Ropex RESISTRON RES-420 Guide

3.11.03
RESISTRON
Replacing
RES-2xx/RES-420
GB
Replacement
Instructions
The RESISTRON temperature controller RES-420 can
be used as an alternative to the following controllers of
the „series 200“:
• RES-210: Analog temperature display,
no alarm function
• RES-211: Digital temperature display,
no alarm function
• RES-220: Analog temperature display,
with alarm function
• RES-221: Digital temperature display,
with alarm function
The steps that are necessary to convert from
RES-2xx-0-x (standard model without modifications) to
RES-420 are described below.
These instructions only provide a brief overview of the
two controllers. If in doubt, please refer to the latest
version of the controller documentation, which is
always binding.
The convertion from controller types RES-2xx-1-x is not
described here. Please contact ROPEX for further
informations.
Comparison of RES-210 (-211, -220, -221) / RES-420
Dimensions
The front panel cutout dimensions of the RES-2xx and
RES-420 controllers are identical. The RES-420 fea-
tures a protective film to IP42 instead of the transparent
hood. A transparent front cover featuring IP65 is avail-
able as a option.
RES-210, -211, -220, -221 RES-420
Exclusive Sales and Service :
www.tossheatseal.com
Toss Machine Components, Inc.
539 S. Main Street, Nazareth. PA 18064
Phone 610 - 759 - 8883 Fax 610 - 759 - 1766
E-mail [email protected]

Page 2 Replacing RES-2xx/RES-420
Set point selection
Temperature indication (actual value)
Zero calibration
RES-210, -211, -220, -221
Selection by means of a 10-turn potentiometer with
a fine control knob.
RES-420
Selection with step 1 in the software menu. If the
controller is active, the set point is also indicated on
the display.
RES-210, -211, -220, -221
RES-210, -220: Indication on a analog
instrument (ATR-x)
RES-211, -221: Indication on a digital
. instrument (DTR-x)
RES-420
Indication on the 4-line display
(dynamic bar and digital value).
RES-210, -211, -220, -221
Zero calibration by means of a 10-turn
potentiometer.
RES-210, -220: The pointer of the indicating
instrument must be set to „Z“
(ref. picture)
RES-211, -221: The display of the indicating
instrument must be set to „20°C“
RES-420
Automatic zero calibration (AUTOCAL) with step 3 in
the software menu.

Replacing RES-2xx/RES-420 Page 3
Alarm output / reset
(RES-220, -221 only)
Manual mode
Line frequency setting (50/60Hz)
RES-220, -221
Indicated by means of a red ALARM LED on the
front panel. Reset by pressing the RESET key.
RES-420
Indicated on the display. The error is identified by a
numeric code (ªRES-420 documentation). Reset
by pressing the RESET key ( ).
ENTER
HAND
RESET
RES-210, -211, -220, -221
Selected by pressing the HAND key. The red ON
LED is lit continuously.
RES-420
Selected by pressing the HAND key ( ) while the
Home position is displayed.
ENTER
HAND
RESET
RES-210, -211, -220, -221
Configured with plug-in jumper.
RES-420
Detected automatically in the 47…63Hz range.
Automatic detection

Page 4 Replacing RES-2xx/RES-420
Installation and setup
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
The information provided here offers no more than a
brief overview. If in doubt, please refer to the latest
version of the controller documentation, which is
always binding (ªsee also section „Safety and
warning notes“ of the RES-420 documentation).
Proceed as follows to replace the RES-2xx controller
and install/start up the RES-420:
1. Switch off the line voltage and verify the safe
isolation from the supply.
2. Remove the existing RES-2xx controller.
3. The supply voltage specified on the nameplate of
the RES-420 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.
4. Set the DIP switches on the RES-420.
The settings of the DIP switches on the
RES-420 are NOT the same as on the
RES-210 (-211, -220, -221). Please set these
switches in accordance with the ROPEX
Application Report in order to avoid malfunctions.
Old setting ranges on the RES-2xx:
New setting ranges on the RES-420:
The table below compares the two controllers.
These settings can be taken as a guide (e.g. when
the controller is started up for the first time):
5. Install the RES-420 controller in place of the
RES-2xx. The terminals of the two controllers are
identical. The existing connector plug-in parts can
be used without rewiring.
6. Switch on the line voltage.
7. A power-up message appears on the display when
the controller is switched on to indicate that it has
been started up correctly.
!
!
12345
ON
12345
Switch
No.
20-603- 10 8- 30 50-80
U
2
V
( )
RES-2xx RES-420
DIP switch ON
U2
11
22
33
43
I254
U (V)
2
I
2
( A)
1-10 6-60 20-120 30 - 100 60 - 200
120 - 400
OFF
OFFOFF
ON
ON ON
DIP-SWITCH
ON
12 3 45
12345
ON

Replacing RES-2xx/RES-420 Page 5
8. One of the following states then appears:
9. Select the language and reset the controller to the
factory settings.
Press the key for at least 2s (to open the
Configuration menu). Step 20 is displayed. Select
the desired language with the keys.
Confirm your selection by pressing . Press the
key to display step 21 (factory settings). Press
the key to confirm the factory settings (an
acknowledgment message appears). Step 22 is
displayed next.
10.Set the temperature range to 500°C
(Only if you have so far been using an
RES-2xx-0-5 controller)
Then set "Alloy 20, max 500°C" with the
keys in step 22. Confirm your selection by pressing
.
11.Return to the Home position
Press the key for at least 2s (to return to the
Home position or Alarm menu).
12.Calibrate the zero point
Activate the AUTOCAL function while the heat-
sealing band is still cold.
Press the key repeatedly until step 3 is dis-
played. Then select the AUTOCAL funtion by pres-
sing the key. If this function is executed cor-
rectly, the Home position is displayed again
automatically.
If the zero has not been calibrated successfully, an
error message appears on the display. In this case
the controller configuration is incorrect (ªsee sec-
tion „Controller configuration“ of the RES-420 docu-
mentation and the ROPEX Application Report).
Configure the controller correctly and repeat the
AUTOCAL function.
13.Set the heatsealing temperature (select the set
point)
Press the key briefly (to display step 1 in the
Setting menu). Set the required temperature with
the keys. Confirm your selection by
pressing . Press the key for at least 2s (to
return to the Home position). The set heatsealing
temperature is displayed in the Home position.
Then activate the "START" signal (HEAT). The
indication on the display (actual value and dynamic
bar) permits the heating and control process to be
observed:
If an error code is displayed, please proceed as
described in section „Error messages“ of the
RES-420 documentation.
RES-420 factory settings / as-delivered condition
If you accept the factory settings (step 21 in the soft-
ware menu, see step 9 above), the following defaults
are restored:
The selected language (step 20 in the software menu)
remains set regardless of the factory settings.
As-delivered condition:
The RES-420 controller is delivered with the above fac-
tory settings and with the language set to "German".
DISPLAY ACTION
Home position
Shows the SET and ACTUAL
temperatures or the dynamic bar
Go to 9
Shows error code 104, 106, 109
or 211
Go to 9
Shows error code 101…103,
201…203, 801 or 9xx
Fault diagnosis
(ªRES-420
documentation)
ENTER
HAND
RESET
ENTER
HAND
RESET
ENTER
HAND
RESET
The controller is now
ready
ENTER
HAND
RESET
ENTER
HAND
RESET
Menu
step Function Value
1 Heatsealing
temperature
0°C
2 Hold mode OFF
22 Alloy/range Alloy A20,
max. 300°C
23 Maximum temperature 300°C
24 Cycle counter 0
25 Alarm relay Closed by
alarm

Page 6 Replacing RES-2xx/RES-420
Menu structure of the RES-420
22 Alloy/range
21 Factory settings
20 Language
Alarm
Autocal
3Autocal?
2Hold mode
1Heatsealing temp.
Home position
Power-up message
24 Cycles
25 Alarm relay
26 Meas. imp. length
23 Max. temperature
Settings Configuration
MOD 1 only
Fault
Autocal
3Autocal?
The relevant menu
steps are shown on
a gray background.