Ropex RESISTRON RES-403 User manual

ROPEX Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen Data subject to change
2.3.18
RESISTRON
RES-403
Important features
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of October 2005)
• Automatic phase angle compensation (AUTOCOMP, as of October 2005)
• Automatic frequency adjustment
• Set point selection with potentiometer
• 0…10VDC analog output for ACTUAL temperature
• Activated with contact or 24VDC signal
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
Operating
Instructions

Page 2 RES-403
Contents
1 General information . . . . . . . . . . . . . . . . . . 3
1.1 Intended use . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W3/-W4 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Standards / CE marking . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Traits of the controller . . . . . . . . . . . . . . . . 5
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 Installation procedure . . . . . . . . . . . . . 6
5.2 Installation steps . . . . . . . . . . . . . . . . . 7
5.3 Power supply . . . . . . . . . . . . . . . . . . . . 8
5.4 Line filter . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Current transformer PEX-W3/-W4 . . . . 9
5.6 Wiring diagram (Standard) . . . . . . . . 10
5.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 11
5.8 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46) . . . . 12
5.9 Startup and operation . . . . . . . . . . . . 13
5.10 View of the controller . . . . . . . . . . . . . 13
5.11 Controller configuration . . . . . . . . . . . 13
5.12 Replacing and "burning in" the heatse-
aling band . . . . . . . . . . . . . . . . . . . . . 15
5.13 Startup procedure . . . . . . . . . . . . . . . 16
6 Controller functions . . . . . . . . . . . . . . . . . 18
6.1 Indicators and controls . . . . . . . . . . . 18
6.2 Temperature setting
(set point selection) . . . . . . . . . . . . . . 19
6.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 21
6.5 "START" signal (HEAT) . . . . . . . . . . . 22
6.6 Measuring impulse duration
(as of October 2005) . . . . . . . . . . . . . 23
6.7 Automatic phase angle
compensation (AUTOCOMP)
(as of October 2005) . . . . . . . . . . . . . 23
6.8 Temperature diagnosis
(as of October 2005) . . . . . . . . . . . . . 24
6.9 Heatup timeout
(as of October 2005) . . . . . . . . . . . . . 25
6.10 Diagnostic interface/visualization software
(as of October 2005) . . . . . . . . . . . . . 25
6.11 System monitoring/alarm output . . . . 25
6.12 Error messages . . . . . . . . . . . . . . . . . 26
6.13 Fault areas and causes . . . . . . . . . . . 31
7 Factory settings . . . . . . . . . . . . . . . . . . . . . 32
8 Technical data . . . . . . . . . . . . . . . . . . . . . . 34
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 36
10 Modifications (MODs) . . . . . . . . . . . . . . . . 36
11 How to order . . . . . . . . . . . . . . . . . . . . . . . . 38
12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General information
RES-403 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, whe-
reby it was subjected to extensive inspections and
tests. As a result of this, the product left our 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 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.
1.2 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-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 leads to
uncontrolled heating of the heatsealing band,
which will ultimately burn out!
The original heatsealing bands must be clealy identified
by means of suitable markings as well as the connector
geometry, length, or other means to ensure that
replacement bands are identical.
1.3 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 (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.
1.4 Current transformer PEX-W3/-W4
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2, PEX-W3 or
PEX-W4 current transformer may be used. Other trans-
formers 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.
TCR 10 4– ×10 K 1– ≥
!

Application
Page 4 RES-403
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
"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 "Power supply"). If periph-
eral components (e.g. the transformer or the line filter)
from other manufacturers are used, no functional guar-
antee can be provided by ROPEX.
1.7 Maintenance
The controller requires no special maintenance.
Regular inspection and / or tightening of the terminals –
including the terminals for the winding connections on
the impulse transformer – is recommended. Dust depo-
sits on the controller can be removed with dry com-
pressed air.
1.8 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 uch waste in an environmentally
sound way.
It must not be disposed of as residual
wase! To guarantee proper disposal and / or the
recover of reusable material, please take the device to
adesignated municipal collectin point and observe local
regulations.
Careless, uncontrolled disposal can cause damage to
thenvironment and human health. By ensuring that
yourproduct is disposed of or recycled in a responsible
way, you can help protect the environment and human
halth.
2 Application
This RESISTRON temperature controller is an integral
part of the "Series 400", the outstanding feature of
which is its microprocessor technology. All RESI-
STRON 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 heat-
sealing processes.
The controller is most commonly used for impulse-
heatsealing PE films in:
• Vertical and horizontal f/f/s machines
DIN EN 61010-1:2001
(2014/35/EU)
Safety requirements for electrical
equipment for measurement,
control and laboratory use
(low-voltage directive):
pollution degree 2,
protection class I,
measurement category I
(for URand IRterminals)
DIN EN 60204-1
(2006/42/EG)
Electrical equipment of
machines (machinery directive)
EN 55011:2009+A1:2010
EN 61000-3-2:2006-04+
A1:2009+A2:2009
EN 61000-3-3:2008
EN 61000-6-4:2007+
A1:2011
(2014/30/EU)
EMC genery emissions:
Group 1, Class A
EN 61000-6-2:2005
(2014/30/EU)
EMC generic immunity:
Class A (ESD, RFI, burst, surge)
Exception:
Line voltage interruption acc. to
EN 61000-4-11 is not fulfilled
(This leads to a designated error
message of the controller)

Principle of operation
RES-403 Page 5
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•etc.
3 Principle of operation
The resistance of the heatsealing band, which is tem-
perature-sensitive, is monitored 50x per second (60x at
60Hz) by measuring the current and voltage. The tem-
perature calculated with the help of these measure-
ments is displayed and compared with the set point.
The primary voltage of the impulse transformer is adju-
sted 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 RESI-
STRON temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the heatse-
aling band are detected and can be corrected quickly
and precisely.
A highly high response thermo-electric control loop is
formed which is highly accurate because purely elec-
trical variables are measured at a high sampling rate. A
high secondary current can be controlled because
power is controlled on the primary side of the trans-
former. This allows optimum adaptation to the load and
to the required dynamic range despite the exceptionally
compact dimensions of the controller.
4 Traits of the controller
• 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
October 2005) 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…63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The ACTUAL temperature of the heatsealing band is
supplied to an analog 0…10VDC output. The real heat-
sealing band temperature can thus be displayed on an
external temperature indicator (e.g. ATR-x).
The RESISTRON temperature controller RES-403 fea-
tures an integrated fault diagnosis function, which tests
both the external system (heatsealing band, wiring etc.)
and the internal electronics and outputs a selective
error message in case of a fault.
To increase operational safety and interference immu-
nity, all 24VDC logic signals are electrically isolated
from the controller and the heating circuit.
Coding switches on the temperature controller itself
can be used to adapt to different heatsealing band
alloys (Alloy-20, NOREX etc.) and set to the required
temperature range (0…300°C, 0…500°C etc.).
The compact design of the RESISTRON temperature
controller RES-403 and the plug-in connections make
this controller easy to install.
5 Installation
ªSee also section 1 "General information" on page 3. Installation and startup may only be per-
formed by technically trained, skilled per-
sons who are familiar with the associated risks and
warranty provisions.
!

Installation
Page 6 RES-403
5.1 Installation procedure
Proceed as follows to install the RESISTRON tempera-
ture controller RES-403:
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 automati-
cally detected by the RESISTRON temperature
controller in the range from 47Hz…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 top hat rail, the
minimum clearance specified in section 8 "Technical
data" on page 34 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 5.3 "Power supply" on page 8, section 5.6
"Wiring diagram (Standard)" on page 10 and the
ROPEX Application Report. The information pro-
vided in section 5.2 "Installation steps" on page 7
must also be heeded additionally.
Check the tightness of all the system connec-
tions, 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-403 Page 7
5.2 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 Sept. 2005)

Installation
Page 8 RES-403
5.3 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
115 VAC, 230 VAC, 400 VAC
50/60 Hz
Over-current protection
Double-pole circuit-breaker or fuses,
(ªROPEX 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
(ªROPEX 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 (ªROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ªROPEX Application Report).
cWires must always be twisted (min. 20 turns/meter).
dThese wires must be twisted (min. 20 turns/meter)
if several control loops are laid together ("crosstalk").
eTwisting (min. 20 turns/meter) is recommended to
improve EMC.

Installation
RES-403 Page 9
5.4 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: ª"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 5.3 "Power
supply" on page 8 must be observed.
5.5 Current transformer PEX-W3/-W4
The PEX-W3/-W4 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 (ªsection 5.3 "Power supply" on
page 8).
!
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 10 RES-403
5.6 Wiring diagram (Standard)
R
IR
UR
START (HEAT)
with
24VDC signal
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
AUTOCAL
with 24VDC signal
NOTE:
AUTOCAL button
also provided on
controller
ALARM
OUTPUT
max. 30V/0,2A
RES-403
(also with MOD 01)
GND 13
12
5
6
8
Contact closed or
opened by ALARM
(see configuration)
11
9
10
7
START (HEAT)
with contact
14
15
18
17
16
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
Cable shielded
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
2
1
4
3
Current transformer
twisted
Impuls
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
U2
prim.
U1
0V
(Internnal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
up to
production
date
September 2005

Installation
RES-403 Page 11
5.7 Wiring diagram with booster
connection (MOD 26)
START (HEAT)
with 24VDC signal
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
AUTOCAL
with 24VDC signal
NOTE:
AUTOCAL button
also provided on
controller
ALARM
OUTPUT
max. 30V/0,2A
RES-403
(also with MOD 01)
GND 13
12
5
6
8
Contact closed or
opened by ALARM
(see configuration)
0V
(Internnal ground)
No external
grounding allowed!
R
Current transformer
Impuls
transformer
11
9
10
7
IR
UR
Heat-
sealing
band
START (HEAT)
with contact
14
15
18
17
16
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
Cable shielded
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
LINE
Booster
NC
NC
2
24
IN
OUT
1
13
Line filter LF-xx480
4
3
sec.
U2
prim.
U1
twisted
20
19
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
up to
production
date
September 2005

Installation
Page 12 RES-403
MOD 26 cannot be used in combination with
MOD 40 ("Temperature OK" signal)
manufactured up to September 2005.
5.8 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46)
MOD 40 cannot be used in combination with
MOD 26 (booster connection) manufactured
prior to September 2005.
MOD 46 cannot be used in combination with
MOD 40.
A
dditional terminals
in housing cover
for MOD 26 (Booster connection)
BOOSTER
1920
4
3
2
1
A
UTOCAL
OUTPUT
HEAT
ALARM
!
+
RES- 403
I max. 50mA
+24VDC
GND GND
+24VDC
4
3
2
1
A
dditional terminals
in housing cover
for MOD 40 (”Temp. reached” signal)
or MOD 46 (”Temp. OK” signal)
AUTOCAL
OUTPUT
HEAT
ALARM
!
!

Installation
RES-403 Page 13
5.9 Startup and operation
5.10 View of the controller
5.11 Controller configuration
The controller must be switched off in order
to configure the coding switches and plug-in
jumpers.
5.11.1 Configuration of the DIP switches
for secondary voltage and current
Automatic configuration (AUTORANGE)
(as of October 2005)
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 the
current is outside the permissible range, an detailed
error message appears on the controller (ªsee
section 6.12 "Error messages" on page 26).
Configuration with coding switches
(up to September 2005)
Set the DIP switches for matching the secondary
voltage U2and the secondary current I2to the correct
position for your application.
Ter m i na l s
Wiring diagramm
LEDs
Button for
Nameplate
AUTOCAL function
Coding switches and
plug-in jumpers
!

Installation
Page 14 RES-403
You can find the exact configuration of the DIP swit-
ches in the ROPEX Application Report calculated for
your particular application.
If the secondary current I2is less than 30A, the sec-
ondary high-current wire must be laid twice (or several
times) through the PEX-W3 or PEX-W4 current trans-
former (ªROPEX Application Report).
5.11.2 Configuration of the rotary coding
switch for the temperature range
and alloy
The settings for a temperature coefficient of 780ppm
(switch position 1 and 5) are only available on control-
lers manufactured as of October 2003.
If the switch is set to "9" (as of October 2005), more
temperature ranges and alloys can be selected by
means of the ROPEX visualization software (ªsee
section 6.10 "Diagnostic interface/visualization soft-
ware (as of October 2005)" on page 25).
3
2
14
5
ON
OFF
1...10V
6...60V
20...120V
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
SWITC
H
ON
Factory settings
2x
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

Installation
RES-403 Page 15
5.11.3 Configuration of the alarm relay
If the plug-jumper is not inserted - or if it is
incorrectly inserted - an error message
appears when the controller is switched on
(ªsection 6.12 "Error messages" on page 26).
If the "Alarm output opened by alarm/PC CONFIGURA-
TION" position is selected (as of October 2005), the
behavior of the alarm output can be configured in more
detail by means of the ROPEX visualization software
(ªsee section 6.10 "Diagnostic interface/visualization
software (as of October 2005)" on page 25).
5.12 Replacing and "burning in" the
heatsealing band
5.12.1 "Burning in" the heatsealing band
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 elec-
trical properties:
The measuring principle applied for this system neces-
sitates a heatsealing band alloy with a suitable tempe-
rature coefficient TCR. Too low a TCR leads to oscilla-
tion 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 appro-
ximately 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 appro-
ximately 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 pre-
treated by the manufacturer.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR has been altered irreversibly.
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 heatse-
aling band.
0
5
1
2
3
4
6
7
8
9
Alarm relay contact
opened by alarm/
PC-CONFIGURATION.
Alarm relay contact
closed by alarm.
(factory setting)
CONFIGURATION
ALARM OUTPUT
DE-ENERGIZED / PC
AT ALARM
ENERGIZED
!
!

Installation
Page 16 RES-403
5.12.2 Replacing the heatsealing band
All power supply leads must be disconnected
from the RESISTRON temperature controller
in order to replace the heatsealing band.
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 pro-
duction-related resistance tolerances. The burn-in pro-
cedure described above should be performed for all
new heatsealing bands.
5.13 Startup procedure
Please also refer to section 1 "General information" on
page 3 and section 2 "Application" on page 4.
Installation and startup may only be per-
formed by technically trained, skilled per-
sons who are familiar with the associated risks and
warranty provisions.
5.13.1 Initial startup
Prerequisites: The controller must be correctly installed
and connected (ªsection 5 "Installation" on page 5).
Proceed as follows to start up the controller for the first
time:
1. Switch off the line voltage and verify that all circuits
are 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 fre-
quency is automatically detected by the tempera-
ture controller in the range from 47…63Hz.
3. In the case of controllers manufactured up to Sep-
tember 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 5.11 "Controller configuration" on
page 13).
4. Make sure that no START signal is activated.
5. Switch on the line voltage.
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.
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 (ªsection 6.10 "Diagnostic interface/
visualization software (as of October 2005)" on
page 25). In order to avoid malfunctions, please
check the controller configuration before
continuing the startup procedure.
7. One of the following states then appears:
Activate the AUTOCAL function while the heatse-
aling band is still cold (either with the manual button
on the controller or by applying an external signal to
terminals 8+13). The yellow "AUTOCAL" LED lights
up the duration of the calibration process (approx.
10…15s). A voltage of app. 0VDC appears at the
same time at the actual value output (terminals
14+15). 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 calibrated suc-
cessfully, the red "ALARM" LED blinks slowly (1Hz).
In this case the controller configuration is incorrect
(ªsection 5.11 "Controller configuration" on
page 13 and ROPEX Application Report). Repeat
the calibration after the controller has been confi-
gured correctly.
8. When the zero point has been calibrated suc-
cessfully, set a defined temperature on the set point
potentiometer and activate the "START" signal
(HEAT). The "HEAT" LED then lights up. The hea-
ting and control process can be observed at the
!
!
!
"ALARM"
LED "OUTPUT" LED ACTION
OFF Short pulses
every 1.2s
Go to 7
BLINKS fast
(4Hz)
OFF Go to 7
Lit
Continuously
OFF Fault diagnosis
(ªsec. 6.12)
!

Installation
RES-403 Page 17
actual value output:
The controller is functioning correctly if the tempera-
ture (which corresponds to the signal change at the
analog output) has a harmonious motion, in other
words it must not jump abruptly, fluctuate or deviate
temporarily in the wrong direction. This kind of beha-
vior would indicate that the URmeasuring wires
have been wired incorrectly.
If an error message is displayed, please proceed as
described in section 6.12 "Error messages" on
page 26.
9. Burn in the heatsealing band (ªsection 5.12
"Replacing and "burning in" the heatsealing band"
on page 15) and repeat the AUTOCAL function.
5.13.2 Restart after replacing the heatse-
aling band
To replace the heatsealing band, proceed as described
in section 5.12 "Replacing and "burning in" the heatse-
aling band" on page 15.
Always use a heatsealing band with the cor-
rect alloy, dimensions and copper-plating in
order to avoid malfunctions and overheating.
Continue with section 5.13.1 steps 4 to 9.
The controller is now
ready
!

Controller functions
Page 18 RES-403
6 Controller functions
See also section 5.6 "Wiring diagram (Standard)" on
page 10.
6.1 Indicators and controls
Manufactured as of October 2005
Manufactured up to September 2005
In addition to the functions shown in the diagram
above, various controller operating states are indicated
4
3
2
1
9
8
6
5
10
11
7
121314 1516 1718
AUTOCAL
OUTPUT
HEAT
ALARM
RESISTRON
RES-403
Made in Germany
ROPEX
Tel:[phone]
Temperature
controller
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.
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
9
8
6
5
10
11
7
121314 1516 1718
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
unless heatsealing band is cold.
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.
!
AUTOCAL
OUTPUT
HEAT
ALARM
ROPEX
INDUSTRIE - ELEKTRONIK
.
RESISTRON
μP-C on troll er

Controller functions
RES-403 Page 19
by the LEDs. These states are described in detail in the
table below:
6.2 Temperature setting
(set point selection)
The heatsealing temperature is set by means of a 2kΩ
potentiometer at terminals 16+17. The connecting
wires between the controller and the potentiometer
must be shielded (ªsection 5.6 "Wiring diagram
(Standard)" on page 10).
Setting range:
0ΩÆ0°C
2kΩÆ300°C (PD-3) or 500°C (PD-5)
(depending on the controller configuration).
The relationship between the potentiometer setting and
the SET temperature is linear.
The terminals 16+17 are not potenial-free and
might have the potential of the secondary
voltage of the impulse transformer.
For the terminals of the external potentio-
meter touch voltage protection must be
installed.
External grounding is not allowed. If this war-
ning is ignored, the controller will be
damaged by frame currents.
If a ROPEX PD-x precision potentiometer is used, the
SET temperature can be adjusted exactly with the help
of the digital display in the window of the dial. The
number which appears on the display corresponds to
the SET temperature in °C.
The set point that is selected for the heatsealing tempe-
rature must be greater than 40°C. If not, the heatse-
aling band will not be heated up when the "START"
signal is activated.
If a potentiometer is not connected, the set
point is assumed to be zero. When you con-
nect the potentiometer, please note the direction of
rotation!
LED Blinks slowly (1Hz) Blinks fast (4Hz) Lit continuously
AUTOCAL
(yellow)
RESET active,
START and AUTOCAL
functions are locked
(as of October 2005)
AUTOCAL requested, but
function disabled AUTOCAL executing
HEAT
(yellow) —START requested,
but function disabled 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 incor-
rectly, run AUTOCAL Fault, ªsection 6.12
e.g. PD-3
Potentiometer P03
with
digital dial KD
3
1
3
1
2
2
RES-403
0V
Set point
selection
input
17
16
cw
2K
Cable shielded
!
!
!
!

Controller functions
Page 20 RES-403
6.3 Temperature indication (actual
value output)
The RES-403 supplies an analog 0…10VDC signal,
which is proportional to the real ACTUAL temperature,
at terminals 14+15.
Voltage values:
0VDC Æ0°C
10VDC Æ300°C (ATR-3) or 500°C (ATR-5)
(depending on the controller configuration)
The relationship between the change in the output
voltage and the ACTUAL temperature is linear.
An indicating instrument can be connected to this
output in order to visualize the temperature of the heat-
sealing band.
The characteristics of the ROPEX ATR-x temperature
indicator (size, scaling, dynamic response) are ideally
suited to this application and this instrument should
therefore always be used (ªsection 10 "Modifications
(MODs)" on page 36).
It not only facilitates SET-ACTUAL comparisons, but
also enables other criteria such as the heating rate, set
point reached within the specified time, cooling of the
heatsealing band etc. to be evaluated.
RES-403
0...10VDC
0V
Actual value
output
0...10VDC
max. 5mA
Temperature
meter
e.g. ATR-3
14
15
+
R=33Ohm
0 - 300°C range
12345678910
300
TemperatureT
°C
20°C
"ZERO"
VDC
V
oltage U
60
90
120
150
180
210
240
270
0.66V
0 - 500°C range
12345678910
500
100
150
200
250
300
350
400
450
0.4V
°C
VDC
20°C
TemperatureT
"ZERO"
Voltage U