Ropex RESISTRON RES-420 User manual

Industrie-Elektronik GmbH Tel: [phone] E-Mail: [email protected]
Gansäcker 21 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
28.7.04
RESISTRON
RES-420 GB
Important features
• Microprocessor technology
• LC display (green), 4 lines, 20 characters, (multilingual)
Alternatively:
VF display (blue), 4 lines, 20 characters, (multilingual)
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic frequency adjustment
• Large current and voltage range
• Booster connection as standard
• Heatsealing band alloy and temperature range selectable
• Alarm function with fault diagnosis
Identical design to and compatible with RES-210, -211, -220, -221
Operating
Instructions

Page 2 RES-420
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2 . . . . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 7
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
7 Dimensions/front panel cutout . . . . . . . . . 10
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Installation procedure . . . . . . . . . . . . 11
8.2 Installation steps . . . . . . . . . . . . . . . . 12
8.3 Power supply . . . . . . . . . . . . . . . . . . . 13
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 14
8.5 Current transformer PEX-W2 . . . . . . 14
8.6 Wiring diagram (standard) . . . . . . . . . 15
8.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 16
9 Startup and operation . . . . . . . . . . . . . . . . 17
9.1 Front view of the controller . . . . . . . . 17
9.2 Rear view of the controller . . . . . . . . . 17
9.3 Controller configuration . . . . . . . . . . . 17
9.4 Heatsealing band . . . . . . . . . . . . . . . 19
9.5 Startup procedure . . . . . . . . . . . . . . . 20
10 Controller functions . . . . . . . . . . . . . . . . . 21
10.1 Indicators and controls . . . . . . . . . . . 21
10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 22
10.3 Navigation in the menus . . . . . . . . . . 23
10.4 Menu structure . . . . . . . . . . . . . . . . . . 25
10.5 Menu steps . . . . . . . . . . . . . . . . . . . . 26
10.6 Temperature setting (set point
selection) . . . . . . . . . . . . . . . . . . . . . . 29
10.7 Temperature indication . . . . . . . . . . . 29
10.8 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 29
10.9 "START" signal (HEAT) . . . . . . . . . . . 30
10.10 Cycle counter . . . . . . . . . . . . . . . . . . . 30
10.11 Hold mode . . . . . . . . . . . . . . . . . . . . . 30
10.12 Disabling the Configuration menu . . . 31
10.13 Setting the display brightness
(VF display only) . . . . . . . . . . . . . . . . 32
10.14 Undervoltage detection . . . . . . . . . . . 32
10.15 Booster connection . . . . . . . . . . . . . . 32
10.16 System monitoring/alarm output . . . . 33
10.17 Error messages . . . . . . . . . . . . . . . . . 34
10.18 Fault areas and causes . . . . . . . . . . . 35
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 36
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 36
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 37
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Safety and warning notes
RES-420 Page 3
1 Safety and warning notes
This RESISTRON temperature controller is
manufactured according to DIN EN 61010-1. In the
course of its manufacture it passed through quality
assurance, whereby it was subjected to extensive
inspections and tests.
It left the 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 Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance 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.
Ensuring such compliance is the personal
responsibility of the user.
1.2 Heatsealing band
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands.
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 too low a
temperature coefficient and incorrect coding
of the RESISTRON temperature controller leads to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by their detailed specification, part
number or some other means to ensure that all
replacement bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one-section bobbin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, 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-W2
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2 current
transformer may be used. Other transformers
may cause the equipment to malfunction.
The current transformer may only be operated if it is
connected to the RESISTRON temperature controller
correctly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
"Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
operating safety. They are not included in the scope of
!
!
TCR 10 4– ×10 K 1– ≥
!
!
!

Application
Page 4 RES-420
supply of the standard control system and are
described in a separate document.
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 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
1.7 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 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
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
DIN EN 61010-1
(VDE 0411-1)
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
DIN EN 60204-1 Electrical equipment of machines
(machinery directive)
EN 50081-1 EMC interference emissions
according to EN 55011, group 1,
class B
EN 50082-2 EMC interference immunity:
ESDs, RF radiation, bursts, surges.

Principle of operation
RES-420 Page 5
•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 displayed 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 temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the
heatsealing 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 high
secondary current can be controlled with only minimal
power loss 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 the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
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

Description of the controller
Page 6 RES-420
4 Description of the controller
The microprocessor technology endows the
RESISTRON temperature controller RES-420 with
previously unattainable 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 controlled system.
• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
• High flexibility: the secondary voltage range from 1 V
to 120V is covered with only 3 DIP switches, with
2 DIP switches for the current range from 30A to
400A.
• 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 process data is represented on an LC display with
4 lines and 20 characters. Devices with a VF display
are available as an option. Various display languages
can be selected.
The real heatsealing band temperature is visualized on
the display both as a digital number in °C and in the
form of a dynamic bar.
The RESISTRON temperature controller RES-420 also
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 24VDC logic signals are electrically
isolated from the controller and the heating circuit.
The menu in the temperature controller itself can be
used to adapt to different heatsealing band alloys
(Alloy-20, NOREX etc.) and set the required
temperature range (0…300°C, 0…500°C etc.).
The RESISTRON temperature controller RES-420 is
designed for installation in a front panel cutout. The
compact design 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 RESISTRON temperature
controller RES-420. 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
temperature controllers (!"Accessories" leaflet).
Line filter LF-xx480
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer ITR-x
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).

Accessories and modifications
RES-420 Page 7
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON
temperature controller RES-420 is suitable for a very
wide range of heatsealing applications.
Modifications (MOD) are available for the RESISTRON
temperature controller RES-420 for implementing
special applications.
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 33
(Software revision 010 or higher)
Important heatsealing process data can be output and
logged via a serial RS232 interface (!§MOD 33"
documentation).
Booster B-xxx400
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).
Monitoring current transformer MSW-1
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2 current transformer.
Transparent front cover TFA-1
For increasing the degree of protection on the front of the controller to IP65.
Also facilitates applications in the food technology sector (GMP).
Adapter for top hat rail mounting, HS-Adapter-01
For mounting the RESISTRON temperature controller RES-420 on a top hat rail
(DIN TS35). Allows the controller to be installed in the electrical cabinet, for instance,
where it is only accessible to authorized persons.
Lockable door TUER-S/K-1
Transparent door (with lock) for mounting on the bezel of the controller. The display
is clearly legible at all times. The keyboard can only be operated, however, by
authorized persons in possession of a key.
Measurement cable UML-1
Twisted measurement cable for the URvoltage measurement.
Trailing cable, halogen and silicone-free.

Technical data
Page 8 RES-420
6 Technical data
Type of construction Housing for front panel mounting
Dimensions (W x H): 144 x 72mm; depth: 161mm (incl. terminals)
Line voltage All controllers manufactured as of January 2004:
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)
All controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version (!Kap. 13 „How to order“ auf Seite 37)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
Several different ranges can be selected on the controller in the Configuration
menu:
Temperature coefficient 410ppm, 0…300°C (SW revision 021 or higher)
Temperature coefficient 460ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 510ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 570ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 630ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 700ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 780ppm (e.g. Alloy L)
0…200°C, 0…300°C, 0…400°C, 0…500°C
(SW revision 011 or higher)
Temperature coefficient 870ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 980ppm, 0…300°C (SW revision 019 or higher)
Temperature coefficient 1100ppm (e.g. Alloy 20):
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 3500ppm (e.g. NOREX:
0…200°C, 0…300°C
Set point selection Via the Settings menu in the controller
Digital logic levels
Terminals 3, 4
LOW (0V): 0…2VDC
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Electrically isolated, reverse polarity-protected
START with contact
Terminals 2+7
Switching threshold: 3.5VDC, Umax = 5VDC, Imax =5mA
Alarm relay
Terminals 5+6
Contact, potential-free, Umax = 50VDC, Imax =0.2A
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Display LC display (green), 4 lines, 20 characters, alternatively:
VF display (blue), 4 lines, 20 characters
Ambient temperature +5…+45°C

Technical data
RES-420 Page 9
Degree of protection Front: IP42 (IP65 with transparent front cover, Art. No. 887000)
Back: IP20
Installation Installed in front panel cutout with (W x H) 138(+-0.2) x68
(+-0.2)mm
Fastened with clips
Weight Approx. 1.0kg (incl. connector plug-in parts)
Housing material Black plastic, type Noryl SE1 GFN2
Connecting cable
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors

Dimensions/front panel cutout
Page 10 RES-420
7 Dimensions/front panel cutout
29
1329
136 66
144 72
138 x 68
±0.2 ±0.2
front panel terminal wires
rubber seal mounting clamp
terminal blocks
outline dimensions
front frame
panel cutout
DIP-switch
to select
U,I
22
front frame

Installation
RES-420 Page 11
8 Installation
!See also Kap. 1 „Safety and warning notes“ auf
Seite 3.
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON
temperature controller RES-420:
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 temperature controller
in the range from 47Hz to 63 Hz.
3. Install the RESISTRON temperature controller in
the front panel cutout. It is fastened by means of two
clips which snap onto the side of the controller
housing.
4. Wire the system in accordance with the instructions
in Kap. 8.3 „Power supply“ auf Seite 13, Kap. 8.6
„Wiring diagram (standard)“ auf Seite 15 and the
ROPEX Application Report. The information
provided in Kap. 8.2 „Installation steps“ auf Seite 12
must be heeded additionally.
Check the tightness of all the system
connections, including the terminals for the
impulse transformer windings.
5. Make sure that the wiring conforms to the relevant
national and international installation regulations.
!
!

Installation
Page 12 RES-420
8.2 Installation steps
Line
Impulse
transformer
Current transformer
PEX-W2
U (prim.)
1
Heatsealing band R= f (T)
U (sec.)
2
A
F
Avoid long
cables
Heatseal element
with coppered ends
Use heatseal bands with
suitable temperature coefficient
No additional
resistance
in secondary
circuit
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
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
Controller
OPTION:
Temperature
meter
ATR-x
Note
polarity
Configure
DIP switches
correctly

Installation
RES-420 Page 13
8.3 Power supply
ROPEX
temperature
controller
UR
IR
R
PRIM.
U1
K2
K1
SEC.
U2
LINE
I > I >
GND/
Earth
N(L2)
L1 (L1)
LINE
FILTER
ON
OFF
K1
3
3
3
1
Short wires
2
2
Line
115VAC, 230VAC, 400VAC
Circuit breaker
Double-pole, Z characteristic
Rated current: 16A, e.g. ABB-STOTZ, Type S282-Z16 (for
all applications)
Short-circuit protection only.
RESISTRON temperature controller not protected.
!
Relay K1
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 lay the filter supply wires (line side) parallel
to the filter output wires (load side).
!
RESISTRON temperature controller belonging to the
"series 4xx".
Relay K2
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
Impulse transformer
Designed according to VDE 0570/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
determined 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).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
"These wires must always be twisted (>20/m)
#These wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
$Twisting (>20/m) is recommended to improve EMC.

Installation
Page 14 RES-420
8.4 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
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 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 8.3 "Power
supply" on page 13 must be observed.
8.5 Current transformer PEX-W2
The PEX-W2 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 8.3 "Power supply" on
page 13).
!!
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
30.0
11,8
38.010.0
45.0
60.0
22.0
68.0
2x flat connectors
6.3 x 0.8mm
Snap-on plate for top hat rail (DIN TS35 rail), 35 x 7.5mm or 35 x 15mm, acc. DIN EN 50022

Installation
RES-420 Page 15
8.6 Wiring diagram (standard)
4
3
START (HEAT)
with 24VDC signal
GND
RES-420
(also with MOD 01)
0V (Internal ground)
Terminal 2
7
START (HEAT)
with contact
R
Impulse
transformer
LINE
8
10
9
11
12
13
15
14
Line filter LF-xx480
IR
UR
+
0V
1
2
Current transformer
PEX-W2
twisted
Heat-
sealing
band
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
0V
(Internnal ground)
No external
grounding allowed!
sec.
U2
prim.
U1
5
6
ALARM
OUTPUT
max. 50V/0.2A
Contact closed or
opened by ALARM
(see configuration)

Installation
Page 16 RES-420
8.7 Wiring diagram with booster
connection
4
3
START (HEAT)
with 24VDC signal
GND
RES-420
(also with MOD 01)
0V (Internal ground)
Terminal 2
7
START (HEAT)
with contact
R
Impulse
transformer
8
10
9
11
12
13
15
14
IR
UR
1
2
Current transformer
PEX-W2
twisted
Heat-
sealing
band
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
0V
(Internnal ground)
No external
grounding allowed!
LINE
Booster
NC
NC
24
IN OUT
13
Line filter LF-xx480
+
0V
sec.
U2
prim.
U1
5
6
ALARM
OUTPUT
max. 50V/0.2A
Contact closed or
opened by ALARM
(see configuration)

Startup and operation
RES-420 Page 17
9 Startup and operation
9.1 Front view of the controller
9.2 Rear view of the controller
9.3 Controller configuration
The possible controller configurations are explained in
the following sections. Proceed as described in
Kap. 9.5.1 „Initial startup“ auf Seite 20 to start up the
controller for the first time.
9.3.1 Configuration of the DIP switches
for secondary voltage and current
The controller must be switched off in order
to configure the DIP switches.
Nameplate
Te r m in a l s
Wiring diagram
DIP switches
(on rear of controller)
Operator keys
Clips
Display
3
2
145
1234567891011
12 13 14 15
3
2
145
ON
OFF
ROPEX
RES- 420
START 24VDC
START
BOOSTER ALARM
FILTER
(only with filter)
U (V)
2
I
2
( A)
1-10 6-60 20-120
30 - 100
60 - 200
120 - 400
OFF
OFFOFF
ON
ON
ON
DIP-SWITCH
ON
12 3 45
U
R
U
R
I
RU
SEC. PRIM.
50V / 0,2A
DIP-SWITCH
N (L1)
(PE)
L1 (L2)
GND
0V
Printed wiring diagram
Terminals DIP switches Terminals
!

Startup and operation
Page 18 RES-420
Set the DIP switches for matching the secondary
voltage U2and the secondary current I2to the correct
position for your application.
You can find the exact configuration of the
DIP switches in the ROPEX Application
Report calculated for your particular application.
If the secondary current I2is less than 30A, the
PEX-W2 current transformer must have two turns
(!ROPEX Application Report).
9.3.2 Setting the language
The menu language can be changed on the controller
without interrupting operation. It is set with step 20 in
the Configuration menu:
The following settings are possible:
English, German, Italian
SW revision 015 or higher also:
French, Spanish, Dutch, Danish, Finnish, Swedish,
Greek, Turkish.
SW revision 024 or higher also: Portuguese.
The language which is selected in this menu
remains set even if the factory settings are
restored (step 21 in the Configuration menu).
9.3.3 Restoring the factory settings
The internal controller settings can be reset to the
factory settings with step 21 in the Configuration menu.
Only the language setting (step 20 in the Configuration
menu) remains unchanged.
Please refer to Kap. 11 „Factory settings“ auf Seite 36
for more information about the factory settings.
If the controller settings are unknown when it
is started up for the first time, the factory
settings must be restored in order to prevent
malfunctions.
9.3.4 Configuration of the alloy and the
temperature range
These parameters are set with step 22 in the
Configuration menu:
Several different ranges can be selected:
1. Temperature coefficient 410ppm, 0…300°C
(software revision 021 or higher)
2. Temperature coefficient 460ppm, 0…300°C
(software revision 019 or higher)
3. Temperature coefficient 510ppm, 0…300°C
(software revision 019 or higher)
!
3
2
145
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
Factory settings
10 11
3
2
145
10 11
3
2
145
ON
OFF
DIP-SWITCH
R
U
Rear view
of the controller
2x
!
!

Startup and operation
RES-420 Page 19
4. Temperature coefficient 570ppm, 0…300°C
(software revision 019 or higher)
5. Temperature coefficient 630ppm, 0…300°C
(software revision 019 or higher)
6. Temperature coefficient 700ppm, 0…300°C
(software revision 019 or higher)
7. Temperature coefficient 780ppm, 0…200°C
(e.g. Alloy L, software revision 011 or higher)
8. Temperature coefficient 780ppm, 0…300°C
(e.g. Alloy L, software revision 011 or higher)
9. Temperature coefficient 780ppm, 0…400°C
(e.g. Alloy L, software revision 011 or higher)
10.Temperature coefficient 780ppm, 0…500°C
(e.g. Alloy L, software revision 011 or higher)
11. Temperature coefficient 870ppm, 0…300°C
(software revision 019 or higher)
12.Temperature coefficient 980ppm, 0…300°C
(software revision 019 or higher)
13.Temperature coefficient 1100ppm, 0…200°C
(e.g. Alloy-20)
14.Temperature coefficient 1100ppm, 0…300°C (•)
(e.g. Alloy-20)
15.Temperature coefficient 1100ppm, 0…400°C
(e.g. Alloy-20)
16.Temperature coefficient 1100ppm, 0…500°C
(e.g. Alloy-20)
17.Temperature coefficient 3500ppm, 0…200°C
(e.g. NOREX)
18.Temperature coefficient 3500ppm, 0…300°C
(e.g. NOREX)
9.3.5 Configuration of the alarm relay
The alarm relay is set with step 25 in the Configuration
menu:
There are two possible settings:
1. "Normal"(••)
Alarm relay contact closed by alarm
2. "Inverse"
Alarm relay contact opened by alarm
9.4 Heatsealing band
9.4.1 General
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, i.e. one whose resistance
increases as the temperature rises.
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 (!Kap. 9.4.2
„Burning in the heatsealing band“ auf Seite 19).
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.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR has been altered irreversibly.
9.4.2 Burning in the heatsealing band
If a new heatsealing band has been used, the zero
point is first of all calibrated while the band is still cold
by activating the "AUTOCAL" function on the controller.
When the "AUTOCAL" function has finished, the
controller outputs the preselected calibration
temperature (default value: 20°C). Adjust the set point
to approximately 250°C and press the "HAND" key
(display in home position) to heat for approximately
1 second. After recooling, the controller usually
indicates a value less than 20°C. Repeat the
"AUTOCAL" function. The heatsealing band has now
been burned in and the change in the alloy properties
stabilized.
(•) Factory setting
(••)Factory setting
!

Startup and operation
Page 20 RES-420
The burn-in effect described here does not occur if the
heatsealing band has already been thermally
pretreated by the manufacturer.
9.4.3 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
production-related resistance tolerances. The burn-in
procedure described above must be performed for all
new heatsealing bands.
9.5 Startup procedure
Please also refer to Kap. 1 „Safety and warning notes“
auf Seite 3 and Kap. 2 „Application“ auf Seite 4.
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
9.5.1 Initial startup
Prerequisites: The controller must be correctly installed
and connected (!Kap. 8 „Installation“ auf Seite 11).
The possible settings are described in detail in Kap. 9.3
„Controller configuration“ auf Seite 17 and Kap. 10
„Controller functions“ auf Seite 21.
The essential controller configurations are described
below:
1. Switch off the line voltage and verify that all circuits
are deenergized.
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 to 63Hz.
3. The settings of the DIP switches on the controller
depend on the ROPEX Application Report and the
heatsealing band that is used (Kap. 9.3 „Controller
configuration“ auf Seite 17).
4. Make sure that a START signal is not present.
5. Switch on the line voltage.
6. A power-up message appears on the display for
approximately 2 seconds when the controller is
switched on to indicate that it has been started up
correctly.
7. One of the following states then appears:
8. Set the controller configuration as described in
Kap. 9.3 „Controller configuration“ auf Seite 17. The
following settings are always required:
9. Activate the AUTOCAL function while the
heatsealing band is still cold (with step 7 in the
Settings menu). The progress of the calibration
process is indicated by a counter on the display
(approx. 10…15s).
When the zero point has been calibrated, the
display is reset to the home position and 20°C is
indicated as the actual value.
If the zero has not been calibrated successfully, an
alarm signal indicates error codes 104…106, 211.
In this case the controller configuration is incorrect
(!Kap. 9.3 „Controller configuration“ auf Seite 17
and ROPEX Application Report). Repeat the zero
point calibration after the controller has been
configured correctly.
10.When the zero point has been calibrated
successfully, the main menu appears on the display
again. Then specify a defined temperature
(heatsealing temperature) with step 1 in the
Settings menu and activate the "START" signal
(HEAT). Alternatively, a heatsealing process can be
!
!
DISPLAY ACTION
Main menu Go to 8
Alarm signal with error codes
104…106, 111…113, 211
Go to 8
Alarm signal with error codes
101…103, 107, 108,
201…203, 801, 9xx
Fault diagnosis
(!10.17)
Setting
Step in
Configuration
menu
Language 20
Restore factory settings 21
Temperature range and
heatsealing band alloy
22