ropex-res-415

ropex-res-415
RESISTRON
RES-415
GB
Operating
Instructions
Important features
Microprocessor technology
•
LC display (green), 4 lines, 20 characters
Alternatively:
VF display (blue), 4 lines, 20 characters
•
Automatic zero calibration (AUTOCAL)
•
Automatic optimization (AUTOTUNE)
•
Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of software revision 100)
•
Automatic frequency adjustment
•
Large current and voltage range
•
Booster connection as standard
•
Reduced menu structure
•
Alarm for „Temperature not OK“
•
Alarm function with fault diagnosis
12.1.09
•
Industrie-Elektronik GmbH
Tel: +49/(0)7142/7776-0
Gansäcker 21
Fax: +49/(0)7142/7776-19
D-74321-Bietigheim-Bissingen (Germany)
E-Mail: info@ropex.de
Internet: www.ropex.de
Data subject to change
Contents
1
Safety and warning notes . . . . . . . . . . . . . . 3
9
Startup and operation . . . . . . . . . . . . . . . . 17
1.1
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1
Front view of the controller . . . . . . . . 17
1.2
Heatsealing band
9.2
Rear view of the controller . . . . . . . . . 17
1.3
Impulse transformer
.............. 3
9.3
Controller configuration . . . . . . . . . . . 18
1.4
Current transformer PEX-W2/-W3 . . . . 3
9.4
Heatsealing band . . . . . . . . . . . . . . . . 20
1.5
Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
9.5
Startup procedure . . . . . . . . . . . . . . . 21
1.6
Warranty provisions . . . . . . . . . . . . . . . 4
1.7
Standards / CE marking . . . . . . . . . . . 4
................ 3
10
Controller functions
. . . . . . . . . . . . . . . . . 22
10.1 Indicators and controls
. . . . . . . . . . . 22
2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 22
3
Principle of operation . . . . . . . . . . . . . . . . . 5
4
Description of the controller
10.3 Temperature setting (set point
selection) . . . . . . . . . . . . . . . . . . . . . . 23
5
Accessories and modifications . . . . . . . . . 6
........... 6
10.4 Temperature indication . . . . . . . . . . . 23
5.1
Accessories . . . . . . . . . . . . . . . . . . . . . 6
10.5 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 24
5.2
Modifications (MODs) . . . . . . . . . . . . . 7
10.6 "START" signal (HEAT) . . . . . . . . . . . 24
6
Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
7
Dimensions/front panel cutout . . . . . . . . . 10
10.7 Measuring impulse duration
(as of software revision 100) . . . . . . . 25
8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1
Installation procedure . . . . . . . . . . . . 11
10.8 Temperature unit
Celsius / Fahrenheit
(as of software revision 106) . . . . . . . 25
8.2
Installation steps . . . . . . . . . . . . . . . . 12
10.9 Undervoltage detection . . . . . . . . . . . 25
8.3
Power supply . . . . . . . . . . . . . . . . . . . 13
8.4
Line filter . . . . . . . . . . . . . . . . . . . . . . 14
10.10 Diagnostic interface/visualization software
(as of software revision 100) . . . . . . . 26
8.5
Current transformer PEX-W3 . . . . . . 14
10.11 Booster connection . . . . . . . . . . . . . . 26
8.6
Wiring diagram (standard) . . . . . . . . . 15
10.12 System monitoring/alarm output . . . . 26
8.7
Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 16
10.13 Error messages . . . . . . . . . . . . . . . . . 26
Page 2
10.14 Fault areas and causes . . . . . . . . . . . 31
11
Factory settings . . . . . . . . . . . . . . . . . . . . . 33
12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 33
13
How to order . . . . . . . . . . . . . . . . . . . . . . . . 34
14
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RES-415
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.
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
1.1
Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance or use contrary to
the intended purpose, there is a risk that
safety will be impaired or that the heatsealing band,
electrical wiring, transformer etc. will overheat.
Ensuring such compliance is the personal
responsibility of the user.
!
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:
–4
TCR  10 10 K
e.g.
Alloy-20:
NOREX:
–1
TCR = 1100 ppm/K
TCR = 3500 ppm/K
Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one section 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 impulse
transformer impairs electrical safety.
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
RES-415
Page 3
Application
operating safety. They are not included in the scope of
supply of the standard control system and are
described in a separate document.
1.7
1.5
DIN EN 61010-1
(VDE 0411-1)
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
DIN EN 60204-1
Electrical equipment of machines
(machinery directive)
EN 50081-1
EMC interference emissions
according to EN 55011, group 1,
class B
EN 50082-2
EMC interference immunity:
ESDs, RF radiation, bursts, surges.
Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6
Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
2
The controller described here complies with the
following standards, provisions and directives:
Compliance with these standards and provisions is only
guaranteed if original accessories and/or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
Application
This RESISTRON temperature controller is an integral
part of the "series 400", the outstanding feature of
which is its microprocessor technology. All
RESISTRON temperature controllers are used to control the temperature of heating elements (heatsealing
bands, beaded bands, cutting wires, heatsealing
blades, solder elements etc.), as required in a variety of
heatsealing processes.
Page 4
Standards / CE marking
The controller is most commonly used for impulseheatsealing PE and PP films in:
•
Vertical and horizontal f/f/s machines
•
Pouch, filling and sealing machines
•
Film wrapping machines
•
Pouch-making machines
•
Group packaging machines
•
L-sealers
RES-415
Principle of operation
•
Increased machine capacity
The use of RESISTRON temperature controllers
results in:
•
Extended life of the heatsealing bands and teflon
coatings
•
Repeatable quality of the heatseals under any conditions
•
Simple operation and control of the sealing process
3
Principle of operation
•
etc.
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.
The thermoelectric control loop which is formed has a
highly dynamic response because purely electrical
variables are measured at a high sampling rate. A high
secondary current can be controlled with only minimal
power loss because power is controlled on the primary
side of the 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 compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Heatsealing band R = f (T)
RESISTRON controller
Current
transformer
U2
sec.
IR UR
Start
U1
prim.
Impulse transformer
Actual value
R=f(T)
_
+
Set point
Indicators
and
controls
or
bus interface
LINE
RES-415
Page 5
Description of the controller
4
Description of the controller
The microprocessor technology endows the
RESISTRON temperature controller RES-415 with previously unattainable capabilities:
•
Very simple operation thanks to AUTOCAL, the
automatic zero calibration function.
•
Good dynamic response of the control system
thanks to AUTOTUNE, which adapts automatically
to the controlled system.
•
High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
•
High flexibility: The AUTORANGE function (as of
software revision 100) covers a secondary voltage
range from 0.4V to 120V and a current range from
30A to 500A.
•
Automatic adjustment to the line frequency in the
range from 47Hz to 63Hz.
5
•
Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The process data is represented on an LC display with
4 lines and 20 characters. Devices with a VF display
are available as an option.
The real heatsealing band temperature is visualized on
the display both as a digital number in °C and in the
form of a dynamic bar.
The RESISTRON temperature controller RES-415 also
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 24VDC logic signals are electrically isolated
from the controller and the heating circuit.
The RESISTRON temperature controller RES-415 is
designed for installation in a front panel cutout. The
compact design and the plug-in connections make this
controller easy to install.
Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the RESISTRON temperature
controller RES-415. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.
5.1
Accessories
The products described below are only a few of the
wide range of accessories available for RESISTRON
temperature controllers ("Accessories" leaflet).
Line filter LF-xx480
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer ITR-x
Designed according to VDE 0570/EN 61558 with a one-section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
( ROPEX Application Report).
Page 6
RES-415
Accessories and modifications
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic interface (DIAG) to the PC (USB port). Associated PC visualization software for displaying setting and configuration data, and for recording SET and ACTUAL temperatures in real time.
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/-W3 current transformer.
Transparent front cover TFA-1
For increasing the degree of protection on the front of the controller to IP65.
Also facilitates applications in the food technology sector (GMP).
Adapter for top hat rail mounting, HS-Adapter-01
For mounting the RESISTRON temperature controller RES-415 on a top hat rail
(DIN TS35). Allows the controller to be installed in the electrical cabinet, for instance,
where it is only accessible to authorized persons.
Lockable door TUER-S/K-1
Transparent door (with lock) for mounting on the bezel of the controller. The display
is clearly legible at all times. The keyboard can only be operated, however, by authorized persons in possession of a key.
Measurement cable UML-1
Twisted measurement cable for the UR voltage measurement.
Trailing cable, halogen and silicone-free.
5.2
Modifications (MODs)
Modifications are not available for the RESISTRON
temperature controller RES-415.
RES-415
Page 7
Technical data
6
Technical data
Type of construction
Housing for front panel mounting
Dimensions (W x H): 144 x 72mm; depth: 161mm (incl. terminals)
Line voltage
All controller manufactured as of February 2006
(as of software revision 100):
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC)
400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
All controllers manufactured as of January 2004 up to January 2006
(up to software revision 027):
115VAC version: 115VAC -15%…120VAC +10% (equivalent to 98…132VAC)
230VAC version: 230VAC -15%…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15%…415VAC +10% (equivalent to 340…456VAC)
All controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version ( Kap. 13 „How to order“ auf Seite 34)
Line frequency
47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
As of software revision 100:
The temperature range and temperature coefficient settings can be specified in
the ROPEX visualization software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on page 26):
Temperature range:
200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Factory setting: Temperature range: 0…300°C
Temperature coefficient: 1100ppm (e.g. Alloy 20)
Set point selection
Via the "UP / "DOWN" keys on the front of the controller
Digital logic levels
Terminals 3, 4
LOW (0V): 0…2VDC
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Electrically isolated, reverse polarity-protected
START with contact
Terminals 2+7
Switching threshold: 3.5VDC, Umax = 5VDC, Imax = 5mA
Alarm relay
Terminals 5+6
Contact, potential-free, Umax = 50V (DC/AC), Imax = 0.2A
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power dissipation
max. 25W
Display
LC display (green), 4 lines, 20 characters, alternatively:
VF display (blue), 4 lines, 20 characters
Ambient temperature
+5…+45°C
Page 8
RES-415
Technical data
Degree of protection
Front:
Back:
IP42 (IP65 with transparent front cover, Art. No. 887000)
IP20
Installation
Installed in front panel cutout with (W x H) 138(+-0.2) x 68(+-0.2) mm
Fastened with clips
Weight
Approx. 1.0kg (incl. connector plug-in parts)
Housing material
Black plastic, type Noryl SE1 GFN2
Connecting cable
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (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-415
Page 9
Dimensions/front panel cutout
7
Dimensions/front panel cutout
panel cutout
138
x 68
±0.2
mounting clamp
72
66
rubber seal
±0.2
outline dimensions
front frame
terminal blocks
front panel
132
29
DIP-switch
to select
U2, I2
144
9
terminal wires
Page 10
RES-415
136
front frame
Installation
8
Installation
cally detected by the temperature controller in the
range from 47Hz to 63Hz.
 See also Kap. 1 „Safety and warning notes“ auf
Seite 3.
Installation and startup may only be per! formed by technically trained, skilled persons who are familiar with the associated risks and
warranty provisions.
8.1
Installation procedure
Proceed as follows to install the RESISTRON temperature controller RES-415:
1. Switch off the line voltage and verify that all circuits
are deenergized.
2. The supply voltage specified on the nameplate of
the RESISTRON temperature controller must be
identical to the line voltage that is present in the
plant or machine. The line frequency is automati-
3. Install the RESISTRON temperature controller in
the front panel cutout. It is fastened by means of two
clips which snap onto the side of the controller
housing.
4. Wire the system in accordance with the instructions
in Kap. 8.3 „Power supply“ auf Seite 13, Kap. 8.6
„Wiring diagram (standard)“ auf Seite 15 and the
ROPEX Application Report. The information provided in Kap. 8.2 „Installation steps“ auf Seite 12
must be heeded additionally.
Check the tightness of all the system connections, including the terminals for the impulse
transformer windings.
!
5. Make sure that the wiring conforms to the relevant
national and international installation regulations.
RES-415
Page 11
Installation
8.2
Installation steps
Use heatseal bands with
suitable temperature coefficient
Heatseal element
with coppered ends
No
push-on
connectors
Heatsealing band R= f (T)
No additional
resistance
in secondary
circuit
F
Sufficient wire
cross-section
Note
number
of turns
A
U2 (sec.)
Connect UR measuring
wires directly to
heatsealing band ends
U1 (prim.)
Twisted
Current transformer
PEX-W2/-W3
Line
Line filter
LF-xx480
OPTION:
Temperature
meter
ATR-x
Avoid long
cables
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
Page 12
Current measuring
wires IR
Impulse
transformer
Controller
Configure
DIP switches
correctly
(up to SW-Rev. 027)
RES-415
Note
polarity
Installation
8.3
Power supply
L1 (L1)
N (L2)
GND/
Earth
LINE
ON
Line
115VAC, 230VAC, 400VAC
50/60Hz
Circuit breaker
Double-pole, C characteristic
( ROPEX Application Report)
Short-circuit protection only.
! RESISTRON temperature controller not protected.
K1
I>
OFF
I>
3
Ka
Relay Ka
For
"HEAT
ON - OFF"
"EMERGENCY STOP".
LINE
FILTER
Short wires
UR
IR
3
ROPEX
temperature
controller
2
3
U2
SEC.
1
2
R
(all-pole)
or
Line filter
The filter type and size must be determined according to
the load, the transformer and the machine wiring
( ROPEX Application Report).
Do not run the filter supply wires (line side) parallel
! to the filter output wires (load side).
RESISTRON temperature controller belonging to the
4xx Series.
Kb
U1
PRIM.
function
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
When using a series resistor RV-....-1 the relay Kb
! shall be installed.
Impulse Transformer
Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.
Use transformers with a one section bobbin. The
! power, duty cycle and voltage values must be determined individually according to the application ( ROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
Wiring
The wire cross-sections depend on the application
( ROPEX Application Report).
Guide values:
Primary circuit:
min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
 These wires must always be twisted (>20/m)
 These wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
 Twisting (>20/m) is recommended to improve EMC.
RES-415
Page 13
Installation
8.4
Line filter
To comply with EMC directives – corresponding to
EN 50081-1 and EN 50082-2 – RESISTRON control
loops must be operated with line filters.
These filters damp the reaction of the phase-angle control on the line and protect the controller against line
disturbances.
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:  "Line filter" documentation.
The use of a suitable line filter is part of the
! standards conformity and a prerequisite of
the CE mark.
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.
ROPEX line filters are specially optimized for use in
RESISTRON control loops. Providing that they are
The wiring instructions contained in section 8.3 "Power
supply" on page 13 must be observed.
!
Large cross-section
wire to ground
max. 1m
PE
ROPEX
temperature
controller
LINE
Do not lay parallel
Large cross-section
wire to ground
8.5
Mounting plate (galvanized)
Large frame contact surface
Current transformer PEX-W3
The PEX-W3 current transformer supplied with the
RESISTRON temperature controller is an integral part
24
23
of the control system. The current transformer may only
be operated if it is connected to the temperature controller correctly ( section 8.3 "Power supply" on
page 13).
75
14
12
14
26
39
terminal
wires
60
28
terminal
block
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
Page 14
RES-415
Installation
8.6
Wiring diagram (standard)
Line filter LF-xx480
RES-415
14
LINE
15
1
+
2 0V
ALARM
OUTPUT
max. 50V/0.2A
6
5
13
12
U1
prim.
Contact closed or
opened by ALARM
(see configuration)
Impulse
transformer
U2
sec.
11
START (HEAT)
3
with 24VDC signal
0V
(Internnal ground) 10
No external
grounding allowed!
9
GND 4
8
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
UR
R
twisted
Heatsealing
band
IR
Current transformer
PEX-W2/-W3
0V (Internal ground)
Terminal 2
up to
production date
January 2006
7
0V
(Internnal ground)
No external
grounding allowed!
RES-415
START (HEAT)
with contact
Page 15
Installation
8.7
Wiring diagram with booster
connection
Line filter LF-xx480
14
RES-415
+
0V
ALARM
OUTPUT
max. 50V/0.2A
6
5
LINE
15
1
Booster
3
1
IN
2
4
OUT
2
13 NC
12 NC
U1
prim.
Contact closed or
opened by ALARM
(see configuration)
Impulse
transformer
U2
sec.
START (HEAT)
3
with 24VDC signal
GND 4
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
11
UR
R
0V
10
(Internnal ground)
twisted
No external
grounding allowed!
9
IR
8
Current transformer
PEX-W2/-W3
0V (Internal ground)
Terminal 2
up to
production date
January 2006
7
0V
(Internnal ground)
No external
grounding allowed!
Page 16
RES-415
Heatsealing
band
START (HEAT)
with contact
Startup and operation
9
Startup and operation
9.1
Front view of the controller
Terminals
Wiring diagram
Diagnostic interface
(on rear of controller)
Nameplate
Operator keys
Clips
Display
9.2
Rear view of the controller
As of software revision 100:
Printed wiring diagram
BOOSTER
0V
START
24VDC
GND
ALARM
START
CONTACT
R
U2
SEC.
U1
PRIM.
FILTER
AUTO U R 0,4 - 120V
RANGE I2 30 - 500A
IR
UR
DIAG
1 2 3 4 5 6 7 8 9 10 11
12 13
14
N (L1)
L1 (L2)
(PE)
(only with filter)
ROPEX
15
50V / 0,2A
Terminals
Diagnostic interface
RES-415
Terminals
Page 17
Startup and operation
Up to software revision 027:
Printed wiring diagram
DIP-SWITCH
ON
ROPEX
RES- 420
1
2
3
4
5 I (A)
2
OFF OFF 30 - 100
1-10 6-60 20-120 ON OFF 60 - 200
ON ON 120 - 400
U
R
U
SEC.
(only with filter)
FILTER
PRIM.
N (L1)
L1 (L2)
(PE)
START
ALARM
START 24VDC
BOOSTER
0V
U2 ( V )
GND
IR
12
UR
1 2 3 4 5 6 7 8 9 10 11
13
14
15
DIP-SWITCH
OFF
1 2 3 4 5
50V / 0,2A
Terminals
9.3
DIP switches
Controller configuration
The possible controller configurations are explained in
the following sections. Proceed as described in
Kap. 9.5.1 „Initial startup“ auf Seite 21 to start up the
controller for the first time.
9.3.1
!
Configuration of the DIP switches
for secondary voltage and current
The controller must be switched off in order
to configure the DIP switches.
Automatic configuration (AUTORANGE)
(as of software revision 100)
Terminals
tion (AUTOCAL). The voltage is configured in the range
from 0.4VAC to 120VAC and the current in the range
from 30A to 500A. If the voltage and/or the current is
outside the permissible range, a detailed error message appears on the controller ( s. section 10.14
"Fault areas and causes" on page 31).
Configuration with coding switches
(up to software revision 027)
Set the DIP switches for matching the secondary
voltage U2 and the secondary current I2 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.
!
The secondary voltage and current ranges are automatically configured by the automatic calibration func-
Page 18
ON
12345
RES-415
Startup and operation
OFF
Factory settings
Rear view
of the controller
ON 1 2 3 4 5
U2
UR
10 11
DIP-SWITCH
10 11
OFF
1 2 3 4 5
ON
12345
DIP switch
1
2
I2
DIP switch
3
4
5
1...10V
ON
OFF OFF
30...100A
OFF
OFF
6...60V
OFF
ON
OFF
60...200A
ON
OFF
OFF OFF
ON
120...400A
ON
ON
20...120V
If the secondary current I2 is less than 30A, the
PEX-W2/W3 current transformer must have two turns
( ROPEX Application Report).
Set+  upper
Actual value
Set
Set+  lower
2x
9.3.2
Temperature diagnosis
The RES-415 checks during the heatsealing phase
whether the ACTUAL temperature is inside a specifiable tolerance band ("OK" window) on either side of
the SET temperature. The lower and upper tolerance
band limits are configured in the factory
to lower = – 15?K and  upper = 10?K . As of software revision 100, these limits can be changed independently of one another in the ROPEX visualization
software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on
page 26).
If the ACTUAL temperature is inside the specified tolerance band when the "START" signal is activated, the
temperature diagnosis is also activated. If the ACTUAL
temperature leaves the tolerance band, the corresponding error code (307, 308) is indicated and the
fault output is switched ( section 10.14 "Fault areas
and causes" on page 31).
Time
Error code
307
If the temperature diagnosis is not activated by the time
the "START" signal is deactivated (i.e. if the ACTUAL
temperature does not exceed the upper or lower tolerance band limit), the corresponding error code
(309, 310) is indicated and the fault relay is switched.
As of software revision 100, an additional delay time
(0..9.9s) can be set in the ROPEX visualization software. The first time the lower tolerance band limit is
exceeded, the temperature diagnosis is not activated
until the parameterized delay time has elapsed. The
temperature diagnosis function can thus be explicitly
deactivated, e.g. if the temperature drops temporarily
owing to the closure of the sealing jaws.
9.3.3
Heatup timeout
This timeout is active as standard on the RES-415 (factory setting: 10.0s). As of software revision 100, the
timeout can be configured in the ROPEX visualization
software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on
page 26).
RES-415
Page 19
Startup and operation
This timeout starts when the START signal is activated.
The RES-415 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
fault relay is switched ( section 10.14 "Fault areas
and causes" on page 31).
Actual value
resistance change results in a zero point error of
20…30°C. The zero point must therefore be corrected
after a few heating cycles ( chap. 9.4.2 „Burning in
the heatsealing band“, page 20).
One very important design feature is the copper or
silver-plating of the heatsealing band ends. Cold ends
allow the temperature to be controlled accurately and
increase the life of the teflon coating and the heatsealing band.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR has been altered irreversibly.
!
Set
95% of Set
9.4.2
Timeout
Heatup time
9.4
Heatsealing band
9.4.1
General
Error code
304
Time
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, i.e. one whose resistance
increases as the temperature rises.
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
Page 20
Burning in the heatsealing band
If a new heatsealing band has been used, the zero
point is first of all calibrated while the band is still cold
by activating the "AUTOCAL" function on the controller.
When the "AUTOCAL" function has finished, the controller outputs 20°C. Adjust the set point to approximately 250°C and activate the "START" signal to heat
for approximately 1 second. After recooling, the controller usually indicates a value less than 20°C. Repeat
the "AUTOCAL" function. The heatsealing band has
now been burned in and the change in the alloy properties stabilized.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally pretreated by the manufacturer.
9.4.3
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 must be performed for all new
heatsealing bands.
RES-415
Startup and operation
9.5
Startup procedure
7. One of the following states then appears:
Please also refer to Kap. 1 „Safety and warning notes“
auf Seite 3 and Kap. 2 „Application“ auf Seite 4.
Installation and startup may only be per! formed by technically trained, skilled persons who are familiar with the associated risks and
warranty provisions.
9.5.1
Initial startup
Prerequisites: The controller must be correctly installed
and connected ( Kap. 8 „Installation“ auf Seite 11).
The possible settings are described in detail in
chap. 9.3 „Controller configuration“, page 18 and
chap. 10 „Controller functions“, page 22.
The essential controller configurations are described
below:
1. Switch off the line voltage and verify that all circuits
are deenergized.
2. The supply voltage specified on the nameplate of
the controller must be identical to the line voltage
that is present in the plant or machine. The line frequency is automatically detected by the temperature controller in the range from 47 to 63Hz.
3. In case of controllers up to software revision 027,
the setting of the DIP switches on the controller are
indicated in the ROPEX Application report and
depend on the heatsealing band (section 9.3 "Controller configuration" on page 18).
4. Make sure that a START signal is not present.
5. Switch on the line voltage.
6. A power-up message appears on the display for
approximately 2 seconds when the controller is
switched on to indicate that it has been started up
correctly.
As of software revision 101:
If "+" characters appear instead of "*" characters in the corners of the top and bottom lines when
the power-up message is displayed, the controller
configuration has been changed in the ROPEX
visualization software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on page 26). In order to avoid
malfunctions, please check the controller configuration before continuing the startup procedure.
!
DISPLAY
ACTION
No alarm indication
Go to 8
Error message with error codes
104…106, 111…113, 211
Go to 8
Error message with error codes
101…103, 107, 108,
201…203, 801, 9xx
Fault diagnosis
( 10.14)
8. Activate the AUTOCAL function while the heatsealing band is still cold. The progress of the calibration process is indicated by a counter on the display
(approx. 10…15s).
When the zero point has been calibrated, 20°C is
indicated as the actual value.
If the zero has not been calibrated successfully, an
erro message indicates error codes 104…106, 211.
In this case the controller configuration is incorrect
( Kap. 9.3 „Controller configuration“ auf Seite 18
and ROPEX Application Report). Repeat the zero
point calibration after the controller has been configured correctly.
9. When the zero point has been calibrated successfully, specify a defined temperature (heatsealing temperature) by means of the "UP" and
"DOWN" keys and activate the "START" signal
(HEAT). The indication of the ACTUAL temperature
on the display (digital value and dynamic bar) permits the heating and control process to be monitored.
The controller is functioning correctly if the temperature indicated on the display has a continuous
curve, in other words it must not jump abruptly, fluctuate or deviate temporarily in the wrong direction.
This kind of behavior would indicate that the UR
measuring wire has been laid incorrectly.
If an error code is displayed, please proceed as
described in section 10.14 "Fault areas and causes"
on page 31.
10.Burn in the heatsealing band ( Kap. 9.4 „Heatsealing band“ auf Seite 20) and repeat the AUTOCAL
function.
RES-415
The controller is now
ready
Page 21
Controller functions
9.5.2
Restart after replacing the heatsealing band
To replace the heatsealing band, proceed as described
in Kap. 9.4 „Heatsealing band“ auf Seite 20.
10
Always use a heatsealing band with the correct alloy, dimensions and copper-plating in
order to avoid malfunctions and overheating.
!
Continue with section 9.5.1, steps 8 and 9.
Controller functions
See also Kap. 8.6 „Wiring diagram (standard)“ auf
Seite 15.
10.1
Indicators and controls
RESISTRON
RES-415
"CAL" key for "Autocal"-function
Hold (> 2 sec.): Start "Autocal"-function
CAL
"RESET" key clears Alarm
RESET
"UP" and "DOWN" keys for setpoint selection
Press (< 2 sec.): Slow change
Hold (> 2 sec.): Fast change
ROPEX
LC display, 4 lines, multilingual
optional:
VF display, 4 lines, multilingual
10.2
Display
This message also includes details of the software version.
10.2.1 Power-up message
A power-up message appears on the display for approximately 2 seconds when the controller is switched on.
Company name
(optional: customer-specific)
Software ID number
Controller type (RES-415)
As of software revision 101:
If "+" characters appear instead of "*" characters in the corners of the top and bottom lines when
the power-up message is displayed, the controller
!
Page 22
configuration has been changed in the ROPEX
visualization software ( section 10.10 "Diagnostic interface/visualization software (as of software
revision 100)" on page 26).
RES-415
Controller functions
10.2.2 Display in home position
If no settings are entered on the controller and no error
message are present, the display is in the home posi-
tion, in other words it indicates the SET temperature as
a digital value and the ACTUAL temperature as a digital
value and a dynamic bar.
Specified heatsealing
temperature
(SET temperature)
Measured ACTUAL
temperature
ACTUAL temperature
as a dynamic bar
10.2.3 Error messages
The fault diagnosis function of the controller is always
active. If a fault is detected, it is indicated on the display
immediately in the form of an error message
( Kap. 10.12 „System monitoring/alarm output“ auf
Seite 26).
Alarm indication
Error code
10.3
Temperature setting (set point
selection)
The heatsealing temperature can be set on the
RES-415 controller by means of the "UP" and "DOWN"
keys.
Changes are accepted immediately even when a
heating process is active.
The set point that is selected for the heatsealing temperature must be greater than 40°C. If not, the heatsealing band will not be heated up when the "START"
signal is activated.
10.4
Temperature indication
If the display is in the home position, the ACTUAL temperature is indicated there as a digital value and as a
dynamic bar.
!
The maximum value of the setting range is
limited to 300°C.
The heating and control process can thus be monitored
at any time.
RES-415
Page 23
Controller functions
10.5
Automatic zero calibration
(AUTOCAL)
Owing to the automatic zero calibration (AUTOCAL)
function, there is no need to adjust the zero point manually on the controller. The "AUTOCAL" function matches the controller to the current and voltage signals
that are present in the system.
This function can be activated by pressing the "CAL"
key for more than 2 seconds.
The automatic calibration process takes around
10…15 seconds. The heatsealing band is not heated
until the calibration process has finished.
A counter which counts down from 13 to 0 appears on
the display while the "AUTOCAL" function is executing.
If the temperature of the heatsealing band varies on
controllers as of software revision 100, the "AUTOCAL"
function is executed a maximum of three times. If the
function still cannot be terminated successfully, an
error message appears ( section 10.14 "Fault areas
and causes" on page 31).
You should always wait for the heatsealing
! band and the bar to cool down (to ambient
temperature) before activating the "AUTOCAL"
function.
and the heatsealing band is heated up to the SET temperature. It remains at this temperature until the signal
is deactivated again.
The "START" signal can be activated in two ways:
•
By means of a 24VDC signal at terminals 3+4.
24VDC
RES-415
START
(HEAT)
+
3
max. 6mA
GND
-
4
HIGH: 12VDC
START (HEAT)
LOW:  2VDC
•
By means of a control contact at terminals 2+7
max.
5mA
Reasons for disabled AUTOCAL function:
1. The "AUTOCAL" function cannot be activated if the
heatsealing band cools down at a rate of more than
0.1K/second. If you try to activate the "AUTOCAL"
function nevertheless by pressing the "CAL" key for
more than 2 seconds, the display shows two flashing stars instead of the countdown.
START
(HEAT)
with
contact
RES-415
7
2
0V
2. If the "START" signal (24VDC or contact) is activated, the AUTOCAL function is not executed.
3. Directly after the controller is powered up, the
AUTOCAL function cannot be activated if a fault
with error code 101…103, 201…203, 801 or 9xx
occurs ( section 10.14 "Fault areas and causes"
on page 31). If the controller has already operated
correctly - a minimum of once - after powering up,
the AUTOCAL function cannot be activated with
error codes 201…203, 304, 308, 801 or 9xx.
10.6
"START" signal (HEAT)
!
The set point that is selected for the heatsealing temperature must be greater than 40°C. If not, the heatsealing band will not be heated up.
The alarm relay is switched if the "START" signal is
activated while an error message is indicating error
codes 104…105, 111…113 or 211 ( section 10.14
"Fault areas and causes" on page 31). The heatsealing
band is likewise not heated.
When the "START" signal is activated, the controllerinternal set/actual comparison is enabled immediately
Page 24
The "START" signal is disabled as long as the
AUTOCAL function is executing.
RES-415
Controller functions
10.7
Measuring impulse duration
(as of software revision 100)
troller still uses Celsius (°C) internally. Value steps
are therefore possible with this function owing to
the conversion from Celsius to Fahrenheit.
The length of the measuring impulses generated by the
controller can be set with this parameter. It may be
necessary to set a measuring impulse that is longer
than the default 1.7ms for certain applications
( ROPEX Application Report).
This parameter can only be set in the ROPEX
visualization software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on page 26).
!
10.8
Temperature unit
Celsius / Fahrenheit
(as of software revision 106)
As of software revision 106 the unit for the temperature
indication and value selection can be switched between
°C (Celsius) and °F (Fahrenheit).
This parameter can only be set in the ROPEX
visualization software ( section 10.10 "Diagnostic interface/visualization software (as of software revision 100)" on page 26).
!
10.9
Undervoltage detection
Trouble-free operation of the temperature controller is
guaranteed within the line voltage tolerance range specified in section 6 "Technical data" on page 8.
If a line voltage which is less than the lower limit of the
permissible range occurs, the controller is switched to
a standby mode. No more heatsealing processes take
place and no more measuring impulses are generated.
The display changes to indicate this.
1. „Celsius“ (Factory setting)
Temperature indication and value selection in
Celsius (°C).
2. „Fahrenheit“
Temperature indication and value selection in
Fahrenheit (°F)
Up to software revision 105 only Celsius (°C) can be
specified on the controller as the temperature unit.
!
The degree unit can be changed on the controller without interrupting operation
!
If you specify temperature indication and
value selection in Fahrenheit (°F), the con-
The main menu is displayed again, and operation is
resumed, when the input voltage returns to the specified tolerance range.
Trouble-free operation of the controller is
only guaranteed within the specified input
voltage tolerance range. An external voltage
monitor must be connected to prevent defective
heatseals as a result of low line voltage.
!
RES-415
Page 25
Controller functions
10.10
Diagnostic interface/visualization
software
(as of software revision 100)
An interface with a 6-pole Western socket is provided
for systemdiagnostics and process visualization. This
interface allows a data connection to be set up to the
ROPEX visualization software using the ROPEX communication interface CI-USB-1.
IR
UR
8 9 10 11
DIAG
12
These features crucially support the system owner in
localizing the cause of an abnormal operating state.
A system fault is reported or differentiated by means of
the following elements.
A.)
Error message on the display:
The cause of a fault can be localized quickly and easily
with the help of the error code that appears on the display. Please refer to section 10.14 "Fault areas and
causes" on page 31 for a list of the possible error
codes.
B.)
Alarm relay (relay contact, terminals 5+6):
This contact is:
•
OPEN if error code 104…106, 111…113 or 211 is
displayed. The contact closes, however, if a
"START" signal is activated in this state.
•
CLOSED if error code 101…103, 107, 108,
201…203, 304, 308, 801 or 9xx appears.
Back view of the controller
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.
!
An error message can be reset by pressing
the "RESET" key or by switching the controller off and then on again.Invalid error messages
!
The ROPEX visualization software is described in a
separate document.
10.11
Booster connection
The RES-415 controller has a connection for an
external switching amplifier (booster) as standard. This
connection (at terminals 1+2) is necessary for high primary currents (continuous current > 5A, pulsed
current > 25A). The switching amplifier should be connected as described in section 8.7 "Wiring diagram with
booster connection" on page 16.
10.12
System monitoring/alarm output
To increase operating safety and to avoid faulty heatsealing, the controller incorporates special hardware and
software features that facilitate selective fault detection
and diagnosis. Both the external wiring and the internal
system are monitored.
Page 26
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.
10.13
Error messages
The table below describes each fault and the required
corrective action. The block diagram in section 10.14
RES-415
Controller functions
"Fault areas and causes" on page 31 permits each fault
to be cleared quickly and efficiently
The error codes described below can also be displayed
in the ROPEX visualization software ( section 10.10
"Diagnostic interface/visualization software (as of soft-
ware revision 100)" on page 26) to facilitate troubleshooting.
RES-415
Page 27
Page 28
RES-415
7
Int. faut, contr. defective
Triac defective
Int. faut, contr. defective
Int. faut, contr. defective
Int. faut, contr. defective
Plug-in jumper for alarm
relay wrong
901
913
914
915
916
917
918
Check
plug-in jumper
Replace controller
Replace controller
Replace controller
Replace controller
Replace controller
Run RESET
Heatup time too long
( section 9.3.3)
304
6
Check
power supply
5
Frequency fluctuation,
inadmissible line frequency
201
202
203
Closed
Temperature too low/high
( section 9.3.2)
4
307
308
309
310
Check
plug-in jumper
Replace controller
Replace controller
Replace controller
Replace controller
Replace controller
Run RESET
Check power supply
Fault area 
(loose contact)
Fault area 
(loose contact)
Temperature step, down
Temperature step, up
107
108
Fault area 
Fault area 
UR and IR signals missing
103
3
Fault area 
Fault area 
UR signal missing
102
Fault area 
Fault area 
IR signal missing
2
Action if machine
already operating,
HS band not chang.
Action
if machine started
for first time
Cause
101
STATUS
of alarm relay
(factory set.)
1
Error
code
Part 1 of 3:
Controller functions
RES-415
9
8
211
303
(AC)
302
(AC)
106
105
104
Error
code
Fault:
Closed
(voltage value
at actual
value output
then no longer
changes)
Warning:
Open
STATUS
of alarm relay
(factory set.)
Data error
temperature too high,
AUTOCAL wasn’t performed, loose contact,
ambient temp. fluctuates
Temperature too low,
AUTOCAL wasn’t performed, loose contact,
ambient temp. fluctuates
UR and/or IR signals
incorrect,
incorrect specification of
impulse-transformer
UR signals incorrect,
incorrect specification of
impulse-transformer
IR signals incorrect,
incorrect specification of
impulse-transformer
Cause
Run AUTOCAL
Run AUTOCAL
and/or
fault area 
(loose contact)
Run AUTOCAL,
Check specification
of transformer,
Fault area 
Action
if machine started
for first time
---
Fault area 
(loose contact)
Action if machine
already operating,
HS band not chang.
NOTE: The specified error messages are initially output as warnings (alarm relay is open)
When the "START" signal is activated, the warning changes to a fault
(alarm relay is closed).
Part 2 of 3:
Controller functions
Page 29
Page 30
RES-415
113
12
13
112
11
116
115
114
111
10
Error
code
Fault:
Closed
(voltage value
at actual
value output
then no longer
changes)
Warning:
Open
STATUS
of alarm relay
(factory set.)
---
Fault area ,
check configuration
UR and IR signals incorrect,
calibration not possible
Ext. calibration
temperature fluctuates
Ext. calibration
temperature too high,
Temperature fluctuates,
calibration not possible
---
Fault area ,
check configuration
---
Fault area ,
check configuration
IR signal incorrect,
calibration not possible
UR signal incorrect,
calibration not possible
Action if machine
already operating,
HS band not chang.
Action
if machine started
for first time
Cause
NOTE: The specified error messages are initially output as warnings (alarm relay is open)
When the "START" signal is activated, the warning changes to a fault
(alarm relay is closed).
Part 3 of 3:
Controller functions
Controller functions
10.14
Fault areas and causes
5
1
2
6
2
9
3
Temperature
controller
4
8
UR
1
IR
7
8
123 45
HARDWARE
9
I2
8
U2
7
The table below explains the possible fault causes.
Fault area

Explanation
Possible causes
Load circuit interrupted after UR
pickoff point
- Wire break, heatsealing band break
- Contacting to heatsealing band defective
PEX-W2/W3 current transformer
signal interrupted
- IR measuring wire from current transformer interrupted
Primary circuit interrupted
- Wire break, triac in controller defective
- Primary winding of impulse transformer interrupted
Secondary circuit interrupted
before UR pickoff point
- Wire break
- Secondary winding of impulse transformer interrupted

UR signal missing
- Measuring wire interrupted

Partial short-circuit (delta R)
- Heatsealing band partially bypassed by conducting part
(clamp, opposite heatsealing bar etc.)

Parallel circuit interrupted
- Wire break, heatsealing band break
- Contacting to heatsealing band defective
Total short-circuit
- Heatsealing band installed incorrectly, insulation at heatsealing bar ends missing or incorrectly installed
- Conducting part bypasses heatsealing band completely
UR signal incorrect
- Up to software revision 027: DIP switches 1 - 3 configured
incorrectly (U2 range)
- As of software revision 100: U2 outside permissible range
from 0.4…120VAC



RES-415
Page 31
Controller functions
Fault area
Explanation
IR signal incorrect
- Up to software revision 027: DIP switches 4+5 configured
incorrectly (I2 range)
- As of software revision 100: I2 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 < 30A)
Internal controller fault
- Hardware fault (replace controller)


Page 32
Possible causes
RES-415
Factory settings
11
Factory settings
The RESISTRON temperature controller RES-415 is
configured in the factory as follows:
DIP switches
for
secondary voltage
U2 and current I2
(Up to software
revision 027)
U2 = 6…60VAC
I2 = 30…100A
OFF
DIP switches:
ON 1 2 3 4 5
2 ON
1, 3, 4, 5 OFF
These switches are automatically set by the AUTORANGE function on all controllers as of software
revision 100.
Measuring impulse
length
Measuring impulse length:
1.7ms
Temperature diagnosis:
ON,
-15K, +10K
Heatup timeout:
ON,
10.0s
Temperature unit:
Celsius
[X]
Temperature
diagnosis
[X]
Heatup timeout
[X]
Temperature unit
(as of software
revision 106)
[X]
[X] As of software revision 100
With ROPEX visualization software only.
12
Maintenance
The controller requires no special maintenance.
Regular inspection and/or tightening of the terminals –
including the terminals for the winding connections on
the impulse transformer – is recommended. Dust deposits on the controller can be removed with dry compressed air.
RES-415
Page 33
How to order
13
How to order
Contr. RES - 415- . / . . . VAC
L / 115: LC display, line voltage 115VAC, Art. No. 741511
L / 230: LC display, line voltage 230VAC, Art. No. 741512
L / 400: LC display, line voltage 400VAC, Art. No. 741513
V / 115: VF display, line voltage 115VAC, Art. No. 741521
V / 230: VF display, line voltage 230VAC, Art. No. 741522
V / 400: VF display, line voltage 400VAC, Art. No. 741523
Scope of supply:
Controller includes connector plug-in parts (current transformer
must be ordered separately)
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-415-L/400VAC + MOD 01
(controller with LC display for 400VAC line voltage
and amplifier for low voltage)
Art. Nos. 741513 + 800001 must be ordered
Current transformer PEX-W3
Art. No. 885105
Line filter LF- . . 480
06: Continuous current 6A, 480VAC, Art. No. 885500
35: Continuous current 35A, 480VAC, Art. No. 885506
Impulse transformer
See ROPEX Application Report for design and ordering
information
Communication interface CI-USB-1
Art. No. 885650
For more accessories: "Accessories" leaflet
Page 34
RES-415
Index
14
Index
A
Accessories 6
Adapter for top hat rail mounting 7
Alarm output 26
Alarm relay 8
Alloy 22
Ambient temperature 8
Application 4
Application Report 11, 14, 18
AUTOCAL 6, 21, 24
Automatic zero calibration 6, 21, 24
AUTOTUNE 6
B
Booster 16
Booster connection 26
Burning in heatsealing band
20, 21
C
Celsius °C 25
Circuit breaker 13
CI-USB-1 7, 26, 34
Communication interface 7, 26, 34
Controller configuration 18
Controls 22
Current transformer 7, 14, 34
D
Degree of protection 9
Diagnostic interface 26
Dimensions 10
DIP switches 18
Display 22
L
Line filter 6, 13, 14, 34
Line frequency 6, 8
Line voltage 8
M
Maintenance 33
Measurement cable 7
Measuring impulse duration 25
Modifications 7, 34
MODs 7, 34
Monitoring current transformer 7
O
Overheating of heatsealing band
6
P
PEX-W2/-W3 3
PEX-W3 14, 34
Power dissipation 8
Power supply 13
Principle of operation
5
R
Replacing heatsealing band
20, 22
S
E
Error messages 26
External switching amplifier
16
F
Factory settings 33
Fahrenheit °F 25
Fault areas 31
Fault diagnosis 6
Front cover 7
Secondary current I2 18
Secondary voltage U2 18
Set point selection 8, 23
Standby mode 25
"START" signal 21, 24
System diagnostics 26
System monitoring 26
T
TCR 3, 20
Temperature coefficient 3, 20
Temperature control 4
Temperature diagnosis 19
Temperature indication 23
Temperature range 8
Temperature setting 23
Temperature unit 25
Transformer 3, 6, 13, 34
Type of construction 8
H
HEAT 21, 24
Heatsealing band type
Heatup timeout 19
Impulse transformer 6, 13, 34
Installation 9, 11
Installation procedure 11
Installation regulations 11
8
I
Impulse heatsealing method
4
RES-415
Page 35
Index
U
Visualization software
Undervoltage detection
25
W
V
View of controller
Page 36
17
Wiring 11, 13
Wiring diagram
RES-415
15, 16
26
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