Ropex RESISTRON RES-406 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
3.3.20 Version 1
RESISTRON
RES-406
Important features
• Complete control via PROFIBUS-DP interface
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of February 2006)
• Automatic phase angle compensation (AUTOCOMP, as of February 2006)
• Automatic frequency adjustment
• Booster connection as standard
• 0…10VDC analog output for ACTUAL temperature
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
Operating
instructions

Page 2 RES-406 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 . . . . . . . . . . . . . . . . 10
5.3 Power supply . . . . . . . . . . . . . . . . . . . 11
5.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12
5.5 Current transformer PEX-W4/-W5 . . . 12
5.6 Wiring diagram (standard) . . . . . . . . . 14
5.7 Wiring diagram with booster connection
15
6 Startup and operation . . . . . . . . . . . . . . . . 16
6.1 View of the controller . . . . . . . . . . . . . 16
6.2 Controller configuration . . . . . . . . . . . 16
6.3 Replacing and "burning in" the heat-
sealing band . . . . . . . . . . . . . . . . . . . 18
6.4 Startup procedure . . . . . . . . . . . . . . . 19
7 Controller functions . . . . . . . . . . . . . . . . . 22
7.1 Indicators and controls . . . . . . . . . . . 22
7.2 PROFIBUS communication “up to Jan.
2006“/“as of Feb. 2006“ . . . . . . . . . . . 24
7.3 Device master file (GSD) . . . . . . . . . . 24
7.4 PROFIBUS protocol . . . . . . . . . . . . . 26
7.5 Input data . . . . . . . . . . . . . . . . . . . . . . 28
7.6 Output data . . . . . . . . . . . . . . . . . . . . 30
7.7 Parameter data . . . . . . . . . . . . . . . . . 34
7.8 DPV1 protocol extension (as of GSD
Version v2.0) . . . . . . . . . . . . . . . . . . . 42
7.9 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 45
7.10 Booster connection . . . . . . . . . . . . . . 47
7.11 Diagnostic interface/visualization software
(as of February 2006) . . . . . . . . . . . . 47
7.12 Total cycle counter (as of February 2006)
47
7.13 Operating hours counter (as of February
2006) . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.14 Log function (as of software
revision 107) . . . . . . . . . . . . . . . . . . . 48
7.15 System monitoring/alarm output . . . . 48
7.16 Error messages . . . . . . . . . . . . . . . . . 49
7.17 Fault areas and causes . . . . . . . . . . . 54
8Factory settings. . . . . . . . . . . . . . . . . . . . . 55
9 Technical data . . . . . . . . . . . . . . . . . . . . . . 57
10 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 59
11 Modifications (MODs) . . . . . . . . . . . . . . . . 59
12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 60
13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

General information
Version 1 RES-406 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-406 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-406 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-406 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-406 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-406 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 February 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 RESISTRON® temperature controller RES-406 is equipped with a PROFIBUS-DP interface. This interface
can be used to control all the controller functions and interrogate controller information.
The ACTUAL temperature of the heatsealing band is supplied to the PROFIBUS interface and to an analog 0 to
10V DC output. The real heatsealing band temperature can thus be displayed on an external temperature meter
(e.g. ATR-x).

Installation
Page 8 RES-406 Version 1
The RES-406 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.
To increase operational safety and interference immunity, all PROFIBUS signals are electrically isolated from the
controller and the heating circuit.
Either coding switches on the temperature controller itself or the PROFIBUS interface 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-406 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-406:
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 9 "Technical data" on page 57 must be allowed between them.
4. Wire the system in accordance with the instructions in section 5.3 "Power supply" on page 11, section 5.6
"Wiring diagram (standard)" on page 14 and the ROPEX Application Report. The information provided in
section 5.2 "Installation steps" on page 10 must also be heeded.
An overcurrent protective device (e.g. a fuse) must be fitted when the controller is installed. The minimum pos-
sible specification for this device must be entered in the ROPEX Application Report based on the calculated
currents. If a larger overcurrent protective device is fitted, you must match the current carrying capacity of the
other components accordingly (e.g. cables, impulse transformer etc.).
!

Installation
Version 1 RES-406 Page 9
5. Connect the RESISTRON® temperature controller to the PROFIBUS master using a cable according to
IEC 61158.
Check the tightness of all the system connections, including the terminals for the impulse trans-
former windings.
6. Make sure that the wiring conforms to the relevant national and international installation regulations.
!

Installation
Page 10 RES-406 Version 1
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 Jan. 2006)

Installation
Version 1 RES-406 Page 11
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.

Installation
Page 12 RES-406 Version 1
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 control on the line and protect the controller against line distur-
bances.
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: "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 5.3 "Power supply" on page 11 must be observed.
Example drawing for LF-06480:
5.5 Current transformer PEX-W4/-W5
The PEX-W4/-W5 current transformer supplied with the RESISTRON® temperature controller is an integral part
of the control system. The current transformer may only be operated if it is connected to the temperature controller
correctly (section 5.3 "Power supply" on page 11).
!
LINE
PE
Large cross-section
wire to ground
Large cross-section
wire to ground
Large frame contact surface
Do not lay parallel Mounting plate (galvanized)
max. 1 m
ROPEX
temperature
controller

Installation
Version 1 RES-406 Page 13
5.5.1 PEX-W4
5.5.2 PEX-W5
Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022).
Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Installation
Page 14 RES-406 Version 1
5.6 Wiring diagram (standard)
RES-406
9
8
7
6
5
4
3
2
1
+24VDC
GND
NC
A
(+5V) VP
DGND
RTS
B
Shield
14
13
12
ALARM OUTPUT
max. 30V / 0,2A
6
7
PROFIBUS-PLUG
SUB-D / 9-POLE
POWER SUPPLY
(+24V pwr. supply) P24
(GND pwr. supply) M24
5
24V
IN 5V
OUT
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
18
17
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
Ground
Must be grounded
externally to prevent
electrostatic
charging!
0V
(Internnal ground)
No external
grounding allowed!
0V
(Internnal ground)
No external
grounding allowed!
R
IR
UR
Current transformer
twisted
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
U2
prim.
U1
up to
production
date
January 2006

Installation
Version 1 RES-406 Page 15
5.7 Wiring diagram with booster connection
RES-406
9
8
7
6
5
4
3
2
1
14
13
12
ALARM OUTPUT
max. 30V / 0,2A
6
7
PROFIBUS-PLUG
SUB-D / 9-POLE
5
24V
IN 5V
OUT
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
18
17
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
Ground
Must be grounded
externally to prevent
electrostatic
charging!
R
Current transformer
twisted
Impulse
transformer
IR
UR
Heat-
sealing
band
LINE
Booster
NC
NC
24
IN OUT
13
Line filter LF-xx480
sec.
U2
prim.
U1
+24VDC
GND
NC
A
(+5V) VP
DGND
RTS
B
Shield
POWER SUPPLY
(+24V pwr. supply) P24
(GND pwr. supply) M24
0V
(Internnal ground)
No external
grounding allowed!
0V
(Internnal ground)
No external
grounding allowed!
up to
production
date
January 2006

Startup and operation
Page 16 RES-406 Version 1
6 Startup and operation
6.1 View of the controller
6.2 Controller configuration
The controller must be switched off in order to configure the coding switches and plug-in jumpers.
6.2.1 Configuration of the DIP switches for secondary voltage and current
Automatic configuration (AUTORANGE)
(as of February 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 120VAC 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 (see section 7.16 "Error messages" on page 49).
Configuration with coding switches
(up to January 2006)
Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to the correct position
for your application.
You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your par-
ticular application.
Termi n a ls LEDs
Wiring diagram Nameplate
Coding switches and
PROFIBUS plug
plug-in jumpers
!

Startup and operation
Version 1 RES-406 Page 17
If the secondary current I2 is less than 30A, the secondary high-current wire must be laid twice (or several times)
through the PEX-W3 or PEX-W4 current transformer (ROPEX Application Report).
6.2.2 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 controllers
manufactured as of October 2003.
The setting of the rotary coding switch for the temperature range and alloy can be overwritten with the parameter
data (section 7.7 "Parameter data" on page 34).
If the switch is set to "9" (as of February 2006), more temperature ranges and alloys can be selected by means of
the ROPEX visualization software (see section 7.11 "Diagnostic interface/visualization software (as of February
2006)" on page 47).
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. A20
e.g. L
e.g. A20
e.g. L
Tem p.
range
Tem p.
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)
9 PC-CONFIGURATION

Startup and operation
Page 18 RES-406 Version 1
6.2.3 Configuration of the rotary coding switches for the station address
The station address of the RES-406 in the PROFIBUS network can be set between 0 and 99 with these coding
switches. A new setting does not take effect until the next time the controller is switched on.
6.2.4 Configuration of the alarm relay
If the jumper is not inserted, the alarm relay is permanently energized when using a controller up to
production date January 2006. The other functions of the controller (e.g. heating, AUTOCAL etc.) are
not impaired by this.
If the plug-jumper is not inserted when using a controller as of production date February 2006 - or if it is
incorrectly inserted - an error message appears when the controller is switched on (section 7.16 "Error
messages" on page 49).
If the "Alarm relay deenergized by alarm/PC CONFIGURATION" position is selected (as of February 2006), the
behavior of the alarm output can be configured in more detail by means of the ROPEX visualization software
(see section 7.11 "Diagnostic interface/visualization software (as of February 2006)" on page 47).
6.3 Replacing and "burning in" the heatsealing band
6.3.1 "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 electrical properties:
The measuring principle applied for this system necessitates a heatsealing band alloy with a suitable temperature
coefficient TCR. 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, i.e. the AUTOCAL function must be repeated.
0
0
0
0
5
5
5
5
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
6
6
6
6
7
7
7
7
8
8
8
8
9
9
9
9
PROFIBUS
STATION ADDRESS
x 1
x 10
Station address im PROFIBUS network between
0 and 99.
01 = Factory setting
Top of housing
0
5
1
2
3
4
6
7
8
9
Alarm relay de-
energized by alarm/
PC-CONFIGURATION.
Alarm relay energized
by alarm.
(factory setting)
CONFIGURATION
ALARM OUTPUT
DE-ENERGIZED / PC
AT ALARM
ENERGIZED
!

Startup and operation
Version 1 RES-406 Page 19
The burn-in effect described here does not occur if the heatsealing band has already been thermally pretreated
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 heatsealing band.
6.3.2 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 manu-
facturer.
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.
6.4 Startup procedure
Please also refer to section 1 "General information" on page 3 and section 2 "Application" on page 7.
Installation and startup may only be performed by technically trained, skilled persons who are
familiar with the associated risks and warranty provisions.
6.4.1 Initial startup
Prerequisites: The controller must be correctly installed and connected (section 5 "Installation" on page 8).
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 frequency is automatically detected by the temperature controller in
the range from 47…63Hz.
3. In the case of controllers manufactured up to January 2006, 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.
The settings of the coding switches on the controller depend on the required station address in the PROFIBUS
network (section 6.2 "Controller configuration" on page 16).
4. Link the device master file into the PROFIBUS master (section 7.3), select the required communication
module ("compact" or "extended" protocol) and start the communication.
5. Make sure that the "ST" bit is not set.
6. Switch on the line voltage and the 24VDC auxiliary supply (the order is arbitrary).
7. When the voltage is switched on, the yellow "AUTOCAL" LED lights up for approximately 0.3seconds to indi-
cate that the controller is being powered up correctly. This LED blinks slowly (1Hz) as long as no PROFIBUS
communication is active. It does not go out again until it detects an active communication.
All controllers manufactured as of February 2006:
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
!
!
!
!
!

Startup and operation
Page 20 RES-406 Version 1
(section 7.11 "Diagnostic interface/visualization software (as of February 2006)" on page 47). In order
to avoid malfunctions, please check the controller configuration before continuing the startup procedure.
8. The green "DATA EXCHANGE" LED lights up to indicate an active PROFIBUS communication.
9. One of the following states then appears:
Up to production date January 2006:
As of production date February 2006:
10.Activate the AUTOCAL function while the heatsealing band is still cold by setting the "AC" bit (AUTOCAL) in
the PROFIBUS protocol (section 7.4 "PROFIBUS protocol" on page 26). The yellow "AUTOCAL" LED lights
up for the duration of the calibration process (approx. 10…15s). The "AA" bit (AUTOCAL active) is set in addi-
tion and a voltage of app. 0V appears at the actual value output (terminals 17+18). 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 successfully, the "AL" bit (alarm active) is set and the red "ALARM"
LED blinks slowly (1Hz). In this case the controller configuration is incorrect (section 6.2 "Controller config-
uration" on page 16 and ROPEX Application Report). Repeat the calibration after the controller has been con-
figured correctly.
11.When the zero point has been calibrated successfully, specify a defined temperature by means of the
"ALARM"
LED
"OUTPUT"
LED ACTION
OFF Short pulses
every 1.2s
Go to 10
BLINKS fast
(4Hz)
OFF Go to 10
Lit continu-
ously
OFF Fault diagnosis
(section 7.16)
"ALARM"
LED
"OUTPUT"
LED ACTION
OFF Short pulses
every 1.2s
Go to 10
BLINKS fast
(4Hz)
OFF Go to 10
Lit continu-
ously
OFF Fault no. 901:
(Fault group: 7):
Supply voltage/
Sync-Signal
missing
(section. 7.2)
Otherwise:
Fault diagnosis
(section. 7.16)