THERMOSALD ISX-LC / IPX-LC
Contents
1. s d x amp e C da E s ANALOGUE OUTPUT INPUT OUTPUT THERMOSALD ISX LC IPX_LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU V3EN Pagina 15 di 30 Data 07 11 2011 LIST OF EXCHANGE SIGNALS List of the connections and related PINS of CN1 POWER TERMINAL BLOCK MODEL WITH CONTROL ON THE SECONDARY PIN1 ALTERNATING POWER SUPPLY PIN2 ALTERNATING POWER SUPPLY PIN3 BAND PIN4 BAND NOTE1 We recommend you twist the power cables CN1 POWER TERMINAL BLOCK MODEL WITH CONTROL ON THE PRIMARY PIN1 ALTERNATING POWER SUPPLY INPUT 230VAC PIN2 PIN3 CONNECT TO OV OF THE POWER SECONDARY TO CHECK GROUND CURRENT PINA PHASED POWER SUPPLY OUTPUT TO THE PRIMARY OF TRANSFORMER NOTE1 We recommend you twist the power cables NOTE2 Alternating supply of the control circuit with the same phase as that of the power circuit CN2 CONTROL CIRCUIT POWER SUPPLY TERMINAL BLOCK PIN1 0 Vac max absorption 0 5 A PIN2 24 max absorption 0 5 A NOTE1 0 24VDC is insulated from the internal power supply and ground CN3 COMMAND TERMINAL BLOCK PIN1 0 V PLC COMMON 24 max absorption 0 1 A PIN2 PREHEATING COMMAND FROM 24 Vdc PLC 0 20 mA max PINS SEALING COMMAND FROM 24 Vdc PLC 02. M 7 4 INSTALLATION epu 8 4 1 WARNINGS AND REQUIREMENTS FOR INSTALLATION 01 000000 0 8 4 2 COMPONENT SELECTION AND TECHNICAL NOTES FOR 8 42 1 SECONDARY PRIMARY THERMOREGULATOR sss eene 8 42 2 POWER TRANSFORMER AND SIZING nennen nennen nennen nnne nnne 8 42 3 SIZING THE PROTECTION DEVICES enne enne nnne nnne 9 424 ELECTROMECHANICAL SYSTE a m u muu a 9 4 2 57 MAINS FILTER eate MAT ities sabe erem Eu EL M rue 9 EE 10 2 2 PB bett s ber o a egens 11 4 3 WIRING DIAGRAMS e bie tt oe to otra i tp Deen pam ton doe ua bedeuten dean 12 43 1 DIGITAL SIGNAL CONNECTIONS ener snnt entes 12 4 3 2 CONTROL ON THE SECONDARY POWER CONNECTIONS THERMOSALD ISX LC 13 4 3 3 CONTROL ON THE PRIMARY POWER CONNECTIONS THERMOSALD IPX LOC 14 4 34 ANALOG CONNECTIONS TO PLC POTENTIOMETERS 15 5 COMMISSIONING iiss Peace cc 18 5 1 COMMISSIONING WARNINGS einen nnne entente nennen ese nnne n
3. V Q Q d IF MUSHROOM BUTTON 1 sq mm a a a a 8 8 8 6 KAC g Hh Z u ui o zx HM E a m gt a 9 m a z KMC INPUT 7 4 AN cx ps THERMOSALD EMERGENCY PLC ALARM CHAIN 0VDC X7 CONSTRUCTION NOTES THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Codice 3ES101 MDU Pagina 12 30 Rev 1 Data 07 11 2011 4 3 2 CONTROL ON THE SECONDARY POWER CONNECTIONS THERMOSALD ISX LC 24VDC 400Vac 50 60Hz CN2 POWER SUPPLY THERMOSALD ISX LC REFERENCES 2 3 4 5 Qo Oa CABLE Twisted Cable SHIELDED SHIELDED BAND REF BAND REF ALARM 1 POWER CN3 COMMANDS 1 2 3 4 1 2 3 4 5 6 7 Power Screened Twisted lt gt Cable Cable TECHNICAL NOTES In observance to the EMC norme the main filter cannot be used CONSTRUCTION NOTES THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice SES101 V3EN Pagina 13 di 30 Data 07 11 2011 433 CONTROL ON THE
4. 10 di 30 Data 07 11 2011 thermoregulator so as to ensure that the cables of a thermoregulator do not get tangled with the cables of another thermoregulator or of another electrical noise units In compliance with EMC requirements MAINS FILTER is not necessary on the application with control on the secondary 4 27 INSTALLATION Electrically disconnect the electrical panel and make sure no voltage is being supplied to the mains connection terminals Screw the thermoregulator on the bottom of the electrical panel Connect the ground wire with the same cross section as the power cables to the thermoregulator s PE bolt Wire the power cables as described previously Wire the reference cables as described previously Perform the safety chain as described previously THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 11 di 30 Data 07 11 2011 4 3 4 3 1 WIRING DIAGRAMS DIGITAL SIGNAL CONNECTIONS THERMOSALD ISX LC IPX LC CN2 POWER SUPPLY CN REFERENCES EXTERNAL COMPONENTS 1 3 4 5 O O O O E a gt amp POWER 523 KMO CN1 POWER BUTTON CN3 COMMANDS 1 2 3 1 2 3 4 Cy 1 O N
5. COOLING DOWN TIME External by PLC WORKING ENVIRONMENT TEMPERAT 40 500 THERMOREGULATOR PROTECTION IP00 RATING POWER UNIT WEIGHT kg 1 6 THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 21 di 30 Data 07 11 2011 8 ORDERING DATA 81 CODES FOR ORDERING MODELS Description CODICE DI ORDINAZIONE THERMOSALD ISX LC 60A Impulse thermoregulator low cost 3ES101S6 SECONDARY 60 Ampere THERMOSALD ISX LC 90A Impulse thermoregulator low cost 3ES101S9 SECONDARY 90 Ampere THERMOSALD IPX LC 400V Impulse thermoregulator low cost 3ES101P4 PRIMARY 400 480 Volts Opzione High Volt Voltage on band 100 140V 0 Levels Z HIVL Opzione Low Volt Voltage on band 3 10V 0 Levels Z LOVL TA Amperometric transformer 3ES080A002 Power transformer Contact technical department for sizing Bands Belts and sealing wires Bands belts and sealing wires with different profiles in metres specifically designed copper plated Teflon coated Installation and user manual in ITALIAN 3ES101 MDU V3IT Installation and user manual in ENGLISH 3ES101 MDU V3EN Installation and user manual in FRENCH 5101 Installation and user manual in GERMAN 3ES101 MDU V3DE Installation and user manual in SPANISH 3ES101 V3SP 8 2 SUGGESTIONS FOR CHOOSING T
6. MANUAL Rev 1 Codice 3 5101 V3EN Pagina 4 di 30 Data 07 11 2011 2 SAFETY INSTRUCTIONS AND CERTIFICATIONS 21 SAFETY INSTRUCTIONS A proper specific and technical knowledge is required to install commission service or use the product Consult this USER MANUAL and follow the instructions contained herein in compliance with the SAFETY REGULATIONS Improper use of the apparatus may result in dangerous conditions for the operator and things and people nearby Do not use the equipment in an explosive atmosphere or with explosive material Do not use the equipment with flammable material without first taking the necessary safety precautions Install and use the thermoregulator only in industrial applications Use bands or wires with an appropriate positive temperature coefficient gt 8 x 10E 4 800ppm K Do not change the temperature coefficient unless you have sufficient know how Mechanically fix the thermoregulator to the plate using the fixing holes Before connecting it to the mains connect the ground protection conductor to the fixing bolt which is identified by a yellow green PE indicator on the heat sink Do not connect the power circuit of the thermoregulator when the machine s mechanical guards are open Do not power the thermoregulator if the protective cover has been removed After a 5 HESET procedure has been performed set the parameters correctly before using the equipm
7. PIN5 CALIBRATION COMMAND FROM 24 Vdc PLC 0 DC PIN6 SEALING ALARM N C CONTACT PIN4 RESET COMMAND FROM 24 Vdc PLC 0 DC 20 mA max SEALING ALARM N C CONTACT 5 PHASE INPUT TERMINAL BLOCK FOR SYNCHRONISM PIN1 230 480 VAC MAIN NET SYNCRONISM 10ma max 2 0 VAC 10ma CN6 REFERENCE TERMINAL BLOCK PIN1 REF BAND REFERENCE 1 mA max PIN2 REF BAND REFERENCE 1 mA max PINS REFO REFERENCE CABLE SHIELD do not connect on the machine side PIN4 CT REFERENCE 500 mA max twisted cable THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101_MDU_V3EN Pagina 16 di 30 Data 07 11 2011 PIN5 CT REFERENCE 500 mA max twisted cable PING N C CN7 POTENTIOMETER CONNECTOR 9 POLES MALE PIN1 4 5V PREHEAT POTENTIOMETER 1 mA max PIN2 REF PREHEAT POTENTIOMETER 1 mA max PIN3 OV PREHEAT POTENTIOMETER 1 mA max PIN4 jumper PIN3 and PIN4 1 mA max PIN5 PIN6 4 5V SEALING POTENTIOMETER 1 mA max REF SEALING POTENTIOMETER 1 mA max PIN8 OV SEALING POTENTIOMETER 1 mA max PIN9 jumper PIN8 and PIN9 1 max NOTE1 if piloted from analogue PLC output use PIN2 PIN3 PIN7 PIN8 and leave PIN4 9 free NOTE2 REF REF we recommend you use a shielded
8. ANTAGES Like the previous impulse thermoregulators THERMOSALD ISX IPX can quickly heat a sealing band or cutting sealing wire to the set temperature without using additional probes This technology makes it possible to obtain very high working speeds for sealing polyethylene polypropylene environment friendly products and plastics in general The temperature is controlled directly on the sealing line and the temperature can be maintained even at high speeds It avoids temperature drift between the first sealing operation and the next ones in production it prevents the support bars from overheating thus avoiding any subsequent mechanical problems caused by expansion A cooling air blow and other precautions may further increase the speed and improve the sealing quality Below is a list of the most important functional technical features of the new THERMOSALD ISX LC IPX LC 24VNS insulated POWER SUPPLY in the THERMOSALD ISX_LC version with control on the secondary it allows the same thermoregulator to be used regardless of the mains voltage POWER TRANSFORMER CONTROL ON THE SECONDARY OR PRIMARY it allows the User to choose the best solution to the problem he she has to solve within a voltage range of 230 to 600 Volts or current range of 150 to 400 Ampere ANALOG INPUT analog input from potentiometer or PLC outputs for settino the preheat or seal temperature ANALOG OUTPUT analog output 0 5Volts to the PLC for sending the tem
9. C IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 20 di 30 Data 07 11 2011 7 DATA 7 4 TECHNICAL DATA FOR THE MODULATION ON THE SECONDARY MODEL CONTROL POWER SUPPLY CN2 24VDC 20 max absorption 0 2 A POWER SUPPLY SECONDARY POWER TRANSFORMER SHORT CIRCUIT CURRENT 300 Ampere MAINS FREQUENCY 50 60 Hz automatic switchover DIGITAL COMMANDS 24 VDC max absorption 20 ma SEALING ALARM CONTACT 250V 4A STANDARD RESOLUTION 0 3 degree REPETITIVENESS 16 PRECISION Depend of the thermic drift of sealing band PREHEATING TEMPERATURE Can be set by analog input 0 300 C SEALING TEMPERATURE Can be set by analog input 0 300 C SEALING AND COOLING DOWN TIME External by PLC WORKING ENVIRONMENT TEMPER 40 506 THERMOREGULATOR PROTECTION IP00 RATING POWER UNIT WEIGHT kg 1 6 7 22 TECHNICAL DATA FOR THE MODULATION ON THE PRIMARY MODEL CONTROL POWER SUPPLY CN2 24VDC 20 max absorption 0 2 A POWER SUPPLY 230 480VAC SHORT CIRCUIT CURRENT 300 Ampere MAINS FREQUENCY 50 60 Hz automatic switchover DIGITAL COMMANDS 24 VDC max absorption 20 ma SEALING ALARM CONTACT 250V 4A REPETITIVENESS 16 PREHEATING TEMPERATURE Can be set by analog input 0 300 C SEALING TEMPERATURE Can be set by analog input 0 300 C SEALING AND
10. F069 GROUND CURRENT Check the band on the machine or the band connection probably grounded NOTE the thermoregulator is grounded via a ground screw the band wires must therefore be disconnected before checking using an electrical instrument F071 HARDWARE FAULT ANALOGUE 4 15V Reset the equipment if the BREAKAGE problem persists contact the supplier F072 HARDWARE FAULT ANALOGUE 5V Reset the equipment if the BREAKAGE problem persists contact the supplier F073 HARDWARE FAULT REFERENCE 5V Reset the equipment if the THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101_MDU_V3EN Pagina 25 di 30 Data 07 11 2011 BREAKAGE problem persists contact the supplier F074 INTERNAL TEMPERATURE PROBE Switch the equipment OFF if the HEAT SINK TEMPERATURE TOO HIGH problem persists contact the supplier F075 WARNING INTERRUPT FIRE BLOCK Verify connection power transformer and Main Frequency F076 IREAD TOO HIGH Check if there is a short circuit on the bands F077 MANUAL CMD FROM THE PANEL NOT Remove the preheat and sealing ACTIVE DUE TO PREHEAT OR SEALING before giving the command FROM OUTSIDE F078 EQUIPMENT NOT CALIBRATED Perform the automatic calibration procedure without giving the preheat or sealing command F079 EMERGENCY CIRCUIT FAULT Check the power contactor check the emergency chain F080 BACK FIRE TIMER CONTROL Reset the equip
11. HE MODEL Use model I 60A for a total band cross section lt 2sq mm Use model 1 904 for a total band cross section gt 2sq mm Use model HV for transformer V voltage gt 100Vac Use model LV for transformer V voltage 10Vac THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Codice 3ES101 MDU Pagina 22 di 30 Rev 1 Data 07 11 2011 APPENDIX A SEALING CYCLE NOTE The sealing cycle suggested is given by way of example only and is not to be considered as a binding usage diagram Experience shows that the timing must be changed according to the specific application i e of the materials dimensions times etc For further information please contact our technical department PRE HEATINGSIGNAL IN THERMOSALD SEALING SIGNAL IN THERMOSALD closed FILM GRIPPER JAWS open closed BAND SEALERS open COOLING FILM FEED THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 23 di 30 Data 07 11 2011 APPENDIX D LIST OF ALARMS AND MESSAGES CAUSES REMEDIES NOTE To reset any alarm raise the RESET command from the interface and press the RESET MODE button NOTE When in the alarm condition the RED LED lights up the alarm number can be deducted from the green and red LED blinking ALARM OF GREEN LED IMPULSES x 10 NO OF RED LED IMPULSES NOTE When in the warning c
12. HE T SHAPE BANDS IN SPECIAL ALLOY Band Width Band Thickness Specific Resistance RO mm mm Q m x o e a O O 4 a 2 2 4 eee x 6 TABLE OF THE BEADED ELEMENT BANDS IN SPECIAL ALLOY i 3 js 60 TABLE OF THE CONCAVE BANDS IN SPECIAL ALLOY Band Width Band Thickness Specific Resistance RO mm mm Q m ABc Jj 2 4 2 8 0 3 THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 Pagina 29 di 30 Data 07 11 2011 APPENDIX COMMISSIONING SHEET SEALING BANDS WIDTH X THICKNESS SEALING BANDS TOTAL LENGTH USEFULL LENGTH TOTAL COPPER TRANSFORMER POWER VA TRANSFORMER PRIMARY VOLTAGE V TRANSFORMER SECONDARY VOLT V THERMOSALD ISX IPX MODEL ORDERED OPTIONS PREHEAT TEMPERATURE C SEALING TEMPERATURE C SEALING TIME Sec THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Codice 3ES101 MDU V3EN Pagina 30 di 30 Rev 1 Data 07 11 2011
13. PRIMARY POWER CONNECTIONS THERMOSALD IPX LC 400Vac OVac 50 60Hz 230 480VAC 24vnC CN2 POWER SUPPLY 2 1 CN5 SYNCHRONISM THERMOSALD IPX LC CN6 REFERENCES 1 4 5 o oo a Q twisted SHIFI DED TA REF SHIFI DFD CARI F BAND RFF BAND ALARM CN1 POWER CN3 COMMANDS 2 1 2 43 4 2 5 D Twisted Cable Grounded terminal Nr 3 Screened Cable Power Twisted Cable TECHNICAL NOTES CONSTRUCTION NOTES THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice SES101 V3EN Pagina 14 di 30 Data 07 11 2011 4 3 4 ANALOG CONNECTIONS PLC POTENTIOMETERS VOLTMETER AN OUT OV IHE CN8 ANALOGUE OUTPUTS CN7 ANALOGUE INPUTS CN2 POWER SUPPLY 2 1 OJO THERMOSALD ISX LC IPX LC CN6 REFERENCES 1 2 3 4 5 O O O O O ALARM CN1 POWER CN3 COMMANDS 1 2 2 3 4 6 7 CN12 ANPLC
14. THERMOSALD ISX LC IPX LC THERMOREGULATOR LOW COST FOR IMPULSE SEALING TECHNICAL FEATURES THERMOREGULATOR LOW COST OF THE LINE THERMOSALD ISX IPX WITH THE SAME STRUCTURE MECHANICAL AND CONNECTIONS SET OF PREHEAT AND SEAL TEMPERATURE BY POTENTIOMETER OR ANALOG OUT OF PLC ANALOG OUTPUT 0 5V TO PLC FOR SEALING TEMPERATURE AND ALARMS NO CONNECTIONS TO THE DISPLAY COMPLETELY AUTOMATIC CALIBRATING COMPLETELY DIAGNOSTIC FOR TROUBLESHOOTING LOW VOLTAGE SUPPLY 24VDC WORKING VOLTAGES FROM 230 TO 600 VOLTS WORKING CURRENTS FROM 10 TO 400 AMPERE COMPATIBILITY WITH ALL PREVIOUS ANALOG MODELS INSTALLATION AND USER MANUAL V3 S r l Via del Maccabreccia 37 4 40012 LIPPO DI CALDERARA BOLOGNA Tel 39 051 6466225 228 E Mail mail 3e3e3e com Fax 39 051 6426252 Pagina web www 3e3e3e com 1 INTRODUCTION MC 4 2 SAFETY INSTRUCTIONS AND CERTIFICATIONS 5 2 1 SAFETY INSTRUCTIONS bo E E P BERTA ad dieses 5 2 2 COMPLIANCE WITH STANDARDS CE MARKING 2 2 021 20200 000000000000 enne nnne 5 3 DESCRIPTION EE 6 3 1 INTRODUCTION ON TAE MARKET uu n u a ete te eee ee 6 3 2 DESCRIPTION OF THE PRODUCT AND 204 040 000000000000000000000 00000 0000 00 6 3 3 OPERATING PRINCIPLE AND ADVANTAGES 6 3 4 APPLICATIONS
15. cturer F096 V I TOO HIGH NOT ACTIVE IN THE ISX IPX MODELS Saturation on the voltage circuit check the system probably a band broke if it is connected in parallel F097 PARTIAL SHORT CIRCUIT BETWEEN THE BANDS Check the bands on the machine Probably they are not insulated correctly If the band is fine and the problem persists let the machine cool down and calibrate Pay attention to the machine s behaviour in the subsequent working phases To remove the problem the PARTIAL SHORT CIRCUIT FACTOR MACHINE DATA can also be raised F099 ALARM UNKNOWN Contact the manufacturer THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 27 di 30 Data 07 11 2011 APPENDIX E MECHANICAL DIMENSIONS THERMOREGULATOR DIMENSIONS 100 x 120 VIEW FROM TOP HEIGHT z 135mm DRILLING TEMPLATE 3 HOLES Dia 4 5 m 120 mm 95 mm 20 mm 100 mm THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 28 di 30 Data 07 11 2011 APPENDIX F TABLE OF BANDS TABLE OF THE CHAMFERED BANDS IN SPECIAL ALLOY Band extension 50PPM 0 05mm metre per degree 5mm metre per 100 degrees Band Width Band Thickness Specific Resistance RO mm mm Q m p e _ o 0 0 0 3 05 096 a _ ee 52 2 ae 0 1 1 2 2 0 51 1 98 j TABLE OF T
16. duled maintenance 1 Power off remove the preheat and sealing commands let the gripper jaws cool down 2 Mount the new bands 3 Power on 4 Calibrate in order to compensate for any minor mechanical differences of the band in most cases ambient temperature does not need to be changed in the setting data 5 THE MACHINE is ready to work 6 2 REPLACING THE BAND WITH THE MACHINE HOT i e bars at operating temperature quick intervention 1 Power off remove the preheat and sealing commands let the gripper jaws cool down so the operator can work comfortably 2 Mount the new bands 3 Power on 4 If there are no great mechanical differences in the bands THE MACHINE is ready to Work 6 3 THERMOREGULATOR MAINTENANCE To be scheduled according to the work environment in any case with routine maintenance intervals should be no longer than 180 days 1 Make sure the connection terminals are properly screwed 2 Periodically check correct operation of the output safety alarm contact 6 4 GRIPPER JAWS MAINTENANCE To be scheduled according to the work environment at periodic intervals 1 Make sure the feedback reference terminals and power terminals are properly screwed 2 Make sure the band s terminals are highly conductive and do not show any oxidation or bad contacts if so service them accurately 3 Check the band s supports in insulating material and Teflon THERMOSALD ISX L
17. e machine according to the emission measurements taken on the mains 4 2 6 WIRING The apparatus must be installed inside an electrical panel screwed on a iron plate zinc plated Warning one end of the band s power circuit is connected to PE this connection is made in the grey power terminal block CN1 terminals 2 and 3 Do not ground the band directly The transformer thermoregulator cables must be twisted The power cables to the band can be laid in a cable duct with other cables but must be twisted to avoid any interference If other apparatus electrically much noise are in the plant electric welder brushless driver inverter it s possibly increase noise immunity using use shielded cables in compliance with EMC requirements Cable cross section 10 sq mm for bands with a total cross section lt 2 0sq mm e g 2 bands in parallel 4 x 0 25 16sq mm for bands with a total cross section gt 2 0sq mm e g 2 bands in parallel 6 x 0 3 The reference cables must be shielded twisted for the best connection fix them directly on the terminals of a band To increase the system s strength and as our long experience has taught us we recommend you to connect wire to a terminal near sealing bands as indicated in the adjacent drawings Set the wiring so as to obtain 1 independent box with the support terminal block for THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU Pagina
18. ennen 18 5 2 18 5 8 CALIBRA TION uya nta Ree e np be eret o ente te Eon be 18 5 4 ANALOG OUTPUT AND DIAGNOST IC 19 6 gn h edm 20 6 1 REPLACING THE BAND WITH THE MACHINE COLD i e bars at ambient temperature scheduled maintenance e n eee D Leste os t een uit tbe tate 20 6 2 REPLACING THE BAND WITH THE MACHINE bars at operating temperature quick Intervention Tor eee eR aaa 20 6 3 THERMOREGULATOR 2 2 0120000000000000000000000000000000 20 6 4 GRIPPER JAWS MAINTENANGCE nennen nnn then rennen nennt 20 feo TECHNICAL DATA un 21 7 1 TECHNICAL DATA FOR THE MODULATION ON THE SECONDARY 21 7 2 TECHNICAL DATA FOR THE MODULATION ON THE PRIMARY 21 8 Ep 22 8 1 CODES FOR ORDERING ao tula a e Ol e Ta Ha E ER Re maia Bae noe 22 8 2 SUGGESTIONS FOR CHOOSING THE MODEL ss
19. ent 2 2 COMPLIANCE WITH STANDARDS CE MARKING II dispositivo conforme ai requisiti essenziali delle seguenti Direttive Comunitarie applicabili al prodotto in riferimento alle seguenti normative armonizzate The device complies with the fundamental requirements set forth in the following European Directives that apply to the product with reference to the harmonized standards below 89 336 EEC EMC Directive and subsequent amendments 92 31 ECC and 93 68 EEC CEI EN 55022 Electromagnetic Compatibility EMC Emission for industrial environments CEI EN 61000 6 2 Electromagnetic Compatibility EMC Part 6 2 Generic Standards Immunity for industrial environments 73 23 LOW VOLTAGE Directive and subsequent amendments 93 68 EEC CEI EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU V3EN Pagina 5 di 30 Data 07 11 2011 3 DESCRIPTION 3 1 INTRODUCTION ON THE MARKET THERMOSALD ISX LC IPX LC are the lower cost thermoregulators of the modular line that can be configured and are compatible with one another THERMOSALD ISX LC IPX LC springs from the company s long experience in the impulse sealing field and maintains total compatibility with previous thermoregulators namely THERMOSALD PWM THERMOSALD SCR THERMOSALD UPSCR and THERMOSALD ISC 3 2 DESCRIPTION OF THE PRODUCT AND ADV
20. fer to paragraph CONFIGURATIONS AND ADVANTAGES below 3 4 APPLICATIONS On all packaging machines that require polyethylene polypropylene environment friendly and plastic films to be sealed or cut sealed vertical and horizontal filling machines bundling machines shoppers vacuum machines etc THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 7 di 30 Data 07 11 2011 4 INSTALLATION 41 WARNINGS AND REQUIREMENTS FOR INSTALLATION BEFORE STARTING to INSTALL carefully read the SAFETY WARNINGS contained in this manual This apparatus must be installed in accordance with the requirements set forth in standard CEI EN60204 This apparatus must be installed carefully following the instructions contained in this USER MANUAL This apparatus must be installed by skilled and properly trained personnel 4 2 COMPONENT SELECTION AND TECHNICAL NOTES FOR INSTALLATION Please refer to the diagrams under paragraph 4 3 Below are the calculations to define the voltage and current required for the best application select the suitable THERMOSALD ISX LC IPX LC from the order table according to the values calculated 4 2 1 SECONDARY PRIMARY THERMOREGULATOR The apparatus must be installed inside an electrical panel protected against dust water and corrosive acids The apparatus does not require special ventilation when used but must be installed in a properly ventilated area whe
21. l CALIBRATION command on terminal CN3 up for 3 seconds NOTA 2 if calibration problems occur perform a MASTER RESET and proceed from step 2 5 4 ANALOG OUTPUT AND DIAGNOSTIC The thermoregulators is equiped by an analog output 0 5V to output temperature in case of standard functionment to output alarm number in case of alarm Case of standard functionment without power warn33 Alarm relay output closed CN3 6 CN3 7 Analog output OV Case of standard functionment with power Alarm relay output closed CN3 6 CN3 7 Analog output temperature 10 degree e g 1Volt 100 degree Case of alarm see alarm table appendix D Alarm relay open CN3 6 CN3 7 Analog output 1 0V alarm 78 equipment not calibrated 1 5V alarm 46 no current signal 2 0V alarm 48 preheat potentiometer connections 2 0V alarm 49 seal potentiometer connections 2 5V alarm 69 ground current 3 0V alarm 89 break of 1 of 2 bands in parallel 3 5V alarm 93 seal command without power 4 0V alarm 94 reference cable interruption 4 5V alarm 97 partial short circuit between the bands 4 5V alarm 76 current too high circuits in saturation 5 0V alarm non specific see the blinking of leds green red alarm THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 19 di 30 Data 07 11 2011 6 MAINTENANCE 6 1 REPLACING THE BAND WITH THE MACHINE COLD i e bars at ambient temperature sche
22. ment if the problem persists contact the supplier F081 HARDWARE FAULT CHECKSUM Inconsistent data have been ALARM found on eeprom proceed carefully Press RESET MODE check MACHINE DATA SETTING DATA and TEMPERATURES set Contact the supplier F082 phase displacement between power CN1 Make sure the two power and control power supply CN2 only supplies are in phase pay primary model attention to the phase phase phase neutral phase displacement F083 REFERENCE CABLES REVERSED WITH Check the reversed reference RESPECT TO THE POWER CABLES cables CN1 3 corresponds to CN6 1 1 4 corresponds to 6 2 F089 BREAK A BAND IN CASE OF BANDS Check the bands CONNECTED IN PARALLEL F090 SHORT CIRCUIT BETWEEN THE BANDS Check the bands check power OR BETWEEN THE BANDS AND cabling between the GROUND thermoregulator and bands F092 POWER COMPONENT FAULTY Reset the equipment if the problem persists contact the manufacturer F093 NO CURRENT ON THE BAND USED FOR Check the power transformer SEALING check for any interruption of the band check for any interruption THERMOSALD ISX LC IPX_LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 26 di 30 Data 07 11 2011 of the power cables F094 REFERENCE CABLE INTERRUPTION Check the reference cables CN6 1 CN6 2 F095 NO MAINS SYNCHRONISM NOT ACTIVE IN THE ISX IPX MODELS Internal hardware problem Contact the manufa
23. n the machine reaches steady state operation check that the heat sink of the thermoregulator does not exceed 606 if so increase ventilation a safety temperature probe is installed in models ISX2 and IPX2 4 2 2 POWER TRANSFORMER AND SIZING A power transformer suitable for the circulating currents must be envisaged to supply power to the sealing band as indicated in the diagrams ref par 4 3 in the case of a overlapped winding transformer place a shield between the primary and secondary to avoid mains leaks on the secondary The power transformer can be sized simply using the thermoregulator s panel diagnosis menu see description the commissioning section or as follows Calculate the band cross section CROSS SECTION sq mm WIDTH mm x THICKNESS mm Calculate rated heating current Inom A 30 A sq mm x CROSS SECTION sq mm Calculate useful resistance Ru ohm Specific resistance ohm m x Useful length m Calculate the rated voltage and power Vnom V Ru ohm x Inom A Vnom x Inom Follow the suggestions of the notes below THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU V3EN Pagina 8 di 30 Data 07 11 2011 NOTE1 maximum theoretical vollage VT and current of the transformer are calculated according to the machine s speed requirements a coefficient x 1 5 x 2 i e VT Vnom x coefficient IT Inom x coefficient can be applied NOTE2 the maximum theoretical power
24. nd power cable connections THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 24 di 30 Data 07 11 2011 047 SIGNAL REVERSED Reverse CT connection F048 PREHEAT POTENTIOMETER NOT Check preheat potentiometer CONNECTED OR CABLES connections INTERRUPTED F049 SEALING POTENTIOMETER NOT Check sealing potentiometer CONNECTED OR CABLES connections INTERRUPTED F051 WIPER IGROSS Switch the equipment OFF and then ON if the problem persists contact the supplier F052 WIPER VGROSS Switch the equipment OFF and then ON if the problem persists contact the supplier F053 WIPER IFINE Switch the equipment OFF and then ON if the problem persists contact the supplier F054 WIPER VFINE Switch the equipment OFF and then ON if the problem persists contact the supplier F060 RESET WITH CALIBRATION IN Repeat calibration PROGRESS F061 IGROSS BALANCE NOT SUCCESSFUL Repeat calibration F062 VGROSS BALANCE NOT SUCCESSFUL Verify if Band Ref connected together Verify if voltage power transf is right Repeat calibration F063 IFINE BALANCE NOT SUCCESSFUL Repeat calibration F064 VFINE BALANCE NOT SUCCESSFUL Repeat calibration F065 SUPERFINE BALANCE NOT Repeat calibration SUCCESSFUL F066 WARNING SYNCHRONISM DUE TO Verify connection power MAINS FREQUENCY OSCILLATION transformer and Main Frequency MAINS SYNCHRONISM INTERFERENCE
25. of the transformer is calculated without considering the first full wave heating impulses and according to a phase modulation mean factor PT VT x ITx 0 7 NOTES the actual mean power of the transformer depends on the number of sealing operations per minute the ratio between the active state and sealing cycle period and the thickness of the film to be sealed due to overall dimension reasons and costs the PT theoretical power can be declassified introducing a SIF intermittent duty type of the transformer which according to experience should be about 5096 4026 NOTE For support CONTACT our TECHNICAL OFFICE 423 SIZING THE PROTECTION DEVICES Envisage a D CURVE protection thermal magnetic circuit breaker to disconnect the mains as indicated in the diagrams ref par 4 3 Calculate the breaking current theoretical heating current IT divided by secondary primary coils ratio Q Ithermal magnetic circuit breaker IT Q NOTE1 the value of the protection device of the power transformer s secondary must be the same as or higher than the calculated theoretical current IT this protection device trips on the cables and band downstream of it Considering that the thermoregulator is already fitted with an electronic protection device on the cables and band s current the fitter should analyze the possibility of not installing said protection device on the basis of the application 2 please note that the suggested protection devices mus
26. ondition the YELLOW LED lights up the warning number be deducted from the green and red LED blinking WARNING OF GREEN LED IMPULSES x 10 NO OF RED LED IMPULSES ALARM DESCRIPTION REMEDY FAULT A thermoregulator completely OFF plus Check the power supply power display completely OFF supply unit faulty contact the supplier F001 EEPROM WRITING INTERRUPTED Switch the equipment OFF and then ON then contact the supplier F002 EEPROM WRITING WITH PREVIOUS Switch the equipment OFF and OPERATION IN PROGRESS then ON then contact the supplier F003 EEPROM WRITING WITH FAULTY Switch the equipment OFF and EEPROM then ON then contact the supplier F007 A D CONVERTER CONVERTER Switch the equipment OFF and WRITING ERROR then ON then contact the supplier F008 INTERNAL I2C X TRANSMISSION Switch the equipment OFF and then ON F009 DO NOT USE F010 A D CONVERTER CHANNEL Switch the equipment OFF and SELECTION ERROR then ON then contact the supplier F033 WARNING no VOLTAGE IN THE POWER Check the CN1 L1 L2 power TRANSFORMER OR BAND NOT supply the power transformer CONNECTED circuit check connection of the power cables on the band F034 DO NOT USE F038 WARNING Waiting for machine to cool To perform a calibration down upon calibration request procedure it is necessary to wait until the sealing bar reaches a stable temperature F046 NO CURRENT SIGNAL Check CT connection and ba
27. perature of the sealing band or the alarms COMPATIBILITY WITH ALL PREVIOUS THERMOREGULATORS that allows spare parts to be replaced on obsolete models COMPLETELY AUTOMATIC CALIBRATION just press the calibration button on the thermoregulator for 3 seconds or high the CALIBRATING INPUT for 3 seconds GOOD DIAGNOSTICS FOR TROUBLESHOOTING in case of alarm the leds of balance lamp to indicate exactly the number of alarm a digital output more an analog output inform the PLC 3 3 OPERATING PRINCIPLE AND ADVANTAGES THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU Pagina 6 di 30 Data 07 11 2011 At all network cycles THERMOSALD ISX IPX reads the voltage and current on the band calculates the resistance and then the temperature which depends on the resistance and controls the current that heats the band in a closed loop this current is generated by a power transformer by means of phase control performed on the secondary of the power transformer in the THERMOSALD ISX configuration and on the primary of the power transformer in the THERMOSALD IPX configuration selection can be made according to machine requirements or company situations The new structure of the thermoregulator allows the user to operate without virtually having voltage or current limits as the problem shifts completely on to the power transformer and the system technical standards For further information and details please re
28. s nennen nennen nennen 22 APPENDIX A SEALING CYCLE J J 23 THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 2 di 30 Data 07 11 2011 APPENDIX D LIST ALARMS AND MESSAGES CAUSES REMEDIES 24 APPENDIX E MECHANICAL DIMENSIONS U u u ennt APPENDIX F TABLE OF BANDS ture isse u EUR xL RASA uu uu 29 APPENDIX G COMMISSIONING 30 THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3 5101 V3EN Pagina 3 di 30 Data 07 11 2011 1 INTRODUCTION This manual is the only complete document concerning the product represented on the front page It contains safety instructions a description of the device and some of its possible applications instructions for installing commissioning servicing and disposing of the product the codes and some examples for placing orders This manual is referred to in all the documents that accompany the product and must be consulted before using the product described In particular read the instructions related to safety installation commissioning servicing and disposal before using the product REVISION OF THE MANUAL Hev 0 Data 15 06 2011 Rev 1 Data 07 11 2011 THERMOSALD ISX LC IPX LC INSTALLATION AND USER
29. t and seal led must be off on the unit Step 2 keep pressed for 6 seconds the RESET CALIBRATION button on the carter of the thermoregulators the 4 LEDs on the equipment remain on for 3 seconds Step at the end of master reset the 4 LEDS will blink to indicate that a CALIBRATING will be necessari NOTE It S possibile also to do a MASTER RESET from far distance keeping the external RESET CALIBRATION command on for 6 seconds 5 3 CALIBRATION POT PRERISCALDO SALDATURA 70 PS CALIBRAZIONE 76 PS RESET ALLARM Step 1 calibrate only after reading the commissioning warnings Step 2 the machine must be at ambient temperature Step 3 the preheat and sealing commands must be deactivated THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU V3EN Pagina 18 di 30 Data 07 11 2011 Step 4 power on the thermoregulator if the thermoregulator is in MASTER RESET without alarm the 6 leds blinking Step 5 in the event of an alarm red ALARM LED on follow the thermoregulator s suggestions and solve Step 6 keep the key CAL for 3 seconds and wait the leds green red of balancing blinking up to the end after about 30 seconds Step 7 set the PREHEAT and SEAL TEMPERATURE by the analog input for POTENZIOMETERS 30 degree 1 tourn for input analog signal 13 33 mv grado NOTA 1 It s also possibile to do a CALIBRATING from far distance keeping the externa
30. t be verified by the designer according to the application 4 2 4 ELECTROMECHANICAL SYSTEM The safety chain must be made like the one in the base drawing ref par 4 3 the emergency output contact must interrupt the power electromechanically in particular it must open the contactor necessary for interrupting the power transformers power supply this contact must be suitable for the circulating currents this interruption is crucial because if the electronic switch inside the thermoregulator fails very rare event only the contactor can prevent the bands from overheating and breaking Install an emergency button as indicated in the diagrams ref Par 4 3 It must only be possible to reset this button manually and must be placed in a non dangerous area that the operator can access easily 4 2 5 MAINS FILTER No cases of interference with equipment nearby have occurred with THERMOSALD ISX phase control on the secondary The system designer has to decide whether or not one single filter should be fitted at the input of the system for the entire machine according to the emission measurements taken on the mains A mains filter is recommended for THERMOSALD IPX phase control on the secondary The system designer has to decide whether or not one single filter should be fitted at the input of THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101 MDU V3EN Pagina 9 di 30 Data 07 11 2011 the system for the entir
31. twisted pair e g TWINAX cable our code 3esd0066 8 ANALOGUE OUTPUT TERMINAL BLOCK PIN1 0 Vdc ANALOGUE 5ma max PIN 2 0 5 Vdc ANALOGUE REFERENCE OUTPUT 5ma max PIN3 ANALOGUE REFERENCE OUTPUT CABLE SHIELD THERMOSALD ISX LC IPX LC INSTALLATION AND USER MANUAL Rev 1 Codice 3ES101_MDU_V3EN Pagina 17 di 30 Data 07 11 2011 5 COMMISSIONING 5 1 COMMISSIONING WARNINGS BEFORE STARTING COMMISSIONING carefully read the SAFETY WARNINGS and INSTALLATION WARNINGS in the USER AND INSTALLATION MANUAL this chapter is an integral part of or a copy of it The system must have been sized as specified in the installation warnings and built in a workmanlike fashion No alarm must be active in the event of an alarm the red ALARM LED on follow the thermoregulator s suggestions and solve the alarm number can be identified by counting the impulses of the green balance LED for tens e g 9 impulses 90 the impulses of the red balance LED for units e g 10 impulses 0 8 impulses 8 For any further information do not hesitate to contact 3E 5 2 MASTER RESET The thermoregulator is provided in the MASTER RESET condition After every MASTER RESET the parameters return to the default status in this case the 6 led on the equipment in the right are blinking To do a MASTER RESET do as follow Step 1 verify the preheat and sealing commands must be deactivated the prehea
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