Ropex RESISTRON RES-5010 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
8.1.13
RESISTRON
RES-5010
GB
Important features
• Microprocessor technology
• Complete control via PROFINET interface ("Conformance Class B", IO / RT acc. to IEC 61784-2)
(2 x RJ-45)
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges (AUTORANGE)
• Automatic phase angle compensation (AUTOCOMP)
• Automatic frequency adjustment
• Large current and voltage range
• Booster connection as standard
• 0…10VDC analog output for ACTUAL temperature
• Alarm function with error diagnosis
• Heatsealing band alloy and temperature range selectable
Operating
instructions

Page 2 RES-5010
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 Standards / CE marking . . . . . . . . . . . 4
1.7 Warranty provisions . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . 7
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 Installation procedure . . . . . . . . . . . . 10
8.2 Installation steps . . . . . . . . . . . . . . . . 11
8.3 Power supply . . . . . . . . . . . . . . . . . . . 12
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 13
8.5 Current transformer PEX-W3 . . . . . . 13
8.6 Wiring diagram (standard) . . . . . . . . . 14
8.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 15
9 Startup and operation . . . . . . . . . . . . . . . . 16
9.1 View of the controller . . . . . . . . . . . . . 16
9.2 Controller configuration . . . . . . . . . . . 16
9.3 Replacing and burning in the heatsealing
band . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.4 Startup procedure . . . . . . . . . . . . . . . 19
10 Controller functions . . . . . . . . . . . . . . . . . 21
10.1 LEDs and controls . . . . . . . . . . . . . . . 21
10.2 PROFINET communication . . . . . . . . 23
10.3 Device master file (GSDML) . . . . . . . 23
10.4 Communication protocol . . . . . . . . . . 24
10.5 Input data . . . . . . . . . . . . . . . . . . . . . . 24
10.6 Output data . . . . . . . . . . . . . . . . . . . . 26
10.7 Parameter data . . . . . . . . . . . . . . . . . 28
10.8 Undervoltage detection . . . . . . . . . . . 32
10.9 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 33
10.10 Booster connection . . . . . . . . . . . . . . 34
10.11 Diagnostic interface / visualization
software . . . . . . . . . . . . . . . . . . . . . . . 35
10.12 Total cycle counter . . . . . . . . . . . . . . 35
10.13 Operating hours counter . . . . . . . . . . 35
10.14 Data memory for error
messages and AUTOCAL . . . . . . . . . 35
10.15 Integrated clock
(date and time) . . . . . . . . . . . . . . . . . 35
10.16 System monitoring / alarm output . . . 36
10.17 Error messages . . . . . . . . . . . . . . . . . 37
10.18 Fault areas and causes . . . . . . . . . . . 40
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 42
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 42
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 43
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Safety and warning notes
RES-5010 Page 3
1 Safety and warning notes
This RESISTRON temperature controller is
manufactured 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.
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
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
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
providing 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
responsibility 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
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 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
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 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 prevented from seeping into
the transformer.
Incorrect installation of the impulse
transformer 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
malfunction.
The current transformer may only be operated if it is
connected to the RESISTRON temperature controller
correctly (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
!
!
TCR 10 4– ×10 K 1– ≥
!
!
!

Application
Page 4 RES-5010
operating safety. They are not included in the scope of
supply of the standard control system and are
described 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
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 8.3,
"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 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
1.7 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
connections, 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.
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
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
DIN EN 61010-1:2001
(2006/95/EG)
Safety requirements for electrical
equipment for measurement,
control and laboratory use
(low-voltage directive):
pollution degree 2,
protection class II,
measurement category I
(for URand IRterminals)
DIN EN 60204-1
(2006/42/EG)
Electrical equipment of
machines (machinery directive)
EN 55011:1998 + A1:1999 +
A2:2002
EN 61000-3-2:2006-04
EN 61000-3-3:1995-01 +
A1:2001 + A2:2005-11
(2004/108/EG)
EMC genery emissions:
Group 1, Class A
EN 61000-6-2:2005
(2004/108/EG)
EMC generic immunity:
Class A (ESDs, RF radiation,
bursts, surges)
Exception:
Line voltage interruption acc.
EN 61000-4-11 is not fulfilled
(This leads to a designated error
message of the controller)

Principle of operation
RES-5010 Page 5
• Film wrapping machines
• Pouch making machines
• Group packaging machines
•L-sealers
•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 heatsealing
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 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 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 dynamic thermoelectric control loop is formed
because purely electrical variables are measured at a
high sampling rate. A very large secondary current
range can be controlled with only minimal power
dissipation – a considerable advantage – because
power is controlled on the primary side of the
transformer. This allows optimal adaptation to the load
and to the required dynamic range despite the
controller's exceptionally compact dimensions.
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 control system's advanced tech-
nology if all of the system components – in other words
the heatsealing band, the impulse transformer, the
wiring, the timing signals, and the controller itself – are
fully 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-5010
4 Description of the controller
The microprocessor technology enriches the
RES-5010 RESISTRON temperature controller with
previously unattainable capabilities:
• Very simple operation thanks to AUTOCAL, the
automatic zero calibration function.
• Good dynamic response thanks to AUTOTUNE,
which automatically adapts to the controlled system.
• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
• High flexibility: The AUTORANGE function 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 RES-5010 RESISTRON temperature controller is
equipped with two PROFINET interfaces. These
interfaces can be used to control all of the controller
functions and query controller information.
The ACTUAL temperature of the heatsealing band is
supplied to the PROFINET interface and to an analog 0
to 10 V DC output. The real heatsealing band
temperature can thus be displayed on an external
temperature meter (e.g. ATR-x).
The RES-5010 features an integrated error 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 PROFINET signals are electrically
isolated from the controller and the heating circuit.
Either coding switches on the temperature controller
itself or the PROFINET interface can be used to adapt
to different heatsealing band alloys (Alloy 20, NOREX
etc.) and set the required temperature range
(0…300°C, 0…500°C etc.).
The compact design of the RES-5010 RESISTRON
temperature 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-5010 RESISTRON
temperature controller. They allow it to be optimally
adapted to your specific heatsealing application as well
as 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.
Line filter LF-xx480
Essential to ensure CE conformity.
Optimized for the RESISTRON temperature controller.

Accessories and modifications
RES-5010 Page 7
5.2 Modifications (MODs)
Owing to its universal design, the RES-5010
RESISTRON temperature controller is suitable for a
very wide range of heatsealing applications.
One modification (MOD) is available for the RES-5010
RESISTRON temperature controller 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.
Impulse transformer TR-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 a diagnostic
interface (DIAG) to the PC (USB port). Associated PC visualization software for
displaying setting and configuration data as well as for recording SET and ACTUAL
temperatures in real time.
Booster
External switching amplifier, necessary for high primary currents (continuous
current > 5A, pulsed current > 25A)
Monitoring current transformer MSW
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/W3 current transformer.
URmeasurement cable UML-1
Twisted cable for measuring the URvoltage.
Suitable for drag chains, contains neither halogens nor silicone.

Technical data
Page 8 RES-5010
6 Technical data
Type of construction 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)
Line voltage 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)
Depending on the version selected (section 13 "How to order" on page 43)
Line frequency 47…63 Hz, automatic adjustment to frequencies in this range
24VDC supply
voltage
Terminals 19+20
24VDC, Imax = 200mA
Tolerance: +10 / -10%
PROFINET
interface "Conformance Class B", IO / RT acc. to IEC 61784-2 2 Ethernet switch ports RJ45
Wiring: IEC61784-5-3
Baud rate: 100MHz
Data transport layer: Ethernet II, IEEE 802.3
Topology discovery: LLDP, SNMP V1, MIB2, physical device
Addressing: DCP or selectable with rotary coding switch
FSU (Fast Startup) support: Yes, but startup time approx. 1.5s.
Heatsealing band
typeandtemperature
range
The temperature range and temperature coefficient settings can also be specified
by means of the ROPEX visualization software (section 10.11 "Diagnostic
interface / visualization software" on page 35) in addition to the rotary coding
switch or the PROFINET interface (see below):
Temperature range: 200°C, 300°C, 400°C, or 500°C
Temperature coefficient: 400…4000ppm/K (variable setting range)
Five different ranges can be set with the rotary coding switch or via the PROFINET
interface:
Temperature coefficient 1100ppm/K, 0…300°C (e.g. Alloy 20)
Temperature coefficient 780ppm/K, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm/K, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780ppm/K, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm /K, 0…300°C (e.g. NOREX)
Analog output
(actual value)
Terminals 17+18
0…10VDC, Imax =5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% plus 50mV
Fault 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
Ambient temperature +5…+45°C

Dimensions
RES-5010 Page 9
7 Dimensions
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
mounting on a vertical top hat rail.
Weight Approx. 0.5kg (incl. connector plug-in parts)
Housing material Plastic, polycarbonate, UL-90-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.
!
75.0 90.0
113.0
135.0

Installation
Page 10 RES-5010
8 Installation
See also section 1 "Safety and warning notes" 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-5010
RESISTRON temperature controller:
1. Switch off the line voltage and verify that the circuit
is de-energized.
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 RESISTRON
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 rail, the minimum
clearance specified in section 6 "Technical data" on
page 8 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 12,
section 8.6 "Wiring diagram (standard)" on page 14,
and the ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 11 must also be heeded.
An overcurrent protective device (e.g. a fuse) must
be fitted when the controller is installed. The
minimum possible specification for this device must
be entered in the ROPEX Application Report based
on the calculated currents. If a larger overcurrent
protective device is fitted, you must match the
current carrying capacity of the other components
accordingly (e.g. cables, impulse transformer etc.).
5. Connect the RESISTRON temperature controller to
the PROFINET controller using a cable.
Check the tightness of all system
connections, including the terminals for the
impulse transformer windings.
6. Make sure the wiring conforms to all relevant
national and international installation regulations.
!
!

Installation
RES-5010 Page 11
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

Installation
Page 12 RES-5010
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
K1
3
3
3
1
Short wires
2
2
Line
115VAC, 230VAC, 400VAC
50/60Hz
Over-current protection
Double-pole circuit-breaker or fuses,
(ROPEX 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
(ROPEX Application Report).
Do not run the filter supply wires (line side) parallel
to the filter output wires (load side).
!
RESISTRON temperature controller belonging to the
4xx Series.
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 (ROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ROPEX Application Report).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
These wires must always be twisted (>20turns/meter).
These wires must be twisted (>20turns/meter)
if several control loops are laid together ("crosstalk").
Twisting (>20turns/meter) is recommended to
improve EMC.

Installation
RES-5010 Page 13
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 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 comp-
liance 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: "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 8.3 "Power
supply" on page 12 must be observed.
8.5 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 (section 8.3 "Power supply" on
page 12).
!
!
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
Page 14 RES-5010
8.6 Wiring diagram (standard)
8
7
5
4
6
3
2
1
+24VDC
GND
Termination
RX-
RX+
TX+
14
13
12
ALARM OUTPUT
max. 30V / 0.2A
19
Ethernet
PORT 1 (RJ45)
POWER SUPPLY
TX-
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
20
24V
IN 5V
OUT
Ethernet
module
electrically
isolated
R
11
9
10
8
4
3
2
1
IR
UR
15
16
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10VDC
0V
(Internal ground)
No external
grounding allowed!
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
6
Shield
Current transformer
PEX-W2/-W3
twisted
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
U2
prim.
U1
5
7NC
NC
RES-5010

Installation
RES-5010 Page 15
8.7 Wiring diagram with booster
connection
8
7
5
4
6
3
2
1
+24VDC
GND
RX-
RX+
TX+
14
13
12
19
Ethernet
PORT 1 (RJ45)
TX-
20
24V
IN 5V
OUT
R
11
9
10
8
4
3
2
1
IR
UR
15
16
18
17
°C
ATR
_
+
6
Shield
Booster
24
IN OUT
13
twisted
Max. length 1m
NC
NC
ALARM OUTPUT
max. 30V / 0.2A
POWER SUPPLY
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
ANALOG OUTPUT
+0...10VDC
0V
(Internal ground)
No external
grounding allowed!
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Current transformer
PEX-W2/-W3
twisted
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
U2
prim.
U1
Ethernet
module
electrically
isolated
Termination
5
7NC
NC
RES-5010

Startup and operation
Page 16 RES-5010
9 Startup and operation
9.1 View of the controller
9.2 Controller configuration
The controller must be switched off in order
to configure the coding switches and plug-in
jumpers.
9.2.1 Configuration of the secondary
voltage and current ranges
The secondary voltage and current ranges are
automatically 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 outside of the permissible range, a detailed error
message appears on the controller (see
section 10.17 "Error messages" on page 37).
If the secondary current I2is less than 30A, the
PEX-W2 or PEX-W3 current transformer must have
two turns (ROPEX Application Report).
Terminals
LEDs
Coding switches
Nameplate
Wiring diagram
and plug-in jumpers
PROFINET
connectors
!
2x

Startup and operation
RES-5010 Page 17
9.2.2 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
overwritten with the parameter data (section 10.7
"Parameter data" on page 28).
If the switch is set to "9", more temperature ranges and
alloys can be selected by means of the ROPEX
visualization software (see section 10.11
"Diagnostic interface / visualization software" on
page 35).
9.2.3 Configuration of the rotary coding
switches for station names
These coding switches can be used to set the names of
the RES-5010 stations in the PROFINET network. A
new setting does not take effect until the next time the
controller is switched on.
The preset station name "RES-5010" is configured as
follows, depending on the settings of the rotary coding
switches:
By assigning station names using rotary coding
switches, it is possible to replace a device in an existing
machine without a programming tool. The replacement
device must simply be configured with the same switch
settings.
If the RES-5010 was named using a suitable
PROFINET tool (e.g. Siemens STEP7), the preset
station 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
controller with 24VDC. No connection to the
PROFINET network is required. When the station
name has been successfully erased, the DATA
EXCHANGE LED (red) blinks at approx. 4Hz. The
power supply to the controller must then be
momentarily interrupted in order for the new switch
settings to take effect.
0
5
1
2
3
4
6
7
8
9
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
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) (NOREX)
9 PC-CONFIGURATION
!
Rotary coding
switch Station name
00 The last name assigned is static
01…FE RES-5010-01…RES-5010-FE
FF The last station name assigned
and the I&M data are 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 18 RES-5010
In addition to the station name, restoring the
controller's factory settings by setting the
rotary coding switches to "0xFF" also erases all
I&M data in the memory.
In order to assign the station name via the
PROFINET interface (e.g. using a
programming tool), the rotary coding switches
must be set to "0x00".
Note: By using a configuring tool (e.g. Siemens STEP7)
to specify the PROFINET topology, you can also assign
names automatically if the controller does not already
have a station name when it is switched on. In this
case, the PLC automatically assigns it the name stored
in the project.
9.2.4 Configuring the fault relay
If the jumper is not inserted – or if it is
incorrectly inserted – an error message
appears when the controller is switched on
(section 10.17 "Error messages" on page 37).
If the "Fault relay de-energized at alarm / PC CONFIG-
URATION" position is selected, the behavior of the
alarm output can be configured in more detail by means
of the ROPEX visualization software (see
section 10.11 "Diagnostic interface / visualization soft-
ware" on page 35).
9.3 Replacing and burning in the
heatsealing band
9.3.1 Burning in the heatsealing band
The heatsealing band is a key component in the control
loop because it is both a heating element and a sensor.
The geometry of the heatsealing band is too complex to
be discussed at length here. We shall therefore only
refer to a few of the most important physical and
electrical properties.
The measuring principle applied 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 this.
The first time the heatsealing band is heated to
approximately 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 repeated.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally
pretreated by the manufacturer.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR 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 accurately and
increase the life of the Teflon coating and the
heatsealing band.
9.3.2 Replacing the heatsealing band
All power supply leads must be disconnected from the
RESISTRON temperature controller in order to replace
the heatsealing band.
!
!
0
5
1
2
3
4
6
7
8
9
Alarm relay de-
energized by alarm/
PC-CONFIGURATION.
Alarm relay energized
by alarm.
(factory setting)
CONFIGURATION
ALARM OUTPUT
DE-ENERGIZED / PC
AT ALARM
ENERGIZED
!
!

Startup and operation
RES-5010 Page 19
The heatsealing band must be replaced in
accordance with the instructions provided by
the manufacturer.
Each time the heatsealing band is replaced, the zero
point must be calibrated with the AUTOCAL function
while the band is still cold in order to compensate
production-related resistance tolerances. The burn-in
procedure described above should be performed for all
new heatsealing bands.
9.4 Startup procedure
Please also refer to section 1 "Safety and warning
notes" on page 3 and section 2 "Application" on
page 4.
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
9.4.1 Initial startup
Prerequisites: The controller must be correctly installed
and connected (section 8 "Installation" on page 10).
Proceed as follows to start up the controller for the first
time:
1. Switch off the line voltage and verify that the circuit
is de-energized.
2. The supply voltage specified on the nameplate of
the controller must be identical to the line voltage
that is present in the plant or machine. The line
frequency is automatically detected by the
RESISTRON temperature controller in the range
from 47…63Hz.
3. Link the device master file (GSDML) into the
PROFINET controller (section 10.3), 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 24VDC auxiliary
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
powered up correctly. The "BUS FAILURE" LED
(red) 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 0.3s in
addition to the yellow "AUTOCAL" LED when
the voltage is switched on, the configuration of this
controller has been changed by means of the
visualization software (section 10.11
"Diagnostic interface / visualization software" on
page 35). In order to avoid malfunctions, please
check the controller configuration before
continuing 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
(section 10.4 "Communication protocol" on
page 24). The yellow "AUTOCAL" LED lights up for
the duration of the calibration process (approx.
10…15s). The "AA" bit (AUTOCAL active) is
additionally set and a voltage of approx. 0VDC
appears at the actual value output (terminals
17+18). If an ATR-x is connected, it indicates
0…3°C.
When the zero point has been calibrated, the
"AUTOCAL" LED goes out and a voltage of
0.66VDC (300°C range) or 0.4VDC (500°C range)
appears at the actual value output instead. If an
ATR-x is connected, it must be set to "Z".
If the zero point has not been successfully
calibrated, the "AL" bit (alarm active) is set and the
red "ALARM" LED blinks slowly (1Hz). In this case
the controller configuration is incorrect (
section 9.2 "Controller configuration" on page 16
and ROPEX Application Report). Repeat the
!
!
"ALARM" LED "OUTPUT"
LED ACTION
OFF Short pulses
every 1.2s
Go to 9
BLINKS fast
(4Hz)
OFF Go to 9
LIT
continuously
OFF Error code 901
(Error group: 7):
No line voltage /
sync signal
(section 10.2)
Otherwise:
Error diagnosis
(section 10.17)
!

Startup and operation
Page 20 RES-5010
calibration after the controller has been configured
correctly.
10.When the zero point has been successfully
calibrated, specify a defined temperature by means
of the PROFINET protocol (set point) and set the
"ST" bit. The "RA" bit (controller active) is then
activated and the "HEAT" LED lights up. The heating
and control process can be observed at the actual
value output.
The controller is functioning correctly if the
temperature (which corresponds to the signal
change at the analog output or the actual value in
the PROFINET protocol) has a harmonious motion,
in other words it must not jump abruptly, fluctuate, or
deviate temporarily in the wrong direction. This kind
of behavior would indicate that the URmeasurement
cable has been laid incorrectly.
If an error message is displayed, please proceed as
described in section 10.17 "Error messages" on
page 37.
11.Burn in the heatsealing band (section 9.3
"Replacing and burning in the heatsealing band" on
page 18) and repeat the AUTOCAL function.
9.4.2 Restart after replacing the
heatsealing band
To replace the heatsealing band, proceed as described
in section 9.3 "Replacing and burning in the
heatsealing band" on page 18.
Always use a heatsealing band with the
correct alloy, dimensions, and copper plating
in order to avoid malfunctions and overheating.
Continue with section 9.4, steps 4 to 11.
The controller is now ready
!