Ropex RESISTRON RES-5006 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
23.9.19 Version 1
RESISTRON
RES-5006
Important features
• PROFIBUS DP interface for complete control
• Automatic zeroing (AUTOCAL)
• Automatic optimisation (AUTOTUNE)
• Automatic configuration of the secondary voltage and current range (AUTORANGE)
• Automatic phase correction (AUTOCOMP)
• Automatic frequency adaptation
• Booster output standard
• Analogue output 0…10 VDC for ACTUAL temperature
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Wide voltage range for the use of 110…415 V
• Eight channels for administration of various calibration values
• Micro-USB interface for ROPEXvisual®
User Guide

Page 2 RES-5006 Version 1
Contents
1 Revision list . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 General information . . . . . . . . . . . . . . . . . . 3
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
2.3 Heatsealing band . . . . . . . . . . . . . . . . 3
2.4 Impulse transformer . . . . . . . . . . . . . . 4
2.5 Current transformer PEX-W4/-W5 . . . . 4
2.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Standards / CE marking . . . . . . . . . . . 4
2.8 Maintenance . . . . . . . . . . . . . . . . . . . . 5
2.9 Transportation . . . . . . . . . . . . . . . . . . . 5
2.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
3Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Functional principle . . . . . . . . . . . . . . . . . . 6
5 Device features . . . . . . . . . . . . . . . . . . . . . . 7
6 Mounting and installation . . . . . . . . . . . . . . 7
6.1 Installation sequence . . . . . . . . . . . . . . 7
6.2 Installation notes . . . . . . . . . . . . . . . . . 9
6.3 Power supply . . . . . . . . . . . . . . . . . . . 10
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 11
6.5 Current transformer PEX-W4/-W5 . . . 11
6.6 Connection diagram (standard) . . . . . 13
6.7 Connection diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 14
7 Commissioning and operation . . . . . . . . . 15
7.1 Device view . . . . . . . . . . . . . . . . . . . . 15
7.2 Device configuration . . . . . . . . . . . . . 15
7.3 Replace and burn in heating element 17
7.4 Commissioning rules . . . . . . . . . . . . . 18
8 Device functions . . . . . . . . . . . . . . . . . . . . 20
8.1 Display and operating elements . . . . 20
8.2 PROFIBUS communication . . . . . . . . 21
8.3 Device master data file (GSD) . . . . . . 21
8.4 PROFIBUS protocol . . . . . . . . . . . . . 22
8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 26
8.6 Output data . . . . . . . . . . . . . . . . . . . . 29
8.7 Parameter data . . . . . . . . . . . . . . . . . 32
8.8 DPV1 protocol expansions . . . . . . . . 40
8.9 Undervoltage detection . . . . . . . . . . . 45
8.10 Temperature display (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 46
8.11 Booster connection . . . . . . . . . . . . . . 47
8.12 USB interface for visualisation software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 47
8.13 AUX interface . . . . . . . . . . . . . . . . . . 48
8.14 Total cycles counter . . . . . . . . . . . . . . 48
8.15 Operating hours counter . . . . . . . . . . 48
8.16 Data storage for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 48
8.17 Integrated clock (date and time) . . . . 48
8.18 System monitoring/alarm output . . . . 49
8.19 Error messages . . . . . . . . . . . . . . . . . 50
8.20 Error ranges and causes . . . . . . . . . . 54
9Factory settings. . . . . . . . . . . . . . . . . . . . . 55
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 56
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 58
12 Modifications (MODs) . . . . . . . . . . . . . . . . 58
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 59
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Revision list
Version 1 RES-5006 Page 3
1 Revision list
2 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.
2.1 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.
2.2 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.
2.3 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-20: TCR = 1100 ppm/K
NOREX: 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.
Version Change
1 • Creation of documentation
TCR 10x10 4– K1– or K 1– or ppm/K=

General information
Page 4 RES-5006 Version 1
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.
2.4 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 (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.
2.5 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.
2.6 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 standards and provisions
mentioned in section 2.7 "Standards / CE marking" on page 4. 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.
2.7 Standards / CE marking
The controller described here complies with the following standards, provisions and directives:
DIN EN 61010-1:2001 (2014/35/EU) Safety requirements for electrical equipment for meas-
urement, control and laboratory use (low-voltage direc-
tive):
pollution degree 2, protection class I, measurement
category I (for UR and IR terminals)
!

General information
Version 1 RES-5006 Page 5
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 fulfills 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 "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.
2.8 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.
2.9 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible damage.
2.10 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.
DIN EN 60204-1 (2006/42/EG) Electrical equipment of machines (machinery directive)
EN 55011:2009+A1:2010
EN 61000-3-2:2006-04+A1:2009+A2:2009
EN 61000-3-3:2008
EN 61000-6-4:2007+A1:2011
(2014/30/EU)
EMC generic emissions:
Group 1, Class A
EN 61000-6-2:2005 (2014/30/EU) EMC generic immunity:
Class A (ESD, RFI, burst, surge)
Exception:
Line voltage interruption acc. to EN 61000-4-11 is not
fulfilled (this leads to a designated error message of the
controller)
2011/65/EU Directive on the restriction of the use of certain haz-
ardous substances in electrical and electronic equip-
ment.
!

Use
Page 6 RES-5006 Version 1
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!
3Use
This RESISTRON® temperature controller is part of the “Series 5000”, whose main characteristic is micropro-
cessor technology. All RESISTRON® temperature controllers provide temperature regulation of heating elements
as are used in a variety of foil sealing processes.
The most common heating elements include:
• ribbon cables (straight and contoured)
• clincher bands
• beaded bands
• cutting wires
• heat-sealing blades
• soldering bows
The main application area is sealing or cutting of thermoplastics using the thermal impulse process.
The most common application areas are:
• vertical and horizontal form-fill-seal machines (VFFS and HFFS)
• bagging, filling and sealing machines
• film-wrapping machines
• bag-production machines
• group packaging machines
• foil sealing devices
• spout and hose sealing
• and much more
4 Functional principle
The resistance of the heating element, which changes with temperature, is measured by means of current and
voltage measurement, displayed and compared with the specified setpoint value. Measurements are made
50 times per second in a 50 Hz network, 60 times per second in a 60 Hz network.
The primary voltage of the impulse transformer is adjusted following the leading edge principle if the measured
values deviate from the setpoint value. The related current change in the heating element results in a rise in tem-
perature and change of resistance. The change in resistance is measured and evaluated by the RES-5006. The
temperature controller adjusts the control variables according to the change and the set setpoint.
Even the smallest thermal loads on the heating element are recorded and can be quickly and precisely corrected.
Measurement of pure electric variables, together with the high measurement rate, result in a highly dynamic ther-
moelectric control circuit. The principle of primary-side transformer control proves to be especially advantageous
as it permits a very large secondary current range with low power loss. This permits an optimal adjustment to the
load and thus the desired dynamics with extremely compact device measurements.
!

Device features
Version 1 RES-5006 Page 7
5 Device features
The RESISTRON® temperature controller RES-5006 is equipped with a PROFIBUS-DP interface. Through this
interface, all functions and parameters can be parameterised by means of the higher level machine controller. In
addition, important controller information is queried and can be processed accordingly.
The ACTUAL temperature of the heating element is output through the PROFIBUS interface and through an ana-
logue output 0…10 VDC. The real heating element temperature can be visualised on an external display instru-
ment (e.g. ATR-x) or via the operating unit of the machine controller.
The RES-5006 has an integrated error diagnosis that checks both the external system (heating element, wiring,
etc.) and the internal electronics. A differentiated error message is output through the PROFIBUS interface in case
of malfunction.
To increase operational security and immunity to interference, all PROFIBUS signals from the controller and
heating circuit are electrically isolated.
Adjustment for different heating element alloys (alloy A20, Vacodil, etc.) and setting of the temperature range to
be used (0…300 °C or 0…500 °C) can be made through coding switches on the temperature controller itself or
through the PROFIBUS interface.
The compact design of the RESISTRON® temperature controller RES-5006 as well as the plug-in connecting ter-
minals make mounting and installation easier.
An overview of the most important features and functions:
• Easy calibration of the heating element through AUTOCAL, the automatic zero-point setting.
• Eight channels permit switching of the calibration parameters during tool change.
• High control dynamics through AUTOTUNE, automatic adjustment to the controlled system.
• High flexibility: The AUTORANGE function covers a secondary voltage range of 0.4 V to 120 V and a current
range of 30 A to 500 A.
• Automatic adjustment to the network frequency in the range of 47 Hz to 63 Hz.
• Wide voltage range for flexible use from 110 VAC to 415 VAC
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
• Comprehensive error diagnosis over the PROFIBUS-DP interface
• Booster output available for connecting a switching amplifier
• High process security through comprehensive options for evaluating the parameter data (e.g. temperature
diagnosis or heat-up time monitoring)
6 Mounting and installation
See also section 2 "General information" on page 3.
Mounting, installation and commissioning may only be performed by qualified and trained persons
who are familiar with the related hazards and warranty stipulations.
The supply voltage to the machine side must lie within the permitted voltage and frequency range
of the RESISTRON® temperature controller. Otherwise, there is the danger of a defect.
6.1 Installation sequence
Proceed as follows during mounting and installation of the RESISTRON® temperature controller:
1. Switch off network voltage and 24 VDC power supply; verify lack of voltage.
!
!

Mounting and installation
Page 8 RES-5006 Version 1
2. Mounting of the RESISTRON® temperature controller in the switching cabinet on a TS35 top hat rail (in accord-
ance with DIN EN 50022). If several devices are mounted, the minimum distance specified in section 10 "Tech-
nical data" on page 56 must be maintained.
3. Wiring of the system in accordance with the regulations in section 6.3 "Power supply" on page 10, section 6.6
"Connection diagram (standard)" on page 13 and the ROPEX application report. The specifications in
section 6.2 "Installation notes" on page 9 must also be observed.
Cables that are connected to control or measurement connections may only run within the building.
4. During installation, an overcurrent protection device with max. 10 A must be provided, e.g.:
- circuit breaker in accordance with EN 60898 (characteristic B, C, D, K or Z)
- circuit breaker in accordance with UL489 (*) (characteristic B, C, D, K or Z)
- protective fuse gG in accordance with IEC 60269
- protective fuse “Class CC” or “Class J” in accordance with UL 248 (*)
The overcurrent protective devices marked with (*) must be used in installations falling under the UL regula-
tions.
If this overcurrent protective device is not sufficient for the sealing application, two separate overcurrent pro-
tective devices must be provided for the controller and the sealing application (ROPEX application report).
The overcurrent protective device must be located in the immediate vicinity of the device.
In the ROPEX application report, the smallest possible specification for this overcurrent protective device is
specified based on the calculated currents. If the protective device is dimensioned differently, the current car-
rying capacity of the components used (e.g. cable, impulse transformer, etc.) must be adjusted accordingly.
5. A disconnect device, which must be marked as belonging to the system and attached in an easily reachable
position, must be provided In the installation.
If a circuit breaker is used, it can take over the function of the disconnect device.
6. Connect the RESISTRON® temperature controller to the PROFIBUS master with a connecting cable in accord-
ance with IEC 61158.
Check all connection terminals of the system – including the terminals for the coil wires on the
impulse transformer – that they are seated firmly.
7. Check the wiring in accordance with the applicable national and international installation and setup stipulations.
!

Mounting and installation
Version 1 RES-5006 Page 9
6.2 Installation notes
Sample depiction
Line
Impulse
transformer
Current transformer
PEX-W4 / W5
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
20 mm clearance if several
controllers installed on
one top hat rail
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-xxxxx
Note
number
of turns

Mounting and installation
Page 10 RES-5006 Version 1
6.3 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.

Mounting and installation
Version 1 RES-5006 Page 11
6.4 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 6.3 "Power supply" on page 10 must be observed.
Example drawing for LF-06480:
6.5 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 6.3 "Power supply" on page 10).
!
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

Mounting and installation
Page 12 RES-5006 Version 1
6.5.1 PEX-W4
6.5.2 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

Mounting and installation
Version 1 RES-5006 Page 13
6.6 Connection diagram (standard)
RES-5006
9
8
7
6
5
4
3
2
1
+24 VDC
GND
NC
A
(+5 V) VP
DGND
NC
B
NC
7
PROFIBUS-PLUG
SUB-D / 9-POLE
POWER SUPPLY
(+24 V pwr. supply) P24
(GND pwr. supply) M24
5
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Current transformer
twisted
Impulse
transformer
Heat-
sealing
band
LINE
Line filter
sec.
U2
prim.
U1
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be groun-
ded externally
to prevent
electrostatic
charging!
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6

Mounting and installation
Page 14 RES-5006 Version 1
6.7 Connection diagram with booster connection
RES-5006
9
8
7
6
5
4
3
2
1
+24 VDC
GND
NC
A
(+5 V) VP
DGND
NC
B
NC
7
PROFIBUS-PLUG
SUB-D / 9-POLE
POWER SUPPLY
(+24 V pwr. supply) P24
(GND pwr. supply) M24
5
PROFIBUS
controller
electrically
isolated
11
9
10
8
4
3
2
1
15
16
R
IR
UR
Current transformer
twisted
Impulse
transformer
Heat-
sealing
band
LINE
Line filter
sec.
U2
prim.
U1
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be groun-
ded externally
to prevent
electrostatic
charging!
18
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6
Booster
24
IN OUT
13
twisted
Max. length 1 m
NC
NC

Commissioning and operation
Version 1 RES-5006 Page 15
7 Commissioning and operation
7.1 Device view
7.2 Device configuration
The controller must be switched off to configure the coding switch and the slide switch.
7.2.1 Configuration of the ranges for secondary voltage and current
The ranges for secondary voltage and current are configured automatically when automatic calibration
(AUTOCAL) is carried out. Configuration takes place in the voltage range of 0.4 VAC to 120 VAC and in the current
range from 30 A to 500 A. If voltage and/or current is outside the allowed range, a detailed error message is output
by the controller (see section 8.19 "Error messages" on page 50).
For secondary currents I2 less than 30 A, the secondary high-current line must be guided 2 times (or several times)
through the transformer PEX-W4 or PEX-W5 (ROPEX application report).
Connection terminals
Display LEDs
Coding and
Rating plate
Terminal plan
slide switch
USB interface
PROFIBUS
connection socket
!
2x

Commissioning and operation
Page 16 RES-5006 Version 1
7.2.2 Configuration of the rotary coding switch for temperature range and alloy
The setting of the rotary coding switch for temperature range and alloy can be overwritten by the
parameter data (section 8.7 "Parameter data" on page 32).
When the switch position “9” is selected, additional temperature ranges and alloys can be set through the ROPEX
visualisation software (section 8.12 "USB interface for visualisation software ROPEXvisual®" on page 47).
7.2.3 Configuration of the station address
On these two rotary coding switches, the station address of the RES-5006 can be set in the PROFIBUS network
from 1 to 99. Changes do not become effective until after switch-on.
With the switch setting 00, the station address with a class 2 master can be set over PROFIBUS with the SSA
service (set slave address). If no address has been assigned, the device has the standard address 126. The
address assigned through SSA remains stored in the device. As soon as a station address not equal to 00 is set
on the rotary coding switches and the 24 VDC power supply of the RES-5006 is switched off and back on again,
the stored address assigned through SSA is erased and the controller uses the set station address. In switch set-
ting 00, the standard address is then 126 again.
With the help of address setting via the rotary coding switch, it is possible to carry out a device change in an
existing machine without a programming tool. Only the same setting of the rotary coding switch can be made in
the replacement device.
Rotary encoder switch Station address
00 Changeable through SSA in the range 0…126
01…99 • Fixed address in the range 1…99
• Stored address is reset to 126
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGIZED
()AT A L A R M
-DE ENERGIZED
SWITCH POS.
1
0
4
5
8
9
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
PC CONFIGURATION
780ppm/K
1100ppm/K
(L)
(A20)
1100ppm/K (A20)
780ppm/K
3500ppm/K
(L)
0
5
1
2
3
4
6
7
8
9
Switch
position
0
1
4
5
8
300°C
300°C
500°C
500°C
300°C
1100ppm/K
780ppm/K
1100ppm/K
780ppm/K
3500ppm/K
e.g. Alloy-20
e.g. Alloy L
e.g. Alloy-20
e.g. Alloy L
Temp.
range
Temp.
coefficient
Band
alloy
0 = Factory settings
9 PC-CONFIGURATION
TEMP. COEFFICIENT
!
0
0
0
0
5
5
5
5
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
6
6
6
6
7
7
7
7
8
8
8
8
9
9
9
9
PROFIBUS
STATION ADDRESS
x 1
x 10
Station address in PROFIBUS network between
0 and 99.
01 = Factory setting

Commissioning and operation
Version 1 RES-5006 Page 17
7.2.4 Configuration of the alarm relay
When the “Alarm relay contact opens with Alarm/PC CONFIGURATION” is selected, additional configurations for
the behaviour of the alarm output can be set through the ROPEX visualisation software (section 8.12 "USB
interface for visualisation software ROPEXvisual®" on page 47).
7.3 Replace and burn in heating element
7.3.1 Burning in the heating element
The heating element is an important component in the control circuit, as it is both a heating element and sensor.
The geometry of the heating element cannot be discussed here due to its diversity. Accordingly, only some impor-
tant physical and electrical characteristics are pointed out here:
The measurement principle used here requires from the heating element alloy a suitable temperature coefficient
TCR. A TCR that is too small results in vibrating of the controller or overheating of the heating element.
If the TCR is large, the controller must be calibrated for it. The RESISTRON® temperature controller is suitable for
temperature coefficients in the range 400…4000 ppm/K.
The first time it is heated to approx. 200…250 °C, the usual alloy undergoes a one-time change in resistance
(burn-in effect). The cold resistance of the heating element is reduced by about 2…3%. But this small change in
resistance generates a zero point error of 20…30°C. The zero point must therefore be corrected after a few
heating cycles, that is, the AUTOCAL function must be carried out again.
To do this, the system must be cooled off completely.
After the first heating and zeroing, the heating element is burned in and the change of resistance stabilised. The
heating element can now be used.
The burn-in effect described here does not need to be considered if the manufacturer pretreated the heating ele-
ment for this purpose.
A damaged or worn-out heating element may no longer be used due to an irreversible TCR change.
A very important design measure is copper-coating or silver-coating of the heating element ends. The thermal
characteristics change in this range through coating of the heating element ends. As a result, the ends remain
cold, which permits exact temperature control and increases the useful life of the heating element.
Alarm relay contact
opened by alarm/
PC-CONFIGURATION.
Alarm relay contact
closed by alarm.
(factory setting) 0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGIZED
(AT ALARM)
DE-ENERGIZED
!

Commissioning and operation
Page 18 RES-5006 Version 1
7.3.2 Changing the heating element
To change the heating element, the supply voltage must be disconnected from the RESISTRON®
temperature controller on all pins.
The heating element must be changed in accordance with the manufacturer’s instructions.
After every heating element change, zeroing must be performed with the AUTOCAL function and with a cold
heating element (and cold surroundings: i.e. silicone, PTFE cover, sealing bar, among others) to compensate for
production-related tolerances of the heating element resistance.
If a new heating element is used, the above-described procedure for burning in must be performed.
7.4 Commissioning rules
Observe here section 2 "General information" on page 3 and section 3 "Use" on page 6.
Mounting, installation and commissioning may only be performed by qualified and trained persons
who are familiar with the related hazards and warranty stipulations.
7.4.1 Initial startup
Requirement: Device is correctly mounted and connected (section 6 "Mounting and installation" on page 7).
Proceed as follows when starting up the controller for the first time:
1. Switch off network voltage and 24 VDC power supply; verify lack of voltage.
2. Set desired station address in the PROFIBUS network (section 7.2 "Device configuration" on page 15).
3. Integrate GSD file in the PROFIBUS master (chap. 8.3) and select desired communication module (protocol
“compact”, “expanded” or “complete”), possibly change parameter data and start communication.
4. Make sure that the higher-level controller does not send values not equal to zero to the RESISTRON® temper-
ature controller.
5. Switch on the network voltage and 24 VDC power supply in any order.
6. After the voltage is switched on, the yellow “AUTOCAL” LED lights up for about 0.3 seconds and displays the
correct switch-on process of the controller. As long as no network voltage is present, this LED flashes slowly
(1 Hz).
At switch-on, if in addition to the yellow “AUTOCAL” LED the red “ALARM” LED lights up for
0.3seconds, the configuration with the visualisation software has been changed for this controller
(section 8.12 "USB interface for visualisation software ROPEXvisual®" on page 47). The controller’s
configuration must be checked to avoid malfunctions before continuing with commissioning.
7. The green “DATA EXCHANGE” LED lights up when the PROFIBUS communication is active.
8. The following statuses can then result:
9. With a cold heating element, activate the AUTOCAL function by setting the ACbit (AUTOCAL) in the
“ALARM” LED “OUTPUT” LED MEASURE
OFF Short pulses every 1.2seconds Continue with item 9
FLASHES quickly (4 Hz) OFF Continue with item 9
Permanently ON OFF Error diagnosis (chap. 8.19)
!
!
!
!

Commissioning and operation
Version 1 RES-5006 Page 19
PROFIBUS protocol (section 8.4 "PROFIBUS protocol" on page 22). The yellow “AUTOCAL” LED lights up
for the duration of the calibration process (approx. 10…15seconds). During this process, the AA bit (AUTOCAL
active) is set and a voltage of 0 VDC is output on the actual value output (terminal 17+18). A connected ATR-x
shows 0…3 °C.
After zeroing is completed, the “AUTOCAL” turns off and the AA bit is erased again. A voltage of 0.66 VDC (in
300 °C range and Autocal temperature = 20 °C) or 0.4 VDC (in 500 °C range) is reached at the actual value
output. A connected ATR x must be on the “Z” marking.
If zeroing is not performed correctly, the AL bit (Alarm active) is set and the red “ALARM” LED flashes slowly
(1 Hz). Then the configuration of the controller is not correct (section 7.2 "Device configuration" on page 15,
ROPEX application report). After the device configuration is correct, perform zeroing again.
10.After successful zeroing, specify a defined temperature over the PROFIBUS protocol (setpoint) and set the
ST bit. The RA bit (Regulation active) is now active and the “HEAT” LED illuminated. The heat-up and control
procedure can be observed at the actual value output:
It is functioning correctly when the temperature (i.e. signal change at the analogue output or the actual value
in the PROFIBUS protocol) is steady, that is, does not jump, oscillate or even go briefly in the wrong direction.
Such action indicates an incorrect placement of the UR measurement line.
When an error message is issued, proceed according to section 8.19 "Error messages" on page 50.
11.Burning in the heating element (section 7.3 "Replace and burn in heating element" on page 17) and repeat
AUTOCAL function.
7.4.2 Placing back into operation after changing the heating element
When changing the heating element, proceed according to section 7.3 "Replace and burn in heating element" on
page 17.
Pay attention to correct alloys, dimensions and copper coating of the new heating element to avoid
malfunctions and overheating.
Continue with chap. 7.4 item 4 to item 11.
!

Device functions
Page 20 RES-5006 Version 1
8 Device functions
See also section 6.6 "Connection diagram (standard)" on page 13.
8.1 Display and operating elements
AUTOCAL
OUTPUT
(yellow LED)
(green LED)
HEAT
ALARM
(yellow LED)
(red LED)
Lit during heating phase.
Lit while AUTOCAL process is
executing.
Lit or blinking to indicate fault.
Indicates pulses in
measurement mode. In control
mode, luminous intensity is
proportional to heating current.
(green )LED
(green )LED
24 V POWER
(red/green
LED)
BUS POWER
(red/green
LED)
BUS FAILURE
DATA EXCH
Lit or blinking if no connection
exists to PROFINET.
Lit if internal power supply for
PROFINET interface is OK.
Lit (green) while data exchange
with PROFINET controller.
Lit if external 24 VDC power
supply is present.
12 13 14 15 16 17 18
9
8
6
5
10
11
7
4
3
2
1
Visual
!
AC
HEAT
OUTPUT
ALARM
BUS FAILURE
DATA EXCHANGE
BUS POWER
24 V POWER
www. .deROPEX
Made in Germany
RES-5006
PROFIBUS