RESISTRON RES-430. Operating Instructions. Important features

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1 RESISTRON Operaing Insrucions Imporan feaures Microprocessor echnology LC display (green), 4 lines, 2 characers (mulilingual) Auomaic zero calibraion (AUTOCAL) Auomaic opimizaion (AUTOTUNE) Auomaic phase angle compensaion (AUTOCOMP, as of sofware revision 1) Auomaic frequency adjusmen Secondary conrol Heasealing band alloy and emperaure range selecable Time conrol, heasealing ime and cooling ime seable Configurable relay oupu, e.g. "end of cycle" Time or emperaure-conrolled cooling phase 1VDC analog oupu for ACTUAL emperaure Load cell inerface for monioring closing pressure Serial daa inerface (opional) Faul diagnosis Indusrie-Elekronik GmbH Tel.: +49 () Gansäcker 21 Fax: +49 () Inerne: D Bieigheim-Bissingen Daa subjec o change

2 Conens 1 Safey and warning noes Use Heasealing band Impulse ransformer Line filer Sandards / CE marking Warrany provisions Applicaion Principle of operaion Descripion of he conroller Modificaions (MODs) / opical daa inerface Modificaions Opional daa inerfaces (piggyback modules) Visualizaion sofware Technical daa Dimensions / fron panel cuou Moherboard Display erminal Insallaion Insallaion procedure Insallaion seps Power supply Wiring diagram wih relay K1 (sandard) Wiring diagram wih solenoid drive (opional) Sarup and operaion View of he conroller General conroller configuraion Time conrol (imer funcion) Temperaurediagnosis (as of sofware revision 7) Load cell inerface / emperaure sensor Heasealing band Sarup procedure Conroller funcions Indicaors and conrols Display Navigaion in he menus Menu srucure Two-digi numbering sysem up o sofware revision Temperaure seing (se poin selecion) Temperaure indicaion / acual value oupu Auomaic zero calibraion (AUTOCAL) "FOOT SWITCH" signal Hold ime for "FOOT SWITCH" signal "START" signal (HEAT) Cycle couner Single/double sealing Hold mode Auomaic phase angle compensaion (AUTOCOMP) (as of sofware revision 1) Locking he "HAND" key and/or he funcion AUTOCAL Temperaure uni Celsius / Fahrenhei (as of sofware revision 12) Locking he Configuraion menu Undervolage deecion Sysem monioring / alarm oupu Error messages Faul areas and causes Facory seings Ropex seings Cusomer seings Mainenance How o order Index Page 2

3 Safey and warning noes 1 Safey and warning noes This RESISTRON emperaure conroller is manufacured according o DIN EN In he course of is manufacure i passed hrough qualiy assurance, whereby i was subjeced o exensive inspecions and ess. I lef he facory in perfec condiion. The recommendaions and warning noes conained in hese operaing insrucions mus be complied wih, in order o guaranee safe operaion. The device can be operaed wihin he limis indicaed in he "Technical Daa" wihou impairing is operaional safey. Insallaion and mainenance may only be performed by echnically rained, skilled persons who are familiar wih he associaed risks and warrany provisions. 1.1 Use RESISTRON emperaure conrollers may only be used for heaing and emperaure conrol of heasealing bands which are expressly suiable for hem, and providing he regulaions, noes and warnings conained in hese insrucions are complied wih. In case of non-compliance or use conrary o! he inended purpose, here is a risk ha safey will be impaired or ha he heasealing band, elecrical wiring, ransformer ec. will overhea. Ensuring such compliance is he personal responsibiliy of he user. 1.2 Heasealing band The emperaure coefficien mus be specified as follows: 4 TCR 1 1 K 1 e.g. Alloy-2: TCR = 11 ppm/k NOREX: TCR = 35 ppm/k The RESISTRON emperaure conroller mus be se and coded according o he emperaure coefficien of he heasealing band. The use of incorrec alloys wih a oo low! emperaure coefficien and incorrec coding of he RESISTRON emperaure conroller lead o unconrolled heaing and ulimaely o burn-ou of he heasealing band! The heasealing bands ha were originally supplied mus be idenified by deail specificaion, par number or some oher means ha will assure ha replacemen bands are idenical. 1.3 Impulse ransformer A suiable impulse ransformer is necessary o ensure ha he conrol loop funcions perfecly. This ransformer mus be designed according o VDE 57/ EN (isolaing ransformer wih reinforced insulaion) and have a one secion bobbin. When he impulse ransformer is insalled, suiable shock proecion mus be provided in accordance wih he naional insallaion regulaions for elecrical equipmen. In addiion, waer, cleaning soluions and conducive fluids mus be prevened from seeping ino he ransformer. A basic prerequisie for reliable and safe operaion of he sysem is he use of suiable heasealing bands.! Incorrec insallaion of he impulse ransformer impairs elecrical safey. The resisance of he heasealing band which! is used mus have a posiive minimum emperaure coefficien in order o guaranee roublefree operaion of he RESISTRON emperaure conroller. 1.4 Line filer The use of an original ROPEX line filer is mandaory in order o comply wih he sandards and provisions menioned in secion 1.5 "Sandards / CE marking" on page 4. This device mus be insalled and conneced according o he insrucions conained in secion 8.3, "Power supply" as well as he separae documenaion enclosed wih he line filer. Page 3

4 Applicaion 1.5 Sandards / CE marking The conroller described here complies wih he following sandards, provisions and direcives: DIN EN 611-1:21 (26/95/EG) DIN EN (26/42/EG) EN 5511: A1: A2:22 EN :26-4 EN : A1:21 + A2:25-11 (24/18/EG) EN :25 (24/18/EG) Safey requiremens for elecrical equipmen for measuremen, conrol and laboraory use (low-volage direcive): polluion degree 2, proecion class II, measuremen caegory I (for U R and I R erminals) Elecrical equipmen of machines (machinery direcive) EMC genery emissions: Group 1, Class A EMC generic immuniy: Class A (ESDs, RF radiaion, burss, surges) Excepion: Line volage inerrupion acc. EN is no fulfilled (This leads o a designaed error message of he conroller) Compliance wih hese sandards and provisions is only guaraneed if original accessories and/or peripheral componens approved by ROPEX are used. If no, hen he equipmen is operaed on he user's own responsibiliy. The CE marking on he conroller confirms ha he device iself complies wih he above-menioned sandards. I does no imply, however, ha he overall sysem also fulfils hese sandards. I is he responsibiliy of he machine manufacurer and of he user o verify he compleely insalled, wired and operaionally ready sysem in he machine wih regard o is conformiy wih he safey provisions and he EMC direcive (see also secion 8.3, "Power supply"). If peripheral componens (e.g. he ransformer or he line filer) from oher manufacurers are used, no funcional guaranee can be provided by ROPEX. 1.6 Warrany provisions The sauory provisions for warranies apply for a period of 12 monhs following he delivery dae. All devices are esed and calibraed in he facory. Devices ha have been damaged due o fauly connecions, dropping, elecrical overloading, naural wear, incorrec or negligen handling, chemical influences or mechanical overloading as well as devices ha have been modified, relabeled or oherwise alered by he cusomer, for example in an aemp o repair hem or insall addiional componens, are excluded from he warrany. Warrany claims mus be examined in he facory and approved by ROPEX. 2 Applicaion This RESISTRON emperaure conroller is an inegral par of he "series 4", he ousanding feaure of which is is microprocessor echnology. All RESISTRON emperaure conrollers are used o conrol he emperaure of heaing elemens (heasealing bands, beaded bands, cuing wires, heasealing blades, solder elemens ec.), as required in a variey of heasealing processes. The conroller is mos commonly used for impulseheasealing PE and PP films in simple able welding machines and welding presses: Pouch, filling and sealing machines Film wrapping machines Pouch-making machines L-sealers ec. The use of RESISTRON emperaure conrollers resuls in: Repeaable qualiy of he heaseals under any condiions Increased machine capaciy Exended life of he heasealing bands and eflon coaings Simple operaion and conrol of he sealing process Page 4

5 Principle of operaion 3 Principle of operaion The resisance of he heasealing band, which is emperaure-sensiive, is moniored 5x per second (6x a 6Hz) by measuring he curren and volage. The emperaure calculaed wih he help of hese measuremens is displayed and compared wih he se poin. The secondary volage of he impulse ransformer is adjused by phase-angle conrol if he measured values deviae from he se poin. The resuling change in he curren hrough he heasealing band leads o a change in he band emperaure and hus also is resisance. This change is measured and evaluaed by he RESISTRON emperaure conroller. The conrol loop is closed: ACTUAL emperaure = SET emperaure. Even minue hermal loads on he heasealing band are deeced and can be correced quickly and precisely. The hermoelecric conrol loop which is formed has a highly dynamic response because purely elecrical variables are measured a a high sampling rae. PLEASE NOTE! RESISTRON emperaure conrollers play a significan role in enhancing he performance of modern machines. However, he full benefi can only be obained from he advanced echnology offered by his conrol sysem if all he sysem componens, in oher words he heasealing band, he impulse ransformer, he wiring, he iming signals and he conroller iself, are compaible wih one anoher. We will be pleased o conribue our many years of experience owards opimizing your heasealing sysem. 4 Descripion of he conroller The microprocessor echnology endows he RESISTRON emperaure conroller wih previously unaainable capabiliies: Very simple operaion hanks o AUTOCAL, he auomaic zero calibraion funcion. Good dynamic response of he conrol sysem hanks o AUTOTUNE, which adaps auomaically o he conrolled sysem. High precision hanks o furher improved conrol accuracy and linearizaion of he heasealing band characerisic. High flexibiliy: Secondary volage range from 12V o 42V, curren range from 2A o 9A. Auomaic adjusmen o he line frequency in he range from 47Hz o 63Hz. Increased proecion agains dangerous condiions, such as overheaing of he heasealing band. A ime conrol (imer) funcion inegraed in he conroller enables he complee heasealing process o be conrolled on simple machines, such as able heasealing ools. A configurable relay oupu can be used o drive moors, energize magnes ec. The process daa is represened on an LC display wih 4 lines and 2 characers. Various display languages can be seleced. The real heasealing band emperaure is visualized on he display boh as a digial number in C and in he form of a dynamic bar. In addiion o he digial and bar indicaions on he display, he ACTUAL emperaure of he heasealing band is supplied o an analog 1VDC oupu. The real heasealing band emperaure can hus be visualized on an exernal emperaure meer (e.g. ATR-x). The RESISTRON emperaure conroller also feaures an inegraed faul diagnosis funcion, which ess boh he exernal sysem (heasealing band, wiring ec.) and he inernal elecronics and oupus a selecive error message in case of a faul. The menu in he emperaure conroller iself can be used o adap o differen heasealing band alloys (Alloy-2, NOREX ec.) and se he required emperaure range ( 3 C, 5 C ec.). The RESISTRON emperaure conroller consiss of wo componens: a moherboard wih a power secion for insallaion in he machine frame and a separae display erminal. The compac design and he plug-in connecions make his conroller easy o insall. Page 5

6 Modificaions (MODs) / opical daa inerface 5 Modificaions (MODs) / opical daa inerface 5.1 Modificaions No modificaions are available for he RESISTRON emperaure conroller. 5.2 Opional daa inerfaces (piggyback modules) Serial RS232 daa inerface A serial RS232 daa inerface (piggyback module) is opionally available for he conroller. This inerface can be ordered separaely and rerofied o he moherboard. I is conneced o a PC by means of a serial daa cable ( secion 13 "How o order" on page 51). Scope of supply / insallaion The serial piggyback module is supplied wih spacers for insallaion on he moherboard of he. Proceed as follows o insall i. 9-pole sub-d socke for serial daa cable moherboard 4x spacer Snap-on Piggyback module Female connecor, 5-pole Male connecor, 5-pole Snap-on side Laching side Laching Fi he 4 spacers o he laching side of he moherboard firs. Then aach he piggyback module o he snap-on side wih he sub-d socke down. The 5-pole male connecor on he moherboard mus be insered ino he 5-pole female connecor on he piggyback module. Page 6

7 Modificaions (MODs) / opical daa inerface Schemaic diagram: Exernal view of he sub-d socke: Pin assignmen: Pin Signal RS232 daa inerface (piggyback module) moherboard 1 n.c. 2 TxD (o PC / PLC) 3 RxD (from PC / PLC) 5 GND 4 DTR + DSR Jumpered inernally 6 7 RTS + CTS Jumpered inernally 8 9 n.c DIAG inerface for CI-USB-1 (sandard as of Augus 213) This daa inerface has a 6-pole Wesern socke for connecing he ROPEX communicaion inerface CI-USB-1. As of Augus 213 his daa inerface is insalled on he moherboard of he conroller as sandard. I can be rerofied in older conrollers ( secion 13 "How o order" on page 51). Only a ROPEX communicaion inerface is! allowed o be conneced o he DIAG inerface. Connecing anoher device (e.g. a elephone cable) could damage he conroller and resul in malfuncions. The ROPEX communicaion inerface CI-USB-1 is described in a separae documen. Scope of supply / insallaion The daa inerface is supplied wih spacers for insallaion on he moherboard of he. Proceed as follows o insall i. Page 7

8 Modificaions (MODs) / opical daa inerface 6-pole socke for connecion of CI-USB-1 moherboard Snap-on Laching Piggyback module Female connecor, 5-pole Male connecor, 5-pole Snap-on side Laching side 4x spacer Fi he 4 spacers o he laching side of he moherboard firs. Then aach he piggyback module o he snap-on side wih he 6-pole socke up. The 5-pole male connecor on he moherboard mus be insered ino he 5-pole female connecor on he piggyback module. Schemaic diagram: DIAG inerface (piggyback module) moherboard 5.3 Visualizaion sofware A visualizaion sofware ool is provided for daa communicaion wih a PC. The sofware shows all he daa for a heasealing cycle (ACTUAL emperaure, closing force). You can expor he daa as a CSV file for furher processing in anoher PC program. In addiion, he sofware permis he values in he Configuraion and Seings menus o be ransferred o he conroller or read from i. The visualizaion sofware is described in a separae documen. Page 8

9 Technical daa 6 Technical daa Type of consrucion moherboard wih power secion: Open design for insallaion in he machine frame Dimensions (L x W): 21 x 11mm, heigh: 45mm (incl. erminals) T-43 display erminal: For insallaion in he machine frame Dimensions (W x H): 144 x 72mm; deph: 66mm (incl. connecing cables) Line volage As of sofware revision 12: 115VAC version: 11VAC -15% 12VAC +1% (equivalen o VAC) 23VAC version: 22VAC -15% 24VAC +1% (equivalen o VAC) Up o sofware revision 11: 115VAC, 23VAC, olerance: +1% / -15% depending on device version ( Kap. 13 How o order auf Seie 51) Line frequency Heasealing band ype and emperaure range Heasealing band volage (secondary volage of impulse ransformer) Max. load curren (max. secondary curren of impulse ransformer) Terminals 5, 6, 7, Hz, auomaic adjusmen o frequencies in his range Several differen ranges can be seleced on he conroller in he Configuraion menu: Defaul: Temperaure coefficien 11ppm (Alloy 2), 3 C 12 42VAC Two heasealing bands: I sec max = 9A (per heasealing band: I max =45A) One heasealing band: I sec max =7A If only one heasealing band is used, erminals 7+8! mus be exernally jumpered wih a high curren cable in order o avoid malfuncions or damage o he conroller. Min. load curren Up o SW revision 7: I sec min =3A SW revision 8 or higher: I sec min =2A Analog oupu (acual value) Terminals V DC, Imax = 5mA Equivalen o 3 C or 5 C Accuracy: ±1% add. 5mV Moherboard and display erminal (wih same serial number) are! aligned on each oher during producion (before firs delivery). When using componens wih differen serial numbers ogeher he analogue oupu has higher olerances. START wih conac Terminals FOOT SWITCH wih conac Terminals Swiching hreshold: 3.5VDC, U max = 5VDC, I max =5mA Swiching hreshold: 3.5VDC, U max = 5VDC, I max =5mA Page 9

10 Technical daa Relay K1 Terminals 19, 2, 21 Solenoid drive oupu (opional, insead of K1) Terminals 15, 16, 17, 18 Load cell inerface Terminals 22, 23, 24, 25 Temperaure sensor Terminals Display Power dissipaion Ambien emperaure Degree of proecion Changeover conac, poenial-free, U max = 24VAC/1VDC, I max =1.5A Inerference suppression wih 47nF / 56ohms for each erminal U max = 3VAC (supply volage a erminals 17+18) I max =2A For load cells wih 2mV/V, R min = 165ohms Supply volage (erminals 22+25): U VCC =5VDC Measuremen range (erminals 23+24): Calibraion range: +1.mV Max: mV Measuring range: +8 C, For connecing a Philips Type KTY emperaure sensor LC display (green), 4 lines, 2 characers max. 4W C Moherboard: IP Display erminal: Fron: IP42 (IP65 wih ransparen fron cover, Ar No. 887) Back: IP2 Insallaion Moherboard: 6 fixing holes (diameer: 3.2mm) for screw mouning Display erminal: Insalled in fron panel cuou wih (W x H) 138 (+-.2) x68 (+-.2) mm Fasened wih clamps Weigh Moherboard: Approx..5kg (incl. connecor plug-in pars) Display erminal: Approx..4kg Housing maerial Display erminal Black plasic, ype Noryl SE1 GFN2 Connecing cables Type / cross-secions Terminals 4 9: Terminals 1 3, 1 27: Rigid or flexible;.2 4.mm² (AWG 24 1) wih screw erminals Rigid or flexible;.2 2.5mm² (AWG 24 12) wih plug-in connecions If ferrules are used, hey mus be crimped in accordance! wih DIN and IEC/EN This is essenial for proper elecrical conac in he erminals. Page 1

11 Dimensions / fron panel cuou 7 Dimensions / fron panel cuou 7.1 Moherboard x fixing hole Diameer: 3.2mm Piggyback module (opional daa inerface) Connecor for T-43 erminal Specified componen heighs for connecors, incl. plug-in pars! Spacing bols wih a minimum lengh of 6mm mus be used o fasen he prined circui board on he underside. All naional and inernaional regulaions mus be complied wih. Page 11

12 Dimensions / fron panel cuou 7.2 Display erminal Panel cuou ±.2 ± x 68 Ouline dimensions of fron frame Rubber seal Mouning clamp Connecor Fron frame Fron panel Connecing cable (lengh: 25mm) Page 12

13 Insallaion 8 Insallaion See also Kap. 2 Applicaion auf Seie 4. Insallaion and sarup may only be performed by echnically rained, skilled per-! sons who are familiar wih he associaed risks and warrany provisions. 8.1 Insallaion procedure Proceed as follows o insall he RESISTRON emperaure conroller : 1. Swich off he line volage and verify ha all circuis are deenergized. 2. The supply volage specified on he nameplae of he RESISTRON emperaure conroller mus be idenical o he line volage ha is presen in he plan or machine. The line frequency is auomaically deeced by he emperaure conroller in he range from 47Hz o 63Hz. 3. Insall he moherboard in he machine frame using he fixing screws. 4. Insall he display erminal in he fron panel cuou. I is fasened by means of wo clamps which snap ono he side of he conroller housing. 5. Wire he sysem in accordance wih he insrucions in Kap. 6 Technical daa auf Seie 9, Kap. 8.4 Wiring diagram wih relay K1 (sandard) auf Seie 15 and he ROPEX Applicaion Repor. The informaion provided in Kap. 8.2 Insallaion seps auf Seie 13 mus be heeded addiionally. Check he ighness of all he sysem connecions, including he erminals for he impulse! ransformer windings. 6. Make sure ha he wiring conforms o he relevan naional and inernaional insallaion regulaions. 8.2 Insallaion seps The following poins should be heeded in addiion o he informaion provided in he ROPEX Applicaion Repor when insalling he : Wiring/cable cross-secions: Use he cable cross-secions indicaed in he ROPEX Applicaion Repor. The cables beween he moherboard and he heasealing band mus no be longer han 1m. Connec he heasealing band direcly o he RES- 43. Addiional clamping poins can cause conac resisances, leading o emperaure conrol errors. The connecing cables beween he moherboard and he heasealing band mus no be! laid hrough closed seel shees or pipes, in order o avoid emperaure conrol errors. The permissible pipe and shee maerials are aluminum and plasic. Impulse ransformer: Specificaion as indicaed in he ROPEX Applicaion Repor. Heasealing band/sealing bar: Use a heasealing band wih a suiable (posiive) emperaure coefficien. Copper he ends of he heasealing band o preven hem from overheaing. Push-on connecors on he sealing bar can lead o loose conacs. Use cables wih screw connecions. Page 13

14 Insallaion 8.3 Power supply L1 (L1) N (L2) GND/ Earh ON LINE Kc I> I> Line 115VAC, 23VAC Over-curren proecion Double-pole circui-breaker or fuses, ( ROPEX Applicaion Repor) Shor-circui proecion only. RESISTRON emperaure conroller no! proeced. OFF Ka 3 Relay Ka For HEAT ON-OFF funcion (all-pole) or EMERGENY STOP. Shor wires Shor wires LINE FILTER U1 PRIM. U2 SEC. ROPEX emperaure conroller 1 2 Line filer The filer ype and size mus be deermined according he load, he ransformer and he machine wiring ( ROPEX Applicaion Repor). Do no run he filer supply wires (line side) parallel! o he filer oupu wires (load side). Impulse Transformer Designed according o VDE 57/EN (isolaing ransformer wih reinforced insulaion). Connec core o ground. Use ransformers wih one secion bobbin. The! power, duy cycle and volage values mus be deermined individually according o he applicaion ( ROPEX Applicaion Repor and Accessories leafle for impulse ransformers). RESISTRON emperaure conroller. Shor wires R 2 Wiring The wire cross-secions depend on he applicaion ( ROPEX Applicaion Repor). Guide values: Primary circui: min. 1,mm², max. 2,5mm² Secondary circui: min. 2,5mm², max. 4,mm² Twising (>2urns/meer) is recommended o improve EMC. Page 14

15 Insallaion 8.4 Wiring diagram wih relay K1 (sandard) GND/ Earh LINE Main swich Over-curren proecion Double-pole circui breaker or fuse (--> ROPEX Applicaion repor) Shor-circui proecion only. conroller no proeced. START FOOT SWITCH ANALOG OUTPUT (ACTUAL emperaure of heasealing band) +...1VDC Impulse ransformer 2 K1 2x 47nF/56R Load cell inerface and emperaure sensor Band 1 Band 2 IMPORTANT: If only ONE heasealing band is used, oupu erminals 7+8 mus be jumped wih a high curren cable in order o avoid malfuncions or damage of he conroller. Sep 24 in he Configuraion menu mus be se o Double for his purpose Heasealing band 9 Page 15

16 Insallaion 8.5 Wiring diagram wih solenoid drive (opional) GND/ Earh LINE Main swich Over-curren proecion Double-pole circui breaker or fuse (--> ROPEX Applicaion repor) Shor-circui proecion only. conroller no proeced. START FOOT SWITCH ANALOG OUTPUT (ACTUAL emperaure of heasealing band) +...1VDC Impulse ransformer Solenoid Line ~ ~ Load cell inerface and emperaure sensor Band 1 Band 2 IMPORTANT: If only ONE heasealing band is used, oupu erminals 7+8 mus be jumped wih a high curren cable in order o avoid malfuncions or damage of he conroller. Sep 24 in he Configuraion menu mus be se o Double for his purpose Heasealing band 9 Page 16

17 Sarup and operaion 9 Sarup and operaion 9.1 View of he conroller Moherboard Connecor for erminal Terminals Connecor for piggyback module (opional daa inerface) Nameplae Terminals Fron view of he erminal Connecing cables Nameplae Mouning clamps Display Operaor keys Page 17

18 Sarup and operaion Rear view of he erminal Nameplae Mouning clamps Connecing cables Mouning clamps 9.2 General conroller configuraion The possible conroller configuraions are explained in he following secions. Proceed as described in secion "Iniial sarup" on page 27 o sar up he conroller for he firs ime. The menu sep numbers indicaed in he following are valid as of sofware revision 7.! Please refer o he reference able in secion 1.4 "Menu srucure" on page 33 for informaion abou he numbers used for older conroller versions Seing he language The menu language can be changed on he conroller wihou inerruping operaion. I is se wih sep 21 in he Configuraion menu: The following seings are possible: English, German, Ialian As of sofware revision 1 also: French, Spanish, Duch, Danish, Finnish, Swedish, Greek, Turkish, Porugese The language which is seleced in his menu! remains se even if he facory seings are resored (sep 22 in he Configuraion menu) Resoring he facory seings The inernal conroller seings can be rese o he facory seings wih sep 22 in he Configuraion menu. Only he language seing (sep 21 in he Configuraion menu) remains unchanged. Please refer o secion 11 "Facory seings" on page 49 for more informaion abou he facory seings. If he conroller seings are unknown when i! is sared up for he firs ime, he facory seings mus be resored in order o preven malfuncions Configuraion of he alloy (emperaure coefficien) The heasealing band alloy and he corresponding emperaure coefficien are se wih seps 23 and 24 in he Configuraion menu: You can selec prese values for he alloy (or he emperaure coefficien) wih sep 23: 1. Temperaure coefficien 78ppm (e.g. Alloy-L) 2. Temperaure coefficien 11ppm (Facory seing) (e.g. Alloy-2) 3. Temperaure coefficien 14ppm (e.g. ROPEX CIRUS sysem) 4. Temperaure coefficien 17ppm (e.g. ROPEX CIRUS sysem) 5. Temperaure coefficien 35ppm (e.g. NOREX) 6. "Variable" emperaure coefficien Addiional seings wih sep 24. The emperaure coefficien can be individually se wih sep 24 for your paricular heasealing band in he range from 4 o 4 ppm. Page 18

19 Sarup and operaion! Menu sep 24 is only available if you seleced "Variable" wih sep 23. The imeou of he inernal ime conrol canno be sared wih his key Configuraion of he emperaure range The emperaure range for he conroller can be se wih sep 25 in he Configuraion menu. You can selec a emperaure range of 2 C, 3 C (Facory seing), 4 C or 5 C. START signal ACTUAL emp. ON T 9.3 Time conrol (imer funcion) Acivaion and indicaion The seings described here are only allowed! o be enered by echnically rained persons. An incorrecly parameerized imer funcion may cause disrupions o operaion and damage o he machine. The imer funcion is always acive and canno be swiched off. The inernal imeou is sared by acivaing he "START" signal. The "START" signal mus remain acivaed unil he end of he parameerized cooling phase. If he "START" signal is deacivaed before he end of he cooling phase, he imeou is inerruped. If ime conrol is on, acivaing he "START" signal sars he inernally parameerized imeou. This imeou comprises: Saring delay (delay a he beginning of he heaing phase) Heaing phase (heaing and conrol process) Cooling phase Relay K1 or opional solenoid drive funcion I is only possible o sar a heaing process! wih he "HAND" key (assuming sep 213 has no been locked in he Configuraion menu and he display is in he home posiion) on he conroller. Relay K1 closed = Saring delay 2 = Heaing phase 3 = Cooling phase The imeou of he inernal ime conrol (imer! funcion) can only be inerruped by swiching off he conroller or by deacivaing he "START" signal. If he display is in he home posiion, he individual imeous can be moniored here. The remaining heasealing ime is indicaed on he display in he form of a coundown a he end of he heaing phase. A direcion arrow indicaes he acive process. The acive cooling phase is subsequenly marked wih he direcion arrow a he end of he heaing phase. Page 19

20 Sarup and operaion The direcion arrow disappears again a he end of he cooling phase (i.e. a he end of he inernal imeou). The curren condiion of relay K1 (or he opional solenoid drive) is indicaed by means of a separae icon. If he icon is visible, he normally open conac of he relay is closed or he solenoid drive is acive Seing he heasealing ime The heasealing ime can be se in he range from o 99.9s wih sep 14 in he Seings menu. The facory seing is 1.s. START signal ON Separae seings can be enered for he individual imeous. These seings are possible wih seps 13, 14 and 15 in he Seings menu and wih seps 21, 211 and 212 in he Configuraion menu. The opions available wih hese advanced seings are described below. ACTUAL emp. T 2 2 = Heaing phase Seing he saring delay The sar of he heaing process can be explicily delayed by enering a saring delay ime wih sep 13 in he Seings menu, e.g. in order o bridge he closing ime of he heasealing bars. When he "START" signal is acivaed, he conroller wais for he ime specified wih his menu sep o elapse before commencing he heaing process. START signal ACTUAL emp. ON T 1 1 = Saring delay The saring delay can be se in he range from o 9.9s. A delay of s is defined as he facory seing. In his case, he heaing process begins as soon as he "START" signal is acivaed Seing he cooling mode Various crieria for he end of he cooling phase can be specified wih sep 21 in he Configuraion menu of he conroller: The possible seings are as follows: 1. "Absolue" (Facory seing) The cooling phase ends when he ACTUAL emperaure of he heasealing band falls below a specified emperaure value T K. This cooling emperaure can be se wih sep 15 in he Seings menu. 2. "Relaive" The cooling phase ends when he ACTUAL emperaure falls o a value corresponding o X% of he SET emperaure. This percenage cooling value can be se wih sep 15 in he Seings menu. Example: SET emperaure = 18 C, cooling value = 6% Cooling phase ends when ACTUAL emperaure 18 C 3. "Time" The cooling phase ends afer a specified ime in seconds and is independen of he ACTUAL emperaure. This cooling ime can be se wih sep 15 in he Seings menu. Page 2

21 Sarup and operaion The various cooling modes are shown below: START signal ACTUAL emp. ON T The possible seings are as follows: 1. "Cooling emp. in C" (if seing wih menu sep 21 = "Absolue") The cooling phase of he inernal imeou ends when he ACTUAL emperaure of he heasealing band falls below he SET emperaure. The minimum seable emperaure is 5 C. This is also he facory seing. The maximum value of he seing range is! limied eiher by he maximum value specified wih sep 26 in he Configuraion menu or by he emperaure range se wih sep 25. Cooling mode T Absolue T = Cooling phase in 2. "Cooling emp. in %" (if seing wih menu sep 21 = "Relaive") The cooling phase of he inernal imeou ends when he ACTUAL emperaure falls o he specified percenage of he SET emperaure. This value can be se beween 4 and 1%. The facory seing is 4%. T Relaive X% 3 3 = Cooling phase as % of se poin 3. "Cooling ime in s" (if seing wih menu sep 21 = "Time") The cooling phase ends when he specified ime elapses. This ime can be se beween and 99.9s. The facory seing is 1.s. Time T 3 3 = Cooling phase in s Seing he cooling value Afer he cooling phase has been configured wih sep 21 in he Configuraion menu ( secion "Seing he cooling mode" on page 2), you can specify he cooling parameers wih sep 15 in he Seings menu. The opions available wih sep 15 in he! Seings menu vary according o he selecion made wih sep 21 in he Configuraion menu. All seings enered wih menu sep 15 are overwrien if sep 21 is changed subsequenly Seing he sar of he heasealing ime The sar condiion for he se heasealing ime (sep 14 in he Seings menu) can be specified wih sep 211 in he Configuraion menu. The following seings are possible: 1. "When heaing sars" The parameerized heasealing ime sars as soon as he se saring delay elapses ( Seings menu, sep 13). If he saring delay = s, he heasealing ime begins as soon as he "START" signal is acivaed. 2. "When emperaure reached" (Facory seing) Once again, he heaing process sars as soon as he se saring delay elapses ( Seings menu, sep 13). The specified heasealing ime does no sar, however, unil he ACTUAL emperaure of he heasealing band reaches 95% of he SET emperaure. Page 21

22 Sarup and operaion These wo alernaives are shown below: START signal ACTUAL emp. ON T Sar of heasealing ime When heaing sars When emperaure reached 95% of se poin Heasealing ime Heasealing ime Relay K1 / solenoid drive (opional) The funcion of relay K1 (or he opional solenoid drive) is specified wih sep 212 in he Configuraion menu. The seings can be seleced as follows (as of sofware revision 7): 1. "When sar signal presen" (Facory seing) The normally open conac of relay K1 (or he solenoid drive) closes as soon as he "START" signal is acivaed and remains closed unil he end of he parameerized imeou (i.e. unil he end of he cooling phase). 2. "When emperaure reached" The normally open conac of relay K1 (or he solenoid drive) closes when he ACTUAL emperaure reaches 95% of he SET emperaure and remains closed unil he end of he parameerized imeou (i.e. unil he end of he cooling phase). 3. "While cooling" The normally open conac of relay K1 (or he solenoid drive) closes a he end of he heaing phase and opens again a he end of he cooling phase. This configuraion permis air cooling o be acivaed wih relay K1 (or he solenoid drive) during he cooling phase, for insance. 4. "End-of-cycle impulse" The normally open conac of relay K1 (or he solenoid drive) closes a he end of he parameerized imeou (i.e. a he end of he cooling phase) and opens again afer approximaely 5ms. If a "START" signal is acivaed while relay K1 is sill closed (or he solenoid drive is acive), he relay opens again immediaely. 5. "OFF" Relay K1 (or he solenoid drive) is deenergized, i.e. i has no funcion. As of sofware revision 8, relay K1 (or he! solenoid drive) canno be re-energized for 2ms afer he end of he parameerized cooling phase, in order o preven bouncing or oscillaion of he driven closing movemen. Page 22

23 Sarup and operaion The possible seings are shown below: START signal ACTUAL emp. Relay K1 ON T When sar sig. presen When emperaure reached While cooling End-ofcycle impulse 95% of se poin End of cooling 5ms Oher names are used for he seings up o! sofware revision 6. The only possible seings are "ON, "When START signal presen" and "OFF". 9.4 Temperaurediagnosis (as of sofware revision 7) olerance band ("OK" window) on eiher side of he SET emperaure. The lower ( Δϑ low ) and upper ( Δϑ high ) limis of he olerance band can be changed by means of seps in he Configuraion menu (facory seing: -1K respecively +1K). If he acual emperaure is ouside he specified olerance during he parameerized monioring ime, he heasealing cycle is immediaely inerruped and he corresponding error code (37, 38) is indicaed ( secion 1.21 "Error messages" on page 45). This monioring funcion serves o mainain a consan emperaure. Sofware revision 7: The emperaure diagnosis funcion is always acive. The diagnosis begins if he ACTUAL emperaure exceeds he lower olerance limi and simulaneously corresponds o 95% of he SET emperaure. The diagnosis ends a he end of he parameerized heasealing phase. As of sofware revision 8: The emperaure diagnosis funcion can be acivaed and deacivaed wih sep 217 in he Configuraion menu. The following seings are possible: 1. "OFF" (Facory seing) Temperaure diagnosis deacivaed 2. "ON" Temperaure diagnosis acivaed If he emperaure diagnosis is no acivaed byl he end of he configured sealing ime (i.e. if he ACTUAL emperaure does no exceed he upper or lower olerance band limi), he corresponding error code (39, 31) is indicaed. If he emperaure diagnosis funcion is acivaed, an addiional delay ime beween and 9.9s can be parameerized for emperaure monioring wih sep 218 in he Configuraion menu. This delay ime sars when he ACTUAL emperaure reaches 95% of he SET emperaure. The emperaure diagnosis funcion is acivaed as soon as he delay ime elapses (in he case of sofware revision 8, he ACTUAL emperaure mus also have exceeded he lower limi of he olerance band in order for he diagnosis funcion o be acivaed). The checks during he heasealing phase wheher he ACTUAL emperaure is wihin a seable Page 23

24 Sarup and operaion The emperaure diagnosis funcion can hus be explicily deacivaed during he closing movemen of he sealing jaws, for insance. Se+ Δϑ high Se+ Δϑ low Se Heaup imeou (as of sofware revision 1) The heaup imeou can be parameerized wih sep 219 in he Configuraion menu ("" = OFF). This imeou sars when he START signal is acivaed. The hen moniors he ime required for he ACTUAL emperaure o reach 95% of he SET emperaure. If his ime is longer han he parameerized ime, he corresponding error code (84) is indicaed ( secion 1.21 "Error messages" on page 45) Se 95% of Se 9.5 Load cell inerface / emperaure sensor General Error message Heaup ime Acual value ACTUAL emp. If he measured force is ouside he specified olerance during he parameerized monioring ime, he heas- Timeou Error code 84 Time Time The conroller can be conneced o a load cell and a emperaure sensor. The load cell is used o measure he closing force of he heasealing mechanism. This force can be moniored by he conroller during he heasealing cycle. If he closing pressure is ouside he specified limi values, he heasealing cycle is inerruped and an alarm is indicaed on he display. The emperaure sensor can be used o monior eiher he inernal machine/equipmen emperaure or he emperaure of he load cell. An alarm is oupu by he conroller if he maximum permissible emperaure is exceeded. The seings for he load cell inerface and he emperaure sensor can be seleced as follows wih sep 241 in he Configuraion menu: 1. "OFF" (Facory seing) Load cell inerface and emperaure sensor no acive 2. "Force" Load cell inerface for force measuremen acive, emperaure sensor no acive 3. "Temperaure" Temperaure sensor acive, load cell inerface no acive 4. "Temperaure and force" Load cell inerface for force measuremen and emperaure sensor acive! The menu seps 242 o 246 described below are accessible if sep 241 is se accordingly Force diagnosis The checks during he heasealing phase (assuming his has been acivaed wih sep 241) wheher he measured force of he conneced load cell is inside a seable olerance band ("OK window"). The upper and lower limi values can be changed separaely by means of seps in he Configuraion menu. Load cell +Vcc + Signal - -Vcc V V Page 24

25 Sarup and operaion ealing cycle is immediaely inerruped and an alarm (error code 817, 818) is indicaed on he display. This monioring funcion serves, among oher hings, o ensure a consan closing force of he sealing jaws. Up o sofware revision 7: The force diagnosis begins 1ms afer he ACTUAL emperaure reaches 95% of he SET emperaure and coninues unil he end of he parameerized cooling phase. As of sofware revision 8: The force diagnosis funcion can be addiionally parameerized by means of sep 247 in he configuraion menu. The following seings are possible: 1. "OFF" (Facory seing) Force diagnosis deacivaed 2. "Acive during heasealing cycle" The force diagnosis is permanenly acive during he heasealing phase unil he end of he parameerized cooling phase. If his seing is acivaed, an addiional delay ime beween and 9.9s can be parameerized wih sep 248 in he Configuraion menu. This delay ime sars when he ACTUAL emperaure reaches 95% of he SET emperaure. The force diagnosis funcion is acivaed as soon as he delay ime elapses. The force diagnosis funcion can hus be explicily deacivaed during he closing movemen of he sealing jaws, for insance. 3. "End of heaing phase" A single force diagnosis akes place a he end of he heasealing phase. 4. "End of cooling phase" A single force diagnosis akes place a he end of he cooling phase. Maximum force Minimum force Error message Force Time Calibraion of he load cell inerface / Force indicaion The inegraed load cell mus be calibraed o he specifics of each machine when he conroller is sared up. The necessary values can be enered wih seps The load cell can be ared wih sep 244 when i is offload. Afer loading he cell wih a defined, known weigh, he associaed reference force mus be enered wih sep 245. A sraigh force measuremen curve is assumed beween hese wo measuring poins (are weigh and reference force). Measured force Reference The measured force is only indicaed if i is wihin he permissible limi values. If he upper or lower limi value is exceeded, he following informaion is indicaed on he display: Measured force Minimum force exceeded (force < -1N) Maximum force exceeded (force > 15N) Lower range limi exceeded (measured value < -2.2mV) Upper range limi exceeded (measured value > 12.2mV) Tare (zero) Reference force Indicaion on display " " " " Error code (if force diagnosis is acive) " LLLLL " 813 " HHHHH " 814 Weigh Load cell no conneced " ***** " 82 Page 25

26 Sarup and operaion Temperaure sensor The maximum permissible emperaure of he sensor can be se wih sep 246 (assuming he emperaure sensor has been acivaed wih sep 241). An alarm is immediaely oupu by he conroller if his maximum emperaure is exceeded. Temp. sensor ϑ If a heasealing cycle is in progress, i is inerruped. The emperaure monioring funcion is acivaed 3s afer he conroller is swiched on. Maximum sensor emp. If a emperaure sensor is no conneced (or if he sensor connecing cable is defecive), an alarm is oupu by he conroller afer 3s (assuming he emperaure sensor has been acivaed wih sep 241). The sensor emperaure measuremen! described here serves o monior and/or limi he load cell or machine emperaure. I canno be used o monior he emperaure of he heasealing band or for emperaure conrol. 9.6 Heasealing band General V Error message Temperaure Time The heasealing band is a key componen in he conrol loop, since i is boh a heaing elemen and a sensor. The geomery of he heasealing band is oo complex o be discussed a lengh here. We shall herefore only refer o a few of he mos imporan physical and elecrical properies: The measuring principle applied for his sysem necessiaes a heasealing band alloy wih a suiable emperaure coefficien TCR, i.e. one whose resisance increases as he emperaure rises. Too low a TCR leads o oscillaion or unconrolled heaing. When heasealing bands wih a higher TCR are used, he conroller mus be calibraed for his. The firs ime he heasealing band is heaed o approximaely 2 25 C, he sandard alloy undergoes a once-only resisance change (burn-in effec). The cold resisance of he heasealing band is reduced by approximaely 2 3%. However, his a firs glance sligh resisance change resuls in a zero poin error of 2 3 C. The zero poin mus herefore be correced afer a few heaing cycles ( secion "Burning in he heasealing band" on page 26). One very imporan design feaure is he copper or silver-plaing of he heasealing band ends. Cold ends allow he emperaure o be conrolled accuraely and increase he life of he eflon coaing and he heasealing band. An overheaed or burned-ou heasealing! band mus no longer be used because he TCR has been alered irreversibly Burning in he heasealing band If a new heasealing band has been used, he zero poin is firs of all calibraed while he band is sill cold by acivaing he "AUTOCAL" funcion on he conroller. When he "AUTOCAL" funcion has finished, he display shows he preseleced calibraion emperaure (defaul value: 2 C). Adjus he se poin o approximaely 25 C and press he "HAND" key (assuming sep 213 has no been locked in he Configuraion menu and he display is in he home posiion) o acivae he "START" signal and hea for approximaely 1 second. Afer recooling, he conroller usually indicaes a value less han 2 C. Repea he "AUTOCAL" funcion. The heasealing band has now been burned in and he change in he alloying properies sabilized. The burn-in effec described here does no occur if he heasealing band has already been hermally prereaed by he manufacurer. Page 26

27 Sarup and operaion Replacing he heasealing band All power supply leads mus be disconneced from he RESISTRON emperaure conroller in order o replace he heasealing band. The heasealing band mus be replaced in! accordance wih he insrucions provided by he manufacurer. Each ime he heasealing band is replaced, he zero poin mus be calibraed wih he AUTOCAL funcion while he band is sill cold, in order o compensae producion-relaed resisance olerances. The burn-in procedure described above mus be performed for all new heasealing bands. 9.7 Sarup procedure Please also refer o secion 2 "Applicaion" on page 4. Insallaion and sarup may only be performed by echnically rained, skilled per-! sons who are familiar wih he associaed risks and warrany provisions Iniial sarup Prerequisies: The conroller mus be correcly insalled and conneced ( secion 8 "Insallaion" on page 13). The possible seings are described in deail in secion 9.2 "General conroller configuraion" on page 18 and secion 1 "Conroller funcions" on page 29. The essenial conroller configuraions are described below: 1. Swich off he line volage and verify ha all circuis are deenergized. 2. The supply volage specified on he nameplae of he conroller mus be idenical o he line volage ha is presen in he plan or machine. The line frequency is auomaically deeced by he emperaure conroller in he range from 47 o 63Hz. 3. Heed he informaion conained in he ROPEX Applicaion Repor as well as he specificaions for he heasealing band ha is used (secion 9.2 "General conroller configuraion" on page 18). 4. Make sure ha a START signal is no presen. 5. Swich on he line volage. 6. A power-up message appears on he display for approximaely 2 seconds when he conroller is swiched on o indicae ha i has been sared up correcly. 7. One of he following saes hen appears: DISPLAY Display in home posiion Go o 8 Error message wih error codes 14 16, , 211, 32, 33 Error message wih error codes 11 13, 17, 18, 21 23, 81, 9xx Go o 8 ACTION 8. Se he conroller configuraion as described in secion 9.2 "General conroller configuraion" on page 18. The following seings are always required: Seing Language 21 Resore facory seings 22 Faul diagnosis ( secion 1.2 1) Sep in Configuraion menu Heasealing band alloy 23, 24 Temperaure range 25 Single/double sealing 24 Page 27

28 Sarup and operaion 9. Acivae he AUTOCAL funcion while he heasealing band is sill cold (wih sep 17 in he Seings menu). The progress of he calibraion process is indicaed by a couner on he display (approx s). A volage of VDC appears a he same ime a he acual value oupu (erminals 1+11). If an ATR-x is conneced, i indicaes C. When he zero poin has been calibraed, he display is rese o he home posiion and he previously se AUTOCAL emperaure is indicaed (defaul: 2 C). A volage of.66vdc (2 C and 3 C ranges) or.4vdc (4 C and 5 C ranges) appears a he acual value oupu a 2 C. If an ATR-x is conneced, i mus be se o "Z" (2 C). If he zero has no been calibraed successfully, an error message indicaes error codes 111, 114, 211. In his case he conroller configuraion is incorrec ( secion 9.2 "General conroller configuraion" on page 18 and ROPEX Applicaion Repor). Repea he zero poin calibraion afer he conroller has been configured correcly. 1.When he zero poin has been calibraed successfully, he main menu appears on he display again. Then specify a defined emperaure (heasealing emperaure) wih sep 11 in he Seings menu and acivae he "START" signal (HEAT). Alernaively, you can sar a heasealing process by pressing he "HAND" key (assuming sep 213 has no been locked in he Configuraion menu and he display is in he home posiion). The indicaion of he ACTUAL emperaure on he display (digial value and dynamic bar) permis he heaing and conrol process o be moniored: The conroller is funcioning correcly if he emperaure indicaed on he display has a coninuous curve, in oher words i mus no jump abruply, flucuae or deviae emporarily in he wrong direcion). If an error code is displayed, please proceed as described in secion 1.21 "Error messages" on page Burn in he heasealing band ( secion 9.6 "Heasealing band" on page 26) and repea he AUTOCAL funcion. The conroller is now ready Resar afer replacing he heasealing band To replace he heasealing band, proceed as described in secion 9.6 "Heasealing band" on page 26. Always use a heasealing band wih he correc alloy, dimensions and copper-plaing in! order o avoid malfuncions and overheaing. Coninue wih secion 9.7.1, seps 9 and 1. Page 28

29 Conroller funcions 1 Conroller funcions See also secion 8.4 "Wiring diagram wih relay K1 (sandard)" on page 15.! The menu sep numbers indicaed in he following are valid as of sofware revision 7. Please refer o he reference able in secion 1.4 "Menu srucure" on page 33 for informaion abou he numbers used for older conroller versions. 1.1 Indicaors and conrols RESISTRON RES-4 ENTER HAND RESET "MENU" key for advancing o nex menu sep or swiching menu < 2 sec. Press: Nex menu sep 1-2 sec. Press: Reurn o previous posiion (as of SW-Revision 1): > 2 sec. Press (Hold): Reurn o home posiion ROPEX "ENTER" key ENTER funcion: Save values HAND funcion: Manual mode RESET funcion: Rese afer alarm "UP" and "DOWN" keys for seing values Press (< 2 sec.): Slow change Hold (> 2 sec.): Fas change LC display, 4 lines, mulilingual 1.2 Display Power-up message A power-up message appears on he display for approximaely 2 seconds when he conroller is swiched on. This message also includes deails of he sofware version. Company name (opional: cusomer-specific) Sofware ID number Conroller ype () Page 29

30 Conroller funcions Display in home posiion If no seings are enered on he conroller and no error message are presen, he display is in he home posiion, in oher words i indicaes he SET emperaure as a digial value and he ACTUAL emperaure as a digial value and a dynamic bar. Specified heasealing emperaure (SET emperaure) Icon indicaes ha NO conac of addiional relay K1 is closed Measured ACTUAL emperaure ACTUAL emperaure as a dynamic bar Heasealing parameers Cooling parameers Seings/Configuraion menus The required parameers are se on wo menu levels: he Seings (conrol) menu and he Configuraion menu ( secion 1.4 "Menu srucure" on page 33). Menu level: Seings or Configuraion menu (Configuraion menu shown here) Posiion in menu (menu sep) Menu conens (max. 3 lines) Error message The faul diagnosis funcion of he conroller is always acive. If a faul is deeced, i is indicaed on he display Alarm indicaion immediaely in he form of an error message ( secion 1.2 "Sysem monioring / alarm oupu" on page 45). Faul descripion and error code Promp o press "RESET" key Page 3

31 Conroller funcions 1.3 Navigaion in he menus Navigaion in menus wihou an alarm A "MENU" key is provided for navigaing hrough he various menu seps and levels. By pressing his key briefly (<1s) a any ime, you can jump o he nex menu sep. As of sofware revision 1, you can also jump o he previous menu sep by pressing he "MENU" key for 1-2s. By pressing he key for longer (>2s), you can Seings reurn o he home posiion from anywhere in he menu srucure, providing a conroller alarm is no acive. In his case, he Alarm menu is opened insead. If he display is in he home posiion or an alarm is indicaed and you press he "MENU" key for longer han 2s, you are aken direcly o he configuraion level (saring a sep 21). In addiion, you always reurn o he home posiion if you do no press any keys for a period of 3s. There is no auomaic reurn afer 3s from "AUTOCAL" or "Alarm". Configuraion Home posiion 21 Language <2s >2s >2s or auomaically afer 3s <2s 11 Heasealing emp. 22 Facory seings >2s or auomaically afer 3s >2s or auomaically afer 3s Page 31

32 Conroller funcions Navigaion in menus wih an alarm If an alarm is signaled, he conroller swiches o he Alarm menu. Some fauls can be acknowledged by pressing he "RESET" key ( secion 1.2 "Sysem monioring / alarm oupu" on page 45). In his case, he conroller swiches back o he home posiion. If he faul can be recified by execuing he AUTOCAL funcion, you can selec he "AUTOCAL" menu sep direcly by briefly pressing he "MENU" key (<2s). You can hen acivae he "AUTOCAL" funcion by pressing he "ENTER" key ( secion 1.8 "Auomaic zero calibraion (AUTOCAL)" on page 37). If you press he "MENU" key for longer han 2s in he Alarm menu, you are aken direcly o he configuraion level (saring a sep 21). You can reurn from he Configuraion menu o he Alarm menu eiher by pressing he "MENU" key for longer han 2s or by no pressing any keys for 3s. Alarm ENTER HAND RESET Home posiion Alarm >2s >2s or auomaically afer 3s 21 Language <2s <2s ENTER HAND RESET 17 Auocal? 22 Facory seings Auocal End of Auocal >2s or auomaically afer 3s Page 32

33 Conroller funcions 1.4 Menu srucure Seings Configuraion Power-up message Home posiion 1) 2) Display acual force 11 Heasealing emp. 12 Preheaing emp. 3) 4) 13 Saring delay 21 Language 22 Facory seings 23 Alloy 5) 6) 24 Temp. coefficien 25 Temperaure range 1) Force sensor acive 2) Force sensor no acive 3) Time conrol: OFF 4) Time conrol: ON 5) TCR no variable 6) TCR = variable 7) Cooling mode: absolue, relaive, ime 8) Cooling mode: none 14 Sealing ime 7) 8) 15 Cooling value 26 Max. emperaure 27 Se poin reached 16 Hold mode 28 Se poin exceeded 17 Auocal? 29 Time conrol 3) 4) Auocal 21 Cooling mode 211 Sar of sealing ime 212 Relay K1 funcion 213 Lock "HAND" key 214 Cycles Faul 215 Alarm relay Alarm 216 Analog oupu 17 Auocal? 217 Temp. diagnosis Auocal 218 Temp. diag. delay Coninued on nex page Page 33

34 Conroller funcions Configuraion Coninued from previous page 219 Heaup imeou 22 Meas. imp. lengh 221 Auocomp 222 Oupu Temperaure uni 24 Sealing mode s/d 241 Sensor mode 1) 2) 242 Minimum force 243 Maximum force 244 Force are 245 Reference force 2) 4) 3) 1) Force sensor or force and emperaure sensor acive 2) Temp. sensor acive 3) No sensors acive 4) Temp. sensor no acive 246 Max. sensor emp. 247 Force diagnosis 248 Force diag. delay 249 Foo swich hold ime Back o home posiion Page 34

35 Conroller funcions 1.5 Two-digi numbering sysem up o sofware revision 6 A sysem of one and wo-digi numbers was used for he Seings and Configuraion menus up o sofware revision 6. Three-digi numbers were inroduced in sofware revision 7 o improve he clariy of he menu srucure. The able below compares he wo numbering sysems: Menu Menu sep Numbering up o SW revision 6 Numbering as of SW revision 7 Seings menu Heasealing emperaure 1 11 Saring delay 3 13 Heasealing ime 4 14 Cooling value 5 15 Hold mode 6 16 AUTOCAL 7 17 Configuraion menu Language 2 21 Facory seings Alloy / TCR Var. emp. coeff Temperaure range Maximum emperaure Cooling mode Sar of heasealing ime Relay K1 funcion Cycle couner Single/double sealing Sensor on/off Load cell minimum force Load cell maximum force Load cell are Load cell reference force Max. sensor emperaure All numbers or menu seps no lised above! are only available as of sofware revision 7 and are described in secion 9 "Sarup and operaion" on page 17 or secion 1.4 "Menu srucure" on page 33. Page 35

36 Conroller funcions 1.6 Temperaure seing (se poin selecion) The heasealing emperaure can be se by means of menu sep 11. The maximum value of he seing range is! limied eiher by he maximum value specified wih sep 26 in he Configuraion menu or by he emperaure range se wih sep 25. The se poin ha is seleced for he heasealing emperaure mus be greaer han 4 C. If no, he heasealing band will no be heaed up when he "START" signal is acivaed or he "HAND" key (assuming sep 213 has no been locked in he Configuraion menu and he display is in he home posiion) is pressed. The se heasealing emperaure is displayed in he main menu once i has been enered. 1.7 Temperaure indicaion / acual value oupu If he display is in he home posiion, he ACTUAL emperaure is indicaed here as a digial value and as a dynamic bar. In addiion, he oupus an analog 1VDC signal, which is proporional o he real ACTUAL emperaure, a erminals Acual value oupu 1VDC R=33ohms max. 5mA 1 V Temperaure meer e.g. ATR-3 Volage values: VDC C 1VDC 3 C or 5 C (depending on he conroller configuraion) The relaionship beween he change in he oupu volage and he ACTUAL emperaure is linear VDC The heaing and conrol process can hus be moniored a any ime C Temperaure T C - 3 C range V Volage U VDC "ZERO" Page 36

37 Conroller funcions Temperaure T C C range 2 C V Volage U VDC "ZERO" Only he 3 C and 5 C emperaure ranges appear a his acual value oupu. If a emperaure range of 2 C is se for he conroller wih sep 25 in he Configuraion menu, i appears a his oupu in he 3 C range. A 4 C emperaure range is indicaed as 5 C. An indicaing insrumen can be conneced o his oupu in order o visualize he emperaure of he heasealing band. If an alarm is signaled, his analog oupu is used in addiion o he value indicaed on he conroller o display a selecive error message ( secion 1.21 "Error messages" on page 45). This oupu is no poenial-free and could! have he poenial of he secondary volage of he impulse ransformer. Exernal grounding is no allowed. If his warning is ignored, he conroller will be damaged by frame currens. Conac volage proecion mus be insalled a he erminals of he exernal emperaure meer. 1.8 Auomaic zero calibraion (AUTOCAL) Owing o he auomaic zero calibraion (AUTOCAL) funcion, here is no need o adjus he zero poin manually on he conroller. The "AUTOCAL" funcion maches he conroller o he curren and volage signals ha are presen in he sysem. You can acivae his funcion by selecing sep 17 in he Seings menu and hen pressing he "ENTER" key. The iniial emperaure (ambien emperaure) of he heasealing bar(s) which is currenly valid for calibraion can be se beforehand in he 4 C range using he "UP" and "DOWN" keys. The zero poin is calibraed in he facory o 2 C. The auomaic calibraion process akes around 1 15 seconds. The heasealing band is no heaed unil he calibraion process has finished. The message "- Calibraion - Please wai..." appears on he display while he "AUTOCAL" funcion is execuing and a couner couns down from 14 o. The acual value oupu (erminals 1+11) is se o C (corresponds o VDC) for he duraion of he calibraion process. You should always wai for he heasealing! band and he bar o cool down (o ambien emperaure) before acivaing he "AUTOCAL" funcion. Reasons for locked AUTOCAL funcion: 1. The "AUTOCAL" funcion canno be acivaed if he heasealing band cools down a a rae of more han.1k/second. This is addiionally indicaed wih sep 17 in he Seings menu by he message "Heasealing band sill ho! Please wai...". 2. If he "START" signal (HEAT) is acivaed, he "AUTOCAL" funcion is no execued. This is addiionally indicaed wih sep 17 in he Seings menu by he message "Auocal locked! (START sig. acive)". 3. The AUTOCAL funcion canno be acivaed if a faul wih error code 11 13, 21 23, 8xx or 9xx occurs ( secion 1.21 "Error messages" on page 45). Page 37

38 Conroller funcions 1.9 "FOOT SWITCH" signal The "FOOT SWITCH" signal is acivaed by means of a conrol conac a erminals FOOT SWITCH wih conac max. 5mA V Acivaing he "FOOT SWITCH" signal energizes relay K1 (or he opional solenoid drive). Among oher hings, his allows he closing movemen of he sealing jaws o be sared. Deacivaing he signal deenergizes relay K1 (or he solenoid drive) again immediaely, providing relay K1 is no energized by he ime conrol ( secion "Relay K1 / solenoid drive (opional)" on page 22). An addiionally parameerizable hold ime for he "FOOT SWITCH" signal is described in secion 1.1 "Hold ime for "FOOT SWITCH" signal" on page 38. The "FOOT SWITCH" signal is disabled as! long as he AUTOCAL funcion is execuing in he Seings menu (wih sep 17) or an alarm is displayed. I is no possible o acivae he "FOOT! SWITCH" signal again (in oher words, relay K1 or he solenoid drive canno be energized) for 2ms afer i is deacivaed in order o preven bouncing or oscillaion of he driven closing movemen. 1.1 Hold ime for "FOOT SWITCH" signal A hold ime beween and 2.s can be parameerized for he "FOOT SWITCH" signal wih sep 249 in he Configuraion menu. The relay (or he solenoid drive) remains closed for he parameerized ime afer his signal is acivaed, even if he signal is deacivaed again. Among oher hings, his permis he closing movemen of he sealing jaws o be sared by briefly acivaing and deacivaing he "FOOT SWITCH" signal. The hold ime is deacivaed if he value enered is "" (facory seing). The ime conrol mus energize relay K1! wihin he parameerized hold ime (acivaion of he "START" signal). If no, he conroller indicaes an alarm (error code 835) "START" signal (HEAT) Acivaing he "START" signal sars he inernally parameerized imeou. The ime a which he heasealing band begins o hea up depends on he seing of his parameer. The "START" signal mus be deacivaed again before he nex imeou is acivaed. Pressing he "HAND" key (assuming sep 213 has no been locked in he Configuraion menu and he display is in he home posiion) while he display is in he home posiion causes he heasealing band o sar heaing up immediaely. The inernal imeou is no sared. The "START" signal is acivaed by means of a conrol conac a erminals START (HEAT) wih conac max. 5mA V The "START" signal is disabled as long as he! "AUTOCAL" funcion is execuing in he Seings menu (wih sep 17). The se poin ha is seleced for he heasealing emperaure (sep 11 in he Seings menu) mus be greaer han 4 C. If no, he heasealing band will no be heaed up. As of sofware revision 8, i is no possible! o acivae he "START" signal again (in oher words, relay K1 or he solenoid drive canno be energized) for 2ms afer i is deacivaed in order o preven bouncing or oscillaion of he driven closing movemen. Page 38

39 Conroller funcions 1.12 Cycle couner Each acivaion of he "START" signal during operaion is deeced by a cycle couner inegraed in he conroller. Acuaions of he "HAND" key are no couned. The couner reading can be displayed wih sep 214 in he Configuraion menu. The cycle couner is rese o if he "ENTER" key is pressed or if he maximum coun of cycles is exceeded Single/double sealing Sep 24 deermines how he wo heasealing bands are heaed, depending on he design of he machine or equipmen. If wo heasealing bands for op and boom heaing are insalled in he machine, one of hese bands can be deacivaed for specific applicaions. The required seings can be configured wih sep 24: 1. "Double" (Facory seing) The wo heasealing bands are heaed simulaneously. The emperaure of boh bands is conrolled ogeher. 2. "Single" If wo heasealing bands are conneced o he conroller, only he firs is heaed. The second band is no used. Only he emperaure of he firs heasealing band is conrolled. If only one heasealing band is conneced o! he conroller, you mus se "Double" wih sep 24. The conroller will oherwise be overloaded and damaged beyond repair. If you change he configuraion wih! sep 24, you mus run he AUTOCAL funcion wih sep 17. If no, he conroller will no longer funcion correcly Hold mode The behavior of he digial indicaion of he ACTUAL emperaure in he home posiion can be changed wih sep 26 in he Seings menu. The following seings are possible: 1. "OFF" (Facory seing) If he main menu is visible on he display, he real ACTUAL emperaure is always indicaed. 2. "ON" If he display is in he home posiion, he ACTUAL emperaure ha was valid a he end of he las heasealing phase is always indicaed as a digial value. When he conroller is swiched on - or afer an alarm is acknowledged - he real ACTUAL emperaure is indicaed unil he end of he firs heaing phase. 3. "2 s" This seing causes he curren ACTUAL emperaure o be displayed as a digial value for an addiional 2 seconds a he end of a heasealing phase. This emperaure is hen indicaed again in real ime unil he end of he nex heaing phase. Hold mode only affecs he digial value on! he display. The ACTUAL emperaure in real ime is always indicaed, regardless of he seing, by he dynamic bar and he acual value oupu. Page 39

40 Conroller funcions The various hold modes are shown below: START signal ON OFF ACTUAL emp. T ACTUAL indicaion Hold OFF T Hold ON Hold 2 s T T Hold Hold Hold Hold 1.15 Auomaic phase angle compensaion (AUTOCOMP) (as of sofware revision 1) I may be necessary o compensae he phase angle displacemen beween he U R and I R measuring signals in cerain heasealing applicaions ( ROPEX Applicaion Repor). The "AUTOCOMP" funcion is provided for his purpose. I can be parameerized wih sep 221 as followed: 1. OFF (Facory seing) The AUTOCOMP funcion is deacivaed. 2. ON The AUTOCOMP funcion is acivaed by pressing he "ENTER" key afer he "AUTOCAL" funcion has been successfully execued ( secion 1.8 "Auomaic zero calibraion (AUTOCAL)" on page 37). The inerval afer he end of he "AUTOCAL" funcion mus be less han 2.s ("Sar AUTOCOMP? Sar wih ENTER" appears on he display during his ime). The subsequen "AUTOCOMP" funcion is execued in approximaely 2.s ("- AUTOCOMP - Please wai " appears on he display during his ime). If he inerval following he successful execuion of he "AUTOCAL" funcion is longer han 2.s, he display reurns o he home posiion and he "AUTO- COMP" funcion is no execued. 2 s 2 s End of Heaing phase The word "Hold" appears on he display if a emperaure value is indicaed in hold mode. I disappears for approximaely 1ms whenever he hold value is updaed. ENTER key pressed Funcion AC <2.s AUTOCAL AP AUTOCOMP The acual value oupu (erminals 1+11) is se o 3 C (i.e. approx. VDC) when he "AUTO- COMP" funcion is execued. Page 4

41 Conroller funcions 3. AUTO (as of sofware revision 11) Wih his seing he AUTOCOMP funcion is acivaed auomaically afer he "AUTOCAL" funcion has been successfully execued. ENTER key pressed Funcion AC AUTOCAL AUTOCOMP The acual value oupu (erminals 1+11) is se o 3 C (i.e. approx. VDC) when he AUTOCAL and "AUTOCOMP" funcions is execued Locking he "HAND" key and/or he funcion AUTOCAL As of sofware revision 7 up o revision 22 The "HAND" key funcion can be configured wih sep 213 in he Configuraion menu when he display is in he home posiion. This prevens he heasealing bands from being heaed if he "HAND" key is pressed inadverenly. The following seings are possible: 1. Lock "OFF" (Facory seing) Pressing he "HAND" key while he display is in he home posiion sars a manual heaing process. The heasealing band is heaed for as long as he "HAND" key remains pressed. 2. Lock "ON" The "HAND" key is locked when he display is in he home posiion, in oher words i has no funcion. As of sofwarew revision 23 The "HAND" key funcion when he display is in he home posiion and he acivaion of he "AUTOCAL" funcion using sep 17 can be configured wih sep 213 in he Configuraion menu. This prevens he heasealing bands from being inadverenly heaed if he "HAND" key is pressed and/or he "AUTOCAL" funcion from being inadverenly acivaed. The following seings are possible: 1. Lock OFF (facory seing) The "HAND" key is unlocked when he display is in he home posiion. Pressing he "HAND" key sars a manual heaing process. The heasealing band is heaed for as long as he "HAND" key remains pressed. In addiion, he "AUTOCAL" funcion using sep 17 can be acivaed by pressing he "ENTER" key 2. Lock HAND The "HAND" key is locked when he display is in he home posiion, in oher words i has no funcion. The "AUTOCAL" funcion can sill be acivaed using sep Lock AUTOCAL The "AUTOCAL" funcion canno be acivaed using sep 17. The "HAND" key funcion can sill be used when he display is in he home posiion 4. Lock HAND/AUTOCAL The "HAND" key is locked when he display is in he home posiion, in oher words i has no funcion. In addiion, he "AUTOCAL" funcion canno be acivaed using sep 17. Page 41

42 Conroller funcions 1.17 Temperaure uni Celsius / Fahrenhei (as of sofware revision 12) As of sofware revision 12, he uni for he emperaure indicaion and value selecion can be swiched beween C (Celsius) and F (Fahrenhei). I can be parameerized wih sep 225: 1. Celsius (Facory seing) Temperaure indicaion and value selecion in Celsius ( C). 2. Fahrenhei Temperaure indicaion and value selecion in Fahrenhei ( F) Up o and including sofware revision 11, only Celsius ( C) can be specified on he conroller as he emperaure uni.! The degree uni can be changed on he conroller wihou inerruping operaion If you specify emperaure indicaion and! value selecion in Fahrenhei ( F), he conroller sill uses Celsius ( C) inernally. Value seps are herefore possible wih his funcion owing o he conversion from Celsius o Fahrenhei Locking he Configuraion menu I is possible o disable all changes o values/parameers in he Configuraion menu. This prevens he conroller configuraion from being ampered wih by unauhorized persons. The Configuraion menu can be locked or unlocked by pressing he "MENU" key for 2seconds while he power-up message is displayed (afer swiching on he conroller, secion "Power-up message" on page 29). The display hen shows a message confirming ha he lock funcion is acive for 2seconds before reurning o he home posiion. The same message is also displayed for 5seconds when you open he Configuraion menu o indicae ha his menu is locked. You can sill display all seps, values and! parameers even if he Configuraion menu is locked. You are no longer allowed o ener or change values, however. The Configuraion menu remains locked unil he lock funcion is canceled again. To do so, repea he above procedure (press he "MENU" key for 2seconds while he power-up message is displayed). The display hen shows a message confirming ha he lock funcion has been canceled. In he facory seing he Configuraion menu is no locked Undervolage deecion (as of sofware revision 7) Trouble-free operaion of he emperaure conroller is guaraneed wihin he line volage olerance range specified in secion 6 "Technical daa" on page 9. If a line volage which is less han he lower limi of he permissible range occurs, he conroller is swiched o a sandby mode. No more heasealing processes ake place and no more measuring impulses are generaed. The display changes o indicae his. The main menu is displayed again, and operaion is resumed, when he inpu volage reurns o he specified olerance range. The sandby mode is indicaed by C (corresponds o V) a he analog oupu. Trouble-free operaion of he conroller is! only guaraneed wihin he specified inpu volage olerance range. An exernal volage monior mus be conneced o preven defecive heaseals as a resul of low line volage. Page 42

43 Conroller funcions Example The example below illusraes he basic design of a pneumaically operaed L-sealer wih a solenoid valve. The heasealing process is sared by means of a foo swich. U Solenoid valve Cylinder Relay K1 START START conac Sealing bar Heasealing band Film Film r Reainer FOOT SWITCH FOOT SWITCH conac The funcional sequence is as follows: 1. The conroller receives he signal for energizing relay K1 via he foo swich. The solenoid valve is hen energized and he sealing jaws are closed. 2. The swich for he "START" signal is acivaed when he sealing jaws reach heir end posiion. This sars he imeou for inernal ime conrol. Relay K1 mus hen be energized immediaely by he ime conrol (he foo swich can hen be opened again bu he jaws remain closed). 3. The heaing process mus begin immediaely wihou a saring delay. 4. The heasealing ime ( 2 = 1s) mus begin when he ACTUAL emperaure reaches 95% of he SET emperaure (T = 18 C). 5. The heasealing bands are no heaed any furher a he end of he heasealing phase (i.e. a he end of he heasealing ime). The cooling phase begins. 6. The cooling phase mus end when he ACTUAL emperaure of he heasealing bands falls o T 8 C. The sealing jaws are sill closed (relay K1 is also sill closed). 7. Relay K1 opens again a he end of he cooling phase. The sealing jaws are also opened again. 8. End of he heasealing process. Page 43

44 Conroller funcions The iming sequence can be represened as follows: Required conroller seings: FOOT SWITCH signal ON OFF START signal ON The following conroller seings are required for ime conrol (he basic seings such as he emperaure range, alloy ec. should already have been enered). The seings should be underaken in he specified order. Sep in Configuraion menu 21 (Cooling mode) "Absolue" Seing OFF ACTUAL emp. 18 C 95% of 18 C 211 (Sar of heasealing ime) "When emperaure reached" 212 (Relay K1 funcion) "When sar signal presen" 8 C Relay K1 1s Then: Sep in Seings menu Seing Closed 11 (Heasealing emperaure) 18 C Open 13 (Saring delay). s 14 (Heasealing ime) 1. s 15 (Cooling value) Cooling emperaure = 8 C Page 44

45 Conroller funcions 1.2 Sysem monioring / alarm oupu To increase operaing safey and o avoid fauly heasealing, he conroller incorporaes special hardware and sofware feaures ha faciliae selecive faul deecion and diagnosis. Boh he exernal wiring and he inernal sysem are moniored. These feaures crucially suppor he sysem owner in localizing he cause of an abnormal operaing sae. A sysem faul is repored or differeniaed by means of he following elemens. A.) Error message on he display: The cause of a faul can be localized quickly and easily wih he help of he error code ha appears on he display. Please refer o Kap Error messages auf Seie 45 for a lis of he possible error codes. Since a emperaure indicaion is no longer necessary if a faul occurs, he acual value oupu is used o display error codes in he even of an alarm. 13 volage levels are offered for his purpose in he 1VDC range, each of which is assigned an error code ( secion 1.21 "Error messages" on page 45). If a sae ha requires AUTOCAL occurs or if he conroller configuraion is incorrec (error codes 14 16, or 211), he acual value oupu jumps back and forh a 1Hz beween he volage value ha corresponds o his error and he end of he scale (1VDC, i.e. 3 C or 5 C). If he "START" signal is acivaed in one of hese saes, he volage value does no change any more (as of sofware revision 8). Selecive faul deecion and indicaion can hus be implemened simply and inexpensively using he analog inpu of a PLC wih a corresponding error message ( secion 1.21 "Error messages" on page 45). An alarm can only be rese by pressing he! "RESET" key or by swiching he conroller off and hen on again. B.) Error code oupu via he o 1VDC acual value oupu (erminals 1+11): 1.21 Error messages The able below shows how he analog volage values ha appear a he acual value oupu are assigned o he fauls ha have occurred. I also describes each faul and he required correcive acion. The block diagram in secion 1.22 "Faul areas and causes" on page 48 permis each faul o be cleared quickly and efficienly. Page 45

46 Conroller funcions Error code xx Ac. value oupu; Volage [V] Temp. 3 C [ C] Temp. 5 C [ C] Cause Curren signal missing Volage signal missing Volage and curren signals missing Temperaure sep down Temperaure sep up Temperaure oo low Temperaure oo high ( sec. 9.4) Frequency flucuaion, inadmissible line frequency Heaup ime exceeded ( sec ) Force sensor measure range overflow ( sec ) Force sensor measure range underflow ( sec ) Closing force oo low ( sec ) Closing force oo high ( sec ) Force sensor missing ( sec ) Temperaure sensor defecive ( sec ) Sensor emperaure oo high ( sec ) Temperaure sensor missing ( sec ) Hold ime exceeded Inernal faul, conroller defecive Acion if machine sared for firs ime Faul area Faul area Faul area Faul areas (loose conac) Check power supply Run RESET Replace conroller Acion if machine already operaing, HS band no chang. Faul area Faul area Faul areas Faul areas (loose conac) Check power supply Run RESET Replace conroller Page 46

47 Conroller funcions Error code Ac. value oupu; Volage [V] Temp. 3 C [ C] Temp. 5 C [ C] Cause Volage and curren signals incorrec Impulse ransformer incorrecly sized Temperaure oo low Temperaure oo high Calibraion failed, loose conac, ambien emperaure flucuaions Daa error Curren signal incorrec, calibraion no possible Volage signal incorrec, calibraion no possible Curren and volage signals incorrec, calibraion no Temperaure flucuaions, calibraion no possible Acion if machine sared for firs ime Run AUTOCAL, check ransformer specificaion, faul areas Run AUTOCAL and/or faul areas (loose conac) Run AUTOCAL Faul area, check configuraion Faul area, check configuraion Faul areas, check configuraion Acion if machine already operaing, HS band no chang. Faul areas (loose conac) Page 47

48 Conroller funcions 1.22 Faul areas and causes Temperaurregler HARDWARE The able below explains he possible faul causes. Faul area Explanaion Possible causes Load circui inerruped Primary circui inerruped Secondary circui inerruped Volage measuremen signal missing, inernal conroller faul - Wire break, heasealing band break - Conacing o heasealing band defecive - Wire break, riac in conroller defecive - Primary winding of impulse ransformer inerruped - Wire break - Secondary winding of impulse ransformer inerruped - Hardware faul (replace conroller) Parial shor-circui (dela R) - Heasealing band parially bypassed by conducing par (clamp, opposie heasealing bar ec.) Parallel circui inerruped Toal shor-circui Conroller volage measuremen signal ouside permissible range Conroller curren measuremen signal ouside permissible range - Wire break, heasealing band break - Conacing o heasealing band defecive - Heasealing band insalled incorrecly, insulaion a heasealing bar ends missing or incorrecly insalled - Conducing par bypasses heasealing band compleely - Check impulse ransformer specificaion, heed informaion in ROPEX Applicaion Repor - Check impulse ransformer specificaion, heed informaion in ROPEX Applicaion Repor Inernal conroller faul - Hardware faul (replace conroller) Page 48

49 Facory seings 11 Facory seings 11.1 Ropex seings The RESISTRON emperaure conroller is configured in he facory as follows (Ropex seings): Seings menu Sep 11 Heasealing emperaure: C Sep 13 Saring delay: s Sep 14 Heasealing ime: 1s Sep 15 Cooling value: Cooling ime: 1 s Absolue cooling emp.: 5 C Relaive cooling emp.: 4 % of heasealing emperaure Sep 16 Hold mode: OFF Sep 17 AUTOCAL emperaure: 2 C Configuraion menu Sep 21 Language German This selecion is NOT changed if he facory seings are resored wih sep 22 in he Configuraion menu Sep 23 Alloy/TCR: 11ppm, Alloy-2 Sep 24 Variable emp. coeff.: 11ppm Sep 25 Temperaure range: 3 C Sep 26 Maximum emperaure: 3 C Sep 27 Se poin reached: -1K Sep 28 Se poin exceeded: +1K Sep 21 Cooling mode: Absolue Sep 211 Sar of heasealing ime: When emperaure reached Sep 212 Relay K1 funcion: Acive when "START" signal presen Sep 213 Lock "HAND" key and/or he funcion AUTOCAL OFF Sep 214 Cycle couner: Sep 217 Temperaure diagnosis: OFF Sep 218 Temp. diagnosis delay: s Sep 219 Heaup imeou: OFF Sep 221 Auocomp: OFF Sep 225 Temperaure uni: Celsius Sep 24 Single/double sealing: Double Sep 241 Sensor mode: OFF Sep 242 Load cell minimum force: N Sep 243 Load cell maximum force: 15N Sep 244 Load cell are: N Sep 245 Load cell reference force: 68N Sep 246 Max. sensor emperaure: 5 C Sep 247 Force diagnosis: OFF Sep 248 Force diagnosis delay s Sep 249 Foo swich hold ime: s Page 49

50 Mainenance 11.2 Cusomer seings The conroller facory seings can be specified or resored wih sep 22 in he Configuraion menu. You can also sore cusomer seings in addiion o he Ropex seings: When he conroller is firs delivered, he! "cusomer seings" are idenical o he Ropex seings. Afer pressing he "ENTER" key in his menu sep, you are asked o confirm he new seings (safey query). The following seings are possible: 1. "Resore Ropex seings" (Facory seing) Selecing his opion resores he menu values lised in secion 11.1 "Ropex seings" on page 49. These values correspond o he facory seings wih which he conroller was delivered. 2. Define cusomer seings" Selecing his opion saves he values ha are currenly se in he conroller Seings and Configuraion menus as "cusomer seings". These "cusomer seings" are independen of he Ropex seings. Machine-specific seings can be sored in he conroller in his way. 3. "Resore cusomer seings" Selecing his opion resores he "cusomer seings" ha were saved as described in 2. Anoher message appears if you now confirm hese seings by pressing he "ENTER" key for approximaely 2seconds. You can also cancel he new seings by pressing he "MENU", cursor "UP" or cursor "DOWN" keys. Sep 23 hen appears on he display. The language which is seleced wih sep 21! in he Configuraion menu remains se even if he previous seings are resored. 12 Mainenance The conroller requires no special mainenance. Regular inspecion and/or ighening of he erminals including he erminals for he winding connecions on he impulse ransformer is recommended. Dus deposis on he conroller can be removed wih dry compressed air. Page 5

51 How o order 13 How o order Conroller RES -43 /... VAC Sandard conroller wih relay K1 115: Line volage 115VAC, Ar. No : Line volage 23VAC, Ar. No Scope of supply: Moherboard (includes connecor plug-in pars) and T-43 erminal As of Augus 213 wih DIAG inerface as sandard Line filer LF- 648 Coninuous curren 6A, 48VAC, Ar. No Impulse ransformer See ROPEX Applicaion Repor for design and ordering informaion Opional serial RS232 daa inerface (piggyback module) Ar. No Sub-D connecing cable for opional RS232 daa inerface (for connecion o piggyback module) Lengh 2m: Ar. No Lengh 5m: Ar. No Lengh 1m: Ar. No Opional DIAG inerface (piggyback module) Ar. No Sandard as of Augus 213 Communicaion inerface CI-USB-1 (for connecion o DIAG inerface) Ar. No Page 51

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