Go to 10 every 1 2s OFF BLINKS fast Hz Go to 10 Lit OFF continuously Fault diagnosis section 10 15 As of production date February 2006 ALARM OUTPUT LED LED ACTION OFF Shortpulses Go to 10 every 1 2s BLINKS fast OFF Go to 10 4 Hz Lit OFF Fault no 901 continuously Fault group 7 Supply voltage Sync Signal mis sing section 10 2 Otherwise Fault diagnosis section 10 15 10 Activate heatsealing band is still cold by setting the AC bit the AUTOCAL function while the AUTOCAL in the PROFIBUS protocol section 10 4 PROFIBUS protocol on page 23 The yellow AUTOCAL LED lights up for the duration of the calibration process approx 10 15s The AA bit AUTOCAL active is set in addition and a voltage of app OV ap
25. allation 8 3 Power supply 115VAC 230VAC 400VAC 50 60Hz L1 L1 N L2 GND Earth Circuit breaker Double pole C characteristic ROPEX Application Report Short circuit protection only RESISTRON temperature controller not protected ON r K1 OFF F Relay Ka 666 For HEAT ON OFF function all pole or EMERGENCY STOP Line filter The filter type and size must be determined according to the load the transformer and the machine vviring ROPEX Application Report Do not run the filter supply vvires line side parallel to the filter output vvires load side ROPEX 557 RESISTRON temperature controller belonging to the controller 4xx Series Relay Kb Load break all pole e g in combination with the alarm output of the temperature controller When using a series resistor RV 1 the relay Kb shall be installed Impulse Transformer Designed according to VDE 0570 EN 61558 isolating transformer with reinforced insulation Connect core to ground Use transformers with a one section bobbin The power duty cycle and voltage values must be determined individually according to the application ROPEX Application Report and Accessories leaflet for impulse transformers I I I Wiring The wire cross sections depend on the application 6 ROPEX Application Report Guide values Primary circuit min 1 5mm max 2 5mm Secondary ci
26. anufactured as of February 2006 and the alarm relay is svvitched This error can be reset by switching on the line voltage again and activating the RS bit section 10 5 3 Reset RS on page 27 The error code that appears if the line voltage is svvit ched off can be easily processed and svvitching of the alarm relay suppressed in the PLC program If controllers manufactured as of February 2006 are installed in an older machine e g in order to carry out repairs this new controller function can lead to unwanted error codes when the line voltage is switched off depen ding on the PLC program Permanently disconnecting the 24VDC power supply terminals 5 7 and PROFIBUS connector pins 7 2 results in the same behavior as on older controllers manufactured up to January 2006 i e a bus fault in the PROFIBUS master 10 3 Device master file GSD Configuring tools for the PROFIBUS DP master that must be configured interpret the contents of the slave device master files and use them to create a master parameter set for the PROFIBUS master which is responsible for useful data communication The ROxy0613 GSD file xy GSD Version e g 15 for version v1 5 of the RES 406 contains all the controller information needed for the configuration e g the possible baud rates parameter descriptions error messages etc The device master files and the associated display files DIB for visualizing states are supplied with the con
27. ate UL 90 V0 Connecting cables Rigid or flexible 0 2 2 5mm AWG 24 12 Type cross sections Plug in connectors If ferrules are used they must be crimped in accordance with DIN 46228 and IEC EN 60947 1 This is essential for proper electrical contact in the terminals RES 406 Page 9 l 3 7 Dimensions 75 0 8 Installation See also section 1 Safety and warning notes on page 3 Installation and startup may only be performed by technically trained skilled persons who are familiar with the associated risks and warranty provisions 8 1 Installation procedure Proceed as follows to install the RESISTRON temperature controller RES 406 1 Switch off the line voltage and verify that the circuit is de energized 2 The supply voltage specified on the nameplate of the RESISTRON temperature controller must be identical to the line voltage that is present in the Dimensions 3 Install the RESISTRON temperature controller in the electrical cabinet on a standard top hat rail DIN TS35 rail according to DIN EN 50022 If several controllers are installed on one top hat rail the minimum clearance specified in section 6 Technical data on page 8 must be allovved betvveen them 4 VVire the system in accordance vvith the instructions in section 8 3 Power supply on page 12 section 8 6 VViring diagram standard on page 14 and the ROPEX Application Report The information provided in sectio
28. cing the performance of modern machines However the full benefit can only be obtained from the advanced technology offered by this control system if all the system components in other words the heatsealing band the impulse transformer the wiring the timing signals and the controller itself are carefully compatible and interrelated We will be pleased to contribute our many years of experience towards optimizing your heatsealing system transformer Indicators and LINE Impulse transformer 12 ogic LINE RES 406 Set point controls or bus interface Page 5 l 5 Description of the controller 4 Description of the controller The microprocessor technology endows the RESISTRON temperature controller RES 406 with previously unattainable capabilities e Very simple operation thanks to AUTOCAL the automatic zero calibration function e Good dynamic response of the control system thanks to AUTOTUNE which adapts automatically to the controlled system e High precision thanks to further improved control accuracy and linearization of the heatsealing band characteristic High flexibility The AUTORANGE function as of February 2006 covers a secondary voltage range from 0 4V to 120V and a current range from 30A to 500A e Automatic adjustment to the line frequency in the range from 47 Hz to 63Hz Increased protection against dangerous conditions such as overh
29. cribed in section 10 15 Error messages on page 35 12 Burn in the heatsealing band section 9 3 Replacing and burning in the heatsealing band on page 18 and repeat the AUTOCAL function The controller is novv ready 9 4 2 Restart after replacing the heatsealing band To replace the heatsealing band proceed as described in section 9 3 Replacing and buming in the heatsealing band on page 18 Alvvays use a heatsealing band vvith the correct alloy dimensions and copper plating in order to avoid malfunctions and overheating Continue vvith section 9 4 steps 5 to 12 RES 406 Controller functions 10 Controller functions See also section 8 6 Wiring diagram standard on page 14 10 1 Indicators and controls Manufactured as of February 2006 RESISTRON RES 406 Temperature controller ROPEX Tel 49 0 7142 7776 0 www ropex de Made in Germany OUTPUT AUTOCAL 24V SUPPLY OOOO BUS POWER OK uC POWER OK DATA EXCHANGE sns sosa J o Sil ya YA YA yA S El JA ALARM red LED R 0 P E X Lights up or blinks to indicate an alarm HEAT yellow LED Lit during heating phase OUTPUT green LED Indicates pulses in measurement mode In control mode luminous intensity is proportional to heating current AUTOCAL yellow LED 24V SUPPLY green LED Remains lit for duration of AUTOCAL process Lit if external 24VDC power supply i
30. d with the line filter 1 6 Warranty provisions The statutory provisions for warranties apply for a period of 12 months following the delivery date All devices are tested and calibrated in the factory Devices that have been damaged due to faulty connections dropping electrical overloading natural wear incorrect or negligent handling chemical influences or mechanical overloading as well as devices that have been modified relabeled or otherwise altered by the customer for example in an attempt to repair them or install additional components are excluded from the warranty Warranty claims must be examined in the factory and approved by ROPEX 2 Application This RESISTRON temperature controller is an integral part of the Series 400 the outstanding feature of which is its microprocessor technology All RESISTRON temperature controllers are used to control the temperature of heating elements heatsealing bands beaded bands cutting wires heatsealing blades solder elements etc as required in a variety of heatsealing processes Page 4 Application 1 7 Standards CE marking The controller described here complies with the following standards provisions and directives DIN EN 61010 1 VDE 0411 1 Safety provisions for electrical measuring control and laboratory devices low voltage directive Overvoltage category Ill pollution severity 2 safety class Il DIN EN 60204 1 Electrical equipment of machines
31. der to avoid false alarms 10 15 Error messages In addition to the fault diagnosis which is coded in the protocol you can also access the PROFIBUS diagnostics function extended controller diagnosis The error codes appear in the configuring tool in plain text because they are stored in the device master file The table below shows how the analog voltage values correspond with the faults that have occurred It also describes the fault and the required corrective action The error messages are listed in two separate tables for controllers up to January 2006 and as of February 2006 The block diagram in section 10 16 Fault areas and causes on page 40 permits each fault to be cleared quickly and efficiently 13 voltage levels for fault diagnostics appear at the actual value output of all controllers manufactured as of February 2006 The error messages are differentiated even more finely in the controller The 3 digit error codes described in brakets below can be displayed with the ROPEX visualization software section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 to facilitate troubleshooting If the actual value output is evaluated in order to identify an error message in the higher level controller for instance the tolerance vvindovv must be adjusted to prevent it from being incorrectly interpreted Please note the tolerances of the actual value output section 6 Technical data o
32. difications MODs 7 6 Technical data 8 T Dimensions 10 8 nstallation 10 8 1 Installation procedure 10 8 2 Installation steps 11 8 3 Powersupply 12 8 4 Line filter 13 8 5 Current transformer PEX W3 13 8 6 Wiring diagram standard 14 87 Wiring diagram with booster 12 connection 15 43 9 Startup and operation 16 44 9 1 View of the controller 16 9 2 Controller configuration 16 93 Replacing and burning in the heatsealing band 18 94 Startup procedure 19 Page 2 RES 406 Controller functions 21 10 1 Indicators and controls 21 10 2 PROFIBUS communication up to Jan 2006 as of Feb 2006 22 10 3 Device master file GSD 23 10 4 PROFIBUS protocol 23 10 5 Inputdata 26 10 6 Outputdata 28 10 7 Parameter data 29 10 8 Temperature indication actual value OU DUt Uu eda ap zan bae ede 31 10 9 Booster connection 32 10 10 Automatic phase angle compensation AUTOCOMP as of February 2006 32 10 11 Temperature diagnosis as of February 2006 33 10 12 Heatup timeout as of February 2006 34 10 13 Diagnostic interface visuali
33. eady been thermally pretreated by the manufacturer An overheated or burned out heatsealing band must no longer be used because the TCR has been altered irreversibly One very important design feature is the copper or silver plating of the heatsealing band ends Cold ends allovv the temperature to be controlled accurately and increase the life of the teflon coating and the heatsealing band 9 3 2 Replacing the heatsealing band All power supply leads must be disconnected from the RESISTRON temperature controller in order to replace the heatsealing band The heatsealing band must be replaced in accordance vvith the instructions provided by the manufacturer Each time the heatsealing band is replaced the zero point must be calibrated vvith the AUTOCAL function while the band is still cold in order to compensate production related resistance tolerances The burn in procedure described above should be performed for all new heatsealing bands 9 4 Startup procedure Please also refer to section 1 Safety and warning notes on page 3 and section 2 Application on page 4 Installation and startup may only be performed by technically trained skilled persons vvho are familiar vvith the associated risks and vvarranty provisions 9 4 1 Prerequisites The controller must be correctly installed and connected section 8 Installation on page 10 Initial startup RES 406 LR O P E Proceed as follows to start up the con
34. eating of the heatsealing band The RESISTRON temperature controller RES 406 is equipped with a PROFIBUS DP interface This interface can be used to control all the controller functions and interrogate controller information The ACTUAL temperature of the heatsealing band is supplied to the PROFIBUS interface and to an analog 0 to 10V DC output The real heatsealing band temperature can thus be displayed on an external temperature meter e g ATR x The RES 406 features an integrated fault diagnosis function which tests both the external system heatsealing band wiring etc and the internal electronics and outputs a selective error message in case of a fault To increase operational safety and interference immunity all PROFIBUS signals are electrically isolated from the controller and the heating circuit Either coding switches on the temperature controller itself or the PROFIBUS interface can be used to adapt to different heatsealing band alloys Alloy 20 NOREX etc and set to the required temperature range 0 300 C 0 500 C etc The compact design of the RESISTRON temperature controller RES 406 and the plug in connections make this controller easy to install 5 Accessories and modifications A wide range of compatible accessories and peripheral devices are available for the RESISTRON temperature controller RES 406 They allow it to be optimally adapted to your specific heatsealing application and to your plant s desig
35. ed or that the heatsealing band electrical wiring transformer etc will overheat Ensuring such compliance is the personal responsibility of the user 1 2 Heatsealing band A basic prerequisite for reliable and safe operation of the system is the use of suitable heatsealing bands The resistance of the heatsealing band which is used must have a positive minimum temperature coefficient in order to guarantee trouble free operation of the RESISTRON temperature controller The temperature coefficient must be specified as follows x 10x10 K TCR 1100 ppm K TCR 3500 ppm K e g Alloy 20 NOREX RES 406 RO P E The RESISTRON temperature controller must be set and coded according to the temperature coefficient of the heatsealing band The use of incorrect alloys with a too low temperature coefficient and incorrect coding of the RESISTRON temperature controller lead to uncontrolled heating and ultimately to burn out of the heatsealing band The heatsealing bands that were originally supplied must be identified by detail specification part number or some other means that will assure that replacement bands are identical 1 3 Impulse transformer A suitable impulse transformer is necessary to ensure that the control loop functions perfectly This transformer must be designed according to VDE 0570 EN 61558 isolating transformer with reinforced insulation and have a one section bobin When the impulse tran
36. f February 2006 more temperature ranges and alloys can be selected by means of the ROPEX visualization software see section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 Page 17 RO PENX 9 223 Configuration of the rotary coding switches for the station address The station address of the RES 406 in the PROFIBUS network can be set between 0 and 99 with these coding Station address im PROFIBUS network between 0 and 99 01 Factory setting 9 2 4 Configuration of the alarm relay If the jumper is not inserted the alarm relay is permanently energized when using a controller up to production date January 2006 The other functions of the controller e g heating AUTOCAL etc are not impaired by this If the plug jumper is not inserted when using a controller as of production date February 2006 or if it is incorrectly inserted an error message appears when the controller is switched on section 10 15 Error messages on page 35 Alarm relay de energized by alarm PC CONFIGURATION Alarm relay energized by alarm factory setting If the Alarm relay deenergized by alarm PC CONFIGURATION position is selected as of February 2006 the behavior of the alarm output can be configured in more detail by means of the ROPEX visualization software see section 10 13 Diagnostic interface visualization software of February 2006 on page 34 Page 18
37. he PROFIBUS master again As of production date February 2006 the controller actual value output changes to 0 3 C i e approximately OVDC while the RS bit is being activated This may be interpreted by the higher level controller e g a PLC as feedback The AUTOCAL function is not aborted if the RS bit is activated while it is still executing The controller performs an internal initialization run lasting approximately 500ms after the RESET signal is deactivated The next heatsealing process cannot be started until it has finished If a contactor Kb is used to deactivate the control loop 5 section 8 3 Power supply on page 12 it must be energized again 50ms at the latest after the RESET signal is deactivated If it is energized too late an error message will be output by the controller 10 5 4 Measurement pause MP No more measuring impulses are generated by the controller as soon as the MP bit is set From then on only fault nos 5 6 and 7 are evaluated and output by the fault diagnosis function In addition the actual value is no longer updated The last valid value before the bit was set is output As soon as the bit is reset new measuring impulses are generated all error messages are evaluated and the actual value is updated again This bit is only active in measuring mode ST RS and AC take priority The bit is suitable for all applications in which the electrical connections of the heatsea
38. he limits are adjustable to max 20K 10 6 6 Controller active RA The RES 406 has processed the START request successfully and entered the control mode if the RA bit 1 10 6 7 Sign VZ In the compact protocol the sign bit indicates whether the actual value is positive or negative 10 6 8 Actual value If you are using the compact protocol the actual value itself is always positive The sign bit VZ then indicates whether the amount of the actual value is positive or negative If an alarm is signaled the actual value contains the error code If you are using the extended protocol all 16 bits of the first word must be interpreted as a signed number twos complement notation During the calibration procedure or if an alarm is signaled the actual value is The error code is contained in separate bits RES 406 Controller functions 10 6 9 Error codes If a fault is signaled AL bit 1 the error code allows the exact cause to be determined The Error code format parameter determines whether two or three digit error codes are output If two digit error codes are specified some faults are grouped together three digit error codes enable a fault to be identified more preci sely In the compact protocol the error code appears instead of the actual value in bits 0 3 error code format 4 bit or 0 9 error code format 10 bit In the extended protocol the error code appears in the second
39. ition for your application You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your particular application RES 406 Startup and operation OFF ETT 12345 ON If the secondary current l is less than 30A the PEX VV2 or PEX VV3 current transformer must have two turns ROPEX Application Report 2x 9 2 2 Configuration of the rotary coding svvitch for the temperature range and alloy Switch Temp Temp Band position range coefficient alloy 0 300 C 1100ppm K e g Alloy 20 e g Alloy L e g Alloy 20 e g Alloy L 300 C 13500ppm K e g NOREX PC CONFIGURATION 500 C 1100ppm K 0 Factory settings The settings for a temperature coefficient of 780ppm switch position 1 and 5 are only available on controllers manufactured as of October 2003 The setting of the rotary coding switch for the temperature range and alloy can be RES 406 20 120V OFF OFF ON RO P E gt Factory settings ON OFF OFF 30 100A 60 200A OFF ON OFF 120 400A SWITCH POS TEMP RANGE ALLOY 0 300 C T100ppmiK A20 1 300 C 4 500 C 5 500 C 8 300 C 780ppm K L 1100ppm K A20 780ppm K L 3500 NOREX Qar L j PC CONFIGURATION overwritten with the parameter data section 10 7 Parameter data on page 29 If the switch is set to 9 as o
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41. ling band need to be disconnected during normal operation without triggering an alarm e g sliding rail contacts In contrast with the RS bit RESET the MP bit does not reset any error message when it is set The controller is activated again as soon as the bit is reset in other words there is no initialization phase When the controller is started it only evaluates the MP bit if the system test including the functional test of the heating circuit is successful This can take several 100 ms Page 27 l 53 The MP bit is available on all controllers manufactured as of July 14 2003 and supplied vvith GSD Version v1 3 10 5 5 Set point A set point of up to 300 C or 500 C is allowed depending on the selected temperature range section 10 7 1 Temperature range and alloy on page 30 If you attempt to enter a higher set point it is limited to 300 C or 500 C internally 10 6 Output data The term output data refers to the data that is transferred from the RES 406 to the PROFIBUS master It contains the current actual value and all important information about the momentary status of the controller If an alarm is signaled the fault can be diagnosed accurately with the help of the error code 10 6 1 AUTOCAL active AA The AA bit indicates that the AUTOCAL function is currently executing 10 6 2 AUTOCAL disabled AG If the AG bit is set the AUTOCAL function is temporarily disabled This is
42. lue selected for the calibration temperature must be entered in the Set point AC temperature input data when the AUTOCAL function is activated AC bit 1 If the specified temperature is too high greater than 40 C or if the selected value varies an error message appears error codes 115 and 116 section 10 15 Error messages on page 35 Page 26 Actual value signed 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 E 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Controller functions Status information The AUTOCAL request AC bit 1 is executed by the controller providing the AUTOCAL function is not disabled The automatic calibration process takes about 10 15 seconds The heatsealing band is not heated during this process The yellow LED on the front panel lights up while the AUTOCAL function is active and the controller reports AUTOCAL active AA bit 1 in the output data The actual value output terminals 17 18 is 0 3 C corresponds to app 0 VDC If the temperature of the heatsealing band varies on controllers manufactured as of February 2006 the AUTOCAL function is executed a maximum of three times If the function still cannot be terminated successfully an error message appears section 10 15 Error messages on page 35 You should alvvays vvait for the heatsealing band and the bar to cool dovvn to ambient temperature before activating the AUTOCAL function Reasons for disabled AUTO
43. me is longer than the parameterized time the corresponding error code 304 is indicated and the alarm relay is svvitched section 10 15 Error messages on page 35 A Actual value Set 95 of Set Timeout N gt N gt lt Time Heatup time Alarm 304 10 13 Diagnostic interface visualization software as of February 2006 An interface with a 6 pole Western socket is provided for systemdiagnostics and process visualization This interface allows a data connection to be set up to the ROPEX visualization software using the ROPEX communication interface CI USB 1 Page 34 Controller functions Only a ROPEX comunication interface is allowed to be connected to the diagnostic interface Connecting another device e g a telephone cable could result in malfunctions or damage to the controller The ROPEX visualization software is described in a separate document 10 14 System monitoring alarm output To increase operating safety and to avoid faulty heat sealing this controller incorporates special hardware and software features that facilitate selective fault detection and diagnosis Both the external wiring and the internal system are monitored These features assist the operator in identifying the cause of abnormal operations A system fault is reported or differentiated by means of the following indications A Red ALARM LED on the controller with three states 1 Blinks fast 4Hz The
44. meter specifies the order of the bytes Intel high low byte Motorola low high byte in the cyclic data for both input and output data section 10 4 PROFIBUS protocol on page 23 We recommend setting low high byte Motorola for Siemens controllers This parameter is available on all controllers manufactured as of July 23 2004 and supplied with GSD Version v1 4 10 7 9 Error code format This parameter specifies the length of the error codes in the eyclic data You can choose betvveen a 4 bit and a 10 bit format section 10 4 PROFIBUS protocol on page 23 4 bit generates tvvo digit error codes in the range 1 3 and is the default setting 10 bit gene rates more detailed three digit error codes section 10 15 Error messages on page 35 This parameter is available on all controllers manufactured as of July 24 2007 and supplied vvith GSD Version v1 6 RES 406 RO P E Temperature indication actual value output 10 8 The RES 406 supplies an analog 0 10VDC signal which is proportional to the real ACTUAL temperature at terminals 17 18 RES 406 Actual value output 0 10VDC Temperature meter e g ATR 3 Voltage values OVDC gt 0 C 10VDC gt 300 C or 500 C depending on the controller configuration Page 31 ol 5 The relationship between the change in the output voltage and the ACTUAL temperature is linear C o 300 x 3 270 5 240 o 210
45. n 8 2 Installation steps on page 11 must also be heeded 5 Connect the RESISTRON temperature controller to the PROFIBUS master using a cable according to IEC 61158 Check the tightness of all the system connections including the terminals for the plant or machine The line frequency is impulse transformer windings automatically detected by the RESISTRON temperature controller in the range from 6 Make sure that the wiring conforms to the relevant 47Hz 63Hz national and international installation regulations Page 10 RES 406 Installation o15 4226 8 2 nstallation steps Use heatseal bands vvith suitable temperature coefficient No push on connectors Heatseal element with coppered ends No additional Connect Un measuring F x _ resistance wires directly to in secondary heatsealing band ends circuit number of turns Sufficient wire cross section Current transformer PEX W2 W3 Current measuring U4 prim vvires R Temperature Avoid long meter cables ATR x Note 4 direction of rotation L at potentiometer PD x Impulse transformer Dimension transformer correctly Secondary voltage Power Duty cycle Configure DIP switches correctly up to Jan 2006 20mm clearance if several controllers installed on one top hat rail RES 406 Page 11 D E x Inst
46. n and operating philosophy in impulse mode 5 1 Accessories The products described below are only a few of the wide range of accessories available for RESISTRON temperature controllers Accessories leaflet Analog temperature meter ATR x For front panel mounting or mounting on a top hat rail DIN TS35 rail Analog indication of the ACTUAL temperature of the heatsealing band in C The meter damping of the unit is optimized for the abrupt temperature changes that occur Digital temperature meter DTR x HOLD function Line filter LF xx480 Page 6 For front panel mounting or mounting on a top hat rail DIN TS35 rail Digital indication of the ACTUAL temperature of the heatsealing band in C with Essential in order to ensure CE conformity Optimized for the RESISTRON temperature controller RES 406 Accessories and modifications ratures in real time Booster B xxx400 Measurement cable UML 1 Impulse transformer ITR x 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 6 ROPEX Application Report LR O P E Communication interface CI USB 1 Interface for connecting a RESISTRON temperature controller with diagnostic inter face DIAG to the PC USB port Associated PC visualization software for dis playing setting and configuration data and for
47. n page 8 Page 35 Controller functions ol 5 Jeduunf ul Snid yo uo Jeduunf ul Snid yo uo BuoiA 1ndino 104 s duunl ul Snici 1 lojJuo5 soR dey 1 lojJuo5 soR dey 1 lojJuo5 soR dey 1 lojJuo5 ZOL dey q v llonuoo soR dey soR dey soR dey v llonuoo soR dey 201 dey q AN p nuo2o ne 14 AN p nuo2o ne 14 AN p nuo2o nE 114 6 BiS Scu S Bel oA lli ou Lasay unu Lasay und 2101 uono s di Buoj oo sw dnyp H Alddns Ajddns 19mod yo uo ul lqissiuipeul LL OL uono s lt uBiu No 00 061400 soo ease lined 061 00 sool 9 6 6 ese 4 dn umop ease yney Q eee yne Buissiw sjeuBbis pue dn eee yne ease ne Bussi jeubis YN Q Q Buissiuu jeuBbis 21 Ajsnon u uoo xI Ov 661 c 990 jou pueq SH pe ule Jl uon y UII 1S1U 10 poyeys J uon ov sneo yes Kel l weje Jo SNLVLS 031
48. nd 5 are only available on controllers manufactured as of October 2003 You must always execute the AUTOCAL function after changing this parameter 10 7 2 Lower temperature OK threshold Lower threshold value for the OK window 10 7 3 Upper temperature OK threshold Upper threshold value for the OK window 10 7 4 Variable calibration temperature The calibration temperature is set to 20 C as default You can change it to another value between 0 C and 40 C in order to adapt it to the temperature of the cooled down heatsealing band Some PROFIBUS masters do not allow the parameter data to be changed during operation It is therefore not possible to adapt the calibration temperature to the pre vailing ambient conditions in the machine As of GSD Version v1 6 the calibration temperature can be activated for setting by means of the input data by selecting the value 1 in the parameter data The Page 30 Controller functions calibration temperature can then be specified via the Set point AC temperature input data section 10 5 1 Automatic zero calibration AUTOCAL AC on page 26 You do not need to execute the AUTOCAL function after changing the calibration temperature 10 7 5 Heating time limit The heating time limit provides additional protection against unwanted permanent heating The controller automatically deactivates the heating impulse after the set heating time limit has elapsed if the start bit
49. o F 180 150 120 0 300 C range 23 4 5 6 7 8 9 10 Voltage VDC ZERO C 0 500 C range e 500 i 2 450 G o 400 o 350 300 250 200 150 100 2 3 4 5 6 7 8 9 10 Voltage U VDC ZERO An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing band The characteristics of the ROPEX ATR x temperature meter size scaling dynamic response are ideally suited to this application and this instrument should therefore always be used section 5 Accessories and modifications on page 6 It not only facilitates SET ACTUAL comparisons but also enables other criteria such as the heating rate set point reached within the specified time cooling of the heatsealing band etc to be evaluated Page 32 Controller functions This meter moreover permits disturbances in the control loop loose connections contacting or wiring problems as well as any line disturbances to be observed extremely effectively and interpreted accordingly The same applies if mutual interference occurs between several neighboring control loops This output is not potential free and might have the potential of the secondary voltage of the impulse transformer External grounding is not allowed If this warning is ignored the cont
50. or until the actual heating time exceeds the preset heating time limit section 10 7 5 Heating time limit on page 30 The HEAT LED on the front panel of the RES 406 lights up continuously for the duration of the heating phase A start request is not processed if the AUTOCAL function is active the controller has reported an alarm the set point is less than 20 C higher than the calibration temperature or the RS bit is set In all these cases the HEAT LED blinks The heating process is terminated if the ST bit is reset or if a PROFIBUS fault occurs The ST bit is only accepted if the AUTOCAL function is deactivated and there are no alarms The alarm relay is svvitched if the ST bit is activated while a warning message is indicating error codes 8 12 as of February 2006 also 104 106 111 114 211 302 oder 303 5 section 10 15 Error messages on page 35 The heatsealing band is no longer heated up 10 5 3 Reset RS This bit resets the controller if the controller reports an alarm No AUTOCAL or START requests are accepted as long as the RS bit is set The povver section is not activated in this state and no measuring impulses are RES 406 LR O P E generated Consequently the actual value is no longer updated The reset request is not processed until the RS bit is reset The PROFIBUS communication is not interrupted by a controller reset The controller simply requests the parameter data from t
51. pears at the actual value output terminals 17 18 If an ATR x is connected it indicates 0 3 C When the zero point has been calibrated the AUTOCAL LED goes out and a voltage of 0 66VDC 300 C range or 0 4VDC 500 C range Page 20 Startup and operation appears at the actual value output instead If an ATR x is connected it must be set to Z If the zero point has not been calibrated successfully the AL bit alarm active is set and the red ALARM LED blinks slowly 1Hz In this case the controller configuration is incorrect section 9 2 Controller configuration on page 16 and ROPEX Application Report Repeat the calibration after the controller has been configured correctly 11 When the zero point has been calibrated successfully specify a defined temperature by means of the PROFIBUS protocol set point and set the ST bit The RA bit controller active is then activated and the HEAT LED lights up The heating and control process can be observed at the actual value output The controller is functioning correctly if the temperature which corresponds to the signal change at the analog output or the actual value in the PROFIBUS protocol has a harmonious motion in other words it must not jump abruptly fluctuate or deviate temporarily in the wrong direction This kind of behavior would indicate that the UR measuring wire have been wired incorrectly If an error code is displayed please proceed as des
52. rcuit min 4 0mm max 25mm These wires must always be twisted gt 20 m These wires must be twisted gt 20 m if several control loops are laid together crosstalk Twisting gt 20 m is recommended to improve EMC Page 12 RES 406 Installation 8 4 Line filter To comply with EMC directives corresponding to EN 50081 1 and EN 50082 2 RESISTRON control loops must be operated with line filters These filters damp the reaction of the phase angle control on the line and protect the controller against line disturbances The use of a suitable line filter is part of the standards conformity and a prerequisite of the CE mark ROPEX line filters are specially optimized for use in RESISTRON control loops Providing that they are Large cross section wire to ground Do not lay parallel N Large cross section wire to ground 8 5 Current transformer PEX W3 The PEX W3 current transformer supplied with the RESISTRON temperature controller is an integral part LR O P E installed and wired correctly they guarantee compliance with the EMC limit values You can find the exact specification of the line filter in the ROPEX Application Report calculated for your particular heatsealing application For more technical information documentation Line filter It is permissible to supply several RESISTRON control loops with a single line filter providing the total current does not exceed the
53. recording SET and ACTUAL tempe External svvitching amplifier necessary for high primary currents continuous current gt 5A pulsed current gt 25A Monitoring current transformer MSVV 1 For detecting frame short circuits on the heatsealing band Used as an alternative to the standard PEX VV2 VV3 current transformer twisted measurement cable for the Up voltage measurement Trailing cable halogene und silicone free 5 2 Modifications MODs MOD 01 Owing to its universal design the RESISTRON temperature controller RES 406 is suitable for a very wide range of heatsealing applications Amplifier for low secondary voltages Up 0 25 16VAC This modification is necessary for example for very short or lovv resistance heatsealing bands One modification MOD is available for the RESISTRON temperature controller RES 406 for implementing special applications RES 406 Page 7 l 5 Technical data 6 Technical data Type of construction Line voltage Line frequency 24VDC Supply voltage Terminals 5 7 or PROFIBUS plug pins 2 7 PROFIBUS DP interface Heatsealing band type and temperature range Page 8 Housing for installation in the electrical cabinet Snaps onto a standard top hat rail DIN TS35 rail 35 mm acc to DIN EN 50022 Dimensions 90 x 75mm height 135mm incl terminals All controllers manufactured as of February 2006 115VAC version 110VAC 15 120VAC 10 equivalent to 94
54. resistance of the heatsealing band which is temperature sensitive is monitored 50x per second 60x at 60Hz by measuring the current and voltage The temperature calculated with the help of these measurements is displayed and compared with the set point The primary voltage of the impulse transformer is adjusted by phase angle control if the measured values deviate from the set point The resulting change in the current through the heatsealing band leads to a change in the band temperature and thus also its resistance This change is measured and evaluated by the RESISTRON temperature controller The control loop is closed ACTUAL temperature SET temperature Even minute thermal loads on the heatsealing band are detected and can be corrected quickly and precisely A highly high response thermo electric control loop is formed which is highly accurate because purely electrical variables are measured at a high sampling rate A high secondary current can be controlled because power is controlled on the primary side of the Current LR O P E Increased machine capacity Extended life of the heatsealing bands and teflon coatings e Simple operation and control of the sealing process transformer This allows optimum adaptation to the load and to the required dynamic range despite the exceptionally compact dimensions of the controller PLEASE NOTE RESISTRON temperature controllers play a significant role in enhan
55. roller will be damaged by frame currents Contact voltage protection must be installed at the terminals of the external temperature meter If an alarm is signaled the analog output at terminals 14 18 is used to display a selective error message section 10 15 Error messages on page 35 10 9 Booster connection The RES 406 controller has a connection for an external switching amplifier booster as standard This connection at terminals 15 16 is necessary for high primary currents continuous current gt 5A pulsed current gt 25A The switching amplifier should be connected as described in section 8 7 Wiring diagram with booster connection on page 15 10 10 Automatic phase angle compensation AUTOCOMP as of February 2006 It may be necessary to compensate the phase angle displacement between the Un and Ip measuring signals for special heatsealing applications 5 ROPEX Application Report The AUTOCOMP function is provided for this purpose t is executed whenever the AUTOCAL function 5 section 10 15 Error messages on page 35 is run twice in quick succession The interval betvveen the end of the first AUTOCAL function and the start of the second AUTOCAL must be shorter than 2 0s The second AUTOCAL function only takes around 2 0s and incorporates the AUTOCOMP function If the interval between the two AUTOCAL functions is longer than 2 0s AUTOCAL is executed normally again the second time RES 406
56. rupted The parameter data has the following structure No Function fault possible 1 values value 0 3 Reserved set to 0 0 0 4 Temperature 10 1 4 5 8 range alloy 10 5 Lower 10K 3 99K temperature OK threshold 6 Upper 10K 3 99K temperature OK threshold 7 Calibration 20 C 1 0 40 C temperature 8 Heating time limit 0 0 250 100ms units 0 25 0s 9 Extended con acti deactivated troller dignostis vated activated 10 1 Measuring 17 17 30 impulse duration 1 7 3 0ms 11 Data format High High Lovv Lovv byte Intel byte Lovv High Intel byte Moto rola 12 Error code format 4 bit 4 bit 10 bit 1 The default value is stored in the device master file and transferred from the PROFIBUS master to the RES 406 when the system is started up Page 29 l 53 10 7 1 Temperature range and alloy This parameter selects both the temperature range and the heatsealing band alloy You can overwrite the setting of the rotary coding svvitch by changing the default value 10 Temperature range Alloy 300 C TCR 1100ppm e g Alloy 20 TCR 780ppm e g Alloy L TCR 1100ppm e g Alloy 20 TCR 780ppm e g Alloy L TCR 3500ppm e g NOREX 300 C 500 C 500 C 300 C Rotary coding switch setting Rotary coding switch setting The settings for a temperature coefficient of 780 ppm values 1 a
57. s Auo e 12 12 A HOA b s payeys sulyoew y sneo Ay wee Jo qa1 9 00S 9 00 3ndino p aulyoew J UND uonoy snivis WHVTV anjeayoy 7043 p zIBi u si wee Ajsnonuiuod 111 q31 wueye saner b pjog s yuo pue yoeq sdwnf 1 Buo ou indino anjen jene ne e o soBueyo Bulusem y peyeanoe si jeuBbls LHVWLS v 21 s Zey l syul g 037 wee s njea OM U M Q yoy pue yoeq sdwnf yndjno jenjoe sBulusem se yndjno ileniul ase seBessoew Joe payioeds eul TALON 900z Aueniqa jo se s Bess ul 10113 JO Z Hed Page 37 RES 406 Controller functions X Q D E qissod jou sejenjony ainjyesodwe uoneiqileo xg lq ssod jou uone q leo yBly oo uone q leo xg lq ssod jou seyenjony uajnid uoleinByuoy qissod jou uoleqiyeo o ooul sjeuBbis di pue Yn u ynud uoleinByuoy D yoleseque ye lq ssod jou uolesqijeo o ooul jeus YQ uajnid uoleinByuoy yolesequa ye lq ssod jou uone q leo o looul euBis J Buo ou usu yndjno jenjoe ye njea B 10A 21 nes 21 A
58. s information Actual value compact if AL 0 ms 4 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit no 15 1 Page 24 RES 406 Controller functions R 0 E 3 10 4 3 Extended protocol with 4 Bit error code The extended protocol transfers 2x 16bits The 2x16 bit input data contains the set point in word and the control functions in word Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 wawam Tololololololololololo Sh c 8 7 6 5 4 3 2 1 0 Bit no 15 14 13 12 11 10 9 The 2x16 bit output data contains the actual value in word and the error code and status information in word Q Actual value signed 1 1 a E 5 P D Bit no 15 Error code Status information od ECCI Bit no 15 10 4 4 Extended protocol with 10 Bit codes must be activated in the parameter data error code section 10 7 9 Error code format on page 31 The 10 Bit error codes are available on all The extended protocol transfers 2x 16bits The 2x16 controllers manufactured as of July 24 2006 bit input data contains the set point in word and the and supplied with GSD Version v1 6 These error Control functions in word Ooo oO O Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PTS sss s s s e l rl 8 7 6 5 4 3 2 1 0 Bit no 15 14 13 12 11 10 9 RES 406 Page 25 l 5 The 2x
59. s present BUS PWR OK green LED Lit if internal 5VDC power supply for Profibus interface is OK uC PWR OK green LED Lit if internal 5VDC power supply for microcontroller is OK DATA EXC green LED RES 406 Remains lit while Profibus data is exchanged with master Page 21 l 3 Manufactured up to January 2006 Controller functions POVVER oN 5 AUTOCAL mal DATA N EXCHANGE i Snquo1d RESISTRON R Pex INDUSTRIE ELEKTRONIK D 74321 BIETIGHEIM GERMANY In addition to the functions shown in the diagram above various controller operating states are indicated Blinks slowly 1 Hz Green LED remains lit as long as power supply is on Yellow LED remains lit for duration of AUTOCAL process Green LED indicated pulses in measuring mode In control mode luminous intensity is proportional to heating current Yellow LED lit during heating phase Red LED lights up or blinks to indicate alarm Green LED remains lit as long as PROFIBUS data is beeing exchanged with master by the LEDs These states are described in detail in the table below Blinks fast 4Hz Lit continuously No PROFIBUS communication or RS Bit is activated AUTOCAL yellow AUTOCAL requested but function disabled AUTOCAL executing HEAT yellow START requested but function disabled START executing OUTPUT
60. sformer is installed suitable shock protection must be provided in accordance with the national installation regulations for electrical equipment In addition water cleaning solutions and conductive fluids must be prevented from seeping into the transformer Incorrect installation of the transformer impairs electrical safety impulse 1 4 Current transformer PEX W2 W3 The current transformer supplied with the RESISTRON temperature controller is an integral part of the control system Only the original ROPEX PEX W2 or PEX W3 current transformer may be used Other transformers may cause the equipment to malfunction The current transformer may only be operated if it is connected to the RESISTRON temperature controller correctly see section 9 Startup and operation The relevant safety instructions contained in section 8 3 Power supply must be obeyed External monitoring modules can be used in order to additionally increase Page 3 l 53 operating safety They are not included in the scope of supply of the standard control system and are described in a separate document 1 5 Line filter The use of an original ROPEX line filter is mandatory in order to comply vvith the standards and provisions mentioned in section 1 7 Standards CE marking on page 4 This device must be installed and connected according to the instructions contained in section 8 3 Power supply as well as the separate documentation enclose
61. switched section 10 15 Error messages on page 35 A Actual value Set A0 pper Set Set A away gt Time Alarm 307 Ifthe temperature diagnosis is not activated by the time the START bit is deactivated i e if the ACTUAL temperature does not exceed the upper or lower tolerance band limit the corresponding error code 309 310 is indicated and the alarm relay is switched An additional delay time 0 9 9s can be set in the ROPEX visualization software The first time the lower tolerance band limit is exceeded the temperature diagnosis is not activated until the parameterized delay time has elapsed The temperature diagnosis function can thus be explicitly deactivated e g if the temperature drops temporarily owing to the closure of the sealing jaws The lower and upper tolerance band limits cannot be set in the ROPEX visualization software The same limits apply as for the TO bit They can only be set by means of the parameter data section 10 7 Parameter data on page 29 Page 33 l 5 10 12 Heatup timeout as of February 2006 An additional heatup timeout can be activated in the ROPEX visualization software section 10 13 Diagnostic interface visualization software as of February 2006 on page 34 This timeout starts when the START bit is activated The RES 406 then monitors the time required for the ACTUAL temperature to reach 9596 of the SET temperature If this ti
62. troller for the first time 1 Switch off the line voltage and verify that all circuits are de energized 2 The supply voltage specified on the nameplate of the controller must be identical to the line voltage that is present in the plant or machine The line frequency is automatically detected by the temperature controller in the range from 47 63Hz 3 In the case of controllers manufactured up to January 2006 the settings of the DIP switches on the controller are indicated in the ROPEX Application Report and depend on the heatsealing band that is used The settings of the coding switches on the controller depend on the required station address in the PROFIBUS network section9 2 Controller configuration on page 16 4 Link the device master file into the PROFIBUS master section 10 3 select the required communication module compact or extended protocol and start the communication 5 Make sure that the ST bit is not set 6 Switch on the line voltage and the 24VDC auxiliary supply the order is arbitrary 7 When the voltage is switched on the yellow AUTOCAL LED lights up for approximately 0 3seconds to indicate that the controller is being powered up correctly This LED blinks slowly 1 Hz as long as no PROFIBUS communication is active It does not go out again until it detects an active communication All controllers manufactured as of February 2006 If the red ALARM LED lights up for 0 3s in
63. troller in German GSG and English GSD or GSE on a diskette They can also be requested by E Mail support ropex de or they be downloaded from our Homepage www ropex de After the required device master file has been linked into the configuring tool you must select one of the two RES 406 LR O P E communication modules compact or extended This determines which protocol will be used by the RES 406 to communicate with the PROFIBUS master If you want to use all features of the controller make sure that the appropriate version of the device master file is used Since production date 06 02 the required device master file version is printed on the housing of the temperature controller required GSD version n EEN MADE IN GERMANY 10 4 PROFIBUS protocol The PROFIBUS protocol can be configured either as compact 16bits for input data and 16bits for output data or as extended 2x16bits for input data and 2x 16bits for output data The protocol is determined at the configuring stage by selecting a module compact or extended The compact protocol is sufficient for efficient communication with the RES 406 The extended protocol separates the set point and the actual value of the RES 406 from the status information and the control functions to enable it to be decoded more easily by the PROFIBUS master Bits 0 7 form the low byte and bits 8 15 the high byte INTEL format Page 23
64. ui 10113 Page 39 RES 406 l 3 10 16 Fault areas and causes The table belovv explains the possible fault causes Fault area f Explanation Controller functions Temperature controller HARDVVARE Possible causes Load circuit interrupted after Up pickoff point Wire break heatsealing band break Contact to heatsealing band is defective PEX W2 W3 current transformer signal interrupted Primary circuit interrupted R measuring wires from current transformer interrupted Wire break triac in controller defective Primary winding of impulse transformer interrupted Secondary circuit interrupted before Up pickoff point Wire break Secondary winding of impulse transformer interrupted Un signal missing Measuring wires interrupted Partial short circuit delta R Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc Parallel circuit interrupted Wire break heatsealing band break Contacting to heatsealing band defective Total short circuit Heatsealing band installed incorrectly insulation at heatsealing bar ends missing or incorrectly installed Conducting part bypasses heatsealing band completely Page 40 Un signal incorrect Up to Jan 2006 DIP switches 1 3 configured incorrectly Uz range As of Feb 2006 U outside permissible range from 0 4 1
65. zation softvvare as of February 2006 34 10 14 System monitoring alarm output 34 10 15 Error messages 35 10 16 Fault areas and causes 40 Factory settings 41 Maintenance 42 Hovv to order 43 deR gaa pasaqa qhata wha hu gabe 44 Safety and warning notes 1 Safety and warning notes This RESISTRON temperature controller is manufactured according to DIN EN 61010 1 In the course of its manufacture it passed through quality assurance whereby it was subjected to extensive inspections and tests It left the factory in perfect condition The recommendations and warning notes contained in these operating instructions must be complied with in order to guarantee safe operation The device can be operated within the limits indicated in the Technical Data without impairing its operational safety Installation and maintenance may only be performed by technically trained skilled persons who are familiar with the associated risks and warranty provisions 1 1 Use RESISTRON temperature controllers may only be used for heating and temperature control of heatsealing bands which are expressly suitable for them and providing the regulations notes and warnings contained in these instructions are complied with In case of non compliance or use contrary to the intended purpose there is a risk that safety will be impair

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