Ropex RESISTRON RES-440 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
27.7.20 Version 1
RESISTRON
RES-440
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 configuration of the secondary voltage and current ranges
(AUTORANGE, as of software revision 100)
• Automatic phase angle compensation (AUTOCOMP, as of software revision 100)
• Automatic frequency adjustment
• Large current and voltage range
• Booster connection as standard
• Heatsealing band alloy and temperature range selectable
• Time control, heatsealing time and cooling time settable
• Preheating
• Configurable relay output, e.g. "end of cycle"
• Time or temperature-controlled cooling phase
• Signal output for "Temperature OK"
• 0…10VDC analog output for ACTUAL temperature
• Alarm function with fault diagnosis
Identical design to and compatible with RES-222, -230, -241, -242
Operating
Instructions

Page 2 RES-440 Version 1
Contents
1 General information . . . . . . . . . . . . . . . . . . 4
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 4
1.3 Heatsealing band . . . . . . . . . . . . . . . . 4
1.4 Impulse transformer . . . . . . . . . . . . . . 5
1.5 Current transformer PEX-W4/-W5 . . . . 5
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 5
1.8 Transportation . . . . . . . . . . . . . . . . . . . 5
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Principle of operation . . . . . . . . . . . . . . . . . 8
4 Description of the controller . . . . . . . . . . . 9
5 Accessories and modifications . . . . . . . . 10
5.1 Accessories . . . . . . . . . . . . . . . . . . . . 10
5.2 Modifications (MODs) . . . . . . . . . . . . 11
6 Technical data . . . . . . . . . . . . . . . . . . . . . . 13
7 Dimensions/front panel cutout . . . . . . . . . 15
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.1 Installation procedure . . . . . . . . . . . . 16
8.2 Installation steps . . . . . . . . . . . . . . . . 17
8.3 Power supply . . . . . . . . . . . . . . . . . . . 18
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 19
8.5 Current transformer PEX-W4/-W5 . . . 19
8.6 Wiring diagram (standard) . . . . . . . . . 21
8.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 22
9 Startup and operation . . . . . . . . . . . . . . . . 23
9.1 Front view of the controller . . . . . . . . 23
9.2 Rear view of the controller . . . . . . . . . 23
9.3 Controller configuration . . . . . . . . . . . 24
9.4 Heatsealing band . . . . . . . . . . . . . . . 31
9.5 Startup procedure . . . . . . . . . . . . . . . 33
10 Controller functions . . . . . . . . . . . . . . . . . 34
10.1 Indicators and controls . . . . . . . . . . . 35
10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3 Navigation in the menus . . . . . . . . . . 37
10.4 Menu structure . . . . . . . . . . . . . . . . . . 39
10.5 Two-digit numbering system up to soft-
ware revision 027 . . . . . . . . . . . . . . . 41
10.6 Menu steps . . . . . . . . . . . . . . . . . . . . 42
10.7 Temperature setting (set point selection)
50
10.8 Temperature indication/actual value
output . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.9 Automatic zero calibration (AUTOCAL) .
53
10.10 "START" signal (HEAT) . . . . . . . . . . . 54
10.11 "PREHEAT" signal (preheating) . . . . 55
10.12 Cycle counter . . . . . . . . . . . . . . . . . . . 57
10.13 Hold mode . . . . . . . . . . . . . . . . . . . . . 57
10.14 Measuring impulse duration (as of soft-
ware revision 026) . . . . . . . . . . . . . . . 58
10.15 Automatic phase angle compensation
(AUTOCOMP) (as of software
revision 100) . . . . . . . . . . . . . . . . . . . 59
10.16 Locking the "HAND" key (as of software
revision 100) . . . . . . . . . . . . . . . . . . . 60
10.17 Temperature unit Celsius / Fahrenheit (as
of software revision 106) . . . . . . . . . . 60
10.18 Disabling the Configuration menu . . . 60
10.19 Setting the display brightness (VF display
only) . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.20 Undervoltage detection . . . . . . . . . . . 61
10.21 Diagnostic interface/visualization software
(as of software revision 100) . . . . . . . 63
10.22 Booster connection . . . . . . . . . . . . . . 63
10.23 Time control (timer function) . . . . . . . 64
10.24 System monitoring/alarm output . . . . 76
10.25 Error messages . . . . . . . . . . . . . . . . . 77
10.26 Fault areas and causes . . . . . . . . . . . 81
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 83
11.1 Customer settings (as of software
revision 100) . . . . . . . . . . . . . . . . . . . 85

Version 1 RES-440 Page 3
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 85
13 How to order . . . . . . . . . . . . . . . . . . . . . . . 86
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

General information
Page 4 RES-440 Version 1
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
Version 1 RES-440 Page 5
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 7. 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
Page 6 RES-440 Version 1
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
Version 1 RES-440 Page 7
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-440 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
Page 8 RES-440 Version 1
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® 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.
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

Description of the controller
Version 1 RES-440 Page 9
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 RESISTRON® temperature controller RES-440 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 software revision 100) 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.
A time control (timer) function integrated in the controller enables the complete heatsealing process to be con-
trolled on simple machines, such as table heatsealing tools. A configurable relay output can be used to drive
motors, energize magnets etc.
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.
In addition to the digital and bar indications on the display, the ACTUAL temperature of the heatsealing band is
supplied to an analog 0…10VDC output. The real heatsealing band temperature can thus be displayed on an
external temperature meter (e.g. ATR-x).
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
Page 10 RES-440 Version 1
The RESISTRON® temperature controller RES-440 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 A20,
LEX3500 etc.) and set the required temperature range (0…300°C, 0…500°C etc.).
The RESISTRON® temperature controller RES-440 is designed for installation in a front panel cutout. The com-
pact 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-440. 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® tem-
perature controllers ("Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35).
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).
Digital indication of the ACTUAL temperature of the heatsealing band in °C, with
HOLD function.
Line filter LF-xx480
Essential in order to ensure CE conformity.
Optimized for the RESISTRON® temperature controller.
Impulse transformer ITR-x
Designed according to 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
Version 1 RES-440 Page 11
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON® temperature controller RES-440 is suitable for a very wide range
of heatsealing applications.
Modifications (MOD) are available for the RESISTRON® temperature controller RES-440 for implementing special
applications.
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (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.
Booster B-xxx400
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.
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-440 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 author-
ized persons in possession of a key.
Measurement cable UML-1
Twisted measurement cable for the UR voltage measurement.
Trailing cable, halogen and silicone-free.

Accessories and modifications
Page 12 RES-440 Version 1
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" documen-
tation).
This modification is only recommended for existing applications. The PC visualization software
(section 10.21 "Diagnostic interface/visualization software (as of software revision 100)" on
page 63) should be used for all new applications.
!

Technical data
Version 1 RES-440 Page 13
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 controller manufactured as of March 2006
(as of software revision 100):
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)
All controllers manufactured as of January 2004 up to February 2006
(up to software revision 027):
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 (section 13 "How to order" on page 86)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
As of software revision 100:
The temperature range and temperature coefficient can be set independently of
one another in the Configuration menu:
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Up to software revision 027:
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 A20):
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 3500ppm (e.g. LEX3500):
0…200°C, 0…300°C
Set point selection Via the Settings menu in the controller
Analog output
(actual value)
Terminals 23+24
0…10VDC, Imax = 5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% add. 50mV

Technical data
Page 14 RES-440 Version 1
Digital logic levels
Terminals 3, 4, 22
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
Switching output
for „"Output 1"/
Temp. OK" signal
Terminals 20+21
Umax = 30VDC, Imax =50mA
UON < 2V (saturation voltage)
Transistor conductive if the temperature is inside the tolerance band.
Alarm relay
Terminals 5+6
Contact, potential-free, Umax = 30V (DC/AC), Imax =0.2A
Relay K1
Terminals 16, 17, 18
Changeover contact, potential-free, Umax = 240VAC/100VDC, Imax =1.5A
Interference suppression with 47nF / 560ohms for each terminal
Maximum load
(primary current of
impulse transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power dissipation max. 25W
Display LC display (green), 4 lines, 20 characters, alternatively:
VF display (blue), 4 lines, 20 characters
Ambient temperature +5…+45°C
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
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.
!

Dimensions/front panel cutout
Version 1 RES-440 Page 15
7 Dimensions/front panel cutout
29
132
9
136
66
144 72
front panel
terminal blocks
terminal wires
rubber seal mounting clamp
terminal blocks
terminal wires
outline dimensions
front frame
panel cutout
138 x 68
±0.2 ±0.2
DIP-switch
to select
U, I
22
front frame

Installation
Page 16 RES-440 Version 1
8Installation
See also section 1 "General information" on page 4.
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-440:
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 63Hz.
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 section 8.3 "Power supply" on page 18, section 8.6
"Wiring diagram (standard)" on page 21 and the ROPEX Application Report. The information provided in
section 8.2 "Installation steps" on page 17 must be heeded additionally.
Check the tightness of all the system connections, including the terminals for the impulse trans-
former windings.
5. Make sure that the wiring conforms to the relevant national and international installation regulations.
!
!

Installation
Version 1 RES-440 Page 17
8.2 Installation steps
Line
Impulse
transformer
Current transformer
PEX-W2/-W3
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:
Tempera ture
meter
ATR-x
Note
polarity
Configure
DIP switches
correctly
(up to SW-Rev. 027)

Installation
Page 18 RES-440 Version 1
8.3 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
Version 1 RES-440 Page 19
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 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 8.3 "Power supply" on page 18 must be observed.
Example drawing for LF-06480:
8.5 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 8.3 "Power supply" on page 18).
!
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
Page 20 RES-440 Version 1
8.5.1 PEX-W4
8.5.2 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