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Operating instructions RES-406

1. 5e d i IIO1 094 1104 i d jne euJ lu S 071 997 4 1494 unu 1493 unu ooz 021 0077 9 dull qissiuipeui Ajddns 1 mod y u Ajddns h 991 001 S AIsnonunuo p zIBi ud 1oe uoo sool 061400 soo 17 days eel 09 992 t 0 6 9 seaieyney 9 sese yne 2 yne Buissiuu sjeubis pue Yn 001 09 00 ease yney eae neg Buissiw jeubis YN 99 Ov 661 c Q eee Q eae 1Ined Bulssiw euBis 66 02 9970 L you pueq SH OUI 1541 10 q s 44o 9e D0 90 A bune s do Ape se p yes ouiyoew y sneo Key Jo 031 2009 2 006 andino 9pO9 aulyoew J UOY uonoy SNLVLS Wav TV yoy 103 9002 Asenuer o dn s bess ul 10119 Page 45 RES 406 R O P M 10 17 Fault areas and causes The table below explains the possible fault causes Fault area Explanation Controller functions Temperature controller HARDWARE m r um CE E 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 f
2. 2 s wee A snonunuo 111 031 wee s n PA bi ploq s yoz pue yoeq 5 ou ndino anjea ne e o seBueyo Hulusem y penye s peusis LHVLS 21 s Syullq 021 wee S D BA OM UNO pue yOeq sdwnf ndi no niPA sHulusem se ndino ileniul aie s Bess u 10119 p lji99ds oul 51 9002 Aseniq i Jo se s Bess ul 10114 JO Hed RES 406 Page 44 n P E Controller functions 1 yo u lq ssod jou uone q leo 009 008 40 GQ sesse yned yauoou sjeubis 4 pue Sin abi 00 27 5072 150087 y uo s lqissod you uoneuqileo 1 Buol ou 00S 00eH OL Q ease ne jeubis YN u u nd no 7 5092 BOCCI LEE LS Bojeue sulig _ 1 yo uo lq ssod jou uone q leo 009 0064 40 ease yne joaooul jeubis 20615 Seees 4007S 5999 OF S V LSAUHA pezibieue s b 00S 006 OL q un eye zH 008 2 5081 0092 baxan p zi5l uz q se 1 9418 FOSA 0064 OL Q se ue yne i Ooo TI jeuBis so pue Yn 5992 50917 SEE GS 8 011400
3. Page 30 deactivated activated RES 406 AUTOCOMP as of Feb 2006 and GSD Version v2 0 Controller functions De fault value 1 Possible Function values TO bit active Off active if Tact Tset active if Tact Tset with latch Temperatur OK if Tact as of Feb 2006 and GSD Version v2 0 Tset Hold mode off off as of Feb 2006 and on GSD Version v2 0 2s 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 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 switch by changing the default value 10 Temperature Alloy 300 C TCR 1100ppm e g Alloy 20 300 C TCR 780ppm e g Alloy L 500 C TCR 1100ppm e g Alloy 20 500 C TCR 780ppm e g Alloy L 300 C TCR 3500ppm e g NOREX PC configuration ROPEX visualization software PC configuration ROPEX Rotary coding switch setting RO 54 The settings for a temperature coefficient of 780ppm values 1 and 5 are only available on controllers manufactured as of October 2003 The setting ROPEX visualization software value 9 is available on controllers manufac tured as of March 2007 and supplied w
4. Svid 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 12 Total cycle counter as of February 2006 The number of heatsealing cycles executed since the controller was first delivered is stored internally ST bit 1 This counter can only be displayed and not reset It can only be displayed in the ROPEX visualiza tion software section 10 11 Diagnostic interface visualization software as of February 2006 on page 39 10 13 Operating hours counter as of February 2006 The number of operating hours since the controller was first delivered is stored internally This counter works with a resolution of six minutes It can only be displayed and not reset It can only be displayed in the ROPEX visualization software section 10 11 Diagnostic interface visualization software as of February 2006 on page 39 Page 39 RO p a lx 10 14 Log function as of software revision 107 As of software revision 107 the RES 406 has a storage function for logging error messages section 10 16 Error messages on page 41 and zero calibrations AUTOCAL function 5 section 10 5 1 Automatic zero calibration AUTOCAL AC on page 26 The log shows the 30 most recent messages The message log is stored
5. 5e d J J lolJuo5 BsoR dey JJUOD nE 141 Ja JO4JUOD 5e d J J9 O4JUOD soR dey AHO Dp 6 ZOL dey Q 201 dey Q BiS cu S BelloA lil ou 135934 und 135934 uns 2120 uonoes 9 002 021 0077 Buoj oo uun dnie H Ajddns 1 mod Aouenba ul qissiuupe u 3 09 uonenjyony 991 001 cee Ajsnon 21 uljuo5 L ZOL uono s h yBiy Mo 00 nle1 duu l cel 08 992 guos oe uoo sool dn days 801 QOQ eae lined QOQ eee yne umop 201 6 Q ease yne eave yney Buissiw sjeuBis pue Yn 001 09 002 601 e se yne4 eave ney Buissiw jeubis Yq 99 Ov 6611 zot Q yne Q yne4 Buissiw jeus S ee 02 9970 LOL jou pueq SH OUI 1511 10 q s 44o 9e do o A BelloA 031 po Apeaye p lie s suiyoew y sneo Aey l wueye jo 5 00S 2 00 yndjno i J 0 0 uonoy SNLVLS Wav lv dwoy dway D PA py 39443 9002 Aueniqe 4 jo se s Bess ul 10113 JO Hed RES 406 Page 42 Rm P E X TWOOLNY unu EEQ sool OOQ eae lined 1 06 400 sool ease yne Jo pue unu soyenjony duu juaique 08 U02 soo p uuoJ d USeM JWOOLNV Blu oo sojyenjony dul
6. HEAT ON OFF function all pole or EMERGENCY STOP Line filter The filter type and size must be determined according to the load the transformer and the machine wiring 6 ROPEX Application Report Do not run the filter supply vvires line side parallel to the filter output vvires load side RESISTRON temperature controller belonging to the 4xx Series Relay Kb Load break all pole e g in combination vvith the alarm output of the temp controller ROPEX recommendation VVhen 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 Wiring The wire cross sections depend on the application 6 ROPEX Application Report Guide values Primary circuit min 1 5mm max 2 5mm Secondary circuit min 4 0mm max 25mm O These wires must always be twisted gt 20turns meter These wires must be twisted gt 20turns meter if several control loops are laid together crosstalk Twisting gt 20turns meter is recommended to improve EMC RES 406 Installation 8 4 Line filter To comply with EMC directives corresponding to EN 50081
7. Ju iquue yOB UOD SOO p uuoJ 13d USEA JWOOLNV MOJ 00 g 2 eae ne JO uoneolulo ds 9 172 1 unu J uuljoJsueJ s nduui JO 4 162110005 o uoSul JOOIIOOU sjeuBis di Jo pue n JO 4 2 1 85 1004 2 s euBis YQ JO 210 05 10 yoalooul s euBis Si J Buo ou usu yndjno anjea jenjoe ye anjea 21 ney 21 BUIUIPAA Ajsnon ulluoo 17 ZHP 1sE syulla BUIUIPAA FOL q 5009 gt Ol Ss SEES gt Dupu jou pueq SH Apeaiye Ji uonoy SWI 1S1 10 sulyoew J uonoy sneo s A40156 Aeja weje Jo SNLVLS 031 90 Do 00S d H L 90 Do 00 d H L A HOA nd no anjea py Page 43 RES 406 Controller functions pezibieus si Aejos wueje A snonunuo il 091 wele sanjea 31 2 ploq s yoy pue yOeq sdwnf ou yndjno anjen penpe ne e o sobueyo Bulusem y payeaijoe 51 jeuBis LHVWLS 94 peziBieue ap si Syullq 037 OM U M Q UO pue yoeq Sdu
8. compact or extended This determines vvhich protocol vvill 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 MADE IN GERMANY Page 23 R O P M 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 Controller functions 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 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 Spare Bit no 15 The 16 bit output data from the RES 406 to the PROFIBUS master contains the
9. 1 add 50mV Umax 50V DC AC Imax 0 2A changeover contact potential free Imax 5A duty cycle 100 Imax 25A duty cycle 20 max 20W 5 45 C IP20 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 Approx 0 7 kg incl connector plug in parts Plastic polycarbonate UL 90 V0 Rigid or flexible 0 2 2 5mm AWG 24 12 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 R O P M 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
10. Current RESISTRON controller Actual value nol 54 The use of RESISTRON temperature controllers results in e Repeatable quality of the heatseals under any conditions Increased machine capacity Extended life of the heatsealing bands and teflon coatings 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 enhancing the performance of modern machines However the full benefit can only be obtained from the advanced technology offered by this control system if all the system components in other words the heatsealing band the impulse transformer the wiring the timing signals and the controller itself are carefully compatible and interrelated We will be pleased to contribute our many years of experience towards optimizing your heatsealing system transformer Indicators and RES 406 Set point controls or bus interface Page 5 R O p a lx 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 Good dyna
11. lit off OUTPUT LED lit off The OUTPUT LED blinks repeatedly when the AUTOCOMP function is executed and the actual value output terminals 17 14 is set to 0 3 C i e app 0 VDC 3 AUTO as of software revision 105 With this setting the AUTOCOMP function is activated automatically after the AUTOCAL function has been successfully executed RES 406 nol 524 AUTOCAL bit 1 AC Function AUTOCOMP AUTOCAL The OUTPUT LED blinks repeatedly when the function is executed and the actual value output terminals 17 14 is set to 0 3 C i e app 0 VDC The AUTOCOMP function must be activated by means of the PROFIBUS parameter data 5 section 10 7 Parameter data on page 30 or the DPV1 protocol extension section 10 8 DPV1 protocol extension as of GSD Version v2 0 on page 35 default setting AUTOCOMP off 10 7 11 Temperature diagnosis as of GSD Version v2 0 An additional temperature diagnosis can be activated by means of the PROFIBUS parameter data or the DPV1 protocol extension The RES 406 checks whether the ACTUAL temperature is within a settable tolerance band OK window on either side of the SET temperature The lovver A owen and upper A uppen 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 1
12. section 8 3 Power supply on page 12 75 14 gt 28 gt terminal wires terminal block Snap on for DIN rail 35 x 7 5mm or 35 x 15mm DIN EN 50022 RES 406 Page 13 0 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 im production 1 date o danuary Current transformer Vv PEX W2 W3 Internnal ground Must be grounded No external externally to prevent electrostatic charging grounding allowed OV 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 DGND 5 controller electrically F5V VP isolated Impulse transformer 24VDC POWER SUPPLY GND Heat sealing ALARM OUTPUT max 50V 0 2A up to production 1 date I January ee Current transformer OV PEX W2 W3 Ground Internnal ground Must be grounded No external externally to prevent electrostatic charging grounding allowed OV Internnal ground ANALOG No external OU
13. 10 9 8 7 6 5 4 3 2 1 0 A8 13 12 11 10 9 8 7 6 5 4 3 2 1 0 appears error codes 115 and 116 section 10 16 Error messages on page 41 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 16 Error messages on page 41 You should always wait for the heatsealing band and the bar to cool down to ambient temperature before activating the AUTOCAL function Reasons for disabled AUTOCAL function 1 The AUTOCAL function cannot be activated until 10 seconds after the controller is switched on 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 down at a rate of more than 0 1K sec If the AC bit is activated the function is executed autom
14. Germany RES 406 Page 21 On 5 Manufactured up to January 2006 Green LED remains lit as long as b power supply is on OUTPUT Yellow LED remains lit for duration e of AUTOCAL process EXCHANGE mode In control mode luminous intensity Green LED indicated pulses in measuring is proportional to heating current Yellovv LED lit during heating phase RESISTRON uP Controller Red LED lights up or blinks to indicate alarm Green LED remains lit as long as PROFIBUS data is beeing exchanged with master INDUSTRIE ELEKTRONIK D 74321 BIETIGHEIM GERMANY In addition to the functions shown in the diagram by the LEDs These states are described in detail in the above various controller operating states are indicated table below Blinks slowly 1Hz Blinks fast 4Hz Lit continuously No PROFIBUS communication or RS Bit is AUTOCAL activated Reset function disabled AUTOCAL executing yellow LED blinks with a different frequency Supply voltages incorrect too low HEAT START requested yellow but function disabled 1 ye n control mode the luminous intensity is proportional to the heating current ALARM Configuration error Controller calibrated i red AUTOCAL not possible incorrectly run AUTOCAL DATA EXCHANGE _ _ Communication with green PROFIBUS master active The following sections
15. actual value or the Bit no 10 4 2 Compact protocol with 10 Bit error code The 10 Bit error codes are available on all controllers manufactured as of July 24 2006 and supplied with GSD Version v1 6 These error 25155 011 0 D e 5 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status information Actual value compact if AL 0 T laTel l lvi 117 15 14 13 12 11 10 9 8 7 Set point AC temperature error code and the status information and has the following structure Error code if AL 1 Telels 5 4 3 2 1 codes must be activated in the parameter data section 10 7 9 Error code format on page 32 6 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 Spare Bit no 15 The 16 bit output data from the RES 406 to the PROFIBUS master contains the actual value or the Status information ame A Bit no 15 Page 24 z ES 1 01 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Error code if AL 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Set point AC temperature error code and the status information and has the following structure Actual value compact if AL 0 RES 406 Controller functions R 0 p 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
16. 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 17 Fault areas and causes on page 46 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 11 Diagnostic interface visualization software as of February 2006 on page 39 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 on page 8 Page 41 Controller functions R O P M Jeduun ul 6njd J dun ul 6njd yndjno wee 104 11 61 v llonuoo eid M J lojlJuo5 soR dey nuoo nE 141 Y llonuoo eid s J9 O4JUOD eid v nuoo nE 141 662 071 99 7 1 01 U09
17. 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 RES 406 Controller functions 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 16 Error messages on page 41 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 order to avoid false alarms 10 16 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 RES 406 RO P E The table below shows how the analog voltage values correspond with the faults that have occurred It
18. describe only contiguration please refer to the description of controller specific functions For general yourPLC information about PROFIBUS and the system Page 22 RES 406 Controller functions 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 24VDC power supply terminals 5 7 and PROFIBUS connector pins 7 2 and the line voltage are present If the line voltage is switched 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 manuf actured as of February 2006 PROFIBUS communica tion is always possible on these controllers as long as the 24VDC power supply is present i e switching off the line voltage no longer results in a bus fault 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 manufactured as of February 2006 and the alarm relay is switched This error can be reset by switching on the line voltage again and activating the RS bit 5 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
19. 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 word at bit positions 8 11 error code format 4 bit or 6 15 error code format 10 bit section 10 16 Error messages on page 41 10 bit error codes are available on all control lers manufactured as of duly 24 2006 and supplied with GSD Version v1 6 Older controllers only show 4 bit error codes Page 29 R O P M 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 gt section 10 7 9 Error code format on page 32 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 heating time limit It is transferred from the PROFIBUS master to the RES 406 each time
20. in section 1 6 Standards CE marking on page 4 This device must be installed and connected according to the instructions contained in section 8 3 Power supply as well as the separate documentation enclosed with the line filter 1 6 Standards CE marking The controller described here complies with the following standards provisions and directives DIN EN 61010 1 2001 2006 95 EG Safety requirements for electrical equipment for measurement control and laboratory use low voltage directive pollution degree 2 protection class Il measurement category for Up and Ip terminals DIN EN 60204 1 2006 42 EG Electrical equipment of machines machinery directive EN 55011 1998 A1 1999 A2 2002 EN 61000 3 2 2006 04 EN 61000 3 3 1995 01 A1 2001 A2 2005 11 2004 108 EG EMC genery emissions Group 1 Class A EN 61000 6 2 2005 2004 108 EG EMC generic immunity Class A ESDs RF radiation bursts surges Exception Line voltage interruption acc EN 61000 4 11 is not fulfilled This leads to a designated error message of the controller 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 Page 4 Application Compliance with these standa
21. o Operating hours counter 39 Output data 28 Over current protection 12 Overheating of heatsealing band 6 P PEX W2 W3 3 PEX VV3 13 49 Phase angle compensation 32 Povver dissipation 9 RES 406 nal p u vu Power supply 12 49 T Principle of operation 5 TCR 3 18 PROFIBUS DP interface 8 TE bit 28 Protocol Temperature coefficient 3 18 Compact 10 Bit error code 24 Temperature control 4 Compact 4 Bit error code 24 Temperature diagnosis 33 Extended 10 Bit error code 25 Temperature indication 38 Extended 4 Bit error code 25 Temperature meter 6 38 49 Temperature OK 28 R Temperature range 8 17 RA bit 20 29 Temperature reached 28 Replacing the heatsealing band 19 20 TO bit 28 Reset 27 Total cycle counter 39 RS bit 27 Transformer 3 7 12 49 Type of construction 8 s Secondary current 12 16 V Secondary voltage 16 View of the controller 16 Set point 28 Visualization software 39 Start 27 START bit 20 W Startup 16 Wiring 11 12 System diagnostics 39 Wiring diagram 14 15 System monitoring 40 RES 406 Page 51
22. present in the plant or machine The line frequency is automatically detected by the RESISTRON temperature controller in the range from Page 10 RES 406 Dimensions 47 Hz 63Hz 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 Wire the system in accordance with the instructions in section 8 3 Power supply on page 12 section 8 6 Wiring diagram standard on page 14 and the ROPEX Application Report The information provided in section 8 2 Installation steps on page 11 must also be heeded An overcurrent protective device e g a fuse must be fitted when the controller is installed The minimum possible specification for this device must be entered in the ROPEX Application Report based on the calculated currents If a larger overcurrent protective device is fitted you must match the current carrying capacity of the other components accordingly e g cables impulse transformer etc Installation m P E 5 Connect the RESISTRON temperature controllerto 6 Make sure that the wiring conforms to the relevant the PROFIBUS master using a cable according to national and international installation regulations IEC 61158 Check the tightness o
23. program If controllers manufactured as of February 2006 are installed in an older machine e g in order to carry out repairs this nevv controller function can lead to unvvanted error codes vvhen the line voltage is svvitched 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 RES 406 neo 54 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 vvhich 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 vvith the controller 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 communication modules
24. real ACTUAL temperature is indicated until the end of the first heating phase 3 2s It causes the current ACTUAL temperature to be displayed as a digital value for an additional 2 seconds at the end of a heatsealing phase This temperature is then indicated again in real time until the end of the next heating phase Hold mode affects the digital value of the real temperature in the PROFIBUS communiction and the numeric temperature display in the ROPEX visualization software only The output of the real temperature on the actual value output and the data record in the graphics window of the ROPEX visua lization software is not affected RES 406 Controller functions The various hold modes are shown below ST bit ACTUAL temp A ACTUAL indication Hold off v Hold on Hold 2 s gt 2s 2 End of heating phase 10 8 DPV1 protocol extension as of GSD Version v2 0 Text in preparation 10 8 1 Identification and maintenance I amp M functions Text in preparation 10 8 2 DPV1 alarm model Text in preparation v RO P E X The Holde mode function must be activated by means of the PROFIBUS parameter data section 10 7 Parameter data on page 30 or the DPV1 protocol extension section 10 8 DPV1 protocol extension as of GSD Version v2 0 on page 35 default setting Hold mode off RES 406 Page 35 R O P M 10 8 3 DPV1 parameter dat
25. revision 100 available Factory setting for software revision 100 102 A heatsealing cycle starts when the ST bit is set The TO bit is set when the actual temperature reaches the temperature tolerance band for the first time during a heatsealing cycle If the actual temperature leaves the tolerance band again while the ST bit is still set the TO bit is reset refer to Fig a If the actual temperature does not leave the tolerance band again while the ST bit is still set the TO bit is not reset until the start of the next heatsealing cycle latch function refer to Fig b RES 406 Controller functions The switching state of the TO bit can thus be queried after the ST bit has been reset and before the start of the next heatsealing cycle a Temperature not OK A Actual value Set AV upper Set sett Av ower Time ST bit af Seer Time TO bit 1 Time b Temperature OK A Actual value Set AV upper Set aaa gt Time ST bit 1 f e o Time TO bit 1 all P Time For controllers with software revision 100 101 and 102 the configuration for the TO bit can be set via the ROPEX visualization software As of software revision 103 the configuration for the TO bit is set in the PROFIBUS parameter data or the DPV1 protocoll extension A configuration with the ROPEX visualization software is no more possible The limits o
26. 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 section 9 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 1Hz 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 addition to the yellow AUTOCAL LED when the voltage is switched on the configuration of this controller has been changed in the visualization software section 10 11 Diagnostic interface visualization software as of February 2006 on page 39 In order to avoid malfunctions please check the controll
27. the cyclic data You can choose between a 4 bit and a 10 bit format 5 section 10 4 PROFIBUS protocol on page 24 4 bit generates two 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 16 Error messages on page 41 This parameter is available on all controllers manufactured as of July 24 2007 and supplied with GSD Version v1 6 10 7 10 Automatic phase angle compensation AUTOCOMP as of GSD Version v2 0 It may be necessary to compensate the phase angle displacement between the and Ip measuring signals for special heatsealing applications 5 ROPEX Application Report The AUTOCOMP function is provided for this purpose The follwing settings are possibe 1 off Factory setting The AUTOCOMP function is switched off RES 406 Controller functions 2 on It is executed whenever the AUTOCAL function section 10 16 Error messages on page 41 is run twice in quick succession The interval between the end of the first AUTOCAL function and the start of the second AUTOCAL must be shorter than 2 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 AUTOCAL bit 1 f t Function AUTOCOMP AUTOCAL AUTOCAL LED
28. 0K and 10K If the actual temperature is inside the specified tolerance band when the START signal is activated the temperature diagnosis is activated as well If the ACTUAL temperature leaves the tolerance band the corresponding error code 307 or 308 is indicated and the alarm relay is switched section 10 16 Error messages on page 41 Page 33 R O P M m Actual value SetrA 9 upper Set SettA jower gt Time Alarm 307 If the 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 by means of the PROFIBUS parameter data or the DV1 protocol extension 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 PROIBUS parameter data section 10 7 Parameter data on page 30 or the DPV1 protocol extension section 10 8 DPV1 protocol extensio
29. 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 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 RO 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 5 Line filter documentation It is permissible to supply several RESISTRON control loops with a single line filter providing the total current does not exceed the maximum current of the filter The wiring instructions contained in section 8 3 Power supply on page 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 gt
30. 1100 ppm K 300 C 1 780 ppm K 300 C 4 1100 ppm K 500 C 5 780 ppm K 500 C 8 3500 ppm K 300 C 9 PC configuration 10 Rotary coding switch 11 variable 3 99 10 Upper temperature limit K 3 99 10 Calibration temperature C 1 variable with cyclic data 0 40 20 Heating time limit 0 1s steps 0 250 0 without limit Extended controller diagnosis 0 deactivated 1 activated Measuring pulse length 0 1 ms steps 17 30 17 Data format Error code format 0 Intel 1 Motorola 0 4 bit 2 digits 1 10 bit 4 digits Page 36 Temperature coefficient ppm K 400 4000 1100 RES 406 Controller functions Parameter RO P E Value range Temperatur range 0 200 C 1 300 C 2 400 C 3 500 C Maximum temperature C 200 500 300 Temperature diagnosis 0 deactivated 1 ac tivated Temperature diagnosis delay time 0 1s steps 0 99 0 Heatup timeout 0 1s steps 999 0 AUTOCOMP on AUTO as 0 0 off 1 2 of softvvare revision 105 TO bit Temperature OK off active if Tact Tset active if Tact Tset with latch Hold mode RES 406 Off on 25 Page 37 R O P M 10 9 Temperature indication actual value output The RES 406 supplies an analog 0 10VDC signal which is proportional t
31. 24 7 12 RESISTRON R P E 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 TelTen 49 0 7142 7776 0 E Mail n info ropex de R 0 P E 7 Gansacker 21 49 0 7142 7776 211 Internetl iHTepHer www ropex de D 74321 Bietigheim Bissingen Data subject to Ha RO P M Contents 1 Safety and warning notes 3 10 11 c y ys l ubapa gobud a aa 3 1 2 Heatsealing band 3 1 3 Impulse transformer 3 1 4 Current transformer PEX W2 W3 3 1 5 Line filter 4 1 6 Standards CE marking 4 1 7 Warranty provisions 4 2 Application 4 3 Principle of operation 5 4 Descr
32. 6 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 gt 8 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 16 Error messages on page 41 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 11 Diagnostic interface visualization software as of February 2006 on page 39 Page 18 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 CONFIGURATION AT ALARM ALARM OUTPUT ENERGIZED 9 3 Replacing and burning in the heatsealing band 9 3 1 Burning in
33. 8 Alarm output 40 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 932 Automatic phase angle compensation 32 Automatic zero calibration 6 20 26 AUTOTUNE 6 B Booster 7 15 49 Booster connection 39 Burning in the heatsealing band 18 20 C Circuit breaker 12 CI USB 1 7 39 49 Communication interface 7 39 49 Controller active 29 Controller configuration 16 Controller diagnosis 32 Current transformer 7 13 49 D Data format 32 Degree of protection 9 Device master file GSD 23 Diagnostic interface 39 Digital temperature meter 6 Dimensions 10 DIP switches 16 DPV1 protocol extension 35 E Error code format 32 Page 50 Index Error messages 41 Extended controller diagnosis 32 External svvitching amplifier 7 15 F Factory settings 47 Fault areas 46 Fault diagnosis 6 Fuse 12 G GSD 23 H Heatsealing band type 8 Heatup timeout 34 mpulse heatsealing method 4 mpulse transformer 7 12 49 nput data 26 nstallation 9 10 nstallation procedure 10 Installation regulations 11 L Line filter 6 12 13 49 Line frequency 6 8 Line voltage 8 Log function 40 Maintenance 48 Measurement cable 7 Measurement pause 27 Measuring impulse duration 32 Modifications MODs 7 49 MODs 7 49 Monitoring current transformer 7 MP bit 27
34. TPUT grounding allowed 0 10VDC RES 406 Page 15 Q P M 9 Startup and operation 9 1 View of the controller Terminals 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 LEDs PROFIBUS plug q Nameplate ja 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 16 Error messages on page 41 Configuration with coding switches up to January 2006 Set the DIP switches for matching the secondary voltage Uz and the secondary current l gt to the correct position 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 PUT Uz 12345 ON 6 60V If the secondary current l is less than 30A the PEX VV2 or PEX VV3 current trans
35. 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 andtemperature 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 132VAC 230VAC version 220VAC 15 240VAC 10 equivalent to 187 264 VAC 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 230VAC 15 240VAC 10 equivalent to 196 264 VAC 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 76 depending on version selected section 13 How to order on page 49 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 45 kbaud 93 75kbaud 187 5kbaud 500kbaud 1 5Mbaud 3Mbaud 6Mbaud 12Mbau
36. a The basic controller settings and functions can be set with the parameter data in the device master file GSD file section 10 7 Parameter data on page 30 Some PLC systems only allow you to change the set tings in the GSD file when you create a new project The settings cannot be changed while the machine or system is operating The DPV1 protocol extension makes it possible to change these settings and functions without interrup ting the operation of the controller The temperature coefficient for the heatsealing band for instance can DPV1 parameter table of the RES 406 Default values are printed bold cursive Parameter Controller functions be altered on the PLC control unit during the validation process This acyclic service supports both reading and writing of the controller parameters The parameter data can optionally be accessed by addressing the slot indexes Since the controller does not store parameters trans ferred to it in this way you must remember to transfer all parameters that deviate from the static configuration again after restarting the controller or the bus Please contact the manufacturer for more information about how your PLC system sup ports the DPV1 protocol extension Value range SM functions IMO Cyclic data Article number serial number version index manufacturer ID section 10 4 PROFIBUS protocol on page 24 Alloy range Lower temperature limit K 0
37. 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 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 and 7 As of February 2006 201 203 901 913 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 heatsealing band need to be disconnected during normal operation without triggering an alarm e g sliding rail contacts Page 27 R O P M In contrast with the RS bit RESET the MP bit does not reset an
38. atically providing the cooling rate has fallen below the above mentioned value RES 406 Controller functions 3 If the START bit ST bit 1 is activated the AUTOCAL function is not executed HEAT LED lit 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 with 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 16 Error messages on page 41 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 4H2 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 or until the actual heating time exceeds the preset heating time limit 5 section 10 7 5 Heating time limit on page 32 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 th
39. ation appears at the actual value output instead If an ATR x is connected it must be set to Z f the zero point has not been calibrated successfully the AL bit alarm active is set and the red ALARM LED blinks slowly 1 Hz 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 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 Up measuring wire have been wired incorrectly If an error code is displayed please proceed as described in section 10 16 Error messages on page 41 12 Burn in the heatsealing band section 9 3 Replacing and burning in the heatsealing band on page 18 and repeat the AUTOCAL function 1 The controller is novv ready 9 4 2 Restart after rep
40. blades solder elements etc as required in a variety of heatsealing processes The controller is most commonly used for impulse heatsealing PE films in Vertical and horizontal f f s machines Pouch filling and sealing machines RES 406 Principle of operation e Film wrapping machines e Pouch making machines e Group packaging machines etc 3 Principle of operation The resistance of the heatsealing band which is temperature sensitive is monitored 50x per second 60x at 60Hz by measuring the current and voltage The temperature calculated with the help of these measurements is displayed and compared with the set point The primary voltage of the impulse transformer is adjusted by phase angle control if the measured values deviate from the set point The resulting change in the current through the heatsealing band leads to a change in the band temperature and thus also its resistance This change is measured and evaluated by the RESISTRON temperature controller The control loop is closed ACTUAL temperature SET temperature Even minute thermal loads on the heatsealing band are detected and can be corrected quickly and precisely A highly high response thermo electric control loop is formed which is highly accurate because purely electrical variables are measured at a high sampling rate A high secondary current can be controlled because power is controlled on the primary side of the Cuna
41. d 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 11 Diagnostic interface visualization software as of February 2006 on page 39 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 Five different ranges can be set with the rotary coding switch or via the PROFIBUS interface Temperature coefficient 1100ppm 0 300 C e g Alloy 20 Temperature coefficient 780ppm 0 300 C e g Alloy L Temperature coefficient 1100ppm 0 500 C e g Alloy 20 Temperature coefficient 780ppm 0 500 C e g Alloy L Temperature coefficient 3500ppm 0 300 C e g NOREX The settings for a temperature coefficient of 780 ppm are only available on controllers manufactured as of October 2003 RES 406 Technical data Analog output actual value Terminals 17 18 Alarm relay Terminals 12 13 14 Maximum load primary current of impulse transformer Power dissipation Ambient temperature Degree of protection Installation Weight Housing material Connecting cables Type cross sections n P E 0 10V DC Imax 5mA Equivalent to 0 300 C or 0 500 C Accuracy
42. d air Page 48 RES 406 How to order neo P E 13 How to order Conir 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 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 480 VAC Art No 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communiction interface CI USB 1 Art No 885650 Temp meter ATR TL 3 300 C range Art No 882130 5 500 C range Art No 882150 Booster B 400 075 Max pulse load 75 400VAC Art 885301 100 Max pulse load 100A 400VAC Art No 885304 For more accessories Accessories leaflet RES 406 Page 49 R O P M 14 Index Nummern 24VDC Supply voltage 8 A AA bit 28 AC bit 26 Actual value 29 Actual value output 38 AG bit 28 AL bit 20 28 Alarm 2
43. e 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 switched 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 section 10 16 Error messages on page 41 The heatsealing band is no longer heated up RES 406 RO P E 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 From then on only fault nos 5 and 7 As of February 2006 201 203 901 913 are evaluated and output by the fault diagnosis function The power section is not activated in this state and no measuring impulses are 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 the 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
44. er configuration before continuing the startup procedure 8 The green DATA EXCHANGE LED lights up to indicate an active PROFIBUS communication Page 19 R O P M 9 One of the following states then appears Up to production date January 2006 ALARM LED OUTPUT LED ACTION OFF Short pulses every 1 2s Go to 10 BLINKS fast 4Hz OFF Go to 10 Lit continuously OFF Fault diagnosis section 10 16 As of production date February 2006 ALARM LED OUTPUT LED ACTION OFF Shortpulses every 1 2s Go to 10 BLINKS fast 4Hz OFF Go to 10 Lit continuously 10 Activate OFF the AUTOCAL function Fault no 901 Fault group 7 Supply voltage Sync Signal mis sing section 10 2 Otherwise Fault diagnosis section 10 16 while the heatsealing band is still cold by setting the AC bit AUTOCAL in the PROFIBUS protocol section 10 4 PROFIBUS protocol on page 24 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 appears 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 oper
45. f all the system 8 2 Installation steps connections including the terminals for the impulse transformer windings Use heatseal bands with suitable temperature coefficient o No push on connectors Heatseal element with coppered ends No additional resistance in secondary circuit Connect measuring vvires directly to heatsealing band ends number of turns Sufficient vvire cross section f Current transformer PEX W2 W3 Current measuring wires IR Line Temperature meter ATR x Line filter LF xx480 Avoid long cables Note direction of rotation Impulse mi transformer O Digital Dimension potentiometer transformer correctly PD x 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 R O P M 8 3 L1 L1 N L2 GND Earth ON r OFF kes Power supply LINE ISLS WIA Kk Page 12 temperature o controller nstallation Line 115VAC 230VAC 400VAC 50 60 Hz Over current protection Double pole circuit breaker or fuses ROPEX Application Report Short circuit protection only RESISTRON temperature controller not protected Relay Ka For
46. f the tolerance band are adjustable to max 99K on controllers manufactured as of RES 406 RO P E February 2006 and supplied with GSD Version v1 5 On older controllers the 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 0 The error code is contained in separate bits 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
47. former must have two turns ROPEX Application Report 2X 9 2 2 Configuration of the rotary coding switch for the temperature range and alloy Switch Temp Temp Band range coefficient alloy 300 C 1100ppm K e g Alloy 20 e g Alloy L e g Alloy 20 e g Alloy L 300 C 350 e g NOREX PC CONFIGURATION The settings for a temperature coefficient of 780ppm switch position 1 and 5 are only available on controllers manufactured as of October 2003 500 C 1100ppm K 0 settings The setting of the rotary coding switch for the temperature range and ally can be overwritten with the parameter data Ssection 10 7 Parameter data on page 30 RES 406 20 120V p a y Factory settings DIP switch lo 2 3 4 ON OFF OFF 30 100A OFF ON OFF 60 200A OFF OFF ON 120 400A gt POS TEMP RANGE ALLOY 300 C 1100ppm K A20 300 C 780ppm K L 500 C 1100ppm K 20 ooo a 8 780ppm K L 300 C 3500ppm K NOREX L j PC CONFIGURATION If the switch is set to 9 as of February 2006 more temperature ranges and alloys can be selected by means of the ROPEX visualization software see section 10 11 Diagnostic interface visualization software as of February 2006 on page 39 Page 17 R O P M 9 2 3 Configuration of the rotary coding switches for the station address The station address of the RES 40
48. h setting RES 406 Page 31 R O P M 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 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 Os and 25 0s 0 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 sup plied with GSD Version v1 2 DPV1 protocol extension alarm model The extended device diagnostic functionality is not available with the DPV1 protocol extension and GSD Vers
49. he 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 bobbin When the impulse transformer is installed suitable shock protection must be provided in accordance with the national installation regulations for electrical equipment In addition water cleaning solutions and conductive fluids must be prevented from seeping into the transformer Incorrect installation of the 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 operating safety They are not included in the scope of supply of the standard control system and are described in a separate document 1 5 Line filter The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions mentioned
50. ing the controller from being started error codes 1 7 of February 2006 also 101 103 107 108 201 203 307 308 801 9xx As a rule it refers to an external wiring fault 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 ENERGIZED in operating state If the alarm relay is configured opposite to the factory setting 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 10 VDC analog output terminals 17 18 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 16 Error messages on page 41 If a state that requires AUTOCAL occurs or if the con troller configuration is not correct error
51. ion v2 0 or higher section 10 8 DPV1 protocol extension as of GSD Version v2 0 on page 35 The DPV1 alarm model section 10 8 2 DPV1 alarm model on page 35 must be used in this configuration instead In this case parameter no 9 in the GSD file switches the so called DPV1 diagnostic interrupt on and off If you want to keep the old extended device diagnostics e g for reasons of software compatibility you must use a GSD version previous to v2 0 The DPV 1 functio nality for the RES 406 is then automatically deactivated in the PROFIBUS master Page 32 Controller functions 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 10 7 8 Data format This parameter 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 24 We recommend setting lovv 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
52. ions 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 31 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 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 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 31 It can be specified in the 0 40 C range The value 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 This selected value must remain entered until the AUTOCAL function has finished If the specified temperature is too high greater than 40 C or if the selected value varies an error message Page 26 Actual value signed 14 13 12 11
53. iption of the controller 6 5 Accessories and modifications 6 5 1 Accessories 6 5 2 Modifications MODs 7 Technical data 8 7 Dimensions 10 8 Installation 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 VV3 13 8 6 Wiring diagram standard 14 8 7 Wiring diagram with booster s connection 15 12 9 Startup and operation 16 13 9 1 View of the controller 16 14 9 2 Controller configuration 16 9 3 Replacing and burning in the heatsealing band 18 9 4 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 23 10 3 Device master file GSD 23 10 4 PROFIBUS protocol 24 10 5 Inputdata 26 10 6 Outputdata 28 10 7 Parameter data 30 10 8 DPV71 protocol extension as of GSD Version v2 0 35 10 9 Temperature indication actual value UPUD e a 38 10 10 Booster connection 39 10 11 Diagnostic in
54. ith GSD Version v2 0 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 Refer section 10 6 5 Temperature OK TO on page 28 and section 10 7 11 Temperature diagnosis as of GSD Version v2 0 on page 33 10 7 3 Upper temperature OK threshold Upper threshold value for the OK window Refer section 10 6 5 Temperature OK TO on page 28 and section 10 7 11 Temperature diagnosis as of GSD Version v2 0 on page 33 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 calibration temperature can then be specified via the Set point AC temperature input data gt section 10 5 1 Automatic zero calibration AUTOCAL AC on page 26 You do not need to execute the AUTOCAL 1507 function after changing the calibration visualization temperature softvvare Rotary coding switc
55. lacing the heatsealing band To replace the heatsealing band proceed as described in section 9 3 Replacing and burning in the heatsealing band on page 18 Always use a heatsealing band with the correct alloy dimensions and copper plating in order to avoid malfunctions and overheating Continue with section 9 4 steps 5 to 12 RES 406 cs U I Ip t 10 Controller functions See also section 8 6 Wiring diagram standard on page 14 10 1 Indicators and controls Manufactured as of February 2006 ALARM 0000 ALARM Lights up or blinks to indicate HEAT on e000 red LED an alarm AUTOCAL 24V SUPPLY OOOO BUS POWER OK uC POWER OK DATA EXCHANGE HEAT Lit during heating phase yellovv LED OUTPUT ndicates pulses in green LED measurement mode n control mode luminous intensity is proportional to heating current AUTOCAL Remains lit for duration of yellovv LED AUTOCAL process o snaisoud J o RESISTRON RES 406 Temperature controller ROPEX Tel 49 0 7142 7776 0 www ropex de 24V SUPPLY Lit if external 24VDC power green LED supply is present BUS PWR OK Lit if internal 5VDC power green LED supply for Profibus interface is OK HC PWR OK Lit if internal 5VDC power green LED supply for microcontroller is OK DATA EXC Remains lit while Profibus data green LED is exchanged with master iS El Made in
56. mic 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 e 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 overheating 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 adap
57. n as of GSD Version v2 0 on page 35 10 7 12 Heatup timeout as of GSD Version v2 0 An additional heatup timeout can be activated by means of the PROFIBUS parameter data or the DPV1 protocol extension This timeout starts when the START bit is activated The RES 406 then monitors the time required for the ACTUAL temperature to reach 95 of the SET temperature If this time is longer than the parameterized time the corresponding error code 304 is indicated and the alarm relay is switched section 10 16 Error messages on page 41 Page 34 Controller functions Actual value Set 95 of Set Timeout N gt N gt lt Time Heatup time Alarm 304 The Heatup timeout function must be activated by means of the PROFIBUS parameter data section 10 7 Parameter data on page 30 or the DPV1 protocol extension section 10 8 DPV1 protocol extension as of GSD Version v2 0 on page 35 default setting Heatup timeout off 10 7 13 Hold mode as of GSD Version v2 0 The behavior of the digital indication of the ACTUAL temperature via the PROFIBUS communication is set by means of the paramters data or the DPV1 protocol extension as followed 1 off Factory setting The real ACTUAL temperature is always indicated 2 on The ACTUAL temperature that was valid at the end of the last heatsealing phase is always indicated as a digital value When the controller is switched on the
58. o the real ACTUAL temperature at terminals 17 18 RES 406 Actual value output 0 10VDC OV 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 38 Controller functions The relationship between the change in the output voltage and the ACTUAL temperature is linear C 300 270 5 240 o 210 o F 180 150 120 0 300 C range 2 3 4 5 6 7 8 9 10 Voltage U ZERO C 500 P 450 5 400 o 350 o F 300 250 200 150 0 500 C range 23 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 RES 406 Controller functions This meter moreover permits disturbances in the cont
59. per 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 m ON 12345 secondary voltage Uz and current l gt up to January 2006 Rotary coding switch for heatsealing band alloy and temperature range Plug in jumper for alarm relay SWITCH POS N 0 RES 406 Us 6 60VAC l2 30 100A DIP switches 2 ON 1 3 4 5 OFF These switches 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 47 D E x Maintenance Rotary coding switches for station address Station address 01 Jec Automatic phase AUTOCOMP off angle compensation AUTOCOMP X Temperature Temperature diagnosis deactivated diagnosis X Heatup timeout Heatup timeout deactivated X X As of February 2006 and GSD Version v2 0 Setting by means of the PROFIBUS parameter data or the DPV1 protocol extension 12 Maintenance The controller requires no special maintenance the impulse transformer is recommended Dust Regular inspection and or tightening of the terminals deposits on the controller can be removed with dry including the terminals for the winding connections on compresse
60. providing the regulations notes and warnings contained in these instructions are complied with In case of non compliance or use contrary to the intended purpose there is a risk that safety will be impaired or that the heatsealing band electrical wiring transformer etc will overheat Ensuring such compliance is the personal responsibility of the user 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 CRx 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 t
61. rds and provisions is only guaranteed if original accessories and or peripheral components approved by ROPEX are used If not then the equipment is operated on the user s own responsibility The CE marking on the controller confirms that the device itself complies with the above mentioned standards It does not imply however that the overall system also fulfils these standards It is the responsibility of the machine manufacturer and of the user to verify the completely installed wired and operationally ready system in the machine with regard to its conformity with the safety provisions and the EMC directive see also section 8 3 Power supply If peripheral components e g the transformer or the line filter from other manufacturers are used no functional guarantee can be provided by ROPEX 1 7 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 heatsealing
62. rol loop loose connections contacting or wiring problems as well as any line disturbances to be observed extremely effectively and interpreted accordingly The same applies if mutual interference occurs between several neighboring control loops This output is not potential free and might have the potential of the secondary voltage of the impulse transformer External grounding is not allowed If this warning is ignored the controller will be damaged by frame currents 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 16 Error messages on page 41 10 10 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 11 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 RES 406 RO P E y ROPEX visualization software using the ROPEX communication interface CI USB 1 LI
63. rom 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 Parallel circuit interrupted Heatsealing band partially bypassed by conducting part clamp opposite heatsealing bar etc 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 46 Un signal incorrect Up to Jan 2006 DIP switches 1 3 configured incorrectly Uz range As of Feb 2006 U gt outside permissible range from 0 4 120VAC RES 406 Factory settings Fault area Explanation RO P E Possible causes R signal incorrect Up to Jan 2006 DIP switches 4 5 configured incorrectly 15 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 jum
64. rovides information about the exact cause of the fault gt section 10 16 Error messages on page 41 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 Page 28 Controller functions mode is exited ST bit 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 AD jower and upper AB upper limits of the tolerance band can be changed independently of one another by means of the parameter data section 10 7 Parameter data on page 30 The following settings are possible 1 off The TO bit is always deactivated 2 Active if Tact Tset Factory setting up to software revision 017 and as of software revision 103 The TO bit is activated if the actual value is inside the specified temperature tolerance band f the actual temperature is outside the tolerance band the TO bit is deactivated see graph below A Actual value SettA upper Set Set A ower TO bit a Time 1 0 P Time Unlike the Temperature reached status bit TE bit the actual temperature is evaluated independently of the control mode 3 Active if Tact Tset with latch function as of software
65. t 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 design 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 R 0 2 Impulse transformer ITR
66. terface visualization software as of February 2006 39 10 12 Total cycle counter as of February 2006 39 10 13 Operating hours counter as of February 2006 39 10 14 Log function as of softvvare revision 107 40 10 15 System monitoring alarm output 40 10 16 Error messages 41 10 17 Fault areas and causes 46 Factory settings 47 Maintenance 48 How to order 49 ndex 50 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
67. 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 already been thermally pretreated by the manufacturer An overheated or burned out heatsealing band must no longer be used because the TCR has been altered irreversibly One very important design feature is the copper or silver plating of the heatsealing band ends Cold ends allow the temperature
68. the system is started up If the parameter data is changed during operation the RES 406 performs a reset The PROFIBUS communication is not interrupted The parameter data has the following structure Possible Function values Reserved set to 0 0 Function Controller functions Possible values Measuring impulse duration as of 14 07 03 and GSD Version v1 3 17 30 1 7 3 0ms Data format as of 23 07 04 and GSD Version v1 4 High Low byte Intel Low High byte Moto rola Error code format as of 24 07 06 and GSD Version v1 6 4 bit 10 bit Temperature coefficient as of Feb 2006 and GSD Version v2 0 Temperature range as of Feb 2006 and GSD Version v2 0 400 4000 ppm 200 300 400 500 C Maximum temperature as of Feb 2006 and GSD Version v2 0 200 500 C Temperature diagnosis as of Feb 2006 and GSD Version v2 0 deactivated activated Temperature range alloy 1 4 5 8 10 Lower temperature OK threshold 3 99K Upper temperature OK threshold 3 99K Temperature dia gnosis delay time 100ms steps as of Feb 2006 and GSD Version v2 0 Calibration temperature 1 0 40 C Heating time limit 100ms units Heatup timeout 100ms steps as of Feb 2006 and GSD Version v2 0 0 999 0 99 9s 0 250 0 25 0s Extended controller dignostis
69. 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 with the instructions provided by the manufacturer Each time the heatsealing band is replaced the zero point must be calibrated with the AUTOCAL function while the band is still cold in order to compensate production related resistance tolerances The burn in procedure described above should be performed for all new heatsealing bands 9 4 Startup procedure Please also refer to section1 Safety and warning notes on page3 and section2 Application on page 4 Installation and startup may only be performed by technically trained skilled persons who are familiar with the associated risks and warranty provisions 9 4 1 Prerequisites The controller must be correctly installed and connected section 8 Installation on page 10 Initial startup RES 406 RO P E Proceed as follows to start up the controller for the first time 1 Switch off the line voltage and verify that all circuits are de energized 2 The supply voltage specified on the nameplate of the controller must be identical to the line voltage that is present in the plant or machine The line frequency is automatically detected by the
70. together with the total cycle counter and the operating hours counter This log can only be displayed and not deleted It can only be displayed in the ROPEX visualization software section 10 11 Diagnostic interface visualization software as of February 2006 on page 39 The log function for error messages and zero calibra tions AUTOCAL function allows you to evaluate ope rating states at a later point in time simplifying fault analyses 10 15 System monitoring alarm output To increase operating safety and to avoid faulty heatse aling 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 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 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 Page 40 Controller functions This indicates that a fault is prevent
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72. word O and the control functions in word Bit no 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 dololololololololololo o MP Rs sr c 8 7 6 5 4 3 2 1 0 Bit no 15 14 13 12 11 10 9 The 2x 16 bit output data contains the actual value in word and the error code and status information in word Actual value signed 25 22 1 j 3 E b 5 i Bit no 15 Error code Status information s CC Bit no 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 32 The 10 Bit error codes are available on all The extended protocol transfers 2x 16bits The 2x16 controllers manufactured as of July 24 2006 input data contains the set point in word and the and supplied with GSD Version v1 6 These error control functions in word Set point AC temperature In C T YEMEYE nE R P Pb UU UE Bit no Control function Crd CC Bit no RES 406 Page 25 0 P M The 2x16 bit output data contains the actual value in word and the error code and status information in word Controller functions Bit no 15 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 funct
73. 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 ROPEX Application Report 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 recording SET and ACTUAL tempe ratures in real time Booster B xxx400 External switching amplifier necessary for high primary currents continuous current gt 5A pulsed current gt 25A Monitoring current transformer For detecting frame short circuits on the heatsealing band Used as an alternative to the standard PEX W2 W3 current transformer Measurement cable UNL 1 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 One modification MOD Amplifier for low secondary voltages Up 0 25 16VAC This modification is necessary for example for very short or lovv resistance is available for the heatsealing bands RESISTRON temperature controller RES 406 for implementing special applications RES 406 Page 7 RO p a lx
74. y 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 The MP bit is available on all controllers manufactured as of July 14 2003 and supplied with 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 31 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 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 p

Operating instructions RES-406

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