RESISTRON RES-445. Operating Instructions. Important features

Transcription

1 RESISTRON GB Operaing Insrucions Imporan feaures Microprocessor echnology LC display (green), 4 lines, 2 characers, (mulilingual) Alernaively: VF display (blue), 4 lines, 2 characers, (mulilingual) Auomaic zero calibraion (AUTOCAL) Auomaic opimizaion (AUTOTUNE) Auomaic configuraion of he secondary volage and curren ranges (AUTORANGE, as of sofware revision 1) Auomaic phase angle compensaion (AUTOCOMP, as of sofware revision 1) Auomaic frequency adjusmen Large curren and volage range Booser connecion as sandard Heasealing band alloy and emperaure range selecable Time conrol, heasealing ime and cooling ime seable Preheaing Configurable relay oupu, e.g. "end of cycle" Time or emperaure-conrolled cooling phase Signal oupu for "Temperaure OK" 1VDC analog inpu for se poin selecion, elecrically isolaed 1VDC analog oupu for ACTUAL emperaure, elecrically isolaed 24VDC conrol inpus for AUTOCAL, PREHEAT and RESET, elecrically isolaed Alarm funcion wih faul diagnosis Idenical design o and compaible wih RES-225 Indusrie-Elekronik GmbH Tel: +49/()7142/ info@ropex.de Gansäcker 21 Fax: +49/()7142/ Inerne: D Bieigheim-Bissingen (Germany) Daa subjec o change

2 Conens 1 Safey and warning noes Use Heasealing band Impulse ransformer Curren ransformer PEX-W2/-W Line filer Warrany provisions Sandards / CE marking Applicaion Principle of operaion Descripion of he conroller Accessories and modificaions Accessories Modificaions (MODs) Technical daa Dimensions/fron panel cuou Insallaion Insallaion procedure Insallaion seps Power supply Line filer Curren ransformer PEX-W Wiring diagram (sandard) Wiring diagram wih booser connecion Sarup and operaion Fron view of he conroller Rear view of he conroller Conroller configuraion Heasealing band Sarup procedure Conroller funcions Indicaors and conrols Display Navigaion in he menus Menu srucure Two-digi numbering sysem up o sofware revision Menu seps Temperaure seing (se poin selecion) Temperaure indicaion/acual value oupu Auomaic zero calibraion (AUTOCAL) "START" signal (HEAT) "PREHEAT" signal (preheaing) "RESET" signal Cycle couner Hold mode Measuring impulse duraion (as of sofware revision 26) Auomaic phase angle compensaion (AUTOCOMP) (as of sofware revision 1) Locking he "HAND" key (as of sofware revision 1) Temperaure uni Celsius / Fahrenhei (as of sofware revision 16) Disabling he Configuraion menu Seing he display brighness (VF display only) Undervolage deecion Diagnosic inerface/visualizaion sofware (as of sofware revision 1) Booser connecion Time conrol (imer funcion) Sysem monioring/alarm oupu Error messages Faul areas and causes Facory seings Cusomer seings (as of sofware revision 1) Page 2

3 12 Mainenance How o order Index Page 3

4 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 A basic prerequisie for reliable and safe operaion of he sysem is he use of suiable heasealing bands. The resisance of he heasealing band which! is used mus have a posiive minimum emperaure coefficien in order o guaranee rouble-free operaion of he RESISTRON emperaure conroller. 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.! Incorrec insallaion of he impulse ransformer impairs elecrical safey. 1.4 Curren ransformer PEX-W2/-W3 The curren ransformer supplied wih he RESISTRON emperaure conroller is an inegral par of he conrol sysem.! Only he original ROPEX PEX-W2 or PEX-W3 curren ransformer may be used. Oher ransformers may cause he equipmen o malfuncion. The curren ransformer may only be operaed if i is conneced o he RESISTRON emperaure conroller correcly (see secion 9, "Sarup and operaion"). The relevan safey insrucions conained in secion 8.3, "Power supply", mus be obeyed. Exernal monioring modules can be used in order o addiionally increase Page 4

5 Applicaion operaing safey. They are no included in he scope of supply of he sandard conrol sysem and are described in a separae documen. 1.5 Line filer The use of an original ROPEX line filer is mandaory in order o comply wih he sandards and provisions menioned in secion 1.7 "Sandards / CE marking" on page 5. 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. 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. 1.7 Sandards / CE marking The conroller described here complies wih he following sandards, provisions and direcives: DIN EN (VDE 411-1) DIN EN EN EN Safey provisions for elecrical measuring, conrol and laboraory devices (low volage direcive). Overvolage caegory III, polluion severiy 2, safey class II. Elecrical equipmen of machines (machinery direcive) EMC inerference emissions according o EN 5511, group 1, class B EMC inerference immuniy: ESDs, RF radiaion, burss, surges. 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. 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: Verical and horizonal f/f/s machines Pouch, filling and sealing machines Film wrapping machines Pouch-making machines Group packaging machines L-sealers Page 5

6 Principle of operaion 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 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 primary 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. A high secondary curren can be conrolled wih only minimal power loss because power is conrolled on he primary side of he ransformer. This allows opimum adapaion o he load and o he required dynamic range despie he excepionally compac dimensions of he conroller. 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. Heasealing band R = f (T) RESISTRON conroller U2 sec. Curren ransformer U1 prim. IR UR R=f(T) _ + Acual value Sar Se poin Indicaors and conrols or bus inerface Impulse ransformer LINE Page 6

7 Descripion of he conroller 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: The AUTORANGE funcion (as of sofware revision 1) covers a secondary volage range from.4v o 12V and a curren range from 3A o 5A. 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. Devices wih a VF display are available as an opion. Various display languages can be seleced. In addiion o he digial and bar indicaions on he display, he ACTUAL emperaure of he heasealing band is supplied o an elecrically isolaed, analog 1VDC oupu. The real heasealing band emperaure can hus be displayed 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. To increase operaional safey and inerference immuniy, all 24VDC logic signals are elecrically isolaed from he conroller and he heaing circui. 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 is designed for insallaion in a fron panel cuou. The compac design and he plug-in connecions make his conroller easy o insall. 5 Accessories and modificaions A wide range of compaible accessories and peripheral devices are available for he RESISTRON emperaure conroller. They allow i o be opimally adaped o your specific heasealing applicaion and o your plan's design and operaing philosophy. 5.1 Accessories The producs described below are only a few of he wide range of accessories available for RESISTRON emperaure conrollers ( "Accessories" leafle). Analog emperaure meer ATR-x For fron panel mouning or mouning on a op ha rail (DIN TS35). Analog indicaion of he ACTUAL emperaure of he heasealing band in C. The meer damping of he uni is opimized for he abrup emperaure changes ha occur in impulse mode. Digial emperaure meer DTR-x For fron panel mouning or mouning on a op ha rail (DIN TS35). Digial indicaion of he ACTUAL emperaure of he heasealing band in C, wih HOLD funcion. Page 7

8 Accessories and modificaions Line filer LF-xx48 Essenial in order o ensure CE conformiy. Opimized for he RESISTRON emperaure conroller. Impulse ransformer ITR-x Designed according o VDE 57/EN wih a one-secion bobbin. Opimized for impulse operaion wih RESISTRON emperaure conrollers. Specified according o he heasealing applicaion ( ROPEX Applicaion Repor). Communicaion inerface CI-USB-1 Inerface for connecing a RESISTRON emperaure conroller wih diagnosic inerface (DIAG) o he PC (USB por). Associaed PC visualizaion sofware for displaying seing and configuraion daa, and for recording SET and ACTUAL emperaures in real ime. Booser B-xxx4 Exernal swiching amplifier, necessary for high primary currens (coninuous curren > 5A, pulsed curren > 25A). Monioringcurren ransformer For deecing frame shor-circuis on he heasealing band. Used as an alernaive o he sandard PEX-W2/-W3 curren ransformer. Transparen fron cover TFA-1 For increasing he degree of proecion on he fron of he conroller o IP65. Also faciliaes applicaions in he food echnology secor (GMP). Adaper for op ha rail mouning, HS-Adaper-1 For mouning he RESISTRON emperaure conroller on a op ha rail (DIN TS35). Allows he conroller o be insalled in he elecrical cabine, for insance, where i is only accessible o auhorized persons. Page 8

9 Accessories and modificaions Lockable door TUER-S/K-1 Transparen door (wih lock) for mouning on he bezel of he conroller. The display is clearly legible a all imes. The keyboard can only be operaed, however, by auhorized persons in possession of a key. Measuremen cable UML-1 Twised measuremen cable for he U R volage measuremen. Trailing cable, halogen and silicone-free. 5.2 Modificaions (MODs) Owing o is universal design, he RESISTRON emperaure conroller is suiable for a very wide range of heasealing applicaions. Modificaions (MOD) are available for he RESISTRON emperaure conroller for implemening special applicaions. MOD 1 Amplifier for low secondary volages (U R =.25 16VAC). This modificaion is necessary, for example, for very shor or low-resisance heasealing bands. MOD 33 (Sofware revision 1 or higher) Imporan heasealing process daa can be oupu and logged via a serial RS232 inerface ( MOD 33" documenaion). This modificaion is only recommended for! exising applicaions. The PC visualizaion sofware ( secion 1.22 "Diagnosic inerface/ visualizaion sofware (as of sofware revision 1)" on page 52) should be used for all new applicaions. Page 9

10 Technical daa 6 Technical daa Type of consrucion Housing for fron panel mouning Dimensions (W x H): 144 x 72mm; deph: 161mm (incl. erminals) Line volage All conroller manufacured as of January 26 (as of sofware revision 1): 115VAC version: 11VAC -15% 12VAC +1% (equivalen o VAC) 23VAC version: 22VAC -15% 24VAC +1% (equivalen o VAC) 4VAC version: 38VAC -15% 415VAC +1% (equivalen o VAC) All conrollers manufacured as of January 24 up o December 25 (up o sofware revision 27): 115VAC version: 115VAC -15% 12VAC +1% (equivalen o VAC) 23VAC version: 23VAC -15% 24VAC +1% (equivalen o VAC) 4VAC version: 4VAC -15% 415VAC +1% (equivalen o VAC) All conrollers manufacured up o December 23: 115VAC, 23VAC or 4VAC, olerance: +1% / -15% depending on device version ( Kap. 13 How o order auf Seie 68) Line frequency Heasealing band ype and emperaure range 47 63Hz, auomaic adjusmen o frequencies in his range As of sofware revision 1: The emperaure range and emperaure coefficien can be se independenly of one anoher in he Configuraion menu: Temperaure range: 2 C, 3 C, 4 C or 5 C Temperaure coefficien: 4 4ppm (variable seing range) Up o sofware revision 27: Several differen ranges can be seleced on he conroller in he Configuraion menu: Temperaure coefficien 41ppm, 3 C (SW revision 21 or higher) Temperaure coefficien 46ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 51ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 57ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 63ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 7ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 78ppm (e.g. Alloy L) 2 C, 3 C, 4 C, 5 C (SW revision 11 or higher) Temperaure coefficien 87ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 98ppm, 3 C (SW revision 19 or higher) Temperaure coefficien 11ppm (e.g. Alloy 2): 2 C, 3 C, 4 C, 5 C Temperaure coefficien 35ppm (e.g. NOREX): 2 C, 3 C Se poin selecion/ analog inpu Terminals 2+23 Via he Seings menu in he conroller or he elecrically isolaed analog inpu: Inpu resisance: 4kohms, reverse polariy-proeced 1VDC, equivalen o 3 C or 5 C Page 1

11 Technical daa Analog oupu (acual value) Terminals 2+24 Digial logic levels Terminals 3, 4, 22, 25, 26 START wih conac Terminals 2+7 Swiching oupu for "Oupu 1"/ Temp. OK" signal Terminals 2+21 Alarm relay Terminals 5+6 Relay K1 Terminals 16, 17, 18 Maximum load (primary curren of impulse ransformer) Power dissipaion Display Ambien emperaure 1VDC, Imax = 5mA Equivalen o 3 C or 5 C Elecrically isolaed Accuracy: ±1% add. 5mV LOW (V): 2VDC HIGH (24VDC): 12 3VDC (max. curren inpu 6mA) Elecrically isolaed, reverse polariy-proeced Swiching hreshold: 3.5VDC, U max = 5VDC, I max =5mA U max = 3VDC, I max =5mA U ON < 2V (sauraion volage) Transisor conducive if he emperaure is inside he olerance band. Conac, poenial-free, U max = 5V (DC/AC), I max =.2A Changeover conac, poenial-free, U max = 24VAC/1VDC, I max =1.5A Inerference suppression wih 47nF / 56ohms for each erminal I max = 5A (duy cycle = 1%) I max = 25A (duy cycle = 2%) max. 25W LC display (green), 4 lines, 2 characers, alernaively: VF display (blue), 4 lines, 2 characers C Degree of proecion Fron: IP42 (IP65 wih ransparen fron cover, Ar. No. 887) Back: IP2 Insallaion Weigh Housing maerial Connecing cable Type / cross-secions Insalled in fron panel cuou wih (W x H) 138 (+-.2) x68 (+-.2) mm Fasened wih clips Approx. 1.kg (incl. connecor plug-in pars) Black plasic, ype Noryl SE1 GFN2 Rigid or flexible;.2 2.5mm² (AWG 24 12) Plug-in connecors 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 11

12 Dimensions/fron panel cuou 7 Dimensions/fron panel cuou panel cuou ±.2 ± x 68 ouline dimensions fron frame rubber seal mouning clamp erminal wires erminal blocks fron frame 9 fron panel DIP-swich o selec U, 2 I erminal wires erminal blocks Page 12

13 Insallaion 8 Insallaion See also Kap. 1 Safey and warning noes 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 RESISTRON emperaure conroller in he fron panel cuou. I is fasened by means of wo clips which snap ono he side of he conroller housing. 4. Wire he sysem in accordance wih he insrucions in Kap. 8.3 Power supply auf Seie 15, Kap. 8.6 Wiring diagram (sandard) auf Seie 17 and he ROPEX Applicaion Repor. The informaion provided in Kap. 8.2 Insallaion seps auf Seie 14 mus be heeded addiionally. Check he ighness of all he sysem connecions, including he erminals for he impulse! ransformer windings. 5. Make sure ha he wiring conforms o he relevan naional and inernaional insallaion regulaions. Page 13

14 Insallaion 8.2 Insallaion seps Heaseal elemen wih coppered ends Use heaseal bands wih suiable emperaure coefficien No push-on connecors Heasealing band R= f (T) Sufficien wire cross-secion F U (sec.) 2 Avoid long cables Dimension ransformer correcly - Secondary volage - Power - Duy cycle A No addiional resisance in secondary circui Impulse ransformer Noe number of urns Curren ransformer PEX-W2/-W3 U (prim.) 1 Conroller Configure DIP swiches correcly (up o SW-Rev. 27) Connec U R measuring wires direcly o heasealing band ends Twised Curren measuring wires IR Line Line filer LF-xx48 OPTION: Temperaure meer ATR-x Noe polariy Page 14

15 Insallaion 8.3 Power supply L1 (L1) N (L2) GND/ Earh ON OFF 1 Ka LINE K1 Shor wires U R IR 2 3 I> I> LINE FILTER ROPEX emperaure conroller U1 PRIM. U2 SEC. R Kb Line 115VAC, 23VAC, 4VAC 5/6Hz Circui breaker Double-pole, C characerisic ( ROPEX Applicaion Repor) Shor-circui proecion only.! RESISTRON emperaure conroller no proeced. Relay Ka For "HEAT ON - OFF" funcion (all-pole) or "EMERGENCY STOP". Line filer The filer ype and size mus be deermined according o 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). RESISTRON emperaure conroller belonging o he 4xx Series. Relay Kb Load break (all-pole), e.g. in combinaion wih he alarm oupu of he emperaure conroller. When using a series resisor RV he relay Kb! shall be insalled. Impulse Transformer Designed according o VDE 57/EN (isolaing ransformer wih reinforced insulaion). Connec core o ground. Use ransformers wih a 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). Wiring The wire cross-secions depend on he applicaion ( ROPEX Applicaion Repor). Guide values: Primary circui: min. 1.5mm², max. 2.5mm² Secondary circui: min. 4.mm², max. 25mm² These wires mus always be wised (>2/m) These wires mus be wised (>2/m) if several conrol loops are laid ogeher ("crossalk"). Twising (>2/m) is recommended o improve EMC. Page 15

16 Insallaion 8.4 Line filer To comply wih EMC direcives corresponding o EN and EN RESISTRON conrol loops mus be operaed wih line filers. These filers damp he reacion of he phase-angle conrol on he line and proec he conroller agains line disurbances. The use of a suiable line filer is par of he! sandards conformiy and a prerequisie of he CE mark. ROPEX line filers are specially opimized for use in RESISTRON conrol loops. Providing ha hey are insalled and wired correcly, hey guaranee compliance wih he EMC limi values. You can find he exac specificaion of he line filer in he ROPEX Applicaion Repor calculaed for your paricular heasealing applicaion. For more echnical informaion: "Line filer" documenaion. I is permissible o supply several! RESISTRON conrol loops wih a single line filer, providing he oal curren does no exceed he maximum curren of he filer. The wiring insrucions conained in secion 8.3 "Power supply" on page 15 mus be observed. Large cross-secion wire o ground max. 1m PE LINE ROPEX emperaure conroller Large cross-secion wire o ground Do no lay parallel Large frame conac surface Mouning plae (galvanized) 8.5 Curren ransformer PEX-W3 The PEX-W3 curren ransformer supplied wih he RESISTRON emperaure conroller is an inegral par of he conrol sysem. The curren ransformer may only be operaed if i is conneced o he emperaure conroller correcly ( secion 8.3 "Power supply" on page 15) erminal wires erminal block Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 522) Page 16

17 Insallaion 8.6 Wiring diagram (sandard) 17 (also wih MOD 1) Line filer LF-xx48 LINE RELAY K1 1VDC/1.5A 24VAC/1.5A x 47nF/56R K V ALARM OUTPUT max. 5V/.2A Conac closed or opened by ALARM (see configuraion) Impulse ransformer U1 prim. GND 2 U2 sec. PREHEAT (CH1) wih 24VDC signal START (HEAT) wih 24VDC signal AUTOCAL wih 24VDC signal RESET wih 24VDC signal TEMP. IN - 1VDC GND Ground for 24VDC signals. Mus be grounded exernally o preven elecrosaic charging! U R V 1 (Inern. ground) No exernal grounding 9 allowed! IR 8 up o producion dae December 25 V (Inern. ground) No exernal grounding allowed! 7 wised R Curren ransformer PEX-W2/-W3 V (Inernal ground) Terminal 2 Heasealing band START (HEAT) wih conac TEMP. OUT - 1VDC PREHEAT (CH1) wih conac Page 17

18 Insallaion 8.7 Wiring diagram wih booser connecion RELAY K1 1VDC/1.5A 24VAC/1.5A x 47nF/56R (also wih MOD 1) K1 + V Line filer LF-xx48 LINE Booser 3 1 IN OUT 4 2 ALARM OUTPUT max. 5V/.2A Conac closed or opened by ALARM (see configuraion) NC NC Impulse ransformer U1 prim. GND 2 U2 sec. PREHEAT (CH1) wih 24VDC signal START (HEAT) wih 24VDC signal AUTOCAL wih 24VDC signal RESET wih 24VDC signal TEMP. IN - 1VDC GND Ground for 24VDC signals. Mus be grounded exernally o preven elecrosaic charging! U R V 1 (Inern. ground) No exernal grounding 9 allowed! IR 8 up o producion dae December 25 V (Inern. ground) No exernal grounding allowed! 7 wised R Curren ransformer PEX-W2/-W3 V (Inernal ground) Terminal 2 Heasealing band START (HEAT) wih conac TEMP. OUT - 1VDC PREHEAT (CH1) wih conac Page 18

19 Sarup and operaion 9 Sarup and operaion 9.1 Fron view of he conroller Nameplae Terminals Wiring diagram Diagnosic inerface (on rear of conroller) Operaor keys Clips Display 9.2 Rear view of he conroller As of sofware revision 1: Prined wiring diagram CH1 CONTACT ROPEX GND BOOSTER V TEMP. OK 2 3 CH1 24VDC START 24VDC GND TEMP.IN -1VDC TEMP.OUT -1VDC ALARM AUTOCAL RESET START CONTACT IR UR R U2 SEC. AUTO UR RANGE I2,4-12V 3-5A DIAG E U1 PRIM K1 FILTER N (L1) L1 (L2) (PE) (only wih filer) 5V /,2A Terminals Diagnosic inerface Terminals Page 19

20 Sarup and operaion Up o sofware revision 27: Prined wiring diagram CH1 Conac GND BOOSTER TEMP. OK CH1 24VDC START 24VDC TEMP. IN - 1VDC TEMP. OUT - 1VDC ALARM ROPEX DIP-SWITCH ON U ( V ) 2 V GND IR UR AUTOCAL START Conac RESET R I 2 ( A ) OFF OFF ON OFF 6-2 ON ON 12-4 U2 SEC. DIP-SWITCH OFF U1 PRIM K FILTER N (L1) L1 (L2) (PE) (only wih filer) 5V /,2A ON Terminals DIP swiches Terminals 9.3 Conroller configuraion The possible conroller configuraions are explained in he following secions. Proceed as described in Kap Iniial sarup auf Seie 26 o sar up he conroller for he firs ime Configuraion of he DIP swiches for secondary volage and curren! The conroller mus be swiched off in order o configure he DIP swiches. Auomaic configuraion (AUTORANGE) (as of sofware revision 1) The secondary volage and curren ranges are auomaically configured by he auomaic calibraion funcion (AUTOCAL). The volage is configured in he range from.4vac o 12VAC and he curren in he range from 3A o 5A. If he volage and/or he curren is ouside he permissible range, a deailed error message appears on he conroller ( s. secion 1.27 "Faul areas and causes" on page 64). Configuraion wih coding swiches (up o sofware revision 27) Se he DIP swiches for maching he secondary volage U 2 and he secondary curren I 2 o he correc posiion for your applicaion. You can find he exac configuraion of he! DIP swiches in he ROPEX Applicaion Repor calculaed for your paricular applicaion. Page 2

21 Sarup and operaion OFF Rear view of he conroller ON Facory seings UR DIP-SWITCH OFF ON U DIP swich 2 I DIP swich V ON OFF OFF 3...1A OFF OFF 6...6V OFF ON OFF 6...2A ON OFF V OFF OFF ON A ON ON If he secondary curren I 2 is less han 3A, he PEX-W2/W3 curren ransformer mus have wo urns ( ROPEX Applicaion Repor). 2x Seing he language The menu language can be changed on he conroller wihou inerruping operaion. I is se wih sep 2 in he Configuraion menu: The following seings are possible: English, German, Ialian Sofware revision 15 or higher also: French, Spanish, Duch, Danish, Finnish, Swedish, Greek, Turkish. Sofware revision 24 or higher also: Poruguese. The language which is seleced in his menu! remains se even if he facory seings are resored (sep 22 [21] in he Configuraion menu). As of sofware revision 13, he language! seing wih sep 22 can sill be changed even if he Configuraion menu is disabled ( secion 1.19 "Disabling he Configuraion menu" on page 51) Resoring he facory seings The inernal conroller seings can be rese o he facory seings wih sep 22 [21] in he Configuraion menu. Only he language seing (sep 21 [2] in he Configuraion menu) remains unchanged. Please refer o secion 11 "Facory seings" on page 65 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 and he emperaure range (up o sofware revision 27) These parameers are se wih sep 22 in he Configuraion menu: Several differen ranges can be seleced: 1. Temperaure coefficien 41ppm, 3 C (sofware revision 21 or higher) 2. Temperaure coefficien 46ppm, 3 C (sofware revision 19 or higher) 3. Temperaure coefficien 51ppm, 3 C (sofware revision 19 or higher) 4. Temperaure coefficien 57ppm, 3 C (sofware revision 19 or higher) 5. Temperaure coefficien 63ppm, 3 C (sofware revision 19 or higher) 6. Temperaure coefficien 7ppm, 3 C (sofware revision 19 or higher) 7. Temperaure coefficien 78ppm, 2 C (e.g. Alloy L, sofware revision 11 or higher) 8. Temperaure coefficien 78ppm, 3 C (e.g. Alloy L, sofware revision 11 or higher) 9. Temperaure coefficien 78ppm, 4 C (e.g. Alloy L, sofware revision 11 or higher) 1.Temperaure coefficien 78ppm, 5 C (e.g. Alloy L, sofware revision 11 or higher) Page 21

22 Sarup and operaion 11. Temperaure coefficien 87ppm, 3 C (sofware revision 19 or higher) 12.Temperaure coefficien 98ppm, 3 C (sofware revision 19 or higher) 13.Temperaure coefficien 11ppm, 2 C (e.g. Alloy-2) 14.Temperaure coefficien 11ppm, 3 C (Facory seings) (e.g. Alloy-2) 15.Temperaure coefficien 11ppm, 4 C (e.g. Alloy-2) 16.Temperaure coefficien 11ppm, 5 C (e.g. Alloy-2) 17.Temperaure coefficien 35ppm, 2 C (e.g. NOREX) 18.Temperaure coefficien 35ppm, 3 C (e.g. NOREX) Configuraion of he alloy (Temperaure coefficien) (as of sofware revision 1) The heasealing band alloy (and he emperaure coefficien respecively) can be se wih seps 23 and 24 in he Configuraion menu. In sep 23 predefined values for he alloy (and he emperaure coefficien repsecively) are available: 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. Temperaure coefficien variable Furher seings in sep 24. In sep 24 he emperaure coefficen can be se in a range of 4 4 ppm individually for he used heasealing band hen.! Sep 24 in he Configuraion menu is available when sep 23 is se o "variable" only Configuraion of he emperaure range (as of sofware revision 1) The emperaure range can be se wih seps 25 in he Configuraion menu. The seing can be 2 C, 3 C (Facory seing), 4 C or 5 C Configuraion of he imer funcion The necessary conroller seings are! explained in he deailed funcional descripions in Kap. 1.6 Menu seps auf Seie 34 and Kap Time conrol (imer funcion) auf Seie 53. They are only allowed o be enered by echnically rained persons. The imer funcion is acivaed wih sep 26 in he Configuraion menu Relay K1 (wihou ime conrol) The funcion of relay K1 is specified wih sep 212 [29] in he Configuraion menu. The following seings are possible when ime conrol is deacivaed: 1. "Off" (Facory seing) Relay K1 has no funcion 2. "Acive if Tac = Tse" Relay K1 is acivaed if he acual value is inside he specified emperaure olerance band (seps 27 [24], 28 [25]). If he acual emperaure is ouside he olerance band, relay K1 is deacivaed (see graph below). Se+ upper Oupu Relay K1 Se Se+ lower closed open Acual value Time Time Page 22

23 Sarup and operaion 3. "Acive if Tac = Tse", wih lach funcion (as of sofware revision 1) Relay K1 is closed if he acual value is inside he specified emperaure olerance band (seps 27, 28). If he acual emperaure leaves he olerance band once while he "START" signal is acive, relay K1 is opened. The relay is no closed again unil he nex "START" signal is acivaed. The swiching sae of relay K1 can hus also be inerrogaed by he higher-level PLC afer a heasealing process (lach funcion, see graph below). The "Oupu 1" signal is available a erminals 2+21 as a digial conrol signal. GND VDC I max 5mA Se+ upper Acual value GND Se Se+ lower NO conac of Relay K1 Closed Open Oher seings are available in his menu when ime conrol (imer funcion) is acive. They are described in secion "Relay K1 (wih ime conrol)" on page Oupu 1 / Temperaure OK signal (wihou ime conrol) Time Time On conrollers up o sofware revision 27,! he swiching oupu a erminals 2+21 was called "Temperaure OK". The more general name "Oupu 1" is used as of sofware revision 1 because his oupu now also suppors oher funcions. Up o sofware revision 27: The checks wheher he ACTUAL emperaure is inside a specifiable olerance band ("OK" window) on eiher side of he SET emperaure. The lower ( lower ) and upper ( upper ) limis of he olerance band can be changed independenly of one anoher by means of seps in he Configuraion menu. If he acual emperaure is inside he specified olerance band, he oupu signal a erminals 2+21 is swiched (see graph below): Se+ upper Soll Se+ lower "Oupu 1" Terminals 2+21 Conducive No conduc. Acual value Time Time The ACTUAL emperaure is evaluaed, and! he oupu signal a erminals 2+21 acivaed, in all operaing saes excep when a faul is signaled. Page 23

24 Sarup and operaion As of sofware revision 1: If ime conrol (imer funcion) is deacivaed, he same configuraion opions are available for "Oupu 1" as for relay K1 ( secion "Relay K1 (wihou ime conrol)" on page 22). The opions for "Oupu 1" are specified wih sep 222 in he Configuraion menu as followed: 1. "Off" "Oupu 1" has no funcion 2. "Acive if Tac = Tse" Oupu 1 is conducive if he acual value is inside he specified emperaure olerance band (seps 27, 28). If he acual emperaure is ouside he olerance band, "Oupu 1" is no conducive. This funcion is he same as for he "Temperaure OK" signal up o sofware revision "Acive if Tac = Tse", wih lach funcion (facory seing) "Oupu 1" is conducive if he acual value is inside he specified emperaure olerance band (seps 27, 28). If he acual emperaure leaves he olerance band once while he "START" signal is acive, "Oupu 1 is no longer conducive. "Oupu 1" does no become conducive again unil he nex "START" signal is acivaed and can hus also be inerrogaed by he higher-level PLC afer a heasealing process. Oher seings are available in his menu when ime conrol (imer funcion) is acive. They are described in secion " Oupu 1 / Temperaure OK signal (wih ime conrol)" on page Temperaure diagnosis (as of sofware revision 1) The emperaure diagnosis funcion can be acivaed by means of sep 217 in he Configuraion menu. The hen checks wheher he ACTUAL emperaure is inside a specifiable olerance band ("OK" window) on eiher side of he SET emperaure. The lower ( lower ) and upper ( upper ) limis of he olerance band can be changed independenly of one anoher by means of seps 27 [24] + 28 [25] (facory seing: -1K or +1K). If he ACTUAL emperaure is inside he specified olerance band when he "START" signal is acivaed, he emperaure diagnosis is also acivaed. If he ACTUAL emperaure leaves he olerance band, he corresponding error code (37, 38) is indicaed and he faul oupu is swiched ( secion 1.27 "Faul areas and causes" on page 64). If a heasealing cycle is in progress, i is immediaely inerruped. Se+ upper Se Se+ lower Acual value If he emperaure diagnosis is no acivaed by he ime he "START" signal is deacivaed (i.e. if he ACTUAL emperaure does no exceed he upper or lower olerance band limi), he corresponding error code (39, 31) is indicaed and he faul relay is swiched. If he emperaure diagnosis funcion is acivaed, an addiional delay ime of o 9.9s can be parameerized for he emperaure imeou wih sep 218 in he Configuraion menu. The firs ime he lower olerance band limi is exceeded, he emperaure diagnosis is no acivaed unil he parameerized delay ime has elapsed. The emperaure diagnosis funcion can hus be explicily deacivaed, e.g. if he emperaure drops emporarily owing o he closure of he sealing jaws Heaup imeou (as of sofware revision 1) Time Error code 37 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 (34) is indicaed and he faul relay is swiched ( secion 1.27 "Faul areas and causes" on page 64). Page 24

25 Sarup and operaion Se 95% of Se Heaup ime Configuraion of he alarm relay The alarm relay is se wih sep 215 [31] in he Configuraion menu. There are wo possible seings: 1. "Normal" (Facory seing) Alarm relay conac closed by a faul 2. "Inverse" Alarm relay conac opened by a faul 9.4 Heasealing band General Acual value Timeou Error code 34 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 ( chap Burning in he heasealing band, page 25). 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 conroller oupus he preseleced calibraion emperaure (defaul value: 2 C). Adjus he se poin o approximaely 25 C and press he "HAND" key (display in home posiion) o 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 alloy properies sabilized. The burn-in effec described here does no occur if he heasealing band has already been hermally prereaed by he manufacurer 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. Page 25

26 Sarup and operaion 9.5 Sarup procedure following seings are always required: Please also refer o Kap. 1 Safey and warning noes auf Seie 4 and Kap. 2 Applicaion auf Seie 5. Seing Sep in Configuraion menu 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 ( Kap. 8 Insallaion auf Seie 13). The possible seings are described in deail in chap. 9.3 Conroller configuraion, page 2 and chap. 1 Conroller funcions, page 27. 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. In case of conrollers up o sofware revision 27, he seing of he DIP swiches on he conroller are indicaed in he ROPEX Applicaion repor and depend on he heasealing band (secion 9.3 "Conroller configuraion" on page 2). 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 Main menu Go o 8 Error message wih error codes 14 16, , 211 Error message wih error codes 11 13, 17, 18, 21 23, 81, 9xx ACTION Go o 8 Faul diagnosis ( 1.27) 8. Se he conroller configuraion as described in Kap. 9.3 Conroller configuraion auf Seie 2. The Language 21 [2] Resore facory seings 22 [21] Temperaure range and heasealing band alloy 23, 24, 25 [22] 9. Acivae he AUTOCAL funcion while he heasealing band is sill cold (wih sep 7 in he Seings menu or by means of he "AUTOCAL" signal, erminals 2+25). The progress of he calibraion process is indicaed by a couner on he display (approx. 1 15s). A volage of app. VDC appears a he same ime a he acual value oupu (erminals 2+24). If an ATR-x is conneced, i indicaes 3 C. When he zero poin has been calibraed, he display is rese o he home posiion and 2 C is indicaed as he acual value. A volage of.66vdc (for he 3 C range) or.4vdc (for he 5 C range, equivalen o 2 C, appears a he acual value oupu. If an ATR-x is conneced, i mus be se o "Z" (2 C). If he zero has no been calibraed successfully, an erro message indicaes error codes 14 16, 211. In his case he conroller configuraion is incorrec ( Kap. 9.3 Conroller configuraion auf Seie 2 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 1 in he Seings menu (or apply a 1VDC volage o he analog inpu, erminals 2+23) and acivae he "START" signal (HEAT). Alernaively, a heasealing process can be sared by pressing he "HAND" key (display in 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. This kind of behavior would indicae ha he U R measuring wire has been laid incorrecly. If an error code is displayed, please proceed as Page 26

27 Conroller funcions described in secion 1.27 "Faul areas and causes" on page 64. If he heasealing emperaure is seleced via! he analog inpu a erminals 2+23, he specified volage value mus be checked wih a volmeer before he heasealing process begins, in order o preven incorrec seings or excessively high heasealing emperaures. 11.Burn in he heasealing band ( Kap. 9.4 Heasealing band auf Seie 25) 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 Kap. 9.4 Heasealing band auf Seie 25. Always use a heasealing band wih he correc alloy, dimensions and copper-plaing in! order o avoid malfuncions and overheaing. Coninue wih secion 9.5.1, seps 9 and 1. 1 Conroller funcions See also Kap. 8.6 Wiring diagram (sandard) auf Seie Indicaors and conrols RESISTRON RES-4 ENTER HAND RESET "MENU" key for advancing o nex menu sep or swiching menu < 1 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 opional: VF display, 4 lines, mulilingual Page 27

28 Conroller funcions 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 () 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. If ime conrol (imer funcion) is acive, he ime conrol seings are also displayed. 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 (only if ime conrol is acive) Cooling parameers (only if ime conrol is acive) Seings/Configuraion menus The required parameers are se on wo menu levels: he Seings (conrol) menu and he Configuraion menu ( Kap. 1.4 Menu srucure auf Seie 31). Menu level: Seings or Configuraion menu (Configuraion menu shown here) Posiion in menu (menu sep) Menu conens (max. 3 lines) Page 28

29 Conroller funcions Error messages 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 ( Kap Sysem monioring/alarm oupu auf Seie 59). Faul descripion and error code Promp o press "RESET" key 1.3 Navigaion in he menus Navigaion in menus wihou a faul 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 reurn o he home posiion from anywhere in he menu Seings 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 [2]). 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 <1s >2s >2s or auomaically afer 3s <1s 11 Heasealing emp. 22 Facory seings >2s or auomaically afer 3s >2s or auomaically afer 3s Page 29

30 Conroller funcions Navigaion in menus wih a faul If an alarm is signaled, he conroller swiches o he Alarm menu. Some fauls can be acknowledged by pressing he "RESET" key ( Kap Sysem monioring/alarm oupu auf Seie 59). 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 1.9 "Auomaic zero calibraion (AUTOCAL)" on page 45). 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 [2]). 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. Faul ENTER HAND RESET Home posiion Alarm >2s >2s or auomaically afer 3s 21 Language <1s <1s 17 Auocal? ENTER HAND RESET Auocal End of Auocal >2s or auomaically afer 3s 22 Facory seings Page 3

31 Conroller funcions 1.4 Menu srucure Seings Configuraion Power-up message Home posiion 11 Heasealing emp. 12 Preheaing emp. 1) 2) 13 Saring delay 21 Language 22 Facory seings 23 Alloy 5) 6) 24 Temp. coefficien 1) Time conrol: ON 2) Time conrol: OFF 3) AUTOCOMP: OFF 4) AUTOCOMP: ON 5) TCR variable 6) TCR no variable 14 Sealing ime 25 Temperaure range 15 Cooling value 26 Max. emperaure 16 Hold mode 27 Se poin reached 17 Auocal? 28 Se poin exceeded Auocal 3) 4) 29 Time conrol 1) 2) 21 Cooling mode 18 Auocomp? 211 Sar of sealing ime Auocomp 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 31

32 Conroller funcions Configuraion Coninued from previous page 219 Heaup imeou 22 Meas. imp. lengh 221 Auocomp 222 "Oupu 1" 225 Temperaure uni Back o home posiion Page 32

33 Conroller funcions 1.5 Two-digi numbering sysem up o sofware revision 27 A sysem of one and wo-digi numbers was used for he Seings and Configuraion menus up o sofware revision 27. Three-digi numbers were inroduced in sofware revision 1 o improve he clariy of he menu srucure. The able below compares he wo numbering sysems: Menu Menu seps Numbering up o sofware revision 27 Numbering as of sofware revision 1 Seings menu Heasealing emperaure 1 11 Preheaing emp. (PREHEAT) 2 12 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 22 23, 24 Maximim emperaure Se poin reached Se poin exceeded Time conrol Cooling mode Sar of heasealing ime Relay K1 funcion Cycles Alarm relay Measuring pulse lengh Analog oupu All number sor menu seps no lised above are only available as of sofware revision 1 and are described in chap. 9 Sarup and operaion, page 19 (and secion 1.4 "Menu srucure" on page 31 respecively).!! The new, hree-digi menu sep numbers are described firs in all relevan secions of his documen. The older, wo-digi numbers are indicaed aferwards in square brackes (e.g. sep 21 [2]). Page 33

34 Conroller funcions 1.6 Menu seps No. Name Descripion Seing range Home posiion The specified se value and he curren acual value are displayed in digial form. The acual value is also represened as a dynamic bar. If ime conrol (sep 29 [26]) is acive, he heasealing ime and he cooling value are also displayed. The heasealing band can be heaed manually (o he specified heasealing emperaure) by pressing he "HAND" key. 11 [1] Heasealing emperaure The required heasealing emperaure (se poin) can be se wih he "UP" and "DOWN" keys. The maximum selecable se poin can be limied wih sep 23 [22] (alloy/range) and sep 24 [23] (max. emperaure). If he heasealing emperaure is o be deermined by a volage a he analog inpu a erminals 2+23, i mus be se o C wih his menu sep. The se poin is indicaed in he home posiion. Depends on seing of sep 25 [22]:, 4 C maximum emperaure (sep 26 [23]) If an exernal heasealing emperaure! (analog inpu, erminals 2+23) and an inernal heasealing emperaure (sep 11 [1]) are specified simulaneously, he higher of he wo emperaures is used and indicaed in he main menu. 12 [2] Preheaing emperaure The required preheaing emperaure can be se wih he "UP" and "DOWN" keys. The maximum emperaure (sep 26 [23]) applies o boh he heasealing emperaure and he preheaing emperaure. The preheaing funcion can be deacivaed by enering C. Depends on seing of sep 25 [22]:, 4 C maximum emperaure (sep 26 [23]) 13 [3] Saring delay This opion allows he heasealing ime o be preceded by a saring delay. This delay ime begins as soon as he sar signal is applied. When i elapses, he heasealing ime is acivaed. This funcion can only be seleced if ime conrol (sep 29 [26]) is acive. 9.9s 14 [4] Heasealing ime The lengh of he heasealing pulse can be se wih he "UP" and "DOWN" keys. The specified heasealing ime is indicaed in he home posiion. This funcion can only be seleced if ime conrol (sep 29 [26]) is acive. 99.9s, EXT Page 34

35 Conroller funcions No. Name Descripion Seing range 15 [5] Cooling value The cooling value can be specified here according o he cooling mode (absolue, relaive, ime) seleced wih sep 21 [27]. Absolue: The cycle ends if he "cooling emperaure" falls below he se value (in C). 5 C o maximum emperaure (sep 26 [23]) Relaive: The cycle ends if he "cooling emperaure" falls below he se percenage value, whereby 1% corresponds o he specified se poin (sep 11 [1]). 4% 1% Time: The cycle ends when he se "cooling ime" in seconds has elapsed. The curren cooling value is indicaed in he home posiion. This funcion can only be seleced if ime conrol (sep 29 [26]) is acive. 99.9s 16 [6] Hold mode If he "Hold" funcion is acivaed, he las measured value a he end of he heaing phase is sored and displayed. The "ACT" (acual value) informaion in he home posiion is replaced by "Hold". This procedure is repeaed for every cycle and he displayed value is updaed. The word "Hold" is invisible for 1ms before he value is updaed. If you selec he "2 second hold" funcion, he display changes back from hold mode o he acual value in real ime afer 2 seconds. The hold funcion is hen acivaed again for 2 seconds a he end of he nex cycle. ON OFF 2s 17 [7] Auocal The AUTOCAL funcion maches he conroller o he curren and volage signals ha are presen in he sysem. The required calibraion emperaure can be se wih he "UP" and "DOWN" keys. Pressing he "ENTER" key sores he se value and sars he "AUTOCAL" funcion. The word "- Calibraion -" appears on he display while he AUTOCAL funcion is execuing and a couner couns down from 15 o. When he conroller has been calibraed successfully, he display swiches back direcly o he home posiion providing he "AUTOCOMP" funcion is deacivaed. If "AUTOCOMP" is acive, he display jumps o sep 18. If he conroller canno be calibraed, he AUTOCAL funcion is abored and an error message is displayed insead. 4 C Page 35

36 Conroller funcions No. Name Descripion Seing range 18 Auocomp Pressing he "ENTER" key sars he "AUTOCOMP" funcion. If he "ENTER" key is no pressed wihin 2s, he display reurns o he home posiion. The home posiion is auomaically displayed if he "AUTOCAL" funcion is successfully execued and "AUTOCOMP" is acive. 21 [2] Language The desired display language can be seleced wih his menu sep. English German Ialian Sofware revision 15 or higher also: French, Spanish, Duch, Danish, Finnish, Swedish, Greek, Turkish. Sofware revision 24 or higher also: Poruguese. 22 [21] Facory seings The conroller can be rese o he facory seings by pressing he "ENTER" key ( secion 11 "Facory seings" on page 65). In addiion, as of sofware revision 1: The "UP" and "DOWN" keys can be used o selec wheher The conroller should be rese o he ROPEX facory seings The curren configuraion should be specified as he defaul seing The conroller should be rese o a previously specified defaul seing Page 36

37 Conroller funcions No. Name Descripion Seing range 22 Alloy/range This sep in he Configuraion menu is! available up o sofware revision 27 only. Various heasealing band alloys and emperaure ranges can be seleced here. The corresponding characerisic for he conroller parameers is calculaed on he basis of his seing.! alloy. Please be very careful o selec he heasealing band maerial wih he correc The emperaure range seing permis he conroller o be mached o he required operaing range. This also deermines he scale for he bar display and he analog oupu. 23 Alloy Various heasealing band alloys can be seleced here. The corresponding characerisic for he conroller parameers is calculaed on he basis of his seing.! alloy. Please be very careful o selec he heasealing band maerial wih he correc (Availabiliy depends on sofware revision) TCR 41ppm, 3 C TCR 46ppm, 3 C TCR 51ppm, 3 C TCR 57ppm, 3 C TCR 63ppm, 3 C TCR 7ppm, 3 C TCR 78ppm, 2 C TCR 78ppm, 3 C TCR 78ppm, 4 C TCR 78ppm, 5 C TCR 87ppm, 3 C TCR 98ppm, 3 C TCR 11ppm, 2 C TCR 11ppm, 3 C TCR 11ppm, 4 C TCR 11ppm, 5 C TCR 35ppm, 2 C TCR 35ppm, 3 C (Availabiliy depends on sofware revision) TCR 78ppm TCR 11ppm TCR 35ppm variable 24 Temperaure coefficien If you seleced "Variable" wih sep 23, you can specify he emperaure coefficien of he heasealing band maerial here in 1ppm incremens using he "UP" and "DOWN" keys. 4 4ppm 25 Temperaure range Various emperaure ranges can be seleced here. The emperaure range seing permis he conroller o be mached o he required operaing range. This also deermines he scale for he bar displayand he analog oupu. 2 C 3 C 4 C 5 C 26 [23] Maximum emperaure This menu iem specifies he maximum selecable se poin (sep 11 [1]) and he maximum selecable preheaing emperaure (sep 12 [2]) wihin he range defined by sep 25 [22]. o max. emperaure range (sep 25 [22]) Page 37

38 Conroller funcions No. Name Descripion Seing range 27 [24] Se poin reached (low limi) As of sofware revision 1: If he acual value is greaer han he swiching hreshold specified here and less han he hreshold se wih sep 28, "Oupu 1" and/or relay K1 can be acivaed depending on he configuraion (sep 212 or 222). -5K -99K Up o sofware revision 27: If he acual value is greaer han he swiching hreshold specified here and less han he hreshold se wih sep 25, he "Temperaure OK" oupu is acivaed. The value is enered in Kelvins (K) and subraced from he se poin in order o calculae he swiching hreshold. 28 [25] Se poin exceeded (upper limi) As of sofware revision 1: If he acual value is less han he swiching hreshold specified here and greaer han he hreshold se wih sep 27, "Oupu 1" and/or relay K1 can be acivaed depending on he configuraion (sep 212 or 222). +5K +99K Up o sofware revision 27: If he acual value is less han he swiching hreshold specified here and greaer han he hreshold se wih sep 24, he "Temperaure OK" oupu is acivaed. The value is enered in Kelvins (K) and added o he se poin in order o calculae he swiching hreshold. 29 [26] Time conrol This menu sep specifies wheher he conroller should operae wih or wihou ime conrol. ON, ON wih START monioring, OFF Page 38

39 Conroller funcions No. Name Descripion Seing range 21 [27] Cooling mode The end of he cooling-down phase (end of cycle) can be configured by specifying he required cooling mode. Absolue: The cycle ends if he acual value falls below he cooling emperaure se here. Absolue (in C) Relaive: The cycle ends if he acual value falls below he relaive cooling emperaure (percenage of he se poin) se here. Relaive (in %) Time: The cycle ends when he se cooling ime has elapsed. Time (in s) This funcion can only be seleced if ime conrol (sep 29 [26]) is acive. 211 [28] Sar of heasealing ime This menu sep specifies wheher he heasealing ime (sep 14 [4]) should begin as soon as he sar signal is applied or when 95% of he se poin is reached. This funcion can only be seleced if ime conrol (sep 29 [26]) is acive. Heasealing ime sars when heaing sars Heasealing ime sars when emperaure reached 212 [29] Relay K1 funcion The energizing behavior of relay K1 can be configured as follows: Time conrol OFF: K1 is no acivaed Relay K1 OFF Relay K1 is energized if he acual value is inside he specified emperaure olerance band (seps 27 [24], 28 [25]). Relay K1 acive if Tac = Tse Page 39

40 Conroller funcions No. Name Descripion Seing range In addiion, as of sofware revision 1: K1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). The relay remains energized a he end of he heasealing cycle and is no deenergized again unil he nex "START" signal is acivaed. Relay K1 acive if Tac = Tse, wih lach funcion Time conrol ON: K1 is no acivaed Relay K1 OFF K1 is energized if he sar signal is presen. The relay is deenergized a he end of he cooling phase. K1 is energized if he acual value reaches 95% of he se poin. The relay is deenergized a he end of he cooling phase. K1 is energized a he end of he heaing phase and deenergized again a he end of he cooling phase. (This seing is possible as of sofware revision 1) K1 is energized for up o.5 seconds a he end of he cooling phase (momenary impulse). The lengh of he momenary impulse can be shorened by applying he sar signal (during he impulse). In addiion, as of sofware revision 1: K1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). In addiion, as of sofware revision 1: K1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). The relay remains energized a he end of he heasealing cycle and is no deenergized again unil he nex "START" signal is acivaed. 213 Lock of "HAND" key You can specify here wheher or no he heasealing band can be heaed in he home posiion by pressing he "HAND" key. Relay K1 acive when START signal presen Relay K1 acive when emperaure reached Relay K1 acive during cooling phase Relay K1 generaes endof-cycle impulse Relay K1 acive if Tac = Tse Relay K1 acive if Tac = Tse, wih lach funcion ON, OFF 214 [3] Cycle couner The number of heaing impulses (no manual impulses) is couned and displayed wih his menu sep. The couner can be rese eiher by pressing he "ENTER" key or by resoring he facory seings. Rese wih "ENTER" key Page 4

41 Conroller funcions No. Name Descripion Seing range 215 [31] Alarm relay This menu sep permis he swiching characerisics of he alarm relay o be configured. Normal: The alarm relay oupu (erminals 5+6) operaes as an NO conac in he even of a faul. Normal Inverse: The alarm relay oupu (erminals 5+6) operaes as an NC conac in he even of a faul. Inverse 216 [33] Analog oupu This menu sep deermines wheher he curren acual value or a 1V reference volage is oupu a he acual value oupu (erminal 24). (This seing is possible as of sofware revision 17). The 1V reference can be used for he connecion of an exernal poeniomeer as emperaure prese. Real emperaure, 1V reference 217 Temperaure diagnosis 218 Temperaure diagnosis delay ime If his value is se o "ON" and he acual emperaure leaves he olerance band (seps 27, 28), a faul signal indicaing error code 37/38 is oupu. This delay ime sars when he acual emperaure eners he olerance band. The emperaure imeou and faul oupu are no acivaed unil afer he delay ime has elapsed. This sep can only be seleced if he emperaure diagnosis funcion (sep 217) is acive. OFF ON 99.9s 219 Heaup imeou If he acual emperaure is ouside he olerance band when he specified ime elapses (afer he "START" signal has been acivaed), a faul signal indicaing error code 34 is oupu. OFF, 99.9s 22 [32] Measuring impulse lengh The lengh of he measuring impulse can be changed here. This funcion is only available wih a few special applicaions (MOD 1) ms 221 Auocomp Acivaes he AUTOCOMP funcion OFF, ON 222 "Oupu 1" The energizing behavior of oupu 1 can be configured as follows: Time conrol OFF: Oupu 1 is no acivaed "Oupu 1" OFF Oupu 1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). "Oupu 1" acive if Tac = Tse Page 41

42 Conroller funcions No. Name Descripion Seing range Oupu 1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). The relay remains energized a he end of he heasealing cycle and is no deenergized again unil he nex "START" signal is acivaed. "Oupu 1" acive if Tac = Tse, wih lach funcion Time conrol ON: Oupu 1 is no acivaed "Oupu 1" OFF Oupu 1 is energized if he sar signal is presen. The relay is deenergized a he end of he cooling phase. Oupu 1 is energized when he acual value reaches 95% of he se poin. The relay is deenergized a he end of he cooling phase. Oupu 1 is energized a he end of he heaing phase and deenergized again a he end of he cooling phase. (This seing is possible as of sofware revision 1) Oupu 1 is energized for up o.5 seconds a he end of he cooling phase (momenary impulse). The lengh of he momenary impulse can be shorened by applying he "START" signal (during he impulse). Oupu 1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). Oupu 1 is energized if he acual value is inside he specified emperaure olerance band (seps 27, 28). The relay remains energized a he end of he heasealing cycle and is no deenergized again unil he nex "START" signal is acivaed. "Oupu 1" acive wih START signal "Oupu 1" acive when emperaure reached "Oupu 1" acive during cooling phase "Oupu 1" generaes endof-cycle impulse "Oupu 1" acive if Tac = Tse "Oupu 1" acive if Tac = Tse, wih lach funcion 225 Temperaure uni Uni for emperaure display and inpu values Celsius Fahrenhei Page 42

43 Conroller funcions 1.7 Temperaure seing (se poin selecion) The heasealing emperaure can be se on he conroller in hree ways: By means of he seing in menu sep 11 [1]. By applying a 1VDC volage o he analog inpu a erminals VDC GND The relaionship beween he applied volage and he SET emperaure is linear. Volage values: VDC C 1VDC 3 C or 5 C (depending on he conroller configuraion). Please refer o Kap. 1.8 Temperaure indicaion/ acual value oupu auf Seie 44 for a circui diagram. If he heasealing emperaure is o be deermined by a volage a he analog inpu a erminals 2+23, i mus be se o C wih menu sep 11 [1]. If an exernal heasealing emperaure! (analog inpu, erminals 2+23) and an inernal heasealing emperaure (sep 11 [1]) are specified simulaneously, he higher of he wo emperaures is used and indicaed in he home posiion. The maximum value of he seing range is! limied eiher by he maximum value specified wih sep 26 [23] in he Configuraion menu or by he heasealing band ype/emperaure range se wih sep 25 [22]. + 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 is pressed. The se heasealing emperaure is displayed in he main menu once i has been enered. If he heasealing emperaure is specified via! he analog inpu a erminals 2+23, he exernal volage mus be acivaed a leas 1ms before he heasealing process sars. If no, he heasealing emperaure will no reach he required value. By connecing a 2kohm poeniomeer (e.g. PD-3 or PD-5) o erminals 2, 23 and 24: (This seing is possible as of sofware revision 17) + Analog inpu 1VDC Poeniomeer wih digial dial PD-x U Ref = 1VDC GND CW PD-x (2k) The conroller is configured for his purpose so ha a fixed 1VDC reference volage is available a he analog oupu a erminal 24 ( menu sep 216 [33], secion 1.8 "Temperaure indicaion/acual value oupu" on page 44). This volage is divided by he PD-x se poin poeniomeer and supplied o he analog inpu a erminal 23. You can hen specify he se emperaure in C in he digial window of he poeniomeer. Once again, he se emperaure mus be se o zero in sep 11 [1]. Page 43

44 Temperaure T Conroller funcions 1.8 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. The heaing and conrol process can hus be moniored a any ime. In addiion, he conroller oupus an elecrically isolaed, analog 1VDC signal, which is proporional o he real ACTUAL emperaure, a erminals Ac. value oupu 1VDC + 33ohms max. 5mA 24 Temperaure meer e.g. ATR-3 2 GND - + 1VDC The relaionship beween he change in he oupu volage and he ACTUAL emperaure is linear Temperaure T C C C C range V Volage U VDC "ZERO" - 5 C range Volage values: VDC C 1VDC 3 C or 5 C (depending on he conroller configuraion) V Volage U VDC "ZERO" Only he wo emperaure ranges 3 C and 5 C appear a his acual value oupu. If a emperaure range of 2 C is se for he conroller wih sep 25 [22] 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. The characerisics of he ROPEX ATR-x emperaure meer (size, scaling, dynamic response) are ideally suied o his applicaion ( secion 5 "Accessories and modificaions" on page 7). 2 C Page 44

45 Conroller funcions I no only faciliaes SET-ACTUAL comparisons, bu also enables oher crieria such as he heaing rae, se poin reached wihin he specified ime, cooling of he heasealing band ec. o be evaluaed. This meer moreover permis disurbances in he conrol loop (loose connecions, conacing or wiring problems) as well as any line disurbances o be observed exremely effecively and inerpreed accordingly. The same applies if muual inerference occurs beween several neighboring conrol loops. If a faul is signaled, his analog oupu is used in addiion o he value indicaed on he conroller o display a selecive error message ( secion 1.27 "Faul areas and causes" on page 64). If you wan a fixed 1V reference volage o appear a he analog oupu (erminal 24), you can configure his in he Configuraion menu, sep 216 [33] (analog oupu): Acual emperaure (Facory seing) The acual value oupu indicaes he curren ACTUAL value as a 1VDC analog volage. 1V reference (This seing is possible as of sofware revision 17) A fixed 1VDC reference volage is oupu a he acual value oupu. 1.9 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. This funcion can be acivaed in wo ways: By means of a 24VDC signal a erminals VDC + - AUTOCAL max. 6mA 25 GND HIGH: 12VDC LOW: 2VDC 2 AUTOCAL.1 5s By selecing sep 17 [7] in he Seings menu and 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 13 o. The acual value oupu (erminals 2+24) is se o 3 C (corresponds o app. VDC) for he duraion of he calibraion process. If he emperaure of he heasealing band varies on conrollers as of sofware revision 1, he "AUTOCAL" funcion is execued a maximum of hree imes. If he funcion sill canno be erminaed successfully, an error message appears ( secion 1.27 "Faul areas and causes" on page 64). Page 45

46 Conroller funcions You should always wai for he heasealing! band and he bar o cool down (o ambien emperaure) before acivaing he "AUTOCAL" funcion. Reasons for disabled 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 [7] in he Seings menu by he message "Heasealing band sill ho! Please wai...". As of sofware revision 12, his message is also displayed if he conroller canno be calibraed when he exernal "AUTOCAL" signal is acivaed (cooling rae oo fas). 2. If he "START" signal (24VDC or conac) or he "PREHEAT" signal (24VDC or conac) is acivaed, he AUTOCAL funcion is no execued. As of sofware revision 24 his is addiionally indicaed wih sep 17 [7] in he Seings menu by he message Auocal locked! (START-Sig. acive) or Auocal locked! (PREHEAT-Sig. acive). 3. Direcly afer he conroller is powered up, he AUTOCAL funcion canno be acivaed if a faul wih error code 11 13, 21 23, 81 or 9xx occurs ( secion 1.27 "Faul areas and causes" on page 64). If he conroller has already operaed correcly - a minimum of once - afer powering up, he AUTOCAL funcion canno be acivaed wih error codes 21 23, 81 or 9xx. 1.1 "START" signal (HEAT) The heaing process is acivaed by means of he "START" signal in differen ways, depending on he ime conrol saus (imer funcion) ( Configuraion menu, sep 29 [26]) : 1. Time conrol off (deacivaed): When he "START" signal is acivaed, he conroller-inernal se/acual comparison is enabled immediaely and he heasealing band is heaed up o he SET emperaure. I remains a his emperaure unil he signal is deacivaed again. This process can also be sared independenly of he "START" signal by pressing he "HAND" key while he display is in he home posiion. 2. Time conrol on (acivaed): If ime conrol (imer funcion) is on, 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 while he display is in he home posiion causes he heasealing band o sar heaing up immediaely (as described in 1). The inernal imeou is no sared. The "START" signal can be acivaed in wo ways: By means of a 24VDC signal a erminals VDC + - START (HEAT) max. 6mA 3 GND HIGH: 12VDC LOW: 2VDC 4 By means of a conrol conac a erminals 2+7 START (HEAT) wih conac max. 5mA 7 2 START (HEAT) or START TIMER V The "START" signal is disabled as long as he! AUTOCAL funcion is execuing in he Seings menu (wih sep 17 [7]) or he "RESET" signal is acive. The se poin ha is seleced for he heasealing emperaure (sep 11 [1] in he Seings menu) mus be greaer han 4 C. If no, he heasealing band will no be heaed up. The alarm relay is swiched if he "START" signal is acivaed while an error message is indicaing error codes 14 15, or 211 ( secion 1.27 Page 46

47 Conroller funcions "Faul areas and causes" on page 64). The heasealing band is likewise no heaed. If a "PREHEAT" signal is used, i is deacivaed inernally during he heaing and conrol process. The heasealing band is no reurned o he se preheaing emperaure unil he "PREHEAT" signal is acivaed again a he end of he conrol process for he main hea (Kap "PREHEAT" signal (preheaing) auf Seie 47). By means of a conrol conac a erminals 2+19 PREHEAT wih conac max. 5mA "PREHEAT" signal (preheaing) 2 V The heasealing band can be heaed o a specified preheaing emperaure wih he "PREHEAT" funcion, in order o shoren he emperaure rise ime o he seleced SET emperaure for ime-criical applicaions. The preheaing emperaure is se wih sep 12 [2] in he Seings menu. The "PREHEAT" signal can be acivaed in wo ways: By means of a 24VDC signal a erminals VDC + - PREHEAT max. 6mA 22 GND HIGH: 12VDC 2 The "START" signal is disabled as long as he! AUTOCAL funcion is execuing in he Seings menu (wih sep 17 [7]). The value ha is seleced for he preheaing emperaure (sep 12 [2] in he Seings menu) mus be greaer han 4 C. If no, he heasealing band will no be heaed up. The alarm relay is swiched if he "PREHEAT" signal is acivaed while an error message is indicaing error codes 14 15, or 211 ( secion 1.27 "Faul areas and causes" on page 64). The heasealing band is likewise no heaed. If a "PREHEAT" signal is acive, i is deacivaed inernally for he duraion of a heaing and conrol process ha is acivaed eiher by means of he "START" signal or by pressing he "HAND" key. "PREHEAT" signal 24VDC LOW: 2VDC PREHEAT "START" signal 24VDC ACTUAL emperaure T 2 T 1 T 1 = Preheaing emperaure (PREHEAT) T 2 = Heasealing emperaure Page 47

48 Conroller funcions The ACTUAL emperaure shows wheher he heasealing band is heaed up o he preheaing emperaure correcly, providing he display is in he home posiion. Please noe he following if he "PREHEAT" funcion is used and he emperaure is seleced via he analog inpu a erminals 2+23: An error message is rese if one is presen 24VDC RESET + max. 6mA 26 The volage a he analog inpu is valid for he preheaing emperaure and he heasealing emperaure. Preheaing canno be acivaed wih he "PREHEAT" signal in conjuncion wih he analog inpu. If his funcion is used, he preheaing emperaure mus be se by alering he volage value a he analog inpu. The "START" signal is always acivaed for his purpose (he "PREHEAT" signal is deacivaed). The iming sequence is shown in he diagram below: GND - HIGH: 12VDC 2 RESET "START" signal 24VDC LOW: 2VDC >.1s Volage a anal. inpu U 2 U 1 ACTUAL emp. T 2 T 1 T 1 = Preheaing emperaure (corresponds o U 1 ) The acual value oupu changes o 3 C (i.e. approximaely VDC) while he "RESET" signal is being acivaed. This may be inerpreed by he higher-level conroller (e.g. a PLC) as feedback. The message "Exernal RESET signal acive" is addiionally displayed on he conroller as of sofware revision 9 when he "RESET" signal is acive. The "AUTOCAL" funcion is no abored if he "RESET" signal is acivaed while i is sill execuing. The conroller execues an inernal iniializaion for approximaely 5ms afer he! "RESET" signal is deacivaed. The nex heasealing process canno be sared unil i has finished "RESET" signal The RESISTRON emperaure conroller can be rese by means of an exernal "RESET" signal a erminals As a resul: A heasealing cycle is abored if one is in progress No more measuring impulses are generaed If a conacor Kb is used o deacivae he! conrol loop ( Kap. 8.3 Power supply auf Seie 15), i mus be energized again 5ms a he laes afer he "RESET" signal is deacivaed. If i is energized oo lae, an error message will be oupu by he conroller 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 [3] in he Configuraion menu. Page 48

49 Conroller funcions The cycle couner is rese o if he "ENTER" key is pressed or if he maximum coun of cycles is exceeded Hold mode The behavior of he digial indicaion of he ACTUAL emperaure in he home posiion can be changed wih sep 16 [6] 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, he real ACTUAL emperaure is indicaed unil he end of he firs heaing phase. 3. "2 s" (Sofware revision 5 or higher) I 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. The various hold modes are shown below: START signal 24VDC ACTUAL emp. T ACTUAL indicaion Hold OFF T Hold ON Hold 2 s T T Hold Hold Hold Hold 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. 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. Page 49

50 Conroller funcions 1.15 Measuring impulse duraion (as of sofware revision 26) The lengh of he measuring impulses generaed by he conroller can be se wih his parameer by means of sep 22 [32]. I may be necessary o se a measuring impulse ha is longer han he defaul 1.7ms for cerain applicaions ( ROPEX Applicaion Repor) 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 1.9 "Auomaic zero calibraion (AUTOCAL)" on page 45). 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. ENTER key pressed Funcion AC <2.s AP AUTOCOMP The acual value oupu (erminals 24+4) is se o 3 C (i.e. approx. VDC) when he "AUTO- COMP" funcion is execued. 3. AUTO (as of sofware revision 15) 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 24+4) is se o 3 C (i.e. approx. VDC) when he "AUTO- COMP" funcion is execued Locking he "HAND" key (as of sofware revision 1) The "HAND" key funcion can be configured wih sep 213 in he Configuraion meun when he display is in home posiion. This prevens he heasealing bands from beeing 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 amanual heaing process. The heasealing band is heaed 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. AUTOCAL Page 5

51 Conroller funcions 1.18 Temperaure uni Celsius / Fahrenhei (as of sofware revision 16) As of sofware revision 16 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 as followed: 1. Celsius (Facory seing) Temperaure indicaion and value selecion in Celsius ( C). 2. Fahrenhei Temperaure indicaion and value selecion in Fahrenhei ( F) Up o sofware revision 15 only Celsius ( C) can be specified on he conroller as he emperaure uni. You can sill display all seps, values and! parameers even if he Configuraion menu is disabled. You are no longer allowed o ener or change values, however. As of sofware revision 13 he language in! menu pos. 21 can be changed while he configuraion menu is locked ( secion "Seing he language" on page 21). The Configuraion menu remains disabled unil he disable funcion is canceled again. To do so, repea he above procedure (press he "MENU" key for 2.seconds while he power-up message is displayed). The display hen shows a message confirming ha he disable funcion has been canceled.! 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 Disabling he Configuraion menu (Sofware revision 1 or higher) 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 disabled or enabled by pressing he "MENU" key for 2.seconds while he power-up message is displayed (afer swiching on he conroller, secion "Power-up message" on page 28). The display hen shows a message confirming ha he disable funcion is acive for 3.seconds before reurning o he home posiion. In he facory seing he Configuraion menu is no disabled. 1.2 Seing he display brighness (VF display only) (Sofware revision 19 or higher) If he display is in he home posiion, he brighness of he VF display (blue) can be se in 4 seps (25%, 5%, 75%, 1%) wih he "UP" and "DOWN" keys. The facory seing is 75%. The same message is also displayed for 5.seconds when you open he Configuraion menu o indicae ha his menu is disabled. The life of he VF display can be prolonged by reducing he brighness. Page 51

52 Conroller funcions 1.21 Undervolage deecion Trouble-free operaion of he emperaure conroller is guaraneed wihin he line volage olerance range specified in secion 6 "Technical daa" on page 1. 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. inerface allows a daa connecion o be se up o he ROPEX visualizaion sofware using he ROPEX communicaion inerface CI-USB-1. IR UR DIAG 12 The main menu is displayed again, and operaion is resumed, when he inpu volage reurns o he specified olerance range. The alarm relay (erminals 5+6) is only swiched by an undervolage condiion in conrollers up o and including sofware revision 2. The las valid emperaure value coninues o appear a he analog oupu (erminals 2+24). The alarm relay in conrollers wih a higher sofware revision number is no swiched if an undervolage condiion occurs. The sandby mode is indicaed by 3 C (corresponds o app. 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 Diagnosic inerface/visualizaion sofware (as of sofware revision 1) Back view of he conroller Only a ROPEX comunicaion inerface is! allowed o be conneced o he diagnosic inerface. Connecing anoher device (e.g. a elephone cable) could resul in malfuncions or damage o he conroller. The ROPEX visualizaion sofware is described in a separae documen Booser connecion The conroller has a connecion for an exernal swiching amplifier (booser) as sandard. This connecion (a erminals 1+2) is necessary for high primary currens (coninuous curren > 5A, pulsed curren > 25A). The swiching amplifier should be conneced as described in secion 8.7 "Wiring diagram wih booser connecion" on page 18. No seings are required in he menu. An inerface wih a 6-pole Wesern socke is provided for sysemdiagnosics and process visualizaion. This Page 52

53 Conroller funcions 1.24 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 acivaed wih sep 29 [26] in he Configuraion menu. There are wo possible seings in his menu: 1. "OFF" (Facory seing) Time conrol (imer funcion) deacivaed 2. "ON" Time conrol (imer funcion) acivaed. The inernal imeou is sared by acivaing he "START" signal. The imeou eiher ends wih he parameerized cooling phase or is inerruped by acivaing he "RESET" signal. 3. "ON wih START monioring" (Sofware revision 21 or higher) Time conrol (imer funcion) acivaed and "START" signal moniored. Once again, he inernal imeou is sared by acivaing he "START" signal. In his seing, however, he "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 - or if he "RESET" signal is acivaed - 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 funcion wih he "HAND" key on he conroller. The imeou of he inernal ime conrol canno be sared wih his key. START signal 24VDC ACTUAL emp. T Relay K1 (example) closed = Saring delay 2 = Heaing phase 3 = Cooling phase The imeou of he inernal ime conrol (imer! funcion) can be inerruped by acivaing he exernal "RESET" signal (sofware revision 9 or higher) or by swiching off he conroller. As of sofware revision 21, i can also be inerruped by deacivaing he "START" signal if ime conrol "ON wih START monioring" is configured. 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.! If ime conrol (imer funcion) is acivaed, i is only possible o sar a heaing process Page 53

54 Conroller funcions The acive cooling phase is subsequenly marked wih he direcion arrow a he end of he heaing phase. 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 heasealing ime 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 is indicaed by means of a separae icon. If he icon is visible, he normally open conac of he relay is closed. Separae seings can be enered for he individual imeous. These seings are possible wih seps 13 [3], 14 [4] and 15 [5] in he Seings menu and wih seps 21 [27], 211 [28] and 212 [29] in he Configuraion menu. The opions available wih hese advanced seings are described below Seing he saring delay The sar of he heaing process can be explicily delayed by enering a saring delay ime wih sep 13 [3] 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 24VDC ACTUAL emp. T 1 1 = Saring delay This menu sep is used o ener he heasealing ime. There are wo possible ways o se he heasealing ime: 1. " 99.9s" The heasealing ime can be se in he range from o 99.9s. The facory seing is 1.s. 2. "EXT" (This seing is possible as of sofware revision 13) The heasealing ime is conrolled by he "START" signal (24VDC signal applied o erminals 3+4 or conac applied o erminals 2+7). The duraion of he heasealing ime is equal o he acive ime of he "START" signal. START signal 24VDC ACTUAL emp. T 2 2 = Heaing phase Seing he cooling mode Various crieria for he end of he cooling phase can be specified wih sep 21 [27] 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. This cooling emperaure can be se wih sep 15 [5] 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 [5] in he Seings menu. Example: Page 54

55 Conroller funcions 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 [5] in he Seings menu. The various cooling modes are shown below: START signal 24VDC ACTUAL emp. T Cooling mode T Absolue T 2 T Relaive X% Time T = Cooling phase in C 3 = Cooling phase as % of se poin 3 = Cooling phase in s Seing he cooling value Afer he cooling phase has been configured wih sep 27 in he Configuraion menu ( secion "Seing he cooling mode" on page 54), you can specify he cooling parameers wih sep 15 [5] in he Seings menu. The opions available wih sep 15 [5] in he! Seings menu vary according o he selecion made wih sep 21 [27] in he Configuraion menu. All seings enered wih menu sep 15 [5] are overwrien if sep 21 [27] is changed subsequenly. The possible seings are as follows: 1. "Cooling emp. in C" (if seing wih menu sep 21 [27] = "Absolue") The cooling phase of he inernal imeou ends when he ACTUAL emperaure of he heasealing band falls below he se 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 [23] in he Configuraion menu or by he heasealing band ype/emperaure range se wih sep 25 [22]. 2. "Cooling emp. in %" (if seing wih menu sep 21 [27] = "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%. 3. "Cooling ime in s" (if seing wih menu sep 21 [27] = "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 Seing he sar of he heasealing ime The condiion for he sar of he se heasealing ime (sep 14 [4] in he Seings menu) can be specified wih sep 211 [28] 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 [3]). 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 [3]). The specified heasealing ime does no sar, however, unil he ACTUAL emperaure of he heasealing band reaches 95% of he SET emperaure. Page 55

56 Conroller funcions These wo alernaives are shown below: START signal 24VDC ACTUAL emp. When heaing sars T Sar of heasealing ime When emperaure reached 95% of se poin Heasealing ime Heasealing ime Relay K1 (wih ime conrol) The funcion of relay K1 when ime conrol is acive is also specified wih sep 212 [29] in he Configuraion menu ( secion "Relay K1 (wihou ime conrol)" on page 22). The seings described here are only possible if ime conrol is acive. These seings can be seleced as follows: 1. OFF Relay K1 wihou funcion 2. "When sar signal presen" The normally open conac of relay K1 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). 3. "When emperaure reached" (Facory seing) The normally open conac of relay K1 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). 4. "While cooling" START signal 24VDC ACTUAL emperaure T Relay K1 When sar signal presen When emperaure reached While cooling (Sofware revision 1 or higher) The normally open conac of relay K1 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 during he cooling phase, for insance. 5. "End-of-cycle impulse" The normally open conac of relay K1 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, he relay opens again immediaely. The possible seings are shown below: End-ofcycle impulse 95% of se poin end of cooling 5ms Page 56

57 Conroller funcions 6. "Acive if Tac = Tse" (This seing is possible as of sofware revision 1) Relay K1 is acivaed if he acual value is inside he specified emperaure olerance band (seps 27, 28). If he acual emperaure is ouside he olerance band, relay K1 is deacivaed (see graph below). Se+ upper Se Acual value Oupu 1 / Temperaure OK signal (wih ime conrol) On conrollers up o sofware revision 27,! he swiching oupu a erminals 2+21 was called "Temperaure OK". The more general name "Oupu 1" is used as of sofware revision 1 because his oupu now also suppors oher funcions. The "Oupu 1" signal is available a erminals 2+21 as a digial conrol signal. Sel+ lower NO conac of Relay K1 Closed Open Time Time GND +24VDC 21 I max 5mA 2 7. "Acive if Tac = Tse", wih lach funcion (This seing is possible as of sofware revision 1) Relay K1 is closed if he acual value is inside he specified emperaure olerance band (seps 27, 28). If he acual emperaure leaves he olerance band once during he heasealing phase, relay K1 is opened. The relay is no closed again unil he nex "START" signal is acivaed. The swiching sae of relay K1 can hus also be inerrogaed by he higherlevel PLC afer a heasealing process (lach funcion, see graph below). Se+ upper Se Se+ lower NO conac of Relay K1 Closed Open Acual value Time Time GND Up o sofware revision 27: The swiching oupu a erminals 2+21 ("Temperaure OK" signal) always has he funcion "Acive if Tac = Tse" ( secion " Oupu 1 / Temperaure OK signal (wihou ime conrol)" on page 23). As of sofware revision 1: If ime conrol (imer funcion) is acive, he swiching oupu a erminals 2+21 ("Oupu 1") can be parameerized in he same way as relay K1. The opions for "Oupu 1" are specified wih sep 222 in he Configuraion menu as followed: 1. "Off" 2. "When sar signal presen" 3. "When emperaure reached" 4. "While cooling" 5. "End-of-cycle impulse" 6. "Acive if Tac = Tse" 7. "Acive if Tac = Tse", wih lach funcion (facory seing) For a deailed descripion of hese funcions, see secion "Relay K1 (wih ime conrol)" on page 56. Page 57

58 Conroller funcions Preheaing (wih ime conrol) If ime conrol is acive, he preheaing emperaure ( secion 1.11 ""PREHEAT" signal (preheaing)" on page 47 is only deacivaed during he heaing phase. Preheaing is acive during he saring delay and he cooling phase. The ACTUAL emperaure consequenly canno fall below he se preheaing emperaure during he cooling phase. The emperaure which is se for he end of he cooling phase ( secion "Seing he cooling value" on page 55) mus always be higher han he preheaing emperaure. If no, he end of he cooling phase is never reached, i.e. he inernal imeou does no elapse. If he cooling emperaure is required o be lower han he preheaing emperaure, he "PREHEAT" signal mus be deacivaed unil he end of he cooling phase and hen acivaed again 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 Conroller Relay K1 Heasealing bar Heasealing band Film Film Reainer Sar Foo conac The funcional sequence is as follows: 1. The conroller receives he "START" signal for inernal ime conrol via he foo swich. 2. The heaing process mus begin immediaely wihou a saring delay. 3. When he ACTUAL emperaure reaches 95% of he SET emperaure (T = 18 C), he normally open conac of relay K1 mus close. The solenoid valve is hen energized and he sealing jaws are closed. The heasealing ime ( 2 = 1s) begins simulaneously. 4. 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. 5. The cooling phase mus end when he ACTUAL emperaure of he heasealing bands falls o T 8 C. The sealing jaws are sill closed (he normally open conac of relay K1 is also sill closed). 6. The normally open conac of relay K1 opens again a he end of he cooling phase. The sealing jaws are also opened again. 7. End of he heasealing process. Page 58

59 Conroller funcions The iming sequence can be represened as follows: 1.25 Sysem monioring/alarm oupu START signal (foo swich) ACT emperaure 95% of 18 C 18 C 8 C NO conac of 1s relay K1 Closed 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: Open Required conroller seings: 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 26 (Time conrol) "ON" Seing 27 (Cooling mode) "Absolue" 28 (Sar of heasealing ime) "When emp. reached" 29 (Relay K1 funcion) "When emp. reached" 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 secion 1.27 "Faul areas and causes" on page 64 for a lis of he possible error codes. B.) Alarm relay (relay conac, erminals 5+6): This conac is se in he facory as follows: OPEN if error code 14 16, or 211 is displayed. The conac closes, however, if a "START" signal is acivaed in his sae. CLOSED if error code 11 13, 17, 18, 21 23, 81 or 9xx appears. If he alarm relay is configured differenly from he facory seing ( secion "Configuraion of he alarm relay" on page 25), hese saes are invered. Then: C.) Error code oupu via he o 1VDC acual value oupu (erminals 2+24): Sep in Seings menu 11 [1] (Heasealing emp.) 18 C 13 [3] (Saring delay). s 14 [4] (Heasealing ime) 1. s Seing 15 [5] (Cooling value) Cooling emp. = 8 C 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 a faul. 13 volage levels (up o sofware revision 27: 12 volage levels) are offered for his purpose in he 1VDC range, each of which is assigned an error code ( secion 1.27 "Faul areas and causes" on page 64). If a sae ha requires AUTOCAL occurs or if he conroller configuraion is incorrec (error codes 14 16, or 211), he acual value oupu Page 59

60 Conroller funcions 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. 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 1.27 "Faul areas and causes" on page 64). An error message can be rese by pressing! he "RESET" key, by acivaing he "RESET" signal a erminals 2+26 ( secion 1.12 ""RESET" signal" on page 48) or by swiching he conroller off and hen on again. Invalid error messages may appear when he! conroller is swiched off owing o he undefined operaing sae. This mus be aken ino accoun when hey are evaluaed by he higherlevel conroller (e.g. a PLC) in order o avoid false alarms Error messages The able below shows how he analog volage values ha appear a he acual value oupu correspond o he fauls ha have occurred. I also describes each faul and he required correcive acion. The block diagram in secion 1.27 "Faul areas and causes" on page 64 permis each faul o be cleared quickly and efficienly The error codes described below can also be displayed in he ROPEX visualizaion sofware ( secion 1.22 "Diagnosic inerface/visualizaion sofware (as of sofware revision 1)" on page 52) o faciliae roubleshooing. If he acual value oupu is evaluaed in order! o idenify an error message - in he higherlevel conroller, for insance - he olerance window mus be adjused o preven i from being incorrecly inerpreed. Please noe he olerances of he acual value oupu ( secion 6 "Technical daa" on page 1). Page 6

61 Conroller funcions Par 1 of 3: Error code Ac. value oupu; Volage [V] 1 11, , , , , , , Temp. 3 C [ C] Temp. 5 C [ C] STATUS of alarm relay (facory se.) Closed Cause I R signal missing U R signal missing U R and I R signals missing Temperaure sep, down Temperaure sep, up Temperaure oo low/high ( secion 9.3.1) Frequency flucuaion, inadmissible line frequency Heaup ime oo long ( secion ) In. fau, conr. defecive Triac defecive In. fau, conr. defecive In. fau, conr. defecive In. fau, conr. defecive Plug-in jumper for alarm relay wrong Acion if machine sared for firs ime Faul area Faul area Faul area Faul area (loose conac) Check power supply Run RESET Replace conroller Replace conroller Replace conroller Replace conroller Replace conroller Check plug-in jumper Acion if machine already operaing, HS band no chang. Faul area Faul area Faul area Faul area (loose conac) Check power supply Run RESET Replace conroller Replace conroller Replace conroller Replace conroller Replace conroller Check plug-in jumper Page 61

62 Conroller funcions Par 2 of 3: NOTE: The specified error messages are iniially oupu as warnings (acual value oupu jumps back and forh beween wo values; alarm relay is open). When he "START" signal is acivaed, he warning changes o a faul (acual value oupu no longer jumps back and forh, see bold ialic values; alarm relay is closed). Error code Ac. value oupu; Volage [V] Temp. 3 C [ C] Temp. 5 C [ C] STATUS of alarm relay (facory se.) Cause Acion if machine sared for firs ime Acion if machine already operaing, HS band no chang. 14 I R signals incorrec, incorrec specificaion of impulse-ransformer (AC) 33 (AC) 5, Warning: Open Faul: Closed (volage value a acual value oupu hen no longer changes) U R signals incorrec, incorrec specificaion of impulse-ransformer U R and/or I R signals incorrec, incorrec specificaion of impulse-ransformer Temperaure oo low, AUTOCAL wasn performed, loose conac, ambien emp. flucuaes emperaure oo high, AUTOCAL wasn performed, loose conac, ambien emp. flucuaes Run AUTOCAL, Check specificaion of ransformer, Faul area Run AUTOCAL and/or faul area (loose conac) Faul area (loose conac) , Daa error Run AUTOCAL --- Page 62

63 Conroller funcions Par 3 of 3: NOTE: The specified error messages are iniially oupu as warnings (acual value oupu jumps back and forh beween wo values; alarm relay is open). When he "START" signal is acivaed, he warning changes o a faul (acual value oupu no longer jumps back and forh, see bold ialic values; alarm relay is closed). Error code Ac. value oupu; Volage [V] Temp. 3 C [ C] Temp. 5 C [ C] STATUS of alarm relay (facory se.) Cause Acion if machine sared for firs ime Acion if machine already operaing, HS band no chang ,66 1 7, Warning: Open I R signal incorrec, calibraion no possible U R signal incorrec, calibraion no possible Faul area, check configuraion Faul area, check configuraion , 1 8, Faul: Closed (volage value a acual value oupu hen no longer changes) U R and I R signals incorrec, calibraion no possible Temperaure flucuaes, calibraion no possible Ex. calibraion emperaure oo high, Ex. calibraion emperaure flucuaes Faul area, check configuraion --- Page 63

64 Conroller funcions 1.27 Faul areas and causes Temperaure conroller HARDWARE UR IR I2 U2 8 7 The able below explains he possible faul causes. Faul area Explanaion Possible causes Load circui inerruped afer U R pickoff poin PEX-W2/W3 curren ransformer signal inerruped Primary circui inerruped Secondary circui inerruped before U R pickoff poin - Wire break, heasealing band break - Conacing o heasealing band defecive -I R measuring wire from curren ransformer inerruped - Wire break, riac in conroller defecive - Primary winding of impulse ransformer inerruped - Wire break - Secondary winding of impulse ransformer inerruped U R signal missing - Measuring wire inerruped Parial shor-circui (dela R) - Heasealing band parially bypassed by conducing par (clamp, opposie heasealing bar ec.) Parallel circui inerruped Toal shor-circui U R signal incorrec - 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 - Up o sofware revision 27: DIP swiches 1-3 configured incorrecly (U 2 range) - As of sofware revision 1: U 2 ouside permissible range from.4 12VAC Page 64

65 Facory seings Faul area Explanaion Possible causes I R signal incorrec Turns hrough PEX-W2/W3 curren ransformer incorrec - Up o sofware revision 27: DIP swiches 4+5 configured incorrecly (I 2 range) - As of sofware revision 1: I 2 ouside permissible range from 3 5A - Check number of urns (wo or more urns required for currens < 3A) Inernal conroller faul - Hardware faul (replace conroller) 11 Facory seings The RESISTRON emperaure conroller is configured in he facory as follows: DIP swiches for secondary volage U 2 and curren I 2 (Up o sofware revision 27) OFF ON U 2 = 6 6VAC I 2 =3 1A DIP swiches: 2 ON 1, 3, 4, 5 OFF These swiches are auomaically se by he AUT- ORANGE funcion on all conrollers as of sofware revision 1. Seings menu No. 11 [1] Heasealing emperaure: C No. 12 [2] Preheaing emperaure: C No. 13 [3] Saring delay: s No. 14 [4] Heasealing ime: 1s No. 15 [5] Cooling value: Cooling ime: 1 s Absolue cooling emperaure: 5 C Relaive cooling emperaure: 4 % of heasealing emperaure No. 16 [6] Hold mode: OFF No. 17 [7] AUTOCAL emperaure: 2 C Page 65

66 Facory seings Configuraion menu No. 21 [2] Language German This selecion is NOT changed if he facory seings are resored wih sep 22 [21] in he Config. menu. No. 23, 24 [22] Alloy/range: Alloy-2/max. 3 C No. 26 [23] Maximum emperaure: 3 C No. 27 [24] Se poin reached: -1K No. 28 [25] Se poin exceeded: +1K No. 29 [26] Time conrol: OFF No. 21 [27] Cooling mode: Absolue No. 211 [28] Sar of heasealing ime: When emperaure reached No. 212 [29] Relay K1 funcion: Acive when emperaure reached No. 213 Lock of HAND key OFF No. 214 [3] Cycle couner: No. 215 [31] Alarm relay: Normal (conac closed by a faul) No. 216 [33] Analog oupu: Acual emperaure No. 217 Temperaure diagnosis: OFF No. 218 Temp.diagnosis delay ime: s No. 219 Heaup imeou: OFF No. 22 [32] Measuring impulse lengh:sandard (1.7ms) No. 221 Auocomp: OFF No. 222 "Oupu 1": Acive if Tac = Tse, wih lach funcion No. 225 Temperaure uni: Celsius Up o sofware revision 27: The conroller can be rese wih sep 21 in he Configuraion menu: The facory seings are resored if he "ENTER" key is pressed. An acknowledgmen message is displayed for approximaely 2s. The language which is seleced wih sep 2! in he Configuraion menu remains se even if he facory seings are resored. Page 66

67 Mainenance 11.1 Cusomer seings (as of sofware revision 1) 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 "Facory seings" on page 65. 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 67

68 How o order 13 How o order Conr. RES /... VAC L / 115: LC display, line volage 115VAC, Ar. No L / 23: LC display, line volage 23VAC, Ar. No L / 4: LC display, line volage 4VAC, Ar. No V / 115: VF display, line volage 115VAC, Ar. No V / 23: VF display, line volage 23VAC, Ar. No V / 4: VF display, line volage 4VAC, Ar. No Scope of supply: Conroller includes connecor plug-in pars (curren ransformer mus be ordered separaely) Modificaion MOD.. (opional, if required) e.g. 1: MOD 1, Ar. No. 81 (amplifier for low volage) Please indicae he aricle numbers of he conroller and he required modificaions (opional) in all orders, e.g. -L/4VAC + MOD 1 (conroller wih LC display for 4VAC line volage and amplifier for low volage) Ar. Nos mus be ordered Curren ransformer PEX-W3 Ar. No Line filer LF : Coninuous curren 6A, 48VAC, Ar. No : Coninuous curren 35A, 48VAC, Ar. No Impulse ransformer See ROPEX Applicaion Repor for design and ordering informaion Communicaion inerface CI-USB-1 Ar. No Temp. meer ATR-. 3: 3 C range, Ar. No : 5 C range, Ar. No Page 68