Ropex RESISTRON RES-440 Guide

Industrie-Elektronik GmbH Tel: [phone] E-Mail: [email protected]
Gansäcker 21 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen Data subject to change
7.3.03
RESISTRON
Replacing
RES-222/RES-440
GB
Replacement
Instructions
The front panel dimensions and terminal assignment of
the RESISTRON RES-440 temperature controller are
compatible with those of the RES-222.
The steps that are necessary to migrate from
RES-222-0-3 or RES-222-0-5 (standard devices
without modifications) to RES-440 are described
below. In addition, the differences between the
controller types are explained.
These instructions provide only a brief overview of the
two controllers. If in doubt, please refer to the latest
version of the controller documentation, which is
always binding.
Comparison of RES-222 / RES-440
Dimensions
The front panel cutout dimensions of the RES-222 and
RES-440 controllers are identical. The RES-440
features a protective film to IP42 instead of the
transparent hood. A transparent front cover featuring
IP65 is available as a option.
Temperature indication (actual value)
RES-222 RES-440
RES-222
Indication on an analog instrument (ATR-3).
RES-440
Indication on the 4-line display
(dynamic bar and digital value).

Page 2 Replacing RES-222/RES-440
Set point selection
Zero calibration
Alarm output / reset
Manual mode
RES-222
Selection by means of a 10-turn potentiometer with
a fine control knob.
RES-440
Selection with step 1 in the software menu. If the
controller is active, the set point is also indicated on
the display.
RES-222
Zero calibration by means of a 10-turn potentiometer
(the pointer of the indicating instrument must be set
to "Z").
RES-440
Automatic zero calibration (AUTOCAL) with step 7 in
the software menu.
RES-222
Indicated by means of a red ALARM LED on the
front panel. Reset by pressing the RESET key.
RES-440
Indicated on the display. The error is identified by a
numeric code (ªRES-440 documentation). Reset
by pressing the RESET key ( ).
ENTER
HAND
RESET
RES-222
Selected by pressing the HAND key. The red ON
LED is lit continuously.
RES-440
Selected by pressing the HAND key ( ) while the
main menu is displayed.
ENTER
HAND
RESET

Replacing RES-222/RES-440 Page 3
"Temperature OK" signal
Line frequency setting (50/60Hz)
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.
The information provided here offers no more than a
brief overview. If in doubt, please refer to the latest
version of the controller documentation, which is
always binding (ªsee also section „Safety and
warning notes“ of the RES-440 documentation).
Proceed as follows to replace the RES-222 controller
and install/start up the RES-440:
1. Switch off the line voltage and verify the safe
isolation from the supply.
2. Remove the existing RES-222 controller.
3. The supply voltage specified on the nameplate of
the RES-440 controller must be identical to the line
voltage that is present in the plant or machine. The
line frequency is automatically detected by the
temperature controller in the range from 47 to 63Hz.
4. Set the DIP switches on the RES-440.
The settings of the DIP switches on the
RES-440 are NOT the same as on the
RES-222. Please set these switches in accordance
with the ROPEX Application Report in order to
avoid malfunctions.
RES-222
Indicated by means of a red LED (T = Ts).
RES-440
Indicated by means of an icon on the display.
RES-222
Configured with a plug-in jumper.
RES-440
Detected automatically in the 47…63Hz range.
Automatic detection
!
!

Page 4 Replacing RES-222/RES-440
Old setting ranges on the RES-222:
New setting ranges on the RES-440:
The table below compares the two controllers.
These settings can be taken as a guide (e.g. when
the controller is started up for the first time):
5. Install the RES-440 controller in place of the
RES-222. The terminals of the two controllers are
identical. The existing connector plug-in parts can
be used without rewiring.
6. Switch on the line voltage.
7. A power-up message appears on the display when
the controller is switched on to indicate that it has
been started up correctly.
8. One of the following states then appears:
9. Select the language and reset the controller to the
factory settings.
Press the key for at least 2s (to open the
Configuration menu). Step 20 is displayed. Select
the desired language with the keys.
Confirm your selection by pressing . Press the
key to display step 21 (factory settings). Press
the key to confirm the factory settings (an
acknowledgment message appears). Step 22 is
displayed next.
10.Set the temperature range to 500°C
(Only if you have so far been using an
RES-222-0-5 controller)
Then set "Alloy 20, max 500°C" with the
keys in step 22. Confirm your selection by pressing
.
11. Set the function of relay K1
Press the key repeatedly until step 29 is
displayed. Select "Relay K1 active if Tact = Tset"
with the keys. Confirm your selection by
pressing . Press the key for at least 2s (to
return to the main or Alarm menu).
12.Calibrate the zero point
Activate the AUTOCAL function while the
heatsealing band is still cold.
Press the key repeatedly until step 7 is
displayed. Then select the AUTOCAL function by
pressing the key. If this function is executed
correctly, the main menu is displayed again
automatically.
If the zero has not been calibrated successfully, an
error message appears on the display. In this case
the controller configuration is incorrect (ªsee
section „Controller configuration“ of the RES-440
documentation and the ROPEX Application Report).
Configure the controller correctly and repeat the
AUTOCAL function.
RES-222 RES-440
DIP switch ON
U2
11
22
33
43
I254
12345
ON
12345
Switch
No.
20-603- 10 8- 30 50-80
U
2
V
( )
U (V)
2
I
2
( A)
1-10 6-60 20-120 30 - 100 60 - 200
120 - 400
OFF
OFFOFF
ON
ON ON
DIP-SWITCH
ON
12 3 45
12345
ON
DISPLAY ACTION
Main menu
Shows the SET and ACTUAL
temperatures or the dynamic bar
Go to 9
Shows error code 104, 106, 109
or 211
Go to 9
Shows error code 101…103,
201…203, 801 or 9xx
Fault diagnosis
(ªRES-440
documentation)
ENTER
HAND
RESET
ENTER
HAND
RESET
ENTER
HAND
RESET
ENTER
HAND
RESET
ENTER
HAND
RESET

Replacing RES-222/RES-440 Page 5
13.Set the heatsealing temperature (select the set
point)
Press the key briefly (to display step 1 in the
Settings menu). Set the required temperature with
the keys. Confirm your selection by
pressing . Press the key for at least 2s (to
return to the main menu). The set heatsealing
temperature is displayed in the main menu.
Then activate the "START" signal (HEAT). The
indication on the display (actual value and dynamic
bar) permits the heating and control process to be
observed:
If an error code is displayed, please proceed as
described in section „Error messages“ of the
RES-440 documentation.
Optional:
Set the switching thresholds
for the "Temperature OK" signal
If you accept the factory settings, the switching
thresholds for activation of the "Temperature OK"
output signal via relay K1 (terminals 16-18) are set to
-10…+10K (RES-222: -5…+5%). If necessary, the high
and low thresholds can be set separately between 5
and 99K. Proceed as follows to do so:
(after working through the above steps 1… 11):
14.Press the key for at least 2s (to open the
Configuration menu). Step 20 is displayed. Press
the key repeatedly until step 24 is displayed.
Select the low switching threshold ("Set point
reached") with the keys. Confirm your
selection by pressing .
15.Press the key once. Step 25 is displayed.
Select the high switching threshold ("Set point
exceeded") with the keys. Confirm your
selection by pressing . Press the key for at
least 2s (to return to the main or Alarm menu).
RES-440 factory settings / as-delivered
condition
If you accept the factory settings (step 21 in the
software menu, see step 9above), the following
defaults are restored:
The selected language (step 20 in the software menu)
remains set regardless of the factory settings.
As-delivered condition:
The RES-440 controller is delivered with the above
factory settings and with the language set to "German".
The controller is now
ready
ENTER
HAND
RESET
ENTER
HAND
RESET
Menu
step Function Value
1 Heatsealing
temperature
0°C
6 Hold mode OFF
22 Alloy/range Alloy A20,
max. 300°C
23 Maximum temperature 300°C
24 Set point reached -10K
25 Set point exceeded +10K
26 Time control OFF
29 Relay K1 function Deactivated
30 Cycle counter 0
31 Alarm relay Closed by
alarm
ENTER
HAND
RESET

Page 6 Replacing RES-222/RES-440
Menu structure of the RES-440
1Heatsealing temp.
22 Alloy/range
21 Factory settings
20 Language
Alarm
Autocal
7Autocal?
6Hold mode
5Cooling value
4Heatsealing time
3Starting delay
2Preheating temp.
Main menu
Power-up message
25 Set point exceeded
26 Time control
27 Cooling mode
29 Relay K1 function
30 Cycles
31 Alarm relay
32 Meas. impulse
24 Set point reached
23 Max. temperature
Settings Configuration
1) 2)
1) Time control ON
2) Time control OFF
1) 2)
28 Start of sealing time
Fault
MOD 1 only
Autocal
7Autocal?
The relevant menu
steps are shown on
a gray background.