Ropex RESISTRON RES-403 User manual

ROPEX Industrie-Elektronik GmbH Tel.: [phone] E-Mail: [email protected]
Adolf-Heim-Str. 4 Fax: [phone] Internet: https://ropex.de
74321 Bietigheim-Bissingen (Germany) Data subject to change
24.7.20 Version 1
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 Version 1
Contents
1 General information . . . . . . . . . . . . . . . . . . 3
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
1.3 Heatsealing band . . . . . . . . . . . . . . . . 3
1.4 Impulse transformer . . . . . . . . . . . . . . 4
1.5 Current transformer PEX-W4/-W5 . . . . 4
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
1.8 Transportation . . . . . . . . . . . . . . . . . . . 4
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Principle of operation . . . . . . . . . . . . . . . . . 7
4 Traits of the controller . . . . . . . . . . . . . . . . 7
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Installation procedure . . . . . . . . . . . . . 8
5.2 Installation steps . . . . . . . . . . . . . . . . . 9
5.3 Power supply . . . . . . . . . . . . . . . . . . . 10
5.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 11
5.5 Current transformer PEX-W4/-W5 . . . 11
5.6 Wiring diagram (Standard) . . . . . . . . 13
5.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 14
5.8 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46) . . . . 15
5.9 Startup and operation . . . . . . . . . . . . 16
5.10 View of the controller . . . . . . . . . . . . . 16
5.11 Controller configuration . . . . . . . . . . . 16
5.12 Replacing and "burning in" the heat-
sealing band . . . . . . . . . . . . . . . . . . . 18
5.13 Startup procedure . . . . . . . . . . . . . . . 19
6 Controller functions . . . . . . . . . . . . . . . . . 20
6.1 Indicators and controls . . . . . . . . . . . 21
6.2 Temperature setting (set point selection)
22
6.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Automatic zero calibration (AUTOCAL) .
25
6.5 "START" signal (HEAT) . . . . . . . . . . . 26
6.6 Measuring impulse duration
(as of October 2005) . . . . . . . . . . . . . 28
6.7 Automatic phase angle
compensation (AUTOCOMP)
(as of October 2005) . . . . . . . . . . . . . 28
6.8 Temperature diagnosis
(as of October 2005) . . . . . . . . . . . . . 30
6.9 Heatup timeout
(as of October 2005) . . . . . . . . . . . . . 32
6.10 Diagnostic interface/visualization software
(as of October 2005) . . . . . . . . . . . . . 32
6.11 System monitoring/alarm output . . . . 33
6.12 Error messages . . . . . . . . . . . . . . . . . 34
6.13 Fault areas and causes . . . . . . . . . . . 39
7Factory settings. . . . . . . . . . . . . . . . . . . . . 40
8 Technical data . . . . . . . . . . . . . . . . . . . . . . 42
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 44
10 Modifications (MODs) . . . . . . . . . . . . . . . . 44
11 How to order . . . . . . . . . . . . . . . . . . . . . . . . 46
12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

General information
Version 1 RES-403 Page 3
1 General information
This RESISTRON® temperature controller is manufactured according to EN 61010-1. In the course of its manu-
facture 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 rep-
lication, publication, editing and translation, 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.
TCR 10x10 4– K1– or K 1– or ppm/K=
!

General information
Page 4 RES-403 Version 1
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.
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 6. 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. Regular inspection and / or tightening of the terminals – including
the terminals for the winding connections on the impulse transformer – is recommended. Dust deposits on the con-
troller 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 recommended.
1.8 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible damage.
!

General information
Version 1 RES-403 Page 5
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 disposal of such waste in an environmentally
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
Page 6 RES-403 Version 1
DECLARATION OF CONFORMITY
We hereby declare that the following device has been developed and manufactured in conformance with the direc-
tives cited below:
Compliant with following standards and directives:
Note:
This declaration of conformity certifies that the device/electronic itself complies with the above-mentioned direc-
tives. 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, transfor-
mers, heatsealing bands and wiring. The final configuration may vary significantly in terms of performance and
physical dimensions. All information provided by us in connection with the line filter is merely intended as a guide
and is based on a typical measuring 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-403 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
Version 1 RES-403 Page 7
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 films in:
• Vertical and horizontal f/f/s machines
• 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 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 dis-
played 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® temper-
ature controller.
The control loop is closed: ACTUAL temperature = SET temperature. Even minute thermal loads on the heat-
sealing 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 electrical
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 transformer. 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 con-
trolled system.
• High precision thanks to further improved control accuracy and linearization of the heatsealing band character-
istic.
• 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 features 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.

Installation
Page 8 RES-403 Version 1
To increase operational safety and interference immunity, 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 A20, LEX3500 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.
5Installation
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.
5.1 Installation procedure
Proceed as follows to install the RESISTRON® temperature 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 automatically 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 42 must be allowed between them.
4. Wire the system in accordance with the instructions in section 5.3 "Power supply" on page 10, section 5.6
"Wiring diagram (Standard)" on page 13 and the ROPEX Application Report. The information provided in
section 5.2 "Installation steps" on page 9 must also be heeded additionally.
Check the tightness of all the system connections, including the terminals for the impulse trans-
former windings.
5. Make sure that the wiring conforms to the relevant national and international installation regulations.
!
!

Installation
Version 1 RES-403 Page 9
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 10 RES-403 Version 1
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
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.