Ropex RESISTRON RES-5008 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
26.01.2021 Version 2
RESISTRON
RES-5008
Important features
• Separate terminal for operation and display
• 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
• 24 VDC control signals for START and PREHEAT with electrical isolation
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Wide voltage range for the use of 110…480 V
• Micro-USB interface for ROPEXvisual®
User Guide

Page 2 RES-5008 Version 2
Table of contents
1 Revision List . . . . . . . . . . . . . . . . . . . . . . . . 4
2 General information . . . . . . . . . . . . . . . . . . 4
2.1 Use of the operating instructions . . . . . 4
2.2 Drawings and illustrations . . . . . . . . . . 4
2.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Warning notices in the operating
instructions . . . . . . . . . . . . . . . . . . . . . 4
3.2 General safety information . . . . . . . . . 6
3.3 Intended Use . . . . . . . . . . . . . . . . . . . . 6
3.4 User qualifications . . . . . . . . . . . . . . . . 6
3.5 DECLARATION OF CONFORMITY . . 7
4 Requirements for the functioning of the con-
trol system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Heating element . . . . . . . . . . . . . . . . . 8
4.2 Impulse transformer . . . . . . . . . . . . . . 9
4.3 Current transformer . . . . . . . . . . . . . . . 9
4.4 Line filter . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Application report . . . . . . . . . . . . . . . . 9
5 Product description . . . . . . . . . . . . . . . . . . 10
5.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Functional principle . . . . . . . . . . . . . . 11
5.3 Regulator features . . . . . . . . . . . . . . . 11
6 Transport and Storage . . . . . . . . . . . . . . . 12
6.1 Scope of Delivery . . . . . . . . . . . . . . . 12
6.2 Transport and Storage . . . . . . . . . . . 12
7 Mounting and Installation . . . . . . . . . . . . . 12
7.1 Installation sequence . . . . . . . . . . . . . 12
7.2 Installation notes . . . . . . . . . . . . . . . . 14
7.3 Mains connection . . . . . . . . . . . . . . . 15
7.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 16
7.5 Current transformer . . . . . . . . . . . . . . 16
7.6 Circuit diagram (standard) . . . . . . . . . 18
7.7 Circuit diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 19
8 Commissioning and operation . . . . . . . . . 20
8.1 Device view . . . . . . . . . . . . . . . . . . . . 20
8.2 Device configuration . . . . . . . . . . . . . 20
8.3 Burning in and changing the heating
element . . . . . . . . . . . . . . . . . . . . . . . 22
8.4 Commissioning rules . . . . . . . . . . . . . 24
9 Device functions . . . . . . . . . . . . . . . . . . . . 26
9.1 Display elements and operating
elements . . . . . . . . . . . . . . . . . . . . . . 26
9.2 Display image of the T-408-1 terminal 27
9.3 Menu navigation . . . . . . . . . . . . . . . . 28
9.4 Menu structure . . . . . . . . . . . . . . . . . . 29
9.5 Menu items . . . . . . . . . . . . . . . . . . . . 30
9.6 Temperature setting (setpoint
specification) . . . . . . . . . . . . . . . . . . . 31
9.7 Temperature display/Actual value
output . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.8 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 33
9.9 Heating up to the sealing temperature
(HEAT) . . . . . . . . . . . . . . . . . . . . . . . . 34
9.10 Preheating (PREHEAT-Signal) . . . . . 34
9.11 Hold mode . . . . . . . . . . . . . . . . . . . . . 36
9.12 Temperature unit Celsius/Fahrenheit 37
9.13 Measurement impulse duration . . . . . 40
9.14 Automatic phase correction
(AUTOCOMP) . . . . . . . . . . . . . . . . . . 40
9.15 Temperature diagnosis . . . . . . . . . . . 42
9.16 Heat-up time monitoring . . . . . . . . . . 43
9.17 Restart delay after Reset . . . . . . . . . . 43
9.18 Maximum measurement pause . . . . . 44
9.19 Communication failure between controller
and terminal . . . . . . . . . . . . . . . . . . . . 44
9.20 Undervoltage detection . . . . . . . . . . . 44
9.21 Booster connection . . . . . . . . . . . . . . 45
9.22 USB-interface for visualisation software
ROPEXvisual®. . . . . . . . . . . . . . . . . . 45
9.23 AUX interface . . . . . . . . . . . . . . . . . . 46
9.24 System monitoring/alarm output . . . . 46
9.25 Error messages . . . . . . . . . . . . . . . . . 48
9.26 Error areas and causes . . . . . . . . . . . 53
9.27 Measures in the event of an error . . . 54

Version 2 RES-5008 Page 3
10 Factory settings . . . . . . . . . . . . . . . . . . . . . 55
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 56
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
13 Technical data . . . . . . . . . . . . . . . . . . . . . . 57
14 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 59
15 Modifications (MODs) . . . . . . . . . . . . . . . . 60
16 How to order . . . . . . . . . . . . . . . . . . . . . . . 61
17 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Revision List
Page 4 RES-5008 Version 2
1 Revision List
2 General information
This RESISTRON® Temperature Controller has been developed and manufactured as per EN 61010-1 and is
checked and monitored several times during manufacture as part of quality assurance. The device is leaving our
factory in perfect condition.
2.1 Use of the operating instructions
These operating instructions are part of the product and describe the installation, start-up, operation, trouble-
shooting and maintenance of the RESISTRON® Temperature Controller.
Please ready the operating instructions carefully before using the RESISTRON® Temperature Controller. Keep
the operating instructions safe, for future reference. Please ensure that the important information and the functions
are always available to the user in the vicinity of the RESISTRON® Temperature Controller.
In order to ensure safe operation, please observe the safety and warning information included in the operating
instructions.
2.2 Drawings and illustrations
The drawings and illustrations in these operating instructions are exemplary. Many details are presented in a sim-
plified manner.
2.3 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.
3 Safety
3.1 Warning notices in the operating instructions
These operating instructions contain warning notices if there is a risk of personal injury or property damage. The
signal words in the warning notices draw attention to the particular dangers and indicate the severity of the danger.
The warning notices contained in the operating instructions must be observed in order to ensure safe operation.
Version Modification
1 • Preparation of documentation
2 • New: section 9.12.1 "TCR Calculator" on page 38
• New: section 9.17 "Restart delay after Reset" on page 43
• New: section 9.18 "Maximum measurement pause" on page 44

Safety
Version 2 RES-5008 Page 5
3.1.1 Meaning of the signal words
The following signal words indicate the risk of personal injury and property damage:
3.1.2 Structure of section-related warnings
Section-related warnings apply to a section, a course of action or a specific procedure. They don't just apply to
a specific act. The hazard symbols used indicate a general or specific hazard.
Section-related warnings are structured as follows:
3.1.3 Structure of embedded warnings
Embedded warnings refer to a specific part within a paragraph. These warning notices apply to information units
smaller than the section-related warning notices.
Embedded warnings are structured as follows:
SIGNAL WORD
Instructions to avoid a dangerous situation
3.1.4 Meaning of the hazard symbols
The hazard symbols in the warning notices have the following meanings:
Signal word Importance
Imminent danger
Consequence: Death or serious injuries
Possibly imminent danger
Consequence: Death or serious injuries
Possibly imminent danger
Consequence: Slight or minor injuries
Possibly imminent danger
Consequence: Damage to property
or environment
Hazard
symbol
SIGNAL WORD
Type of danger and possible consequences
Measures to avert the danger
Warning of a danger point or dangerous situation
Warning of electrical voltage
DANGER
WARNING
CAUTION
ATTENTION

Safety
Page 6 RES-5008 Version 2
3.1.5 Information code
The following symbol indicates important information:
3.2 General safety information
3.3 Intended Use
RESISTRON® Temperature Controllers may be used only for heating and temperature control of heating elements
that are expressly suitable for this purpose, in compliance with the regulations, notes and warnings listed in these
instructions.
3.4 User qualifications
Only qualified specialists are allowed to carry out work such as assembly, installation, start-up and operation as
well as troubleshooting and maintenance of the RESISTRON® Temperature Controller. Qualified specialists are
persons who have been instructed in electrical engineering and who have the minimum qualifications required for
their work. These persons are familiar with the dangers and the guarantee provisions and they have read and
understood the operating instructions.
important information on the correct handling of the product
WARNING
Danger to life and danger of serious physical injuries as well as property damage if all warnings,
regulations and information are not followed.
Strictly follow all warnings, regulations and information in these operating instructions!
WARNING
Danger to life and risk of serious physical injuries as well as property damage if the work is not
carried out in a professional and professional manner.
Installation, electrical connection, start-up and maintenance of the RESISTRON® Temperature
Controller may be carried out only by qualified, trained personnel in accordance with these
operating instructions. Unauthorized and improperly carried out work during installation and
reconstruction, electrical connection, start-up and maintenance is prohibited for safety reasons!
NOTE
In case of non-compliance or improper use, there is a risk of impairment of safety or
overheating of heating elements, electrical lines, transformers, etc. This is the user's own
responsibility.

Safety
Version 2 RES-5008 Page 7
3.5 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/CIRUS temperature controller with accessories
Type: 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)

Requirements for the functioning of the control system
Page 8 RES-5008 Version 2
4 Requirements for the functioning of the control system
4.1 Heating element
The resistance of the heating element used must have a positive temperature coefficient for the proper functioning
of the RESISTRON® Temperature Controller.
In order to achieve an optimal sealing result, the heating element and the type of connection must be adapted to
the sealing application. The geometry of the heating element cannot be discussed here due to its diversity.
Accordingly, only some important physical and electrical characteristics are pointed out here:
The measurement principle used here requires a suitable temperature coefficient TCR from the heating element
alloy. The RESISTRON® Temperature Controller is suitable for temperature coefficients in the range
400…4000 ppm/K.
As the heating element heats up, the resistance value increases, through which the control is made possible. If
the temperature coefficient of the heating element is below the range, the control circuit oscillates or the heating
element overheats.
The temperature coefficient must be given as follows:
E.g. Alloy A20: TCR = 1100 ppm/K
Alloy L: TCR = 780 ppm/K
LEX3500: TCR = 3500 ppm/K
Vacodil: TCR = 1100 ppm/K
The setting or coding of the RESISTRON® Temperature Controller has to be carried out according to the temper-
ature coefficient of the heating element used.
The temperature coefficient must be taken from the ROPEX application report and must be set accordingly.
More information:
• High-resistance heating elements, such as NiCr 80/20, are not suitable for an operation with a RESISTRON®
Temperature Controller.
•Parallel wiring: In order to achieve an uniform temperature of both the heating elements, symmetrical cabling
must be taken into account in case of parallel wiring of heating elements.
•Series wiring: When heating elements are connected in series, it must be ensured that the heating elements
do not touch each other when they are heated on both sides. This would lead to an overcurrent and conse-
quently to a selective increase in temperature.
NOTE
If the temperature coefficient of the heating element is greater than the set value, the real tem-
perature is lower than the displayed temperature. However, if the temperature coefficient of
the heating element is greater than the set value, the real temperature is higher than the dis-
played temperature.
WARNING
The use of the wrong alloys with a temperature coefficient, which is too low, or the wrong coding
of the RESISTRON® Temperature Controller leads to uncontrolled heating and possibly to
the burning up of the heating element!
TCR 10x10 4– K1– or K 1– or ppm/K=

Requirements for the functioning of the control system
Version 2 RES-5008 Page 9
• 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 and the wear
materials (e.g. silicone underlayment, heating band cover).
4.2 Impulse transformer
A suitable impulse transformer is required for the control loop to function properly. The power and the secondary
voltage must be laid out for the control loop. According to EN 61558 or UL 5058, the transformer must be laid out
as an isolating transformer with reinforced insulation and have a single-chamber structure. Adequate protection
against accidental contact must be provided when assembling the impulse transformer. The relevant national
installation and construction regulations must be observed, while doing so. Water, cleaning solutions and / or con-
ductive liquids may not come into contact with the impulse transformer.
The cable cross-sections must be designed as per the ROPEX application report.
Incorrect assembly and installation of the impulse transformer impair electrical safety.
The terminals on the pulse transformer must be checked and tightened regularly.
4.3 Current transformer
The current transformer appropriate for RESISTRON® Temperature Controller is part of the control system.
In order to avoid malfunctions, only the original ROPEX current transformers or ROPEX monitoring current trans-
formers may be used.
The current transformer may be operated only if it is correctly connected to the RESISTRON® Temperature Con-
troller (See Chapter “Start-up”). The safety-related information in the “Mains connection” chapter must be
observed. External monitoring modules can be used to increase operational safety furthermore. Monitoring mod-
ules are not part of the standard control system and are described in separate documentation.
4.4 Line filter
ROPEX offers line filters in various performance classes. The ROPEX Application Report lists the suitable line
filter, which can be ordered.
For fulfilling the guidelines mentioned in the section 1.5 "DECLARATION OF CONFORMITY" on page 6, it has
been stipulated to use an original ROPEX line filter. Installation and connection must be carried out in accordance
with the instructions in the "Mains connection" chapter or the separate documentation for the respective line filter.
4.5 Application report
The ROPEX application report contains all the important technical information on your sealing applications. If you
have several applications in a system, these are displayed in the application report on different pages and col-
umns. This allows you to easily differentiate between them. The application report is created individually by
the ROPEX application team and is the basis for the electro-technical design of your sealing applications.
The ROPEX application report contains the following information among other things:
• List of the different heating element dimensions
• Specification of the necessary temperature coefficient

Product description
Page 10 RES-5008 Version 2
• Electro-technical data as the basis for the electrical components
• Parts list and schematic diagram for the necessary components
• Instructions and recommendations for mechanical design
• Instructions for installing the cables and components
To receive a ROPEX application report, please fill out our questionnaire completely. When you send the completed
questionnaire, a new window opens with a reference number (e.g. AR1234) and a link to the questionnaire you
created. This link enables you to reopen the questionnaire for your next inquiry. We therefore recommend that you
save the link and the reference number.
Subsequently, you will have the opportunity to send us further information on this questionnaire, such as for
example, technical descriptions or pictures.
The ROPEX application team then creates the application report based on the data you have entered. If relevant
data is missing, we will contact you to clarify the open points. As soon as the application report has been created,
you will receive it by email. We will then send you an offer for the components listed in the application report.
If you cannot judge whether your material can be sealed or what cycle rate is possible, we can also create sealing
samples for you. We will then use our system and your material to check the possibility for sealing and incorporate
the findings into the application report.
In this case you are welcome to contact [email protected]. Your request will then be passed on to the application
team to coordinate the next steps.
5 Product description
5.1 Use
This RESISTRON® Temperature Controller is part of the “RES-5000 Series”. All RESISTRON® Temperature
Controllers are used for regulating the temperature of heating elements. Heating elements are used in a wide
variety of foil sealing processes.
The most common heating elements include:
• flat bands (straight and contoured)
• tapered bands
• beaded bands
• cutting wires (straight and contoured)
• heated sealing and cutting knifes
• soldering brackets
The main application area is sealing or cutting of thermoplastics using the thermal impulse process.
The most common application areas are:
• vertical and horizontal flow wrapping machines (VFFS and HFFS)
• bagging, filling and sealing machines
• film-wrapping machines
• bag-production machines
• group packaging machines
• film sealing devices
• spout and tube sealing
• and much more.

Product description
Version 2 RES-5008 Page 11
5.2 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 mains, 60 times per second in a 60 Hz mains.
The primary voltage of the impulse transformer is adjusted following the phase angle control principle, if the meas-
ured values deviate from the setpoint value. The related current change in the heating element results in a rise in
temperature and change of resistance. This change in resistance measured and evaluated by the RESISTRON®
Temperature Controller RES-5008. The temperature controller adjusts the control variables according to the
change and the adjusted setpoint value.
Even the smallest thermal loads on the heating element are recorded and can be quickly and precisely corrected.
The measurement of pure electric variables, together with the high measurement rate, result in a highly dynamic
thermoelectric control circuit. The principle of primary-side transformer control proves to be especially advanta-
geous 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.
5.3 Regulator features
The RESISTRON® Temperature Controller RES-5008 is controlled through the separate T-408-1 operator
terminal. The T-408-1 operator terminal can be used to adjust functions and parameters and also to display
important controller information.
The ACTUAL temperature of the heating element is output through the operator terminal and through an analogue
output 0…10 VDC. The real heating element temperature can be visualised on an additional external display
instrument.
The RES-5008 has an integrated error diagnosis. The error diagnosis checks the external system (heating
element, wiring, etc.) as well as the internal electronics. A differentiated error message is output through
the T-408-1 operator terminal, in case of malfunction.
The adjustment for different heating element alloys (alloy A20, Vacodil, etc.) and the adjustment of
the temperature range to be used (0…300 °C or 0…500 °C) can be made through coding switches on
the RESISTRON® Temperature Controller RES-5008 or through the ROPEXvisual®.
The compact design of the RESISTRON® Temperature Controller RES-5008 as well as the plug-in connecting
terminals make mounting and installation easier.
An overview of the most important features and functions:
• AUTOCAL - Easy calibration of the heating element by automatic zeroing.
• AUTOTUNE - high regulation dynamics by automatic adaptation to the regulating line.
• AUTORANGE - automatic configuration of the secondary voltage range and current range, high flexibility due
to the coverage of a secondary voltage range from 0.4 V to 120 V and a current range from 30 A to 500 A.
• AUTOCOMP - automatic phase correction
• Automatic adjustment to the mains frequency in the range of 47 Hz to 63 Hz.
• Wide voltage range for flexible use from 110 VAC to 480 VAC
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
• Comprehensive error diagnosis
• Booster output available for connecting a switching amplifier

Transport and Storage
Page 12 RES-5008 Version 2
6 Transport and Storage
6.1 Scope of Delivery
After taking delivery, check if the delivery is complete immediately, with the help of the accompanying documents.
After taking delivery, perform a visual inspection for possible damage.
6.2 Transport and Storage
Transport and store the device in its original box. For the ambient conditions, please refer to the technical data
(section 13 "Technical data" on page 57). After a longer period of storage of the RESISTRON® Temperature
Controller RES-5008, ROPEX Industrie-Elektronik GmbH will handle the functionality testing for a fee.
7 Mounting and Installation
See also section 4 "Requirements for the functioning of the control system" on page 8.
7.1 Installation sequence
Proceed as follows during mounting and installation of the RESISTRON® Temperature Controller RES-5008:
1. Switch off mains voltage and 24 VDC power supply; verify lack of voltage.
2. Installation of the RESISTRON® Temperature Controller in the switching cabinet on a TS35 top-hat rail in
accordance with EN 60715. If several devices are mounted, the minimum distance specified in section 12
"Disposal" on page 56 must be maintained.
3. Installation of the operator terminal in the panel cut-out. It is fastened with four clips that snap into place laterally
at the terminal housing.
NOTE
ROPEX Industrie-Elektronik GmbH does not assume any guarantee for defects that are sub-
sequently claimed.
WARNING
The assembly, installation and commissioning may be performed only by technically trained
and competent persons. The persons must be familiar with the dangers associated with it and
guarantee provisions.
CAUTION
The supply voltage to the machine side must lie within the permitted voltage and frequency
range of the temperature controller. Otherwise, there is the danger of a defect.

Mounting and Installation
Version 2 RES-5008 Page 13
4. Wiring of the system in accordance with the regulations in section 7.3 "Mains connection" on page 15,
section 7.6 "Circuit diagram (standard)" on page 18 and the ROPEX application report. The specifications
in section 7.2 "Installation notes" on page 14 must also be observed.
Cables that are connected to control or measurement connections may only run within the building.
5. 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 regulations.
If the specified overcurrent protection device is not sufficient for the sealing application, two separate
overcurrent protective devices must be provided for the regulator 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 protection device is
specified based on the calculated currents. If the protection device is dimensioned differently, the current load
capacity of the components used (e.g. cable, impulse transformer, etc.) must be adjusted accordingly.
6. A disconnect device must be provided during installation. The disconnect device must be properly marked as
part of the system and attached in an easily accessible position.
If a circuit breaker is used, it can take over the function of the disconnect device.
7. Connection of the RESISTRON® Temperature Controller RES-5008 with the operator terminal T-408-1 using
the appropriate cable.
CAUTION
Check all connection terminals of the system – including the terminals for the coil wires on
the impulse transformer – as to whether they are fixed firmly.
8. Check the wiring in accordance with the applicable national and international installation and setup
requirements.

Mounting and Installation
Page 14 RES-5008 Version 2
7.2 Installation notes
NOTE
The correct dimensioning of the system components is crucial for the correct functioning of
the control loop. Please take this data from the ROPEX application report.
NOTE
In order to enable a good and stable regulation, additional resistances (fuses, long lines, plug
connections, ...) must be avoided in the secondary circuit.
Additional resistances influence the regulation and can make the system prone to errors,
in the long term.
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
Tw is t ed
Current measuring
wires IR
R
Connect U measuring
wires directly to
heatsealing band ends
Line filter
LF-xxxxx
Note
number
of turns
Basic body made
of aluminium,
NO steel

Mounting and Installation
Version 2 RES-5008 Page 15
7.3 Mains connection
Line
To avoid disturbances while measuring, place several con-
trol loops on the same phase if possible.
Overcurrent device
2-Pole circuit breaker or fuses,
(ROPEX application report).
ATTENTION - protection only in the event of
a short circuit.
No protection of the RESISTRON®
Temperature Controller.
Contactor Ka
For all-pole disconnection, EMERGENCY OFF or EMER-
GENCY STOP.
Dimensioning ROPEX application report
Line filter
Filter type and filter size must be based on load, trans-
former and machine cabling (ROPEX application
report).
CAUTION Do not lay filter supply lines (mains
side) parallel to filter output lines (load side).
RESISTRON® Temperature Controller
Contactor Kb
CAUTION To increase machine safety by
switching off the load on all poles in the event
of a fault, e.g. in combination with the ALARM
output of the RESISTRON® Temperature Controller.
Dimensioning ROPEX application report I1max
(for Ka and Kb)
Impulsetransformer
Design according to EN 61558 or UL 5058 (isolating trans-
former with reinforced insulation). Ground core.
CAUTION Use only single-chamber design.
Power, ED number and voltage values must be
determined individually depending on
the application (ROPEX application report).
Wiring
Cable cross-sections depend on the application
(ROPEX application report).
Make sure to twist (min. 20 beats/meter,
Accessories “twisted measuring line”)
Twisting (min. 20 beats/meter) necessary if
several control loops are laid together
(“Crosstalk”).
Twisting (min. 20 beats/meter) recommended to
improve EMC properties.
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

Mounting and Installation
Page 16 RES-5008 Version 2
7.4 Line filter
In order to comply with the EMC directive, RESISTRON control loops must be operated with earthed line filters.
The earthed line filters serve to attenuate the effect of the phase-anglecontrol on the line and to protect the con-
troller against line disturbances.
CAUTION
The use of a suitable line filter is part of compliance with the standards and a prerequisite for CE
marking.
ROPEX line filters are specially optimized for use in RESISTRON control loops and guarantee compliance with
the EMC limit values when installed and wired correctly. The specification of the line filter can be found in the
ROPEX-application report created for your sealing application.
Further technical information: Documentation “line filter”.
The supply of several control loops via a line filter is permitted if the total current does not exceed the maximum
current of the filter.
The instructions in the section 7.3 "Mains connection" on page 15 with regard to cabling must be complied with.
Example drawing for LF-06480:
7.5 Current transformer
The current transformer PEX-W4/-W5 appropriate for RESISTRON® Temperature Controller is part of the control
system. The current transformer may be operated only if it is correctly connected to the temperature controller
(section 7.3 "Mains connection" on page 15).
If several heating elements are operated with one control circuit, the installation can be found in the ROPEX appli-
cation report. In special applications with RESISTRON® Temperature Controller it is necessary that a short circuit
between the heating element and earth/housing is detected and the control system is switched off immediately.
The MSW-2 monitoring current transformer can be used for this.
Further technical information can be found in the separate documentation for the current transformer and moni-
toring current transformer.
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
Version 2 RES-5008 Page 17
7.5.1 PEX-W4
7.5.2 PEX-W5
The current transformer is mounted on a hat rail measuring 35 x 7.5 mm or 35 x 15 mm in accordance with
EN 60715.
If the high-current line cannot be conducted through the opening provided due to the diameter, an HCB-1 high-
current rail must be used.
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (EN 60715)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Mounting and Installation
Page 18 RES-5008 Version 2
7.6 Circuit diagram (standard)
RES-5008
7
5
+24 VDC
GND
POWER SUPPLY
R
Current transformer
Impulse
transformer
LINE
11
9
10
8
4
3
2
1
IR
UR
Heat-
sealing
band
sec.
U2
prim.
U1
twisted
Line filter
ALARM OUTPUT
max. 30 V / 1 A
Ground
Must be grounded
externally to pre-
vent electrostatic
charging!
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6
716
18
BOOSTER
OUTPUT
HO LD
PREHEAT
SEALHEAT
EN TER
HAND
RESET
ROPE X
Display and
operation panel
T-408
PREHEAT
with 24 VDC signal
START (HEAT)
with 24 VDC signal
15
7

Mounting and Installation
Version 2 RES-5008 Page 19
7.7 Circuit diagram with booster connection
RES-5008
7
5
+24 VDC
GND
POWER SUPPLY
R
Current transformer
Impulse
transformer
11
9
10
8
4
3
IR
UR
Heat-
sealing
band
sec.
U2
prim.
U1
twisted
ALARM OUTPUT
max. 30 V / 1 A
Ground
Must be grounded
externally to pre-
vent electrostatic
charging!
17
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
14
13
12
6
716
18
HO LD
PREHEAT
SEALHEAT
EN TER
HAND
RESET
ROPE X
Display and
operation panel
T-408
PREHEAT
with 24 VDC signal
START (HEAT)
with 24 VDC signal
LINE
4
3
2
1
15
prim.
U1
Booster
24
IN OUT
13
Line filter
twisted
Length: max. 1 m
NC
NC
7

Commissioning and operation
Page 20 RES-5008 Version 2
8 Commissioning and operation
8.1 Device view
RESISTRON® Temperature Controller RES-5008:
Terminal T-408-1:
8.2 Device configuration
NOTE
The regulator must be switched off to configure the coding switch and the slide switch.
Connection terminals
Display LEDs
Coding and
Rating plate
Terminal plan
Slide switch
USB interface
Circuit
Terminal
Indicator display
Operating keys
Cable connection
Fastening
Rating plate
hooks (4x)