Resistron RES-5010 User manual

RESISTRON
Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen Data subject to change
21.7.16
RES-5010
Operating
instructions

Page 2 of 49 RES-5010
Contents
1 General information . . . . . . . . . . . . . . . . . . 3
1.1 Intended use . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3/-W4 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Standards / CE marking . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Mounting and installation . . . . . . . . . . . . . . 6
4.1 Installation procedure . . . . . . . . . . . . . 6
4.2 Installation steps . . . . . . . . . . . . . . . . . 7
4.3 Power supply . . . . . . . . . . . . . . . . . . . . 8
4.4 Line filter . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Current transformer PEX-W3/-W4 . . . . 9
4.6 Wiring diagram (standard) . . . . . . . . . 10
4.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 11
5 Startup and operation . . . . . . . . . . . . . . . . 12
5.1 View of the device . . . . . . . . . . . . . . . 12
5.2 Device configuration . . . . . . . . . . . . . 12
5.3 Replacing and burning in the heatsealing
band . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Startup procedure . . . . . . . . . . . . . . . 15
6 Device functions . . . . . . . . . . . . . . . . . . . . 17
6.1 LEDs and controls . . . . . . . . . . . . . . . 17
6.2 PROFINET communication . . . . . . . . 19
6.3 Device master file (GSDML) . . . . . . . 19
6.4 Communication protocol . . . . . . . . . . 20
6.5 Input data . . . . . . . . . . . . . . . . . . . . . . 20
6.6 Output data . . . . . . . . . . . . . . . . . . . . 23
6.7 Parameter data . . . . . . . . . . . . . . . . . 24
6.8 Integrated web server . . . . . . . . . . . . 31
6.9 Undervoltage detection . . . . . . . . . . . 33
6.10 Temperature meter (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 33
6.11 Booster connection . . . . . . . . . . . . . . 34
6.12 USB interface for visualization software
(ROPEXvisual®) . . . . . . . . . . . . . . . . 34
6.13 AUX interface . . . . . . . . . . . . . . . . . . 35
6.14 Total cycle counter . . . . . . . . . . . . . . 35
6.15 Operating hours counter . . . . . . . . . . 35
6.16 Data memory for error
messages and AUTOCAL . . . . . . . . . 35
6.17 Built-in clock (date and time) . . . . . . . 35
6.18 System monitoring / alarm output . . . 36
6.19 Error messages . . . . . . . . . . . . . . . . . 36
6.20 Fault areas and causes . . . . . . . . . . . 40
7 Factory settings . . . . . . . . . . . . . . . . . . . . . 42
8 Technical data . . . . . . . . . . . . . . . . . . . . . . 43
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 45
10 Accessories and modifications . . . . . . . . 45
10.1 Accessories . . . . . . . . . . . . . . . . . . . . 45
10.2 Modifications (MODs) . . . . . . . . . . . . 46
11 How to order . . . . . . . . . . . . . . . . . . . . . . . . 47
12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

General information
RES-5010 Page 3 of 49
1 General information
This RESISTRON temperature controller is manufac-
tured according to DIN EN 61010-1. In the course of its
manufacture it passed through quality assurance,
whereby it was subjected to extensive inspections and
tests. As a result of this, the product left our factory in
perfect condition.
The recommendations and warning notes contained in
these operating instructions must be complied with, in
order to guarantee safe operation.
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational
safety. Installation and maintenance may only be
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
1.1 Intended use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly approved for them, and
providing the regulations, notes and warnings
contained in these instructions are observed.
In case of non-observance or use contrary to the
intended purpose, there is a risk that safety will be
impaired or that the heatsealing band, electrical wiring,
transformer etc. will overheat. This is the personal
responsibility of the user.
1.2 Heatsealing band
The use of suitable heatsealing bands is a basic
prerequisite for reliable and safe operation of the
system.
The resistance of the heatsealing band which is used
must have a positive minimum temperature coefficient
in order to guarantee trouble-free operation of the
RESISTRON temperature controller.
The temperature coefficient must be specified as
follows:
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
The RESISTRON temperature controller must be set
and coded according to the temperature coefficient of
the heatsealing band.
The use of incorrect alloys with a too low
temperature coefficient and incorrect coding
of the RESISTRON temperature controller leads to
uncontrolled heating of the heatsealing band,
which will ultimately burn out!
The original heatsealing bands must be clealy identified
by means of suitable markings as well as the connector
geometry, length, or other means to ensure that
replacement bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary in order to
guarantee trouble-free operation of the control loop.
This transformer must be designed according to
VDE 0570 / EN 61558 (isolating transformer with
reinforced insulation) and have a one section bobbin.
When the impulse transformer is installed, suitable
touch protection must be provided in accordance with
the national installation regulations for electrical
equipment. In addition to this, water, cleaning solutions
and conductive fluids must be prevented from seeping
into the transformer.
Incorrect installation of the impulse transformer impairs
electrical safety.
1.4 Current transformer PEX-W2/-W3/-
W4
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2, PEX-W3 or PEX-
W4 current transformer may be used. Other trans-
formers may cause the equipment to malfunction.
The current transformer may only be operated if it is
correctly connected to the RESISTRON temperature
controller (see section "Startup and operation"). The
relevant safety instructions contained in section "Power
supply", must be observed. External monitoring
modules can be used in order to additionally increase
operating safety. They are not included in the scope of
supply of the standard control system and are
described in a separate document.
TCR 10 4– ×10 K 1– ≥
!

Application
Page 4 of 49 RES-5010
1.5 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.6 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6 Standards / CE marking
The controller described here complies with the
following standards, provisions and directives:
Compliance with these standards and provisions is only
guaranteed if original accessories and / or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section "Power supply"). If periph-
eral components (e.g. the transformer or the line filter)
from other manufacturers are used, no functional guar-
antee can be provided by ROPEX.
1.7 Maintenance
The controller requires no special maintenance. Reg-
ular inspection and / or tightening of the terminals –
including the terminals for the winding connections on
the impulse transformer – is recommended. Dust
deposits on the controller can be removed with dry
compressed air.
1.8 Disposal
This device is subject to Directive 2012/
19/EU concerning the reduction of the
increasing amount of waste electrical
and electronic equipment and the dis-
posal of uch waste in an environmentally
sound way.
It must not be disposed of as residual
wase! To guarantee proper disposal and / or the
recover of reusable material, please take the device to
adesignated municipal collectin point and observe local
regulations.
Careless, uncontrolled disposal can cause damage to
thenvironment and human health. By ensuring that
yourproduct is disposed of or recycled in a responsible
way, you can help protect the environment and human
halth.
2 Application
This RESISTRON temperature controller is an integral
part of the "5000" series, the key feature of which is its
microprocessor technology. All RESISTRON tempera-
ture controllers are used to control the temperature of
heating elements (heatsealing bands, beaded bands,
cutting wires, heatsealing blades, solder elements
etc.), as required in a variety of heatsealing processes.
The controller is particularly used for impulse-
heatsealing PE films in:
• Vertical and horizontal f/f/s machines
DIN EN 61010-1:2001
(2014/35/EU)
Safety requirements for electrical
equipment for measurement,
control and laboratory use
(low-voltage directive):
pollution degree 2,
protection class I,
measurement category I
(for URand IRterminals)
DIN EN 60204-1
(2006/42/EG)
Electrical equipment of
machines (machinery directive)
EN 55011:2009+A1:2010
EN 61000-3-2:2006-04+
A1:2009+A2:2009
EN 61000-3-3:2008
EN 61000-6-4:2007+
A1:2011
(2014/30/EU)
EMC genery emissions:
Group 1, Class A
EN 61000-6-2:2005
(2014/30/EU)
EMC generic immunity:
Class A (ESD, RFI, burst, surge)
Exception:
Line voltage interruption acc. to
EN 61000-4-11 is not fulfilled
(This leads to a designated error
message of the controller)

Principle
RES-5010 Page 5 of 49
• Pouch, filling, and sealing machines
• Film wrapping machines
• Pouch making machines
• Group packaging machines
•L-sealers
•etc.
The use of RESISTRON temperature controllers
enables:
• Repeatable heatseal quality under any conditions
• Increased machine capacity
• Extended life of the heatsealing bands and Teflon
coatings
• Simple operation and control of the heatsealing pro-
cess
3 Principle
The resistance of the heatsealing band, which is tem-
perature sensitive, is monitored 50x per second (60x at
60 Hz) by measuring the current and voltage. The tem-
perature calculated with the help of these measure-
ments is indicated and compared with the set point.
The primary voltage of the impulse transformer is
adjusted by phase-angle control if the measured values
deviate from the set point. The resulting change in the
current through the heatsealing band leads to a change
in the band’s temperature and thus also its resistance.
This change is measured and evaluated by the
RESISTRON temperature controller.
The control loop is thus closed: ACTUAL temperature =
SET temperature. Even very small thermal loads on the
heatsealing band are detected and can be corrected
quickly and precisely.
A highly dynamic thermoelectric control loop is formed
because purely electrical variables are measured at a
high sampling rate. A very wide secondary current
range can be controlled with only minimal power loss –
a considerable advantage – because power is con-
trolled on the primary side of the transformer. This
allows optimal adaptation to the load and to the
required dynamics in spite of the controller's extremely
compact dimensions.
Note:
RESISTRON temperature controllers play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the control system's advanced tech-
nology if all of the system components – in other words
the heatsealing band, impulse transformer, wiring,
timing signals, and the controller itself – are fully com-
patible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Control
logic
R=f(T)
+
_
Set point
Start
Indicators
and
controls
or
bus interface
Actual value
LINE
RESISTRON controller
Heatsealing band R = f (T)
Current
transformer
Impulse transformer
UR
IR
prim.
U1
sec.
U2

Mounting and installation
Page 6 of 49 RES-5010
4 Mounting and installation
ªSee also section 1 "General information" on page 3.
Mounting, installation and startup may only
be performed by authorized persons who
have received suitable instruction and are familiar
with the associated risks and warranty provisions.
4.1 Installation procedure
Proceed as follows to install the RESISTRON
RES-5010 temperature controller:
1. Switch off the line voltage and the 24 VDC supply,
and verify that the circuit is de-energized.
2. The supply voltage indicated on the nameplate of
the RESISTRON temperature controller must be
identical to the line voltage that is present in the
system or machine. The line frequency is automati-
cally detected by the RESISTRON temperature
controller in the range from 47 Hz to 63 Hz.
3. Mount the RESISTRON temperature controller on a
standard top hat rail (DIN TS35 rail according to
DIN EN 50022) in the electrical cabinet. If several
controllers are mounted on one rail, the minimum
clearance specified in section 8 "Technical data" on
page 43 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 4.3 "Power supply" on page 8, section 4.6
"Wiring diagram (standard)" on page 10, and the
ROPEX Application Report. The information pro-
vided in section 4.2 "Installation steps" on page 7
must also be observed.
Wires used for control or measuring connections
must always be laid inside the building.
5. An overcurrent protective device with a maximum
rating of 10 A must be fitted when the device is
installed, e.g.:
- Miniature circuit breaker to EN 60898
(B, C, D, K, or Z characteristic)
- Miniature circuit breaker to UL 489 (*)
(B, C, D, K, or Z characteristic)
- Fuse gG to IEC 60269
- Class CC or Class J fuse to UL 248 (*)
The overcurrent protective devices marked (*)
should be used in installations conforming to UL
standards.
If one such device is not adequate for the
heatsealing application, two separate overcurrent
protective devices should be provided – one for the
controller and one for the application (ªROPEX
Application Report).
The overcurrent protective device must be located
directly adjacent to the controller.
The minimum possible specification for this device
is indicated in the ROPEX Application Report based
on the calculated currents. If a larger overcurrent
protective device is fitted, you must match the cur-
rent carrying capacity of the other components
accordingly (e.g. cables, impulse transformer etc.).
6. A disconnecting device must be provided when the
system is installed; it must be marked as belonging
to the system and fitted in a readily accessible posi-
tion.
If a miniature circuit breaker is used, it can also per-
form the function of this device.
7. Connect the RESISTRON temperature controller to
the PROFINET controller using a suitable (standard
compliant) cable.
Check that all system connections –
including the terminals for the impulse trans-
former windings – are securely attached.
8. Make sure the wiring conforms to all relevant
national and international installation regulations.
!
!

Mounting and installation
RES-5010 Page 7 of 49
4.2 Installation steps
Line
Impulse
transformer
Current transformer
PEX-W2/-W3/-W4
U (prim.)
1
Heatsealing band R= f (T)
U (sec.)
2
A
F
Controller
Temperature
meter
ATR-x
Digital
potentiometer
PD-x
Avoid long
cables
Heatseal element
with coppered ends
Use heatseal bands with
suitable temperature coefficient
20mm clearance if several
controllers installed on
one top hat rail
Note
polarity
No additional
resistance
in secondary
circuit
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
Sufficient wire
cross-section
No
push-on
connectors
Twisted
Current measuring
wires IR
R
Connect U measuring
wires directly to
heatsealing band ends
Line filter
LF-xx480
Note
direction
of rotation
Note
number
of turns

Mounting and installation
Page 8 of 49 RES-5010
4.3 Power supply
ROPEX
temperature
controller
UR
IR
R
PRIM.
U1
Kb
Ka
SEC.
U2
LINE
I > I >
GND/
Earth
N (L2)
L1 (L1)
LINE
FILTER
ON
OFF
Kc
3
3
3
1
Short wires
2
2
Line
115 VAC, 230 VAC, 400 VAC
50/60 Hz
Over-current protection
Double-pole circuit-breaker or fuses,
(ªROPEX Application Report)
Short-circuit protection only.
RESISTRON temperature controller not protected.
!
Relay Ka
For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".
Line filter
The filter type and size must be determined according to
the load, the transformer and the machine wiring
(ªROPEX Application Report).
Do not run the filter supply wires (line side) parallel
to the filter output wires (load side).
!
RESISTRON temperature controller
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temp. controller (ROPEX recommendation).
When using a series resistor RV-....-1 the relay Kb
shall be installed.
!
Impulse Transformer
Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.
Use transformers with a one section bobbin. The
power, duty cycle and voltage values must be deter-
mined individually according to the application (ªROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ªROPEX Application Report).
Guide values:
Primary circuit: min. 1.5 mm², max. 2.5 mm²
Secondary circuit: min. 4.0 mm², max. 25 mm²
cWires must always be twisted (min. 20 turns/meter).
dThese wires must be twisted (min. 20 turns/meter)
if several control loops are laid together ("crosstalk").
eTwisting (min. 20 turns/meter) is recommended to
improve EMC.

Mounting and installation
RES-5010 Page 9 of 49
4.4 Line filter
To comply with EMC directives – corresponding to
EN 50081-1 and EN 50082-2 – RESISTRON control
loops must be operated with line filters.
These filters damp the reaction of the phase-angle con-
trol on the line and protect the controller against line
disturbances.
The use of a suitable line filter is part of the
standards conformity and a prerequisite of
the CE mark.
ROPEX line filters are specially optimized for use in
RESISTRON control loops. Providing that they are
installed and wired correctly, they guarantee compli-
ance with the EMC limit values.
You can find the exact specification of the line filter in
the ROPEX Application Report calculated for your par-
ticular heatsealing application.
For more technical information: ª"Line filter" docu-
mentation.
It is permissible to supply several RESISTRON control
loops with a single line filter, providing the total current
does not exceed the maximum current of the filter.
The wiring instructions contained in section 4.3 "Power
supply" on page 8 must be observed.
4.5 Current transformer PEX-W3/-W4
The PEX-W3/-W4 current transformer supplied with the
RESISTRON temperature controller is an integral part
of the control system. The current transformer may only
be operated if it is connected to the temperature con-
troller correctly (ªsection 4.3 "Power supply" on
page 8).
!
LINE
PE
Large cross-section
wire to ground
Large cross-section
wire to ground
Large frame contact surface
Do not lay parallel Mounting plate (galvanized)
max. 1m
ROPEX
temperature
controller
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Mounting and installation
Page 10 of 49 RES-5010
4.6 Wiring diagram (standard)
14
13
12
7
5
Ethernet
module
18
17
6
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Current transformer
twisted
Impulse
transformer
Heat-
sealing
band
LINE
sec.
U2
prim.
U1
Line filter LF-xx480
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30V / 0.2A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10VDC
V+
V-
24VDC POWER SUPPLY
RES-5010

Mounting and installation
RES-5010 Page 11 of 49
4.7 Wiring diagram with booster
connection
R
Current
transformer
Impulse
transformator
LINE
11
9
10
8
4
3
2
1
IR
UR
15
16
twisted
Booster
IN OUT
13
Line filter LF-xx480
NC
NC
14
13
12
7
5
Ethernet
module
18
17
6
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30V / 0.2A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10VDC
V+
V-
24VDC POWER SUPPLY
Heat-
sealing
band
sec.
U2
prim.
U1
twisted
Max. length 1m
24
RES-5010

Startup and operation
Page 12 of 49 RES-5010
5 Startup and operation
5.1 View of the device
5.2 Device configuration
The controller must be switched off in order
to configure the coding and slide switches.
5.2.1 Configuration of the secondary
voltage and current ranges
The secondary voltage and current ranges are auto-
matically configured during the automatic calibration
function (AUTOCAL). The voltage is configured in the
range from 0.4 VAC to 120 VAC and the current in the
range from 30 A to 500 A. If the voltage and / or current
are outside of the permissible range, a detailed error
message appears on the controller (ªsection 6.19
"Error messages" on page 36).
If the secondary current I2is less than 30 A, the sec-
ondary high-current wire must be laid twice (or several
times) through the PEX-W2, PEX-W3, or PEX-W4 cur-
rent transformer (ªROPEX Application Report).
Terminals
LEDs
Coding switches
Nameplate Wiring diagram
and jumpers
PROFINET
ports
USB interface
!
2x

Startup and operation
RES-5010 Page 13 of 49
5.2.2 Configuration of the rotary coding
switch for the temperature range
and alloy
The setting of the rotary coding switch for the
temperature range and alloy can be over-
written with the parameter data (ªsection 6.7
"Parameter data" on page 24).
If the switch is set to "9", more temperature ranges and
alloys can be selected in the ROPEX visualization soft-
ware (ªsection 6.12 "USB interface for visualization
software (ROPEXvisual®)" on page 34).
5.2.3 Configuration of the rotary coding
switches for device names
These coding switches can be used to set the names of
the RES-5010 devices in the PROFINET network. A
new setting does not take effect until the next time the
controller is switched on.
The preset device name "RES-5010" is configured as
follows, depending on the settings of the rotary coding
switches:
By assigning device names using rotary coding
switches, you can replace a device in an existing
machine without a programming tool. Simply configure
the replacement device with the same switch settings.
If the RES-5010 was named using a suitable
PROFINET tool (e.g. Siemens STEP7), the preset
device name can be erased by means of the rotary
coding switches. To do this, make sure the controller is
de-energized, then set the switches to 0xFF and switch
the controller on again. It is sufficient to supply the con-
troller with 24 VDC. No connection is required to the
PROFINET network. After the device name has been
successfully erased, the red DATA EXCHANGE LED
blinks at approx. 4 Hz. The power supply to the con-
troller must then be momentarily interrupted in order for
the new switch settings to take effect.
In addition to the device name, restoring the
factory settings by setting the rotary coding
switch to "0xFF" also erases all I&M data in the
memory.
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGIZED
(AT ALARM)
DE-ENERGIZED
SWITCH POS.
1
0
4
5
8
9
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
PC CONFIGURATION
ALLOY
780ppm/K
1100ppm/K (L) (A20
)
1100ppm/K (A20
)
780ppm/K
3500ppm/K (L) (NORE
X)
0
5
1
2
3
4
6
7
8
9
Switch
position
0
1
4
5
8
300°C
300°C
500°C
500°C
300°C
1100ppm/K
780ppm/K
1100ppm/K
780ppm/K
3500ppm/K
e.g. Alloy-20
e.g. Alloy L
e.g. Alloy-20
e.g. Alloy L
e.g. NOREX
Temp.
range
Temp.
coefficient
Band
alloy
0 = Factory settings
9 PC-CONFIGURATION
!
Rotary coding
switch Device name
00 Last name assigned is static
01…FE RES-5010-01…RES-5010-FE
FF Last device name assigned and
I&M data erased
0
0
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1
Station name selectable.
00 = Factory settings
0...F
0...F
(Controller_type: RES-5010 / UPT-6010)
Device name selectable
by PROFINET config tool
Device name preset to
“Controller_type-XX”
Erase name
00
01...FE
FF
0
0
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1
!

Startup and operation
Page 14 of 49 RES-5010
In order to assign the device name via the
PROFINET interface (e.g. using a program-
ming tool), the rotary coding switch must be set to
"0x00".
Note: By using a configuring tool (e.g. Siemens STEP7)
to specify the PROFINET topology, you can also assign
a name automatically if the controller does not already
have a device name when it is switched on. In this case,
the PLC automatically assigns it the name stored in the
project.
5.2.4 Configuration of the alarm relay
If the switch is set to "Alarm relay de-energized at
alarm / PC CONFIGURATION", you can select more
alarm output configurations in the ROPEX visualization
software (ªsection 6.12 "USB interface for visualiza-
tion software (ROPEXvisual®)" on page 34).
5.3 Replacing and burning in the
heatsealing band
5.3.1 Burning in the heatsealing band
The heatsealing band is a key component in the control
loop because it is not only a heating element but also a
sensor. The geometry of the heatsealing band is too
complex to be discussed at length here. We shall there-
fore only refer to a few of the most important physical
and electrical properties.
The measuring principle used for this system requires
a heatsealing band alloy with a suitable temperature
coefficient TCR. Too low a TCR leads to oscillation or
uncontrolled heating.
If a heatsealing band with a higher TCR is used, the
controller must be calibrated for it.
The first time the heatsealing band is heated to approx-
imately 200…250°C, the standard alloy undergoes a
once-only resistance change (burn-in effect). The cold
resistance of the heatsealing band is reduced by
approximately 2…3%. However, this at first glance
slight resistance change results in a zero point error of
20…30°C. The zero point must therefore be corrected
after a few heating cycles, i.e. the "AUTOCAL" function
must be run again.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally pre-
treated by the manufacturer.
An overheated or burned-out heatsealing
band must no longer be used because the
temperature coefficient has been irreversibly
altered.
One very important design feature is the copper or
silver-plating of the heatsealing band ends. Cold ends
allow the temperature to be controlled precisely and
extend the life of the Teflon coating and the heatsealing
band.
5.3.2 Replacing the heatsealing band
The supply voltage (all poles) must be disconnected
from the RESISTRON®temperature controller in order
to replace the heatsealing band.
The heatsealing band must be replaced in
accordance with the instructions provided by
the manufacturer.
Each time the heatsealing band is replaced, you must
calibrate the zero point with the "AUTOCAL" function
while the band (and the environment, i.e. silicone,
!
Alarm relay contact
opened by alarm/
PC-CONFIGURATION.
Alarm relay contact
closed by alarm.
(factory setting)
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGIZED
(AT ALARM)
DE-ENERGIZED
!
!

Startup and operation
RES-5010 Page 15 of 49
PTFE cover, sealing bar etc.) is still cold in order to
compensate production-related resistance tolerances.
The burn-in procedure described above should be per-
formed for all new heatsealing bands.
5.4 Startup procedure
Please also refer to section 1 "General information" on
page 3 and section 2 "Application" on page 4.
Mounting, installation and startup may only
be performed by authorized persons who
have received suitable instruction and are familiar
with the associated risks and warranty provisions.
5.4.1 Initial startup
Condition: The device must be correctly installed and
connected (ªsection 4 "Mounting and installation" on
page 6).
Proceed as follows to start up the controller for the first
time:
1. Switch off the line voltage and the 24 VDC supply,
and verify that the circuit is de-energized.
2. The supply voltage indicated on the nameplate of
the controller must be identical to the line voltage
that is present in the system or machine. The line
frequency is automatically detected by the tempera-
ture controller in the range from 47 to 63 Hz.
3. Link the device master file (GSDML) into the
PROFINET controller (ªsection 6.3), then select
the required parameters, assign a name to the
device, and start the communication.
4. Make sure the "ST" bit is not set.
5. Switch on the line voltage and the 24 VDC supply
(the order is arbitrary).
6. When the voltage is switched on, the yellow
"AUTOCAL" LED lights up for approximately 0.3
seconds to indicate that the controller is being pow-
ered up correctly. The red "BUS FAILURE" LED
lights up as long as no PROFINET communication
is active. It does not go out again until it detects an
active communication.
If the red "ALARM" LED lights up for
0.3…1.5 s when the voltage is switched on in
addition to the yellow "AUTOCAL" LED, the config-
uration of this controller has been changed in the
visualization software (ªsection 6.12 "USB inter-
face for visualization software (ROPEXvisual®)" on
page 34). In order to avoid malfunctions, please
check the controller configuration before con-
tinuing the startup procedure.
7. The green "DATA EXCHANGE" LED lights up to
indicate an active PROFINET communication.
8. One of the following states then appears:
9. Activate the "AUTOCAL" function while the
heatsealing band is still cold by setting the "AC" bit
(AUTOCAL) in the PROFINET protocol
(ªsection 6.4 "Communication protocol" on
page 20). The yellow "AUTOCAL" LED lights up for
the duration of the calibration process (approx.
10…15 s). The "AA" bit (AUTOCAL active) is addi-
tionally set and a voltage of approximately 0 VDC
appears at the actual value output (terminals
17+18). If an ATR-x is connected, it indicates
0…3°C.
After the zero point has been calibrated, the
"AUTOCAL" LED goes out and a voltage of
0.66 VDC (300°C range) or 0.4 VDC (500°C range)
appears at the actual value output. If an ATR-x is
connected, it must be set to "Z".
If the zero point was not calibrated successfully, the
"AL" bit (alarm active) is set and the red "ALARM"
LED blinks slowly (1 Hz). In this case the controller
configuration is incorrect (ªsection 5.2 "Device
configuration" on page 12, ROPEX Application
Report). Repeat the calibration after correcting the
controller configuration.
10.After the zero point has been successfully cali-
brated, specify a defined temperature by means of
the PROFINET protocol (set point) and set the "ST"
bit. The "RA" bit (control active) is then activated
!
!
"ALARM" LED "OUTPUT"
LED ACTION
OFF Short
impulses
every 1.2 s
Go to step 9
BLINKS fast
(4 Hz)
OFF Go to step 9
LIT continu-
ously
OFF Error code 901
(error group: 7):
No line voltage /
sync signal
(ªsection 6.2)
Otherwise:
Error diagnosis
(ªsection 6.19)

Startup and operation
Page 16 of 49 RES-5010
and the "HEAT" LED lights up. The heating and con-
trol process can be observed at the actual value
output.
The controller is functioning correctly if the temper-
ature (which corresponds to the signal change at the
analog output or the actual value in the PROFINET
protocol) is a regular curve, in other words it must
not jump abruptly, fluctuate, or temporarily deviate in
the wrong direction. This kind of behavior would
indicate that the URmeasurement cable was laid
incorrectly.
If an error code is displayed, proceed as described
in section 6.19 "Error messages" on page 36.
11.Burn in the heatsealing band (ªsection 5.3
"Replacing and burning in the heatsealing band" on
page 14) and run the "AUTOCAL" function again.
5.4.2 Restart after replacing the
heatsealing band
To replace the heatsealing band, proceed as described
in section 5.3 "Replacing and burning in the
heatsealing band" on page 14.
Always use a heatsealing band with the cor-
rect alloy, dimensions, and copper plating in
order to avoid malfunctions and overheating.
Continue with section 5.4, steps 4 to 11.
!

Device functions
RES-5010 Page 17 of 49
6 Device functions
See also section 4.6 "Wiring diagram (standard)" on
page 10.
6.1 LEDs and controls
In addition to the functions shown above, the LEDs also
indicate various controller operating states. These
states are described in detail in the table below:
121314 15161718
9
8
6
5
10
11
7
4
3
2
1
V
isual
BUS FAILURE
(red/green
LED)
DATA EXCH
(red/green
LED)
µC POWER
(green LED)
24V POWER
(Green LED)
Lit or blinking if no connection
exists to PROFINET.
Lit (green) while data exchange
with PROFINET controller.
Lit if internal power supply for
PROFINET interface is OK.
Lit if external 24VDC power
supply is present.
AUTOCAL
(yellow LED)
OUTPUT
(Green LED)
HEAT
(yellow LED)
ALARM
(Red LED)
Lit while AUTOCAL process is
executing.
Indicates pulses in
measurement mode. In control
mode, luminous intensity is
proportional to heating current.
Lit during heating phase.
Lit or blinking to indicate fault.
RX/TX
(yellow LED)
LINK
(green LED)
Lit or blinking if Ethernet
frames are transmitted.
Lit if connection exists to
Ethernet.
www.ROPEX.de
!
PROCESS CONTROL
EQUIPMENT
E464680

Device functions
Page 18 of 49 RES-5010
LED Blinks slowly (1 Hz) Blinks fast (4 Hz) Lit continuously
AUTOCAL
(yellow)
"RS" bit set (reset)
AUTOCAL requested but
function blocked (e.g.
START active)
AUTOCAL executing
LED blinks at a different frequency:
Supply voltages incorrect (too low)
HEAT
(yellow) —
START requested but func-
tion blocked (e.g.
AUTOCAL active, set tem-
perature < 40°C)
START executing
OUTPUT
(green) In control mode, luminous intensity is proportional to heating current.
ALARM
(red)
Configuration error, no
AUTOCAL possible
Controller calibrated incor-
rectly, run AUTOCAL Error, ªsection 6.19
DATA EXCHANGE
(red / green) —
Rotary coding switches for
device name set to 0xFF
(factory setting restored)
Green: Communication
with PROFINET controller
is active
Red: Internal error in
PROFINET module
BUS FAILURE
(red / green)
Blinks red for3sat2Hz:
No data exchange
Blinks (green or yellow) at 2 Hz:
DCP signal service activated via bus
Red: No communication or
slow / no physical connec-
tion
LINK PORT 1, 2
(green) ——
Connection exists to
Ethernet
RX / TX PORT 1, 2
(yellow) Device is transmitting / receiving Ethernet frames

Device functions
RES-5010 Page 19 of 49
6.2 PROFINET communication
The following sections only describe controller-specific
functions. For general information on the PROFINET
interface and the system configuration, please refer to
the description of your PLC.
The PROFINET interface of the RES-5010 supports
"Conformance Class C" with IO/RT and IRT according
to IEC 61784-2.
The controller can communicate via the PROFINET
interface provided the 24 VDC supply voltage
(terminals 19+20) is present.
If no line voltage is present however (e.g. if it is
switched off in order to open a door), error code 901 or
201 (error group 7, no line voltage / sync signal)
appears on the controller and the alarm relay is
switched. This happens due to the absence of line
voltage. The error message can be reset by switching
on the line voltage again and setting the "RS" bit
(ªsection 6.5.3 "Reset (RS)" on page 22).
You can easily process the error code that appears if
the line voltage is switched off – or suppress switching
of the alarm relay – in the PLC program.
6.3 Device master file (GSDML)
The configuring tools for the PROFINET controller
interpret the content of the device master files
(GSDML) and use this information to create a param-
eter set for the PROFINET controller which controls
user data traffic. The GSDML-V2.32-ROPEX-0150-
RES-5010-20151014.XML file of the RES-5010 con-
tains all essential controller information for the configu-
ration, e.g. the I/O data description, parameter descrip-
tions, error messages etc. The device master files and
the associated image files (.BMP) for visualization in
the configuring tool can be requested by e-mail
([email protected]e) or downloaded from our website
(www.ropex.de). If the controller already has an IP
address, the device master file can also be downloaded
from the integrated web server.
After linking the required device master file into the con-
figuring tool, you must assign a unique name to the
controller (device initialization). The controller is
shipped without a name. You must also select the
desired parameter values.

Device functions
Page 20 of 49 RES-5010
6.4 Communication protocol
The communication protocol consists of 2x16 bit input
words and 3x16 bit output words (from the point of view
of the controller). This protocol separates the set point
and the actual value of the RES-5010 from the status
information and the control functions, to simplify
decoding by the PROFINET controller.
Bits 0…7 form the low byte and bits 8…15 the high byte
("INTEL format").
The 2 x 16-bit input data contains the set point in
word cand the control functions in word d:
The 3 x 16-bit output data contains the actual value in
word c, the status information in word d, and the error
code in word e:
If the optional "Temperatures" submodule has been
configured, the controller returns another 16-bit output
word with the start temperature:
6.5 Input data
The term "input data" refers to the data that is trans-
ferred from the PROFINET controller to the RES-5010.
It contains the set point as well as the control functions
such as START or AUTOCAL for the RES-5010. These
functions are explained in the following.
If the PROFINET controller marks its output data with
the IOPS "bad" or does not transmit any data at all, all
cSpare Set point / AC temperature
Name:0000000
Bitno.:1514131211109876543210
dSpare Channel Spare Control function
Name:00000
CH2 CH1 CH0 000MAMPRSSTAC
Bitno.:1514131211109876543210
cActual value (signed)
Name:
Bitno.:1514131211109876543210
dSpare Channel Status information
Name: 0 0 0 0 CH2 CH1 CH0 SA IA WA AA AG AL TE TO RA
Bitno.:1514131211109876543210
eError code
Name: 0 0 0 0 0 0 A9A8A7A6A5A4A3A2A1A0
Bitno.:1514131211109876543210
cStart temperature (signed)
Name:
Bitno.:1514131211109876543210