Ropex RESISTRON RES-440 Leitfaden

Industrie-Elektronik GmbH Tel: +49/(0)7142/7776-0 E-Mail: [email protected]

Gansäcker 21 Fax: +49/(0)7142/7776-19 Internet: www.ropex.de

D-74321-Bietigheim-Bissingen Data subject to change

7.3.03

RESISTRON

Replacing

RES-222/RES-440

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

I254

12345

Switch

No.

20-603- 10 8- 30 50-80

( )

U (V)

( A)

1-10 6-60 20-120 30 - 100

60 - 200

120 - 400

OFF

OFFOFF

ON ON

DIP-SWITCH

12 3 45

12345

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

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.

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