Ropex Resistron RES-5011 User manual

RESISTRON
Industrie-Elektronik GmbH Tel.Тел: [phone] E-MailЭл. почта: [email protected]
Adolf-Heim-Str. 4 FaxФакс: [phone] InternetИнтернет: www.ropex.de
74321-Bietigheim-Bissingen (Germany)(Germania)(RFA)(Германия)(Alemania) Technische Änderun-
29.7.20
RES-5011
Important features
• Microprocessor technology
• Complete control via PROFINET interface (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-5011
Contents
1 General information . . . . . . . . . . . . . . . . . . 3
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
1.3 Heatsealing band . . . . . . . . . . . . . . . . 3
1.4 Impulse transformer . . . . . . . . . . . . . . 3
1.5 Current transformer PEX-W4/-W5 . . . . 3
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
1.8 Transportation . . . . . . . . . . . . . . . . . . . 4
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Principle of operation . . . . . . . . . . . . . . . . . 6
4 Description of the controller . . . . . . . . . . . 7
5 Accessories and modifications . . . . . . . . . 8
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 8
5.2 Modifications (MODs) . . . . . . . . . . . . . 9
6 Technical data . . . . . . . . . . . . . . . . . . . . . . 10
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.1 Installation procedure . . . . . . . . . . . . 13
8.2 Installation steps . . . . . . . . . . . . . . . . 14
8.3 Power supply . . . . . . . . . . . . . . . . . . . 15
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 16
8.5 Current transformer PEX-W4/-W5 . . . 16
8.6 Wiring diagram (standard) . . . . . . . . . 18
8.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 19
9 Startup and operation . . . . . . . . . . . . . . . . 20
9.1 View of the controller . . . . . . . . . . . . . 20
9.2 Controller configuration . . . . . . . . . . . 20
9.3 Replacing and burning in the heatsealing
band . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.4 Startup procedure . . . . . . . . . . . . . . . 23
10 Controller functions . . . . . . . . . . . . . . . . . 25
10.1 LEDs and controls . . . . . . . . . . . . . . . 25
10.2 EtherNet/IP communication . . . . . . . . 27
10.3 Device description file (EDS) . . . . . . . 27
10.4 Communication protocol . . . . . . . . . . 28
10.5 Input data . . . . . . . . . . . . . . . . . . . . . . 28
10.6 Output data . . . . . . . . . . . . . . . . . . . . 30
10.7 Parameter object (class: 0x0F) . . . . . 32
10.8 Undervoltage detection . . . . . . . . . . . 41
10.9 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 41
10.10 Booster connection . . . . . . . . . . . . . . 42
10.11 Diagnostic interface / visualization
software . . . . . . . . . . . . . . . . . . . . . . . 43
10.12 Total cycle counter . . . . . . . . . . . . . . 43
10.13 Operating hours counter . . . . . . . . . . 43
10.14 Data memory for error
messages and AUTOCAL . . . . . . . . . 43
10.15 Integrated clock
(date and time) . . . . . . . . . . . . . . . . . 43
10.16 System monitoring / alarm output . . . 44
10.17 Error messages . . . . . . . . . . . . . . . . . 45
10.18 Fault areas and causes . . . . . . . . . . . 48
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 50
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 50
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 51
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General information
RES-5011 Page 3
1 General information
This RESISTRON® temperature controller is manufac-
tured according to EN 61010-1. In the course of its
manufacture it passed through quality assurance,
whereby it was subjected to extensive inspections and
tests. As a result of this, the product left our factory in
perfect condition.
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 replication, publication, editing and transla-
tion, 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.
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.
TCR 10x10 4– K1– or K 1– or ppm/K=
!

General information
Page 4 RES-5011
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 5. 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. Reg-
ular inspection and / or tightening of the terminals –
including the terminals for the winding connections on
the impulse transformer – is recommended. Dust
deposits on the controller can be removed with dry
compressed air.
Dust deposits and dirt from liquids result in a
loss of function. Accordingly, installation in a
switch cabinet or terminal cabined with IP54 is rec-
ommended.
1.8 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible
damage.
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 dis-
posal of such waste in an environmen-
tally 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
RES-5011 Page 5
DECLARATION OF CONFORMITY
We hereby declare that the following device has been
developed and manufactured in conformance with the
directives cited below:
Compliant with following standards and directives:
Note:
This declaration of conformity certifies that the device/
electronic itself complies with the above-mentioned
directives. 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,
transformers, heatsealing bands and wiring. The final
configuration may vary significantly in terms of perfor-
mance and physical dimensions. All information pro-
vided by us in connection with the line filter is merely
intended as a guide and is based on a typical measu-
ring 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-5011 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
Page 6 RES-5011
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
• 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

Description of the controller
RES-5011 Page 7
wiring, the timing signals, and the controller itself – are
fully compatible with one another.
4 Description of the controller
The microprocessor technology enriches the
RES-5011 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-5011 RESISTRON temperature controller is
equipped with two EtherNet/IP 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 EtherNet/IP 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-5011 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 EtherNet/IP signals are electrically
isolated from the controller and the heating circuit.
Either coding switches on the temperature controller
itself or the EtherNet/IP interface can be used to adapt
to different heatsealing band alloys (Alloy A20,
LEX3500 etc.) and set the required temperature range
(0…300°C, 0…500°C etc.).
The compact design of the RES-5011 RESISTRON
temperature controller and the plug-in connections
make this controller easy to install.
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
Page 8 RES-5011
5 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the RES-5011 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.
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.
UR measurement cable UML-1
Twisted cable for measuring the UR voltage.
Suitable for drag chains, contains neither halogens nor silicone.

Accessories and modifications
RES-5011 Page 9
5.2 Modifications (MODs)
Owing to its universal design, the RES-5011
RESISTRON temperature controller is suitable for a
very wide range of heatsealing applications.
One modification (MOD) is available for the RES-5011
RESISTRON temperature controller for implementing
special applications.
MOD 01
Amplifier for low secondary voltages
(UR= 0,2…60VAC). This modification is necessary, for
example, for very short or low-resistance heatsealing
bands.

Technical data
Page 10 RES-5011
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 51)
Power supply system Balanced TN or TT system, max. 415VAC
Installation category III
Operation in a potential-free system (e.g. an IT system) is only per-
mitted after consultation with ROPEX.
Current consumption
(primary current of
impulse
transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Line frequency 47…63 Hz, automatic adjustment to frequencies in this range
24VDC supply
voltage
Terminals 19+20
24VDC, Imax = 200mA
Tolerance: +10 / -10%
Measuring range Secondary voltage UR: 0.4…120VAC
Secondary current IR: 30…500A (with PEX-W2/-W3 current transformer)
ROPEX Application report
EtherNet/IP
interface
2 Ethernet switch ports RJ45
Wiring: IEC61784-5-3
Baud rate: 10 or 100Mbit/s
Data transport layer: Ethernet II, IEEE 802.3
Addressing: DHCP or selectable with rotary coding switch
ACD and DLR support: Yes
Heatsealing band
type and temperature
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 43) in addition to the rotary coding
switch or the EtherNet/IP 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 EtherNet/
IP interface:
Temperature coefficient 1100ppm/K, 0…300°C (e.g. Alloy A20)
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. LEX3500)
!

Dimensions
RES-5011 Page 11
7 Dimensions
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
Power dissipation Max. 20W
Ambient temperature +5…+45°C
Degree of protection IP20
Installation A minimum safety clearance of 20mm all round
(e.g. from other devices and wiring) must be
allowed when installing the controller.
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-94-V0
Connecting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors
Screw terminals: Clamping torque: 0.5…0.6Nm
(Screw driver size: SZS 0.6x3.5mm)
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 12 RES-5011
75.0 90.0
113.0
135.0

Installation
RES-5011 Page 13
8Installation
 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-5011
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 10 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 15,
section 8.6 "Wiring diagram (standard)" on page 18,
and the ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 14 must also be heeded.
An overcurrent protective device (e.g. a fuse) with a
maximum rating of 10A must be fitted when the
controller is installed provided this is adequate for
the heatsealing application. If not, two separate
overcurrent protective devices should be provided,
one for the controller and one for the application
(ROPEX Application report).
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 EtherNet/IP scanner 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
Page 14 RES-5011
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
Tempera ture
meter
ATR-x
Digital
potentiometer
PD-x
Avoid long
cables
Heatseal element
with coppered ends
Use heatseal bands with
suitable temperature coefficient
20mm clearance if several
controllers installed on
one top hat rail
Note
polarity
No additional
resistance
in secondary
circuit
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
Sufficient wire
cross-section
No
push-on
connectors
Twisted
Current measuring
wires IR
R
Connect U measuring
wires directly to
heatsealing band ends
Line filter
LF-xx480
Note
direction
of rotation
Note
number
of turns

Installation
RES-5011 Page 15
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.

Installation
Page 16 RES-5011
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 compli-
ance with the EMC limit values.
You can find the exact specification of the line filter in
the ROPEX Application Report calculated for your par-
ticular heatsealing application.
For more technical information: "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 15 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 con-
troller correctly (section 8.3 "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. 1 m
ROPEX
temperature
controller

Installation
RES-5011 Page 17
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

Installation
Page 18 RES-5011
8.6 Wiring diagram (standard)
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
14
13
12
ALARM OUTPUT
max. 30V / 0.2A
19
Ethernet
PORT 1 (RJ45)
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
sec.
U2
prim.
U1
5
7NC
NC
Line filter LF-xx480
V+
V-
24VDC POWER SUPPLY
RES-5011

Installation
RES-5011 Page 19
8.7 Wiring diagram with booster
connection
8
7
5
4
6
3
2
1
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
twisted
Max. length 1m
NC
NC
ALARM OUTPUT
max. 30V / 0.2A
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
sec.
U2
prim.
U1
Ethernet
module
electrically
isolated
Termination
5
7NC
NC
LINE
Booster
24
IN OUT
13
Line filter LF-xx480
V+
V-
24VDC POWER SUPPLY
RES-5011

Startup and operation
Page 20 RES-5011
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 45).
If the secondary current I2 is less than 30A, the sec-
ondary high-current wire must be laid twice (or several
times) through the PEX-W2 or PEX-W3 current trans-
former (ROPEX Application Report).
Terminals
LEDs
Coding switches
Nameplate
Wiring diagram
and plug-in jumpers
EtherNet/IP
connectors
!
2x