Ropex RESISTRON RES-409 User manual

ROPEX Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: https://ropex.de
74321 Bietigheim-Bissingen (Germany) Data subject to change
3.3.20 Version 1
RESISTRON
RES-409
Important features
• Microprocessor technology
• Complete control via CAN-Bus interface (CAN 2.0A according ISO 11898)
Remark: CANopen is not supported
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of February 2007)
• Automatic phase angle compensation (AUTOCOMP, as of February 2007)
• Automatic frequency adjustment
• Large current and voltage range
• 0…10VDC analog output for ACTUAL temperature
• Additional 24VDC control signals for START 0 (Set 0) and START 1 (Set 1)
(as of February 2007)
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
• Booster connection as standard (as of February 2007)
Operating
instructions

Page 2 RES-409 Version 1
Contents
1 General information . . . . . . . . . . . . . . . . . . 3
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
1.3 Heatsealing band . . . . . . . . . . . . . . . . 3
1.4 Impulse transformer . . . . . . . . . . . . . . 4
1.5 Current transformer PEX-W4/-W5 . . . . 4
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
1.8 Transportation . . . . . . . . . . . . . . . . . . . 4
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Principle of operation . . . . . . . . . . . . . . . . . 7
4 Description of the controller . . . . . . . . . . . 8
5 Accessories and modifications . . . . . . . . . 9
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 9
5.2 Modifications (MODs) . . . . . . . . . . . . 10
6 Technical data . . . . . . . . . . . . . . . . . . . . . . 11
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Montage und Installation . . . . . . . . . . . . . 14
8.1 Installation procedure . . . . . . . . . . . . 14
8.2 Installation steps . . . . . . . . . . . . . . . . 16
8.3 Power supply . . . . . . . . . . . . . . . . . . . 17
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 18
8.5 Current transformer PEX-W4/-W5 . . . 18
8.6 Wiring diagram (standard) . . . . . . . . . 20
8.7 Wiring diagram with booster connection
(MOD 26) . . . . . . . . . . . . . . . . . . . . . . 21
9 Startup and operation . . . . . . . . . . . . . . . . 22
9.1 View of the controller . . . . . . . . . . . . . 22
9.2 Controller configuration . . . . . . . . . . . 22
9.3 Heatsealing band . . . . . . . . . . . . . . . 27
9.4 Startup procedure . . . . . . . . . . . . . . . 28
10 Controller functions . . . . . . . . . . . . . . . . . 30
10.1 Indicators and controls . . . . . . . . . . . 30
10.2 CAN protocol . . . . . . . . . . . . . . . . . . . 31
10.3 Receiving CAN messages . . . . . . . . . 32
10.4 Sending CAN messages . . . . . . . . . . 38
10.5 Temperature meter (actual value output)
42
10.6 Hold mode . . . . . . . . . . . . . . . . . . . . . 43
10.7 Measuring impulse length (as of February
2007) . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.8 Automatic phase compensation (AUTO-
COMP, as of February 2007) . . . . . . 45
10.9 Temperature monitoring / "temperature
OK" bit (as of February 2007) . . . . . . 47
10.10 Temperature diagnosis (as of February
2007) . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.11 Heatup timeout (as of February 2007) 49
10.12 Diagnostic interface / visualization soft-
ware (as of February 2007) . . . . . . . . 50
10.13 Booster connection . . . . . . . . . . . . . . 50
10.14 Undervoltage detection (as of February
2007) . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.15 System monitoring / fault output . . . . 51
10.16 Error messages . . . . . . . . . . . . . . . . . 52
10.17 Fault areas and causes . . . . . . . . . . . 57
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 58
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 59
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 60
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

General information
Version 1 RES-409 Page 3
1 General information
This RESISTRON® temperature controller is manufactured according to EN 61010-1. In the course of its manu-
facture 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.
Please carefully read through the operating manual before using the RESISTRON® temperature controller. Keep
the operating manual for later reference and make sure that information and functions important for the user are
available.
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 Copyright
All contents, in particular texts, photographs and graphics, are protected by copyright. All rights, including to rep-
lication, publication, editing and translation, are reserved.
1.2 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.
1.3 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 A20: TCR = 1100 ppm/K
LEX3500: TCR = 3500 ppm/K
Vacodil: TCR = 1100 ppm/K
The RESISTRON® temperature controller must be set and coded according to the temperature coefficient of the
heatsealing band.
The temperature coefficient must be taken from the ROPEX application report and must be set accordingly.
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 clearly identified by means of suitable markings as well as the connector
geometry, length, or other means to ensure that replacement bands are identical.
TCR 10x10 4– K1– or K 1– or ppm/K=
!

General information
Page 4 RES-409 Version 1
1.4 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 EN 61558 or UL 5058 (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.
1.5 Current transformer PEX-W4/-W5
The current transformer supplied with the RESISTRON® temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W4 or PEX-W5 current transformer may be used. Other transformers 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.
1.6 Line filter
ROPEX provides line filters in different power classes. The ROPEX application report lists the suitable line filter
which can be ordered accordingly.
The use of an original ROPEX line filter is mandatory in order to comply with the directives mentioned in section
"DECLARATION OF CONFORMITY" on page 6. 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.
1.7 Maintenance
The controller requires no special maintenance. Regular inspection and / or tightening of the terminals – including
the terminals for the winding connections on the impulse transformer – is recommended. Dust deposits on the con-
troller can be removed with dry compressed air.
Dust deposits and dirt from liquids result in a loss of function. Accordingly, installation in a switch
cabinet or terminal cabined with IP54 is recommended.
1.8 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible damage.
!

General information
Version 1 RES-409 Page 5
1.9 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 disposal of such waste in an environmentally
sound way.
To guarantee proper disposal and / or the recover of reusable material, please take the device to a
designated municipal collection point and observe local regulations.
Careless, uncontrolled disposal can cause damage to the environment and human health. By
ensuring that your product is disposed of or recycled in a responsible way, you can help protect the
environment and human health.
This device must not be disposed of as residual waste!
!

General information
Page 6 RES-409 Version 1
DECLARATION OF CONFORMITY
We hereby declare that the following device has been developed and manufactured in conformance with the direc-
tives cited below:
Compliant with following standards and directives:
Note:
This declaration of conformity certifies that the device/electronic itself complies with the above-mentioned direc-
tives. The CE mark on the device/electronic does not relieve the machinery manufacturer of his duty to verify the
conformity of the completely installed, wired and operationally ready system in the machine with the EMC directive.
Comments:
RESISTRON/CIRUS temperature controllers are not independently operable devices. They are used by the
machinery manufacturer to form a sealing system by adding EMC-relevant components such as filters, transfor-
mers, heatsealing bands and wiring. The final configuration may vary significantly in terms of performance and
physical dimensions. All information provided by us in connection with the line filter is merely intended as a guide
and is based on a typical measuring setup. It serves to demonstrate that compliance with the EMC directive can
be achieved by using a line filter that is suitable for the overall system. The line filter and current transformer must,
however, be determined on the basis of the respective application. We also wish to point out that the transformer
which is used must be designed in accordance with VDE 0551/EN 61558 or UL 5058 for safety reasons.
ROPEX Industrie-Elektronik GmbH
Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)
Designation: RESISTRON temperature controller with accessories
Type: RES-409 with line filter and current transformer
Operating principle: Impulse sealing of films and plastics
EN 61010-1 Safety requirements for electrical equipment, control, and laboratory use
2014/35/EU low voltage directive
2014/30/EU electromagnetic compatibility directive
2011/65/EU RoHS directive
July 12, 2020
J. Kühner (CEO)

Application
Version 1 RES-409 Page 7
2 Application
This RESISTRON® temperature controller is an integral part of the "Series 400", the outstanding feature of which
is its microprocessor technology. All RESISTRON 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 heatsealing processes.
The controller is most commonly used for impulse-heatsealing PE films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•etc.
The use of RESISTRON temperature controllers results in:
• Repeatable quality of the heatseals under any conditions
• 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 temperature-sensitive, is monitored 50x per second (60x at 60Hz)
by measuring the current and voltage. The temperature calculated with the help of these measurements is
displayed 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
temperature and thus also its resistance. This change is measured and evaluated by the RESISTRON®
temperature controller.
The control loop is closed: ACTUAL temperature = SET temperature. Even minute thermal loads on the
heatsealing band are detected and can be corrected quickly and precisely.
A highly high response thermo-electric control loop is formed which is highly accurate because purely electrical
variables are measured at a high sampling rate. A high secondary current can be controlled 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

Description of the controller
Page 8 RES-409 Version 1
the system components, in other words the heatsealing band, the impulse transformer, the wiring, the timing
signals and the controller itself, are carefully compatible and interrelated.
4 Description of the controller
The microprocessor technology endows the RESISTRON® temperature controller RES-409 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 February 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 RESISTRON® temperature controller RES-409 is equipped with a CAN-Bus interface type CAN 2.0A
according ISO 11898 (Remark: CANopen is not supported). This interface can be used to control all the controller
functions and interrogate controller information.
The ACTUAL temperature of the heatsealing band is supplied to the CAN-Bus interface and to an analog
0 to 10VDC output. The real heatsealing band temperature can thus be displayed on an external temperature
meter (e.g. ATR-x).
The RES-409 features 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 immunity, all CAN-Bus signals are electrically isolated from the
controller and the heating circuit.
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

Accessories and modifications
Version 1 RES-409 Page 9
Either coding switches on the temperature controller itself or the CAN-Bus interface can be used to adapt to
different heatsealing band alloys (Alloy A20, LEX3500 etc.) and set to the required temperature range (0…300°C,
0…500°C etc.).
The compact design of the RESISTRON® temperature controller RES-409 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 RESISTRON® temperature
controller RES-409. 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 ("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 LF-xx480
Essential in order to ensure CE conformity.
Optimized for the RESISTRON® temperature controller.
Impulse transformer ITR-x
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
(ROPEX Application Report).
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL temper-
atures in real time.

Accessories and modifications
Page 10 RES-409 Version 1
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON® temperature controller RES-409 is suitable for a very wide range
of heatsealing applications.
Two modifications (MOD) are available for the RESISTRON® temperature controller RES-409 for implementing
special applications.
MOD 01
Amplifier for low secondary voltages (UR= 0.25…16VAC). This modification is necessary, for example, for very
short or low-resistance heatsealing bands.
MOD 26 (up to January 2007)
Additional terminal for connecting an external switching amplifier (booster). This modification is necessary for high
primary currents (continuous current > 5A, pulsed current > 25A).
This modification is supplied as standard with all controllers manufactured as of February 2007
(section 10.13 "Booster connection" on page 50)
Booster B-xxx400
External switching amplifier, necessary for high primary currents (continuous
current > 5A, pulsed current > 25A).
Monitoring current transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/-W3 current transformer.
Measurement cable UML-1
twisted measurement cable for the UR-voltage measurement.
Trailing cable, halogene und silicone free.
!

Technical data
Version 1 RES-409 Page 11
6 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35 mm) acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Line voltage All controllers manufactured as of February 2007:
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)
All controllers manufactured as of January 2004 up to January 2007:
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)
All controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on version selected (section 13 "How to order" on page 60)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
CAN-Bus interface CAN Bus-interface type CAN 2.0A according ISO 11898
(CANopen is not supported)
2 x 3-pole M8 circular connector acc. to IEC 947-5-2
All controllers manufactured as of February 2007:
Baud rates: 20kBaud; 50kBaud; 100kBaud, 125kBaud; 205kBaud;
250kBaud; 500kBaud; 800kBaud; 1MBaud
All controllers manufactured up to January 2007:
Baud rates: 10kBaud; 50kBaud; 125kBaud; 205kBaud;
250kBaud; 500kBaud; 800kBaud; 1MBaud

Technical data
Page 12 RES-409 Version 1
Heatsealing band
type and temperature
range
All controllers manufactured as of February 2007:
The temperature range and temperature coefficient settings can also be specified
in the ROPEX visualization software (section 10.12 "Diagnostic interface /
visualization software (as of February 2007)" on page 50) in addition to using the
rotary coding switch (see below) or the CAN interface:
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Five different ranges can be set with the rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20)
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. LEX3500)
Various ranges can be selected via the CAN interface:
Temperature coefficient 1100ppm (e.g. Alloy A20)
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 780ppm (e.g. Alloy L)
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 3500ppm (e.g. LEX3500)
0…200°C, 0…300°C, 0…400°C, 0…500°C
All controllers manufactured as of February 2007:
The settings with the rotary coding switch are considered to be the
factory setting. This corresponds to CAN message address 8, value 10 (dec)
(section 10.3 "Receiving CAN messages" on page 32).
All controllers manufactured up to January 2007:
Six different ranges can be set via the CAN interface:
Temperature coefficient 1100ppm, 0…200°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…400°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 3500ppm, 0…200°C (e.g. LEX3500)
Temperature coefficient 3500ppm, 0…300°C (e.g. LEX3500)
Analog output
(actual value)
Terminals 17+18
0…10V DC, Imax = 5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% add. 50mV
Digital logic levels
Terminals 5, 7
(As of February 2007)
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected
Alarm relay
Terminals 12, 13, 14
Umax = 30V (DC/AC), Imax = 0.2A, changeover contact, potential-free
Maximum load
(primary current of
impulse
transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power dissipation max. 20W
!

Technical data
Version 1 RES-409 Page 13
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 mechanical fix the controller must be fitted at both ends for
mounting on a vertical top hat rail.
Weight Approx. 0.7kg (incl. connector plug-in parts)
Housing material Plastic, polycarbonate, UL-94-V0
Connecting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors
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.
!

Dimensions
Page 14 RES-409 Version 1
7 Dimensions
8 Montage und Installation
See also section 1 "General information" on page 3.
Installation and startup may only be performed by technically trained, skilled persons who are
familiar with the associated risks and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RES-409 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 automatically detected by the
temperature controller in the range from 47Hz to 63Hz.
3. Install 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 installed on one top hat rail, the minimum
clearance specified in section 6 "Technical data" on page 11 must be allowed between them.
75.0 90.0
113.0
135.0
!

Montage und Installation
Version 1 RES-409 Page 15
4. Wire the system in accordance with the instructions in section 8.3 "Power supply" on page 17, section 8.6
"Wiring diagram (standard)" on page 20 and the ROPEX Application Report. The information provided in
section 8.2 "Installation steps" on page 16 must be additionally heeded.
5. Connect the RESISTRON® temperature controller to the CAN master using a cable according to IEC 947-5-2.
Check the tightness of all system connections, including the terminals for the impulse transformer
winding wires.
6. Make sure that the wiring conforms to all relevant national and international installation regulations.
!

Montage und Installation
Page 16 RES-409 Version 1
8.2 Installation steps
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
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
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
direction
of rotation
Note
number
of turns
(up to Jan. 2007)

Montage und Installation
Version 1 RES-409 Page 17
8.3 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
Over-current protection
Double-pole circuit-breaker or fuses,
(ROPEX Application Report)
Short-circuit protection only. RESISTRON® temper-
ature 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
(ROPEX 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 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 (ROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ROPEX Application Report).
Wires must always be twisted (min. 20 turns/meter).
These wires must be twisted (min. 20 turns/meter)
if several control loops are laid together ("crosstalk").
Twisting (min. 20 turns/meter) is recommended to
improve EMC.

Montage und Installation
Page 18 RES-409 Version 1
8.4 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 control on the line and protect the controller against line distur-
bances.
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 compliance with the EMC limit values.
You can find the exact specification of the line filter in the ROPEX Application Report calculated for your particular
heatsealing application.
For more technical information: "Line filter" documentation.
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 8.3 "Power supply" on page 17 must be observed.
Example drawing for LF-06480:
8.5 Current transformer PEX-W4/-W5
The PEX-W4/-W5 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 controller
correctly (section 8.3 "Power supply" on page 17).
!
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. 1 m
ROPEX
temperature
controller

Montage und Installation
Version 1 RES-409 Page 19
8.5.1 PEX-W4
8.5.2 PEX-W5
Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022).
Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Montage und Installation
Page 20 RES-409 Version 1
8.6 Wiring diagram (standard)
The START 0 and START 1 functions at terminals 5 and 7 are only available on controllers manufac-
tured as of February 2007.
14
13
12
4
4
1
1
3
3
L
L
H
H
6
5
7
GND
R
11
9
10
8
4
3
2
1
IR
UR
15
16
18
17
°C
ATR
_
+
U2
prim.
U1
ALARM OUTPUT
max. 30V / 0.2A
Ground
Must be grounded
externally to prevent
electrostatic charging!
Bus GND
Bus GND
CAN bus
Plug 1
3-pole
CAN bus
Plug 2
3-pole
CAN bus
Plug assignment
(RES-409)
START 0 (Set 0)
with 24 VDC signal
START 1 (Set 1)
with 24 VDC signal
ANALOG
OUTPUT
+0...10VDC
RES-409
(also with MOD 01)
CAN bus
Controller
electrically
isolated
Impulse
transformer
Heatsealing
band
LINE
Line filter LF-xx480
sec.
Twisted
0V
(Internnal ground)
No external
grounding allowed!
0V
()
Internnal ground
No external
grounding
allowed!
up to
production
date
January 2007
4
3 3 = blue
4 = black
1 = brown
1
Current transformer
!