Ropex RESISTRON RES-402 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
15.3.06
RESISTRON
RES-402 GB
Important features
• Microprocessor technology
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of January 2006)
• Automatic frequency adjustment
• Temperature range: 300°C
• Large current and voltage range
• Electrically isolated analog input for set point selection with potentiometer or 0…10VDC
• Electrically isolated 0…10VDC analog output for ACTUAL temperature
• 24VDC control signals for START, AUTOCAL and RESET with electrical isolation
• Alarm function
Operating
Instructions

Page 2 RES-402
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 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 Auxiliary voltage . . . . . . . . . . . . . . . . 14
8.7 Wiring diagram . . . . . . . . . . . . . . . . . 14
9 Startup and operation . . . . . . . . . . . . . . . . 15
9.1 View of the controller . . . . . . . . . . . . . 15
9.2 Controller configuration . . . . . . . . . . . 15
9.3 Heatsealing band . . . . . . . . . . . . . . . . 16
9.4 Startup procedure . . . . . . . . . . . . . . . 17
10 Controller functions . . . . . . . . . . . . . . . . . 19
10.1 Indicators and controls . . . . . . . . . . . 19
10.2 Temperature setting
(set point selection) . . . . . . . . . . . . . . 20
10.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 21
10.4 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 21
10.5 "START" signal (HEAT) . . . . . . . . . . . 23
10.6 "RESET" signal . . . . . . . . . . . . . . . . . 23
10.7 Diagnostic interface/visualization software
(as of January 2006) . . . . . . . . . . . . . 24
10.8 System monitoring/alarm output . . . . 24
10.9 Error messages . . . . . . . . . . . . . . . . . 24
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 25
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 25
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 26
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Safety and warning notes
RES-402 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 bobin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be 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-402
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 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
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.
1.7 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.
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 and PP films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•L-sealers
DIN EN 61010-1
(VDE 0411-1)
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
DIN EN 60204-1 Electrical equipment of machines
(machinery directive)
EN 50081-1 EMC interference emissions
according to EN 55011, group 1,
class B
EN 50082-2 EMC interference immunity:
ESDs, RF radiation, bursts, surges.

Principle of operation
RES-402 Page 5
•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.
The thermoelectric control loop which is formed has a
highly dynamic response because purely electrical
variables are measured at a high sampling rate. A very
wide secondary current range can be controlled with
only minimal power loss - a considerable advantage -
because power is controlled on the primary side of the
transformer. This allows optimum adaptation to the
load and to the required dynamic range despite the
exceptionally compact dimensions of the controller.
PLEASE NOTE!
RESISTRON temperature controller play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
R=f(T)
+
_
Set point
Start
Indicators
and
controls
or
bus interface
Actual value
LINE
RESISTRON controller
Heatsealing band R = f (T)
Current
transformer
Impulse transformer
UR IR
prim.
U1
sec.
U2

Description of the controller
Page 6 RES-402
4 Description of the controller
The microprocessor technology endows the
RESISTRON temperature controller RES-402 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
January 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 electrically isolated analog interfaces for the
temperature set point and the actual temperature
(0-10VDC) allow the temperature to be set either
directly on the machine PLC or by means of an external
potentiometer (PD-3).
Similarly, the real heatsealing band temperature can be
visualized either on the display of the machine PLC or
on an external temperature meter (ATR-3).
To increase operational safety and interference
immunity, all 24VDC logic signals are electrically
isolated from the controller and the heating circuit.
An external 24VDC auxiliary voltage is required to
supply the isolating amplifiers and optocouplers. The
compact design of the RESISTRON temperature
controller RES-402 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-402. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.
5.1 Accessories
The products described below are only a few of the
wide range of accessories available for RESISTRON
temperature controllers (ª"Accessories" leaflet).
Analog temperature meter ATR-3
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-3
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.
Set point potentiometer PD-3
Front panel-mounting version for setting the required SET heatsealing temperature
of the RESISTRON temperature controller. The number which appears on the
display corresponds to the SET heatsealing temperature in °C.

Accessories and modifications
RES-402 Page 7
5.2 Modifications (MODs)
Modifications are not available for the RES-402.
Line filter
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer
Designed according to VDE 0570/EN 61558 with a one-section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
(ªROPEX Application Report).
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 tempe-
ratures in real time.
Monitoring current transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2 current transformer.

Technical data
Page 8 RES-402
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 All controllers manufactured as of January 2006:
115VAC version: 110VAC -15%…120VAC +10 % (equivalent to 94…132VAC)
230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC)
400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
All controllers manufactured up to December 2005:
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)
Depending on the controller version (ªsection 13 "How to order" on page 26)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Auxiliary voltage
Terminals 14+13
24VDC, +20%, -10%, reverse polarity-protected
Current input: max. 1.0A
Heatsealing band
type and temperature
range
Default value 300°C, Alloy-20
Analog input
(set point)
Terminals 15+12
0…10VDC, Imax = 5mA, electrically isolated
Equivalent to 0…300°C
or with an external PD-3 precision potentiometer (R = 2kohms)
0…2kohms equivalent to 0…300°C
Analog output
(actual value)
Terminals 11+12
0…10VDC, Imax = 5mA, electrically isolated
Equivalent to 0…300°C
Accuracy: ±1% add. 50mV
Reference voltage +10VDC / ±5%, Imax =5mA
Digital logic levels
Terminals 16, 17, 18
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected
Alarm output UON < 3V (saturation voltage), Imax = 200mA, electrically isolated,
short-circuit proof
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
Degree of protection IP20

Dimensions
RES-402 Page 9
7 Dimensions
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-90-V0
Connecting cables
Type / cross-sections
Terminals 1…4: Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Terminals 5…18: Rigid or flexible: 0.2…1.5mm² (AWG 24…16)
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-402
8 Installation
ªSee 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 RESISTRON
temperature controller RES-402:
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 63 Hz.
3. Install the RESISTRON temperature controller in
the electrical cabinet on a standard top hat rail (DIN
TS35 rail, according to DIN EN 50022). If several
controllers are installed on one top hat rail, the
minimum clearance specified in section 6 "Technical
data" on page 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 "Auxiliary voltage" on page 14 and the
ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 11 must be heeded additionally.
Check the tightness of all the system
connections, including the terminals for the
impulse transformer windings.
5. Make sure that the wiring conforms to the relevant
national and international installation regulations.
!
!

Installation
RES-402 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
(up to Dec. 2005)

Installation
Page 12 RES-402
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
Circuit breaker
Double-pole, Z characteristic
Rated current: 16A, e.g. ABB-STOTZ, Type S282-Z16 (for
all applications)
Short-circuit protection only.
RESISTRON temperature controller not protected.
!
Relay Ka
For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".
Line filter
The filter type and size must be determined according to
the load, the transformer and the machine wiring
(ªROPEX Application Report).
Do not run the filter supply wires (line side) parallel
to the filter output wires (load side).
!
RESISTRON temperature controller belonging to the
4xx Series.
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
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
determined individually according to the application
(ªROPEX Application Report and "Accessories" leaflet
for impulse transformers).
!
Wiring
The wire cross-sections depend on the application
(ªROPEX Application Report).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
cThese wires must always be twisted (>20/m)
dThese wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
eTwisting (>20/m) is recommended to improve EMC.

Installation
RES-402 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
control 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
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: ª"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 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
controller correctly (ªsection 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-402
8.6 Auxiliary voltage
Since the inputs and outputs of the RES-402 are
electrically isolated, a 24VDC auxiliary voltage must be
applied to terminals 14+13. The auxiliary voltage has a
maximum current input of 1,0A and it is also protected
against reverse polarity.
8.7 Wiring diagram
GND
GND
+24VDC
12
14
17
18
16
R
6
8
5
7
4
3
2
1
IR
UR
U
REF
+10VDC
15
11
10
13
9
=
=
Auxiliary
supply
15
10
12
cw
2K
OPTION:
SET POINT
POTENTIOMETER
PD-3
RES-402
Current transformer
PEX-W2/-W3
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
Twisted
U2
prim.
U1
RESET
with 24VDC signal
START (HEAT)
with 24VDC signal
CH1
ALARM
OUTPUT
+24VDC
ANALOG
OUTPUT
(real temperatur)
+0...10VDC
ANALOG
INPUT
(set point)
+0...10VDC
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
until
production
date
12.05

Startup and operation
RES-402 Page 15
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.
9.2.1 Configuration of the DIP switches
for secondary voltage and current
Automatic configuration (AUTORANGE)
(as of January 2006)
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 80VAC and the current in the
range from 30A to 500A. If the voltage and/or the
current is outside the permissible range, a detailed
error message appears on the controller (ªsee
section 10.9 "Error messages" on page 24).
Configuration with coding switches
(up to December 2005)
Set the DIP switches for matching the secondary
voltage U2and the secondary current I2to the correct
position for your application.
You can find the exact configuration of the
DIP switches in the ROPEX Application
Report calculated for your particular application.
Te r m in a l s
Wiring diagram
LEDs
Nameplate
Button for
AUTOCAL function
!
!

Startup and operation
Page 16 RES-402
If the secondary current I2is less than 30 A, the
PEX-W2 or PEX-W3 current transformer must have
two turns (ªROPEX Application Report).
9.3 Heatsealing band
9.3.1 General
The heatsealing band is a key component in the control
loop, since 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
necessitates a heatsealing band alloy with a suitable
temperature coefficient TCR, i.e. one whose resistance
increases as the temperature rises.
Too low a TCR leads to oscillation or uncontrolled
heating.
When heatsealing bands with a higher TCR are 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 (ªsection 9.3.2
"Burning in the heatsealing band" on page 16).
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.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR has been altered irreversibly.
9.3.2 Burning in the heatsealing band
If a new heatsealing band has been used, the zero
point is first of all calibrated while the band is still cold
by activating the "AUTOCAL" function on the controller.
When the "AUTOCAL" function has finished, the
controller outputs a voltage equivalent to a temperature
of 20°C at the actual value output. Adjust the set point
to approximately 250°C and activate the "START"
signal to heat for approximately 1 second. After
recooling, the controller usually outputs an actual value
of less than 20°C. Repeat the "AUTOCAL" function.
The heatsealing band has now been burned in and the
change in the alloy stabilized.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally
pretreated by the manufacturer.
9.3.3 Replacing the heatsealing band
All power supply leads must be disconnected from the
RESISTRON temperature controller in order to replace
the heatsealing band.
3
2
145
ON
OFF
1...10V
6...60V
20...80V
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
30...100A
60...200A
120...400A
OFF
ON
ON
OFF
OFF
ON
DIP switch DIP switch
12
U
2
I
2
345
3
2
145
4
3
ON
OFF
U (V)
2
1-10
SWITCH
ON
Factory settings
2x
!

Startup and operation
RES-402 Page 17
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 (ªsection 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 all circuits
are deenergized.
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
temperature controller in the range from 47 to 63Hz.
3. In the case of controllers manufactured up to
December 2005, the settings of the DIP switches on
the controller are indicated in the ROPEX
Application Report and depend on the heatsealing
band that is used (section 9.2 "Controller
configuration" on page 15).
4. Make sure that no START signal is present.
5. Apply the auxiliary voltage (24VDC).
6. Switch on the line voltage.
7. 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.
As of SW-Revision 106:
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 in the visualization
software (ª
ªª
ªsection 10.7 "Diagnostic interface/
visualization software (as of January 2006)" on
page 24). In order to avoid malfunctions, please
check the controller configuration before
continuing the startup procedure.
8. One of the following states then appears:
9. Activate the AUTOCAL function while the
heatsealing band is still cold (by pressing the button
on the cover of the housing). The yellow
"AUTOCAL" LED lights up for the duration of the
calibration process (approx. 10…15s). A voltage of
app. 0V appears at the same time at the actual
value output (terminals 11+12). If an ATR-3 is
connected, it indicates 0…3°C.
When the zero point has been calibrated, the
"AUTOCAL" LED goes out and a voltage of 0.66V
appears at the actual value output instead. If an
ATR-3 is connected, it must be set to "Z".
If the zero point has not been calibrated
successfully, the red "ALARM" LED blinks slowly
(1Hz). In this case the controller configuration is
incorrect (ªsection 9.2 "Controller configuration"
on page 15 and ROPEX Application Report).
Repeat the calibration after the controller has been
configured correctly.
10.When the zero point has been calibrated
successfully, set a defined temperature at the set
point input (terminal 15) and apply the "START"
signal (HEAT). The "HEAT" LED then 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) follows a harmonious
curve, in other words it must not jump abruptly,
fluctuate or deviate temporarily in the wrong
!
!
!
"ALARM"
LED
"OUTPUT"
LED ACTION
OFF Short pulses
every 1.2s
Go to 9
BLINKS fast
(4Hz)
OFF Go to 9
Lit
continuously
OFF Fault diagnosis
(ªsection 10.9
)

Startup and operation
Page 18 RES-402
direction. This kind of behavior would indicate that
the URmeasuring wires have been laid incorrectly.
If an error code is displayed, please proceed as
described in section 10.9 "Error messages" on
page 24.
11.Burn in the heatsealing band (ªsection 9.3.2
"Burning in the heatsealing band" on page 16) and
repeat the AUTOCAL function.
9.4.2 Restart after replacing the
heatsealing band
To replace the heatsealing band, proceed as described
in section 9.3.2 "Burning in the heatsealing band" on
page 16 .
Always use a heatsealing band with the
correct alloy, dimensions and copper-plating
in order to avoid malfunctions and overheating.
Continue with section 9.4.1, steps 4 to 11.
The controller is now
ready
!

Controller functions
RES-402 Page 19
10 Controller functions
See also section 8.6 "Auxiliary voltage" on page 14.
10.1 Indicators and controls
Manufactured as of January 2006
Manufactured up to December 2005
Yellow LED, remains lit for duration
of AUTOCAL process.
Green LED, indicates pulses in measure-
ment mode. In control mode, luminous
intensity is proportional to heating current.
Yellow LED, lit during heating phase.
Red LED, lights up or blinks to indicate ALARM.
4
3
2
1
18171615141312111098765
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.
RESISTRON
RES- 402
Made in Germany
ROPEX
Tel:[phone]
Temperature
controller
AUTOCAL
OUTPUT
HEAT
ALARM
Yellow LED, remains lit for duration
of AUTOCAL process.
Green LED, indicates pulses in measure-
ment mode. In control mode, luminous
intensity is proportional to heating current.
Yellow LED, lit during heating phase.
Red LED, lights up or blinks to indicate ALARM.
4
3
2
1
ROPEX
INDUSTRIE - ELEKTRONIK
.
RESISTRON
µP-Controller
!
18171615141312111098765
AUTOCAL
OUTPUT
HEAT
ALARM
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.

Controller functions
Page 20 RES-402
In addition to the functions shown in the diagram
above, various controller operating states are indicated
by the LEDs. These states are described in detail in the
table below:
10.2 Temperature setting
(set point selection)
The heatsealing temperature of the RES-402 can be
set in two ways:
• By applying a 0…10VDC voltage to the analog input
terminals 15 + 12:
The relationship between the applied voltage and the
SET temperature is linear.
Setting range:
0VDC Æ0°C
10VDC Æ300°C
Please refer to section 10.3 "Temperature indication
(actual value output)" on page 21 for a circuit diagram.
• By connecting a 2 kohm potentiometer to
terminals 10, 12, 15:
In order to be able to select the set point with a
potentiometer, the controller makes a +10VDC (±5%)
reference voltage available at terminal 10.
The relationship between the potentiometer setting and
the SET temperature is linear.
The connecting wires between the controller and the
potentiometer must be shielded.
If a ROPEX PD-3 precision potentiometer is used, the
SET temperature can be adjusted exactly with the help
LED Blinks slowly (1Hz) Blinks fast (4Hz) Lit continuously
AUTOCAL
(yellow)
RESET active,
START and AUTOCAL
functions are locked
AUTOCAL requested, but
function is locked AUTOCAL executing
HEAT
(yellow) —HEAT requested,
but function is locked START executing
OUTPUT
(green) In control mode the luminous intensity is proportional to the heating current.
ALARM
(red)
Configuration error,
AUTOCAL not possible
Controller calibrated
incorrectly, run AUTOCAL Fault, ªsection 10.9
RES-402
0…10VDC
+
15
12
+
-
GND
13
RES-402
10
13
15
12
UREF 10VDC
IN 0…10VDC
2K
CW
GND
12
15
10
3
1
2
Potentiometer with
digital dial PD-3