Ropex RESISTRON RESM-4 Guide

Industrie-Elektronik GmbH Tel: [phone] E-Mail:[email protected]
Gansäcker 21 Fax: [phone] Internet:www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
3.6.14
RESISTRON
RESM-4/RESM-5
Replacement
GB
Replacement
instruction
The RESM-5 monitoring unit can be used as an
alternative to the RESM-4.
The steps necessary to convert from RESM-4 to
RESM-5 are described below.
These instructions provide only a brief overview of the
two monitoring units. If in doubt, please refer to the
latest version of the monitoring unit documentation,
which is always binding.
The electrical connections of the RESM-4 and RESM-5
monitoring units are NOT compatible (see wiring
diagrams).
The two models are also operated differently. Whereas
potentiometers are used to calibrate the RESM-4 and
set the alarm threshold, you do this on the RESM-5 with
a display and four keys.
Older RESM-1 monitoring units (for
temperature controllers in the "2xx" series)
cannot be converted using the RESM-5.
Preparation
1. Select the unit
Select an RESM-5 with the same line voltage as the
old RESM-4 monitoring unit (115VAC, 230VAC, or
400VAC). The RESM-5 monitoring unit has the
following order numbers:
Line voltage: 115VAC RESM-5/115VAC
Art. No. 885241
230VAC RESM-5/230VAC
Art. No. 885242
400VAC RESM-5/400VAC
Art. No. 885243
The line frequency is automatically detected
by the RESM-5 monitoring unit in the range
from 47 to 63Hz.
2. Select the required components
Trouble-free operation of the RESM-5 monitoring
unit is only guaranteed in combination with the
following components:
- PEX-W2 or PEX-W3: Current transformer
- Alternatively: MSW-1 or MSW-2:
Monitoring current transformer
- LF-06480: Line filter 6A, 480VAC
In order to avoid malfunctions, the RESM-5 is
only allowed to be operated with the
specified components.
!
!

Page 2 RESM-4/RESM-5 Replacement
Installation and startup
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
Please also refer to the relevant product
documentation as well as to the ROPEX
Application Report.
The information provided here offers no more than a
brief overview. If in doubt, please refer to the latest
version of the product documentation, which is always
binding (see also section 1 of the RESM-5
documentation, "Safety and warning notes").
Proceed as follows to replace the RESM-4 monitoring
unit and install / start up the RESM-5:
1. Switch off the line voltage and verify that the circuit
is de-energized.
2. Remove the old RESM-4 monitoring unit.
3. The supply voltage specified on the nameplate of
the RESM-5 monitoring unit must be identical to the
line voltage that is present in the plant or machine.
The line frequency is automatically detected by the
controller in the range from 47 to 63Hz.
The RESM-4 has coding switches on the
housing for setting the secondary voltage
and current ranges.
The RESM-5 has been provided with an
AUTORANGE function instead of these switches.
The voltage and current ranges are automatically
set when you run AUTOCAL.
Old setting ranges on the RESM-4:
AUTORANGE function on the RESM-5:
The RESM-5 monitoring unit has no coding switches on
the housing. The voltage (0.4…120V) and current
(30…500A) ranges are automatically set when you run
the AUTOCAL function. Heed the information provided
in the ROPEX Application Report in order to avoid
malfunctions.
4. The number of times the wire is laid through the
PEX-W2/-3 or MSW-1/-2 current transformer for the
RESM-5 must be the same as for the RESISTRON
temperature controller. Heed the information
provided in the ROPEX Application Report in order
to avoid malfunctions.
5. Install the RESM-5 monitoring unit in place of the
RESM-4. The terminals of the two devices are NOT
compatible (see wiring diagrams).
6. Make sure no START signal is applied to the
RESISTRON temperature controller.
7. Switch on the line voltage.
8. A power-up message appears on the display when
you switch on the monitoring unit to indicate that it is
being powered up correctly.
9. One of the following states then appears:
!
!
32
1
45
ON
U ( V )
2
3 -
Switch
No.
1
3 - 10
8 - 30
20 - 60 50 - 80 I > 80A
2
Switch No.
13452
U V
2
( )
R
Coding switches
DISPLAY ACTION
Display in home position Go to step 10
Error message with error code
104…106, 111…113, 211 Go to step 10
Error message with error code
118 Reconnect/ Interchange UR
measuring wire
to terminals
8+9.
Then return to
step 7
Error message with error code
101…103, 107, 108,
201…203, 801, 9xx
Error diagnosis
(document.
RESM-5)

RESM-4/RESM-5 Replacement Page 3
10.Configure the RESM-5:
Configure the RESM-5 as described in the
"Configuration" section of the product
documentation. The following settings must always
be configured:
Step nos. 204 (temperature range), 205
(heatsealing band alloy), and 206 (maximum
temperature) should be set according to the
heatsealing application and the heatsealing bands
used. To prevent dangerous situations, refer to the
risk analysis for the machine or plant.
11.Deactivate alarms to simplify startup (if
necessary):
To start up the RESISTRON temperature controller
independently of the RESM-5 (e.g. in order to run
AUTOCAL), you can deactivate the alarm output of
the RESM-5 for a defined time. To do this, set any
time up to 5 minutes with step 215 (alarm output).
This time only applies once and is canceled if the
RESM-5 is switched on or off.
The alarm relay is no longer switched by the
RESM-5 if the alarm output is deactivated. In
this case, error messages/signals are no longer
transferred to the higher-level controller. You
should therefore only use this function if the risk
analysis for the machine or plant allows.
To calibrate the zero point (AUTOCAL) on the
RESM-5:
Run the AUTOCAL function while the heatsealing band
is cold.
Press the key repeatedly until menu step 107 is
displayed. Then select the AUTOCAL function by
pressing the key. If this function is executed
correctly, the main menu is automatically displayed
again.
If AUTOCAL was not performed successfully, an error
message appears on the display. In this case the
controller configuration is incorrect (see
"Configuration" section of the RESM-5 documentation
and ROPEX Application Report). Configure the
controller correctly and run the AUTOCAL function
again.
The AUTOCAL function must be executed
correctly on the RESISTRON temperature
controller before it can be run here (i.e. the
RESISTRON temperature controller must generate
measuring impulses).
Setting Step in Configuration
menu
Language 201
Restore factory settings 202
Temperature range and
heatsealing band alloy 204, 205
Maximum temperature
(alarm threshold) 206
Alarm output function 215
ALARM-IN/RESET input function 229
!
The monitoring unit is
now ready
!
ENTER
HAND
RESET
!

Page 4 RESM-4/RESM-5 Replacement
RESM-5 factory settings / as-shipped
condition
By restoring the factory settings (step 21 in the
software menu, see step 10 above), you reset the unit
to the following defaults:
The selected language (step 201 in the software menu)
is not changed when you restore the factory settings.
As-shipped condition:
The RESM-5 monitoring unit is shipped with the above
factory settings and with the language set to "German".
Menu Function Value
107 AUTOCAL temperature 20°C
204 Alloy 400ppm/K
205 Range 300°C
206 Maximum temperature
(alarm threshold) 40°C
213 Key lock No key
215 Alarm output Normal
(energized at
alarm)
225 Temperature unit Celsius
228 Screensaver 5min
229 ALARM-IN/RESET input Normal

RESM-4/RESM-5 Replacement Page 5
Menu structure of the RESM-5
203 Alloy
202 Factory settings
201 Language
Alarm
Autocal
107 Autocal?
106 Hold mode
105 Cooling value
104 Heatsealing time
103 Starting delay
101 Heatsealing temp.
Home position
Power-up message
208 Set point exceeded
206 Max. temperature
210 Cooling mode
212 Relay K1 function
213 Key lock
207 Set point reached
205 Temperature range
Setting Configuration
211 Heatslg. time start
Error 215 Alarm output
204 Temp. coefficient
214 Cycles
107 Autocal?
102 Preheat temp.
Autocal
5) 6)
209 Time control
1) 2)
216 Analog output
1) 2)
217 Temp. diagnosis
218 Temp. diag. delay
Continued on next page
Autocomp
108 Autocomp?
3) 4)
7) 8)

Page 6 RESM-4/RESM-5 Replacement
221 Autocomp
220 Meas. imp. length
219 Heatup timeout
Configuration
222 "Output 1"
Continued from previous page
Back to home position
225 Temperature unit
226 System time
227 Visualization
228 Screensaver
229 RESET input

RESM-4/RESM-5 Replacement Page 7
Wiring diagram of the RESM-5 (new)
ALARM-IN/RESET
with 24VDC signal
START (HEAT)
with 24VDC signal
AUTOCAL
with 24VDC signal
ALARM
OUTPUT
+24VDC
RESM-5
GND
GND
+24VDC
14
12
7
6
5
R
Impulse
transformer
9
8
4
3
2
1
UR
Heat-
sealing
band
16
17
15
13
18
sec.
U2
prim.
U1
Twisted
Auxilary
power supply
ANALOG
OUTPUT
(actual value)
+0...10VDC
0V
(Internal ground)
NO EXTERNAL
GROUNDIG
ALLOWED!
Current
transformer
PEX-W2/-W3
11
10
IR
NC
NC
NC
NC
1
2
7/8
8/7
5
6
XTerminals
on RESM-4
See RESM-5
documentation
See RESM-5
documentation
Note:
If error code 118 appears when
you switch on the RESM-5,
these cables should be
reversed/interchanged.
9, 10,
11 or
12
13, 14
or
15
()
*
()
*
Ground
Must be grounded
externally to
prevent electro-
static charging!
LINE
Line filter LF-xx480

Page 8 RESM-4/RESM-5 Replacement
Wiring diagram of the RESM-4 (old)
U
I
RM
R
R
CURRENT TRANSFORMER
CONTROL
VOLTAGE
Suppress contactor
coil
HEATSEALING BAND
Or
from MAIN CONTROLLER RES
U
R
CONTACT
CONTACT LOGIC SIGNAL
or
24VDC
0V +signal
5
6
7
8
2
1
Tw i s t e d
LINE
13
NO
1291110
14
NC
15
C
A
LARM OUTPUT
RELAY: max. 100VDC
240VAC
1.5A
ALARM INPUT
(FROM MAIN CONTROLLER)
ALARM OUTPUT RES
MAIN CONTROLLER
RESM-4
Relay
energized in
“go” state
0
+24V
In phase with
RES controller