Ropex RESISTRON RES-408 User manual

Industrie-Elektronik GmbH Tel: [phone] E-Mail: [email protected]
Gansäcker 21 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
26.6.06
RESISTRON
RES-408 GB
Important features
• Microprocessor technology
• Separate terminal for operation and display
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of May 2006)
• Automatic phase angle compensation (AUTOCOMP, as of June 2006)
• Automatic frequency adjustment
• Wide current and voltage range
• 0…10VDC analog output for ACTUAL temperature
• 24VDC control signals for START and PREHEAT with electrical isolation
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable as standard (as of June 2006)
Operating
Instructions

Page 2 RES-408
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 8
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
7 Controller/terminal compatibility . . . . . . . 11
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 12
9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.1 Installation procedure . . . . . . . . . . . . 13
9.2 Installation steps . . . . . . . . . . . . . . . . 14
9.3 Power supply . . . . . . . . . . . . . . . . . . . 15
9.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 16
9.5 Current transformer PEX-W3 . . . . . . 16
9.6 Wiring diagram (standard) . . . . . . . . . 17
9.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 18
10 Startup and operation . . . . . . . . . . . . . . . . 19
10.1 View of the controller . . . . . . . . . . . . . 19
10.2 Controller configuration . . . . . . . . . . . 20
10.3 Heatsealing band . . . . . . . . . . . . . . . 21
10.4 Startup procedure . . . . . . . . . . . . . . . 22
11 Controller functions . . . . . . . . . . . . . . . . . 24
11.1 Indicators and controls . . . . . . . . . . . 24
11.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 27
11.3 Navigation in the menus . . . . . . . . . . 27
11.4 Menu structure . . . . . . . . . . . . . . . . . . 28
11.5 Menu steps . . . . . . . . . . . . . . . . . . . . 29
11.6 Temperature setting
(set point selection) . . . . . . . . . . . . . . 31
11.7 Temperature indication / actual value
output . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.8 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 32
11.9 Heating to the heatsealing
temperature (HEAT) . . . . . . . . . . . . . 33
11.10 "PREHEAT" signal . . . . . . . . . . . . . . . 34
11.11 Hold mode . . . . . . . . . . . . . . . . . . . . . 34
11.12 Measuring impulse duration (as of
June 2006) . . . . . . . . . . . . . . . . . . . . . 35
11.13 Automatic phase compensation (AUTO-
COMP) (as of June 2006) . . . . . . . . . 35
11.14 Temperature diagnosis
(as of June 2006) . . . . . . . . . . . . . . . . 36
11.15 Heatup timeout
(as of June 2006) . . . . . . . . . . . . . . . . 37
11.16 Diagnostic interface / visualization soft-
ware (as of June 2006) . . . . . . . . . . . 37
11.17 System monitoring / alarm output . . . 37
11.18 Error messages . . . . . . . . . . . . . . . . . 38
11.19 Fault areas and causes . . . . . . . . . . . 43
12 Factory settings . . . . . . . . . . . . . . . . . . . . . 44
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 45
14 How to order . . . . . . . . . . . . . . . . . . . . . . . . 46
15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Safety and warning notes
RES-408 Page 3
1 Safety and warning notes
This RESISTRON-Temperaturregler is manufactured
according to DIN EN 61010-1. In the course of its
manufacture it passed through quality assurance, whe-
reby it was subjected to extensive inspections and
tests.
It left the 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 per-
formed by technically trained, skilled persons who are
familiar with the associated risks and warranty provi-
sions.
1.1 Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and provi-
ding the regulations, notes and warnings contained in
these instructions are complied with.
In case of non-compliance 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.
Ensuring such compliance is the personal respon-
sibility of the user.
1.2 Heatsealing band
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands.
The resistance of the heatsealing band which
is used must have a positive minimum tem-
perature coefficient in order to guarantee trouble-
free operation of the RESISTRON-Temperatur-
regler.
The temperature coefficient must be specified as fol-
lows:
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
The RESISTRON-Temperaturreglers 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-Temperaturreglers lead to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by detail specification, part number
or some other means that will assure that replacement
bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This trans-
former must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced insula-
tion) and have a one section bobin. When the impulse
transformer is installed, suitable shock protection must
be provided in accordance with the national installation
regulations for electrical equipment. In addition, water,
cleaning solutions and conductive fluids must be pre-
vented from seeping into the transformer.
Incorrect installation of the impulse trans-
former impairs electrical safety.
1.4 Current transformer PEX-W2/-W3
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2 or PEX-W3
current transformer may be used. Other
transformers may cause the equipment to mal-
function.
The current transformer may only be operated if it is
connected to the RESISTRON-Temperaturregler cor-
rectly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
"Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
operating safety. They are not included in the scope of
!
!
TCR 10 4– ×10 K 1– ≥
!
!
!

Application
Page 4 RES-408
supply of the standard control system and are des-
cribed in a separate document.
1.5 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions men-
tioned in section 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty connec-
tions, dropping, electrical overloading, natural wear,
incorrect or negligent handling, chemical influences or
mechanical overloading as well as devices that have
been modified, relabeled or otherwise altered by the
customer, for example in an attempt to repair them or
install additional components, are excluded from the
warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
1.7 Standards / CE marking
The controller described here complies with the follo-
wing 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 responsi-
bility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned stan-
dards.
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 8.3, "Power supply"). If peri-
pheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
2 Application
This RESISTRON temperature controller is an integral
part of the "series 400", the outstanding feature of
which is its microprocessor technology. All RESIS-
TRON temperature 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 heat-
sealing processes.
The controller is most commonly used for impulse-
heatsealing PE and PP films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•L-sealers
•etc.
DIN EN 61010-1
(VDE 0411-1)
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
DIN EN 60204-1 Electrical equipment of machines
(machinery directive)
EN 50081-1 EMC interference emissions accor-
ding to EN 55011, group 1, class B
EN 50082-2 EMC interference immunity:
ESDs, RF radiation, bursts, surges.

Principle of operation
RES-408 Page 5
The use of RESISTRON temperature controllers
results in:
• Repeatable quality of the heatseals under any con-
ditions
• Increased machine capacity
• Extended life of the heatsealing bands and teflon
coatings
• Simple operation and control of the sealing process
3 Principle of operation
The resistance of the heatsealing band, which is tem-
perature-sensitive, is monitored 50x per second (60x at
60Hz) by measuring the current and voltage. The tem-
perature calculated with the help of these measure-
ments is displayed and compared with the set point.
The primary voltage of the impulse transformer is adju-
sted 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 temperature and thus also its resistance.
This change is measured and evaluated by the RESIS-
TRON temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the heat-
sealing band are detected and can be corrected quickly
and precisely.
The thermoelectric control loop which is formed has a
highly dynamic response 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 controlled on the primary side of the
transformer. This allows optimum adaptation to the
load and to the required dynamic range despite the
exceptionally compact dimensions of the controller.
PLEASE 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 advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
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

Description of the controller
Page 6 RES-408
4 Description of the controller
The microprocessor technology endows the RES-408
RESISTRON temperature controller with previously
unattainable capabilities:
• Very simple operation thanks to AUTOCAL, the
automatic zero calibration function.
• Good dynamic response of the control system
thanks to AUTOTUNE, which adapts automatically
to the controlled system.
• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
• High flexibility: The AUTORANGE function (as of
June 2006) covers a secondary voltage range from
0.4V to 120V and a current range from 30A to
500A.
• Automatic adjustment to the line frequency in the
range from 47Hz to 63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The temperature can be set on the separate T-408-1
(or T-400) operator terminal.
The real heatsealing band temperature is also visua-
lized on the operator terminal.
The RES-408 RESISTRON temperature controller fea-
tures an integrated fault diagnosis function, which tests
both the external system (heatsealing band, wiring etc.)
and the internal electronics and outputs a selective
error message in case of a fault.
To increase operational safety and interference immu-
nity, all 24VDC logic signals are electrically isolated
from the controller and the heating circuit.
Coding switches on the temperature controller itself
can be used to adapt to different heatsealing band
alloys (Alloy 20, NOREX etc.) and set the required tem-
perature range (0...300°C, 0...500°C etc.) on all con-
trollers manufactured as of June 2006.
The compact design of the RES-408 RESISTRON tem-
perature controller and the plug-in connections make
this controller easy to install.
5 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the RES-408 RESISTRON
temperature controller. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.
5.1 Accessories
The products described below are only a few of the
wide range of accessories available for RESISTRON
temperature controllers (ª"Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Analog indication of the ACTUAL temperature of the heatsealing band in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
in impulse mode.
Digital temperature meter DTR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Digital indication of the ACTUAL temperature of the heatsealing band in °C, with
HOLD function.
Line filter
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.

Accessories and modifications
RES-408 Page 7
Impulse transformer
Designed according to VDE 0570/EN 61558 with a one-section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
(ªROPEX Application Report).
CI-USB-1 communication interface
Interface for connecting a RESISTRON temperature controller with a diagnostic
interface (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL tempe-
ratures in real time.
Booster
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/W3 current transformer.

Accessories and modifications
Page 8 RES-408
5.2 Modifications (MODs)
Owing to its universal design, the RES-408 RESIS-
TRON temperature controller is suitable for a very wide
range of heatsealing applications.
Various modifications (MODs) are offered for the
RES-408 RESISTRON temperature controller for
implementing special applications.
The modifications described here are just a few of the
large number available. Separate documentation is
supplied for all modifications.
MOD 01
Amplifier for low secondary voltages
(UR= 0.25…16VAC). This modification is necessary,
for example, for very short or low-resistance heat-
sealing bands.
MOD 26
Additional terminal for connecting an external switching
amplifier (booster). This modification is necessary for
high primary currents (continuous current > 5A, pulsed
current > 25A).
MOD 37 (up to May 2006)
Additional rotary coding switch for the heatsealing band
alloy and the temperature range. Various heatsealing
band alloys (e.g. Alloy 20, NOREX) and temperature
ranges (e.g. 300 °C, 500°C) can be selected.
This modification is supplied as standard
with all controllers manufactured as of
June 2006 (ª
ªª
ªsection 10.2.2 "Configuration of the
rotary coding switch for the temperature range and
alloy (as of June 2006)" on page 21).
!
Switch
position
Temp.
range
Temp.
coefficient
Band
alloy
0
5
1
2
3
4
6
7
8
9
0
5
1
2
3
4
6
7
8
9
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
0 = Factory settings
SWITCH POS.
1
0
4
5
8
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
ALLOY
780ppm/K
1100ppm/K
(L)
(A20)
1100ppm/K (A20)
780ppm/K
3500ppm/K
(L)
(NOREX)

Technical data
RES-408 Page 9
6 Technical data
Type of construction Controller: Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm)
acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Terminal: Housing for installation in the electrical cabinet
Dimensions (W x H): 96 x 48mm; depth: 55mm (excl. connector)
Line voltage Controllers manufactured as of June 2006:
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC)
400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
Controllers manufactured between January 2004 and May 2006:
115VAC version: 115VAC -15%…120VAC +10% (equivalent to 98…132VAC)
230VAC version: 230VAC -15%…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15%…415VAC +10% (equivalent to 340…456VAC)
Controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version (ªsection 14 "How to order" on page 46)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
Controllers manufactured as of June 2006:
The temperature range and temperature coefficient settings can also be specified
in the ROPEX visualization software (ªsection 11.16 "Diagnostic interface /
visualization software (as of June 2006)" on page 37) in addition to using the
rotary coding switch (see below):
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Five different ranges can be set on the controller with the rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20), default
Temperature coefficient 780ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780ppm, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm, 0…300°C (e.g. NOREX)
Controllers manufactured up to May 2006:
Default value 300°C, Alloy 20
The temperature range and alloy can be selected with MOD 37.
Analog output
(actual value)
Terminals 17+18
0…10VDC, Imax =5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% plus 50mV
Digital logic levels
Terminals 5+7
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30V DC (max. current input 6mA)
Reverse polarity-protected

Technical data
Page 10 RES-408
Alarm relay
Terminals 12, 13, 14
Umax =50VDC,I
max = 0.2A, changeover contact, potential-free
Can be inverted by means of a plug-in jumper
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power loss max. 22W
Ambient
temperature
+5…+45°C
Degree of protection IP20
Installation If several controllers are installed on one top hat rail
(DIN TS35 rail), a clearance of at least 20mm should
be allowed between them.
The moving clip required for fastening must be facing
down for mounting on a horizontal top hat rail.
End holders to mechanically fix the controller must be fitted at both ends for moun-
ting on a vertical top hat rail.
Weight Controller: Approx. 0.7kg (incl. connector plug-in parts)
Terminal: Approx. 0.15kg
Housing material Controller: Plastic, polycarbonate, UL-90-V0
Terminal: Black plastic, type Noryl SE1 GFN2
Controller connec-
ting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
with plug-in connections
If ferrules are used, they must be crimped in accordance
with DIN 46228 and IEC/EN 60947-1.
This is essential for proper electrical contact in the terminals.
!

Controller/terminal compatibility
RES-408 Page 11
7 Controller/terminal compatibility
All RES-408 RESISTRON temperature controllers
manufactured as of June 2006 are supplied as an
upgraded version.
Among other things, the data transfer between the con-
troller and the terminal has been modified. These
changes were necessitated by the new European
RoHS/WEEE Directives. Lead has now been banned
from some of the electronic components used in our
products.
As a result, all RES-408 controllers manufac-
tured up to May 2006 can only be operated
with a T-400 terminal. Controllers manufactured as
of June 2006 can only be operated with a T-408-1.
Malfunctions or damage may otherwise occur.
This has no effect on temperature control or on the
external PLC control signals.
RES-408 controllers manufactured as of
June 2006 are fully electrically compatible
with the old version (as far as the PLC control
signals are concerned).
Please pay attention to the controller and terminal ver-
sions when ordering spare parts. The controller may
have to be exchanged together with the terminal. Refer
to the compatibility table below:
New version (as of June 2006):
Old version (up to May 2006):
!
!
Controller type Art. No. Compatible with
RES-408/115VAC 740841 Terminal T-408-1
Art. No. 885441
RES-408/230VAC 740842
RES-408/400VAC 740843
Controller type Art. No. Compatible with
RES-408-0-3/115VAC 740801 or 740831
Terminal T-400
Art. No. 885440
RES-408-0-3/230VAC 740802 or 740832
RES-408-0-3/400VAC 740803 or 740833
RES-408-0-5/xxxVAC 740805, 740806, 740807, 740835, 740836 or 740837
RES-408-1-x/xxxVAC 740811, 740812, 740813, 740815, 740816 or 740817

Dimensions
Page 12 RES-408
8 Dimensions
RES-408 controller
T-400 or T-408-1 terminal
75.0 90.0
113.0
135.0
42.0 90.0
48.0 96.0
9.0 55.0
front panel
56.0
outline dimensions front frame
92 x 45
+0.8
- 0 - 0
+0.6
panel cutout
o 5mm

Installation
RES-408 Page 13
9 Installation
ªSee also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be per-
formed by technically trained, skilled per-
sons who are familiar with the associated risks and
warranty provisions.
9.1 Installation procedure
Proceed as follows to install the RES-408 RESISTRON
temperature controller:
1. Switch off the line voltage and verify that all circuits
are deenergized.
2. The supply voltage specified on the nameplate of
the RESISTRON temperature controller must be
identical to the line voltage that is present in the
plant or machine. The line frequency is automati-
cally detected by the temperature controller in the
range from 47Hz to 63Hz.
3. Install the RESISTRON temperature controller in
the electrical cabinet on a standard top hat rail (DIN
TS35 rail according to DIN EN 50022). If several
controllers are installed on one top hat rail, the
minimum clearance specified in section 6 "Technical
data" on page 9 must be allowed between them.
4. Install the terminal in the front panel cutout. It is
fastened by means of four clips which snap onto the
side of the terminal housing.
5. Connect the controller and terminal together with
the cable provided for this purpose.
Controllers manufactured up to May 2006 are
only allowed to be operated with a T-400 ter-
minal. Controllers manufactured as of June 2006
can only be operated with a T-408-1. Malfunctions
or damage may otherwise occur (ª
ªª
ªsection 7 "Con-
troller/terminal compatibility" on page 11).
6. Wire the system in accordance with the instructions
in section 9.3 "Power supply" on page 15 and the
ROPEX Application Report. The information pro-
vided in section 9.2 "Installation steps" on page 14
must be heeded additionally.
Check the tightness of all system connec-
tions, including the terminals for the impulse
transformer winding wires.
7. Make sure that the wiring conforms to the relevant
national and international installation regulations.
!
!
!

Installation
Page 14 RES-408
9.2 Installation steps
Terminal
Line
Impulse
transformer
Current transformer
PEX-W2/-W3
U (prim.)
1
Heatsealing band R= f (T)
U (sec.)
2
A
F
Controller
Temperature
meter
ATR-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 Configure
DIP switches
correctly
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
number
of turns
(up to May 2006)

Installation
RES-408 Page 15
9.3 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
K1
3
3
3
1
Short wires
2
2
Line
115VAC, 230VAC, 400VAC
Circuit breaker
Double-pole, C characteristic
(ªROPEX Application Report)
Short-circuit protection only.
RESISTRON-Temperaturreglers 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-Temperaturregler belonging to the 4xx
Series.
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
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. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
cThese wires must always be twisted (>20/m)
dThese wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
eTwisting (>20/m) is recommended to improve EMC.

Installation
Page 16 RES-408
9.4 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 com-
pliance 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 RESIS-
TRON 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 9.3 "Power
supply" on page 15 must be observed.
9.5 Current transformer PEX-W3
The PEX-W3 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 9.3 "Power supply" on
page 15).
!!
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

Installation
RES-408 Page 17
9.6 Wiring diagram (standard)
RES-408
(also with MOD 01)
GND 6
7
5
R
11
9
10
8
4
3
2
1
IR
UR
U2
prim.
U1
12
14
13
18
17
°C
ATR
+
HOLD
PREHEAT
SEALHEAT
ENTER
HAND
RESET
ROPE X
Current transformer
PEX-W2/-W3
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
twisted
PREHEAT
with 24VDC-Signal
START (HEAT)
with 24VDC-Signal
ALARM
OUTPUT
max. 50V/0,2A
ANALOG
OUTPUT
+0...10VDC
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
Display- and
operation panel
Up to production date March 2003 the standard output power circuit
(terminals 3+4) has NO function when the booster-connection
(MOD 26) is installed.
As of April 2003 the terminals 3+4 are active too when the
booster-connection is installed.
T-4 08
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
up to
production
date
May 2006

Installation
Page 18 RES-408
9.7 Wiring diagram with booster
connection (MOD 26)
RES-408
(also with MOD 01)
R
11
9
10
8
IR
UR
U2
NC
NC
2
24
IN OUT
1
13
prim.
4
3
16
15
U1
PREHEAT
with 24VDC-Signal
START (HEAT)
with 24VDC-Signal
GND 6
7
5
ALARM
OUTPUT
max. 50V/0,2A
12
14
13
18
17
°C
ATR
+
ANALOG
OUTPUT
+0...10VDC
HOLD
PREHEAT
SEALHEAT
ENTER
HAND
RESET
ROPE X
Display- and
operation panel
Up to production date March 2003 the standard output power circuit
(terminals 3+4) has NO function when the booster-connection
(MOD 26) is installed.
As of April 2003 the terminals 3+4 are active too when the
booster-connection is installed.
+
Current transformer
PEX-W2/-W3
Impulse
transformer
Heat-
sealing
band
LINE
Booster
Line filter LF-xx480
sec.
twisted
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
T-4 08
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
up to
production
date
May 2006

Startup and operation
RES-408 Page 19
10 Startup and operation
10.1 View of the controller
RES-408 controller
T-400 or T-408-1 terminal
Te r m in a ls
Wiring diagram
LEDs
Coding switches and
plug-in jumpers
Nameplate
Connection for
terminal
Display
Operator keys
Cable connection
Fixing
Nameplate
clips (4x)

Startup and operation
Page 20 RES-408
10.2 Controller configuration
The controller must be switched off in order
to configure the coding switches and plug-in
jumpers.
10.2.1 Configuration for secondary
voltage and current
Automatic configuration (AUTORANGE)
(as of June 2006)
The secondary voltage and current ranges are automa-
tically configured by the automatic calibration function
(AUTOCAL). The voltage is configured in the range
from 0.4VAC to 120VAC and the current in the range
from 30A to 500A. If the voltage and/or current are out-
side the permissible range, a detailed error message
appears on the controller (ªsee section 11.18 "Error
messages" on page 38).
Configuration with coding switches
(up to May 2006)
Set the DIP switches for matching the secondary
voltage U2and the secondary current I2to the correct
position for your application.
You can find the exact configuration of the
DIP switches in the ROPEX Application
Report calculated for your particular application.
If the secondary current I2 is less than 30A, the PEX-
W2 or PEX-W3 current transformer must have two
turns (ªROPEX Application Report).
!
!
3
2
145
ON
OFF
1...10V
6...60V
20...120V
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
30...100A
60...200A
120...400A
OFF
ON
ON
OFF
OFF
ON
DIP switch DIP switch
12
U
2
I
2
345
3
2
145
4
3
ON
OFF
U (V)
2
1-10
SWITCH
ON
Factory settings
2x