Ropex RESISTRON RES-408 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-408
Important features
• Microprocessor technology
• Separate terminal for operation and display
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of May 2006)
• Automatic phase angle compensation (AUTOCOMP, as of June 2006)
• Automatic frequency adjustment
• Wide current and voltage range
• 0…10VDC analog output for ACTUAL temperature
• 24VDC control signals for START and PREHEAT with electrical isolation
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable as standard (as of June 2006)
Operating
Instructions

Page 2 RES-408 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 Description of the controller . . . . . . . . . . . 8
5 Accessories and modifications . . . . . . . . . 9
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 9
5.2 Modifications (MODs) . . . . . . . . . . . . 10
6 Technical data . . . . . . . . . . . . . . . . . . . . . . 12
7 Controller/terminal compatibility . . . . . . . 13
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.1 Installation procedure . . . . . . . . . . . . 16
9.2 Installation steps . . . . . . . . . . . . . . . . 18
9.3 Power supply . . . . . . . . . . . . . . . . . . . 19
9.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 20
9.5 Current transformer PEX-W4/-W5 . . . 20
9.6 Wiring diagram (standard) . . . . . . . . . 22
9.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 23
10 Startup and operation . . . . . . . . . . . . . . . . 24
10.1 View of the controller . . . . . . . . . . . . . 24
10.2 Controller configuration . . . . . . . . . . . 25
10.3 Heatsealing band . . . . . . . . . . . . . . . 27
10.4 Startup procedure . . . . . . . . . . . . . . . 27
11 Controller functions . . . . . . . . . . . . . . . . . 30
11.1 Indicators and controls . . . . . . . . . . . 30
11.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3 Navigation in the menus . . . . . . . . . . 34
11.4 Menu structure . . . . . . . . . . . . . . . . . . 35
11.5 Menu steps . . . . . . . . . . . . . . . . . . . . 36
11.6 Temperature setting (set point selection)
38
11.7 Temperature indication / actual value
output . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.8 Automatic zero calibration (AUTOCAL) .
40
11.9 Heating to the heatsealing temperature
(HEAT) . . . . . . . . . . . . . . . . . . . . . . . . 41
11.10 "PREHEAT" signal . . . . . . . . . . . . . . . 43
11.11 Hold mode . . . . . . . . . . . . . . . . . . . . . 44
11.12 Temperature unit Celsius / Fahrenheit (as
of controller SW revision 106 and terminal
SW revision 103) . . . . . . . . . . . . . . . . 45
11.13 Measuring impulse duration (as of
June 2006) . . . . . . . . . . . . . . . . . . . . . 47
11.14 Automatic phase compensation (AUTO-
COMP) (as of June 2006) . . . . . . . . . 47
11.15 Temperature diagnosis (as of
June 2006) . . . . . . . . . . . . . . . . . . . . . 48
11.16 Heatup timeout (as of June 2006) . . . 49
11.17 Communication error between the con-
troller and the terminal (as of June 2006)
50
11.18 Undervoltage detection (as of
June 2006) . . . . . . . . . . . . . . . . . . . . . 50
11.19 Diagnostic interface / visualization soft-
ware (as of June 2006) . . . . . . . . . . . 51
11.20 System monitoring / alarm output . . . 51
11.21 Error messages . . . . . . . . . . . . . . . . . 52
11.22 Fault areas and causes . . . . . . . . . . . 58
12 Factory settings . . . . . . . . . . . . . . . . . . . . . 59
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 60
14 How to order . . . . . . . . . . . . . . . . . . . . . . . . 61
15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

General information
Version 1 RES-408 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-408 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-408 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-408 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-408 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-408 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 and PP films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•L-sealers
•etc.
The use of RESISTRON temperature controllers results in:
• Repeatable quality of the heatseals under any conditions
• Increased machine capacity
• Extended life of the heatsealing bands and teflon coatings
• Simple operation and control of the sealing process
3 Principle of operation
The resistance of the heatsealing band, which is temperature-sensitive, is monitored 50x per second (60x at 60Hz)
by measuring the current and voltage. The temperature calculated with the help of these measurements is 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 tempera-
ture 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.
The thermoelectric control loop which is formed has a highly dynamic response because purely electrical variables
are measured at a high sampling rate. A very wide secondary current range can be controlled with only minimal
power loss - a considerable advantage - because power is controlled on the primary side of the transformer. This
allows optimum adaptation to the load and to the required dynamic range despite the exceptionally compact
dimensions of the controller.
PLEASE NOTE!
RESISTRON temperature controllers play a significant role in enhancing the performance of modern machines.
However, the full benefit can only be obtained from the advanced technology offered by this control system if all

Description of the controller
Page 8 RES-408 Version 1
the system components, in other words the heatsealing band, the impulse transformer, the wiring, the timing sig-
nals and the controller itself, are compatible with one another.
4 Description of the controller
The microprocessor technology endows the RES-408 RESISTRON temperature controller with previously unat-
tainable capabilities:
• Very simple operation thanks to AUTOCAL, the automatic zero calibration function.
• Good dynamic response of the control system thanks to AUTOTUNE, which adapts automatically to the 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 June 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 temperature can be set on the separate T-408-1 (or T-400) operator terminal.
The real heatsealing band temperature is also visualized on the operator terminal.
The RES-408 RESISTRON temperature controller 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 mes-
sage in case of a fault.
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 the required temperature range (0...300°C, 0...500°C etc.) on all controllers
manufactured as of June 2006.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Control
logic
R=f(T)
+
_
Set point
Start
Indicators
and
controls
or
bus interface
Actual value
LINE
RESISTRON controller
Heatsealing band R = f (T)
Current
transformer
Impulse transformer
UR
IR
prim.
U1
sec.
U2

Accessories and modifications
Version 1 RES-408 Page 9
The compact design of the RES-408 RESISTRON temperature controller and the plug-in connections make this
controller easy to install.
5 Accessories and modifications
A wide range of compatible accessories and peripheral devices are available for the RES-408 RESISTRON tem-
perature controller. They allow it to be optimally adapted to your specific heatsealing application and to your plant's
design and operating philosophy.
5.1 Accessories
The products described below are only a few of the wide range of accessories available for RESISTRON temper-
ature controllers ("Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Analog indication of the ACTUAL temperature of the heatsealing band in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
in impulse mode.
Digital temperature meter DTR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Digital indication of the ACTUAL temperature of the heatsealing band in °C, with
HOLD function.
Line filter
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer
Designed according to VDE 0570/EN 61558 with a one-section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
(ROPEX Application Report).
CI-USB-1 communication interface
Interface for connecting a RESISTRON temperature controller with a diagnostic
interface (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL temper-
atures in real time.

Accessories and modifications
Page 10 RES-408 Version 1
5.2 Modifications (MODs)
Owing to its universal design, the RES-408 RESISTRON temperature controller is suitable for a very wide range
of heatsealing applications.
Various modifications (MODs) are offered for the RES-408 RESISTRON temperature controller for implementing
special applications.
The modifications described here are just a few of the large number available. Separate documentation is supplied
for all modifications.
MOD 01
Amplifier for low secondary voltages (UR= 0.25…16VAC). This modification is necessary, for example, for very
short or low-resistance heatsealing bands.
MOD 26
Additional terminal for connecting an external switching amplifier (booster). This modification is necessary for high
primary currents (continuous current > 5A, pulsed current > 25A).
MOD 37 (up to May 2006)
Additional rotary coding switch for the heatsealing band alloy and the temperature range. Various heatsealing
band alloys (e.g. Alloy A20, LEX3500) and temperature ranges (e.g. 300°C, 500°C) can be selected.
Booster
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/-W3 current transformer.

Accessories and modifications
Version 1 RES-408 Page 11
This modification is supplied as standard with all controllers manufactured as of June 2006
(section 10.2.2 "Configuration of the rotary coding switch for the temperature range and alloy (as
of June 2006)" on page 26).
!
Switch
position
Tem p.
range
Tem p.
coefficient
Band
alloy
0
5
1
2
3
4
6
7
8
9
0
5
1
2
3
4
6
7
8
9
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
0 = Factory settings
SWITCH POS.
1
0
4
5
8
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
ALLOY
780ppm/K
1100ppm/K
(L)
(A20)
1100ppm/K (A20)
780ppm/K
3500ppm/K
(L)

Technical data
Page 12 RES-408 Version 1
6 Technical data
Type of construction Controller: Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm)
acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Terminal: Housing for installation in the electrical cabinet
Dimensions (W x H): 96 x 48mm; depth: 55mm (excl. connector)
Line voltage Controllers manufactured as of June 2006:
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC)
400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
Controllers manufactured between January 2004 and May 2006:
115VAC version: 115VAC -15%…120VAC +10% (equivalent to 98…132VAC)
230VAC version: 230VAC -15%…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15%…415VAC +10% (equivalent to 340…456VAC)
Controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version (section 14 "How to order" on page 61)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
Controllers manufactured as of June 2006:
The temperature range and temperature coefficient settings can also be specified
in the ROPEX visualization software (section 11.19 "Diagnostic interface / vis-
ualization software (as of June 2006)" on page 51) in addition to using the rotary
coding switch (see below):
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Five different ranges can be set on the controller with the rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20), default
Temperature coefficient 780ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780ppm, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm, 0…300°C (e.g. LEX3500)
Controllers manufactured up to May 2006:
Default value 300°C, Alloy A20
The temperature range and alloy can be selected with MOD 37.
Analog output
(actual value)
Terminals 17+18
0…10VDC, Imax =5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% plus 50mV
Digital logic levels
Terminals 5+7
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30V DC (max. current input 6mA)
Reverse polarity-protected

Controller/terminal compatibility
Version 1 RES-408 Page 13
7 Controller/terminal compatibility
All RES-408 RESISTRON temperature controllers manufactured as of June 2006 are supplied as an upgraded
version.
Among other things, the data transfer between the controller and the terminal has been modified. These changes
were necessitated by the new European RoHS/WEEE Directives. Lead has now been banned from some of the
electronic components used in our products.
As a result, all RES-408 controllers manufactured up to May 2006 can only be operated with a T-400
terminal. Controllers manufactured as of June 2006 can only be operated with a T-408-1. Malfunc-
tions or damage may otherwise occur.
This has no effect on temperature control or on the external PLC control signals.
RES-408 controllers manufactured as of June 2006 are fully electrically compatible with the old ver-
sion (as far as the PLC control signals are concerned).
Alarm relay
Terminals 12, 13, 14
Umax = 30V (DC/AC), Imax = 0.2A, changeover contact, potential-free
Can be inverted by means of a plug-in jumper
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power loss max. 22W
Ambient
temperature
+5…+45°C
Degree of protection IP20
Installation If several controllers are installed on one top hat rail
(DIN TS35 rail), a clearance of at least 20mm should
be allowed between them.
The moving clip required for fastening must be facing
down for mounting on a horizontal top hat rail.
End holders to mechanically fix the controller must be fitted at both ends for
mounting on a vertical top hat rail.
Weight Controller: Approx. 0.7kg (incl. connector plug-in parts)
Terminal: Approx. 0.15kg
Housing material Controller: Plastic, polycarbonate, UL-94-V0
Terminal: Black plastic, type Noryl SE1 GFN2
Controller con-
necting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
with plug-in connections
If ferrules are used, they must be crimped in accordance
with DIN 46228 and IEC/EN 60947-1.
This is essential for proper electrical contact in the terminals.
!
!
!

Controller/terminal compatibility
Page 14 RES-408 Version 1
Please pay attention to the controller and terminal versions when ordering spare parts. The controller may have
to be exchanged together with the terminal. Refer to the compatibility table below:

Dimensions
Version 1 RES-408 Page 15
New version (as of June 2006):
Old version (up to May 2006):
8 Dimensions
RES-408 controller
Controller type Art. No. Compatible with
RES-408/115VAC 740841 Terminal T-408-1
Art. No. 885441
RES-408/230VAC 740842
RES-408/400VAC 740843
Controller type Art. No. Compatible with
RES-408-0-3/115VAC 740801 or 740831
Terminal T-400
Art. No. 885440
RES-408-0-3/230VAC 740802 or 740832
RES-408-0-3/400VAC 740803 or 740833
RES-408-0-5/xxxVAC 740805, 740806, 740807, 740835, 740836 or 740837
RES-408-1-x/xxxVAC 740811, 740812, 740813, 740815, 740816 or 740817
75.0 90.0
113.0
135.0

Installation
Page 16 RES-408 Version 1
T-400 or T-408-1 terminal
9Installation
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.
9.1 Installation procedure
Proceed as follows to install the RES-408 RESISTRON temperature controller:
1. Switch off the line voltage and verify that all circuits are deenergized.
2. The supply voltage specified on the nameplate of the RESISTRON temperature controller must be identical to
the line voltage that is present in the plant or machine. The line frequency is automatically detected by the tem-
perature controller in the range from 47Hz to 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 6 "Technical data" on page 12 must be allowed between them.
4. Install the terminal in the front panel cutout. It is fastened by means of four clips which snap onto the side of
the terminal housing.
5. Connect the controller and terminal together with the cable provided for this purpose.
Controllers manufactured up to May 2006 are only allowed to be operated with a T-400 terminal.
Controllers manufactured as of June 2006 can only be operated with a T-408-1. Malfunctions or
damage may otherwise occur (section 7 "Controller/terminal compatibility" on page 13).
6. Wire the system in accordance with the instructions in section 9.3 "Power supply" on page 19 and the ROPEX
Application Report. The information provided in section 9.2 "Installation steps" on page 18 must be heeded
additionally.
42.0 90.0
48.0 96.0
9.0 55.0
front panel
56.0
outline dimensions front fram
e
92 x 45
+0.8
- 0 - 0
+0.6
panel cutout
o 5mm
!
!

Installation
Version 1 RES-408 Page 17
Check the tightness of all system connections, including the terminals for the impulse transformer
winding wires.
7. Make sure that the wiring conforms to the relevant national and international installation regulations.
!

Installation
Page 18 RES-408 Version 1
9.2 Installation steps
Terminal
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
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
number
of turns
(up to May 2006)

Installation
Version 1 RES-408 Page 19
9.3 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 20 RES-408 Version 1
9.4 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 9.3 "Power supply" on page 19 must be observed.
Example drawing for LF-06480:
9.5 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 9.3 "Power supply" on page 19).
!
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