Ropex RESISTRON RES-5012 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
28.7.20 Version 2
RESISTRON
RES-5012
Important features
• Complete control via EtherCAT® interface1 (2 x RJ-45)
• 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
• 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®
• cULus approval
1. EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automa-
tion GmbH, Germany.
Operating
instructions

Page 2 RES-5012 Version 2
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 Maintenance . . . . . . . . . . . . . . . . . . . . 4
2.8 Transportation . . . . . . . . . . . . . . . . . . . 5
2.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
3Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Functional principle . . . . . . . . . . . . . . . . . . 7
5 Device features . . . . . . . . . . . . . . . . . . . . . . 7
6 Mounting and installation . . . . . . . . . . . . . . 8
6.1 Installation sequence . . . . . . . . . . . . . . 8
6.2 Installation steps . . . . . . . . . . . . . . . . 10
6.3 Power supply . . . . . . . . . . . . . . . . . . . 11
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12
6.5 Current transformer PEX-W4/-W5 . . . 12
6.6 Wiring diagram (standard) . . . . . . . . . 14
6.7 Wiring diagram with booster connection
15
7 Startup and operation . . . . . . . . . . . . . . . . 16
7.1 View of the device . . . . . . . . . . . . . . . 16
7.2 Device configuration . . . . . . . . . . . . . 16
7.3 Replacing and burning in the heatsealing
band . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 Startup procedure . . . . . . . . . . . . . . . 19
8 Device functions . . . . . . . . . . . . . . . . . . . . 21
8.1 LEDs and controls . . . . . . . . . . . . . . . 21
8.2 EtherCAT® communication . . . . . . . . 23
8.3 EtherCAT® Slave Information (ESI) . . 23
8.4 Communication protocol . . . . . . . . . . 24
8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 24
8.6 Output data . . . . . . . . . . . . . . . . . . . . 27
8.7 Object dictionary . . . . . . . . . . . . . . . . 30
8.8 Integrated web server . . . . . . . . . . . . 42
8.9 Undervoltage detection . . . . . . . . . . . 45
8.10 Temperature meter (actual value output)
46
8.11 Booster connection . . . . . . . . . . . . . . 47
8.12 USB interface for visualization software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 48
8.13 AUX interface . . . . . . . . . . . . . . . . . . 48
8.14 Total cycle counter . . . . . . . . . . . . . . 48
8.15 Operating hours counter . . . . . . . . . . 48
8.16 Data memory for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 49
8.17 Built-in clock (date and time) . . . . . . . 49
8.18 System monitoring / alarm output . . . 49
8.19 Error messages . . . . . . . . . . . . . . . . . 50
8.20 Fault areas and causes . . . . . . . . . . . 55
9Factory settings. . . . . . . . . . . . . . . . . . . . . 57
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 57
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 60
12 Modifications . . . . . . . . . . . . . . . . . . . . . . . 60
12.1 Modifications (MODs) . . . . . . . . . . . . 60
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 61
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Revision list
Version 2 RES-5012 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 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.
Version Change
2 • Creation of documentation
TCR 10x10 4– K1– or K 1– or ppm/K=

General information
Page 4 RES-5012 Version 2
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 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.
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 directives mentioned in section
"DECLARATION OF CONFORMITY" on page 6. This device must be installed and connected according to the
instructions contained in section "Power supply" as well as the separate documentation enclosed with the line
filter.
2.7 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.
!
!

General information
Version 2 RES-5012 Page 5
2.8 Transportation
Store and transport the device in its original carton.
After transport, perform a visual inspection for possible damage.
2.9 Disposal
This device is subject to Directive 2012/19/EU concerning the reduction of the increasing amount of
waste electrical and electronic equipment and the disposal of such waste in an environmentally
sound way.
To guarantee proper disposal and / or the recover of reusable material, please take the device to a
designated municipal collection point and observe local regulations.
Careless, uncontrolled disposal can cause damage to the environment and human health. By
ensuring that your product is disposed of or recycled in a responsible way, you can help protect the
environment and human health.
This device must not be disposed of as residual waste!
!

General information
Page 6 RES-5012 Version 2
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-5012 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)

Use
Version 2 RES-5012 Page 7
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 RESISTRON®
temperature controller. 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.
5 Device features
The RESISTRON® temperature controller RES-5012 is equipped with a EtherCAT® interface. Through this inter-
face, all functions and parameters can be parameterised by means of the higher level machine controller. In addi-
tion, important controller information is queried and can be processed accordingly.

Mounting and installation
Page 8 RES-5012 Version 2
The ACTUAL temperature of the heating element is output through the EtherCAT® 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-5012 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 EtherCAT® interface in case
of malfunction.
To increase operational security and immunity to interference, all EtherCAT® 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 EtherCAT® interface.
The compact design of the RESISTRON® temperature controller RES-5012 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 EtherCAT® 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 startup may only be performed by authorized persons who have received
suitable instruction and are familiar with the associated risks and warranty provisions.
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 to install the RESISTRON® temperature controller RES-5012:
1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
2. Mount the RESISTRON® temperature controller on a standard top hat rail (DIN TS35 rail according to
DIN EN 50022) in the electrical cabinet. If several controllers are mounted on one rail, the minimum clearance
specified in section 10 "Technical data" on page 57 must be allowed between them.
3. Wire the system in accordance with the instructions in section 6.3 "Power supply" on page 11, section 6.6
!
!

Mounting and installation
Version 2 RES-5012 Page 9
"Wiring diagram (standard)" on page 14, and the ROPEX Application Report. The information provided in
section 6.2 "Installation steps" on page 10 must also be observed.
Wires used for control or measuring connections must always be laid inside the building.
4. An overcurrent protective device with a maximum rating of 10 A must be fitted when the device is installed, e.g.:
- Miniature circuit breaker to EN 60898 (B, C, D, K, or Z characteristic)
- Miniature circuit breaker to UL 489 (*) (B, C, D, K, or Z characteristic)
- Fuse gG to IEC 60269
- Class CC or Class J fuse to UL 248 (*)
The overcurrent protective devices marked (*) should be used in installations conforming to UL standards.
If one such device is not adequate for the heatsealing application, two separate overcurrent protective devices
should be provided – one for the controller and one for the application (ROPEX Application Report).
The overcurrent protective device must be located directly adjacent to the controller.
The minimum possible specification for this device is indicated in the ROPEX Application Report based on the
calculated currents. If a larger overcurrent protective device is fitted, you must match the current carrying
capacity of the other components accordingly (e.g. cables, impulse transformer etc.).
5. A disconnecting device must be provided when the system is installed; it must be marked as belonging to the
system and fitted in a readily accessible position.
If a miniature circuit breaker is used, it can also perform the function of this device.
6. Connect the RESISTRON® temperature controller to the EtherCAT® master using a suitable (standard com-
pliant) cable.
Check that all system connections – including the terminals for the impulse transformer windings
– are securely attached.
7. Make sure the wiring conforms to all relevant national and international installation regulations.
!

Mounting and installation
Page 10 RES-5012 Version 2
6.2 Installation steps
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
Version 2 RES-5012 Page 11
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® tem-
perature 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
Page 12 RES-5012 Version 2
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 11 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 11).
!
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-5012 Page 13
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
Page 14 RES-5012 Version 2
6.6 Wiring diagram (standard)
14
13
12
7
5
Ethernet
module
18
17
6
11
9
10
8
4
3
2
1
15
16
R
IR
UR
twisted
Impulse
transformer
Heat-
sealing
band
LINE
sec.
U2
prim.
U1
Line filter
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
V+
V-
24 VDC POWER
SUPPLY
Current
transformer
BOOSTER
OUTPUT
RES-5012

Mounting and installation
Version 2 RES-5012 Page 15
6.7 Wiring diagram with booster connection
R
Current
transformer
Impulse
transformer
LINE
11
9
10
8
4
3
2
1
IR
UR
15
16
twisted
Booster
IN OUT
13
Line filter
NC
NC
14
13
12
7
5
Ethernet
module
18
17
6
8
7
5
4
6
3
2
1
Termination
RX-
RX+
TX+
Ethernet
PORT 1 (RJ45)
TX-
Ethernet
PORT 2 (RJ45)
(for assignment
see PORT 1)
Shield
ALARM OUTPUT
max. 30 V / 0.2 A
Ground
Must be grounded
externally to
prevent
electrostatic
charging!
°C
ATR
_
+
ANALOG OUTPUT
+0...10 VDC
V+
V-
24 VDC POWER
SUPPLY
Heat-
sealing
band
sec.
U2
prim.
U1
twisted
Max. length 1 m
24
RES-5012

Startup and operation
Page 16 RES-5012 Version 2
7 Startup and operation
7.1 View of the device
7.2 Device configuration
The controller must be switched off in order to configure the coding and slide switches.
7.2.1 Configuration of the secondary voltage and current ranges
The secondary voltage and current ranges are automatically configured during the automatic calibration function
(AUTOCAL). The voltage is configured in the range from 0.4 VAC to 120 VAC and the current in the range from
30 A to 500 A. If the voltage and / or current are outside of the permissible range, a detailed error message
appears on the controller (section 8.19 "Error messages" on page 50).
If the secondary current I2 is less than 30 A, the secondary high-current wire must be laid twice (or several times)
through the PEX-W4, or PEX-W5 current transformer (ROPEX Application Report).
Connection terminals
LEDs
Nameplate
Terminal plan
USB interface
Coding and slide
switches
EtherCAT®
ports
!
2x

Startup and operation
Version 2 RES-5012 Page 17
7.2.2 Configuration of the rotary coding switch for the temperature range and alloy
The setting of the rotary coding switch for the temperature range and alloy can be overwritten with
the parameter data (section 8.7 "Object dictionary" on page 30).
If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization software
(section 8.12 "USB interface for visualization software ROPEXvisual®" on page 48).
7.2.3 Configuration of the rotary coding switch for the Device ID
These coding switches allow you to set the least significant byte of the Device ID of the RES-5012 in the
EtherCAT® network to a value between 0x0000 and 0x00FF. A new setting does not take effect until the next time
the controller is switched on. The preset Device ID of the RES-5012 is configured as follows, depending on the
settings of the rotary coding switches:
rotary coding switch Device ID
00…FF 0x0000…0x00FF
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGIZED
( )AT ALARM
-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
)
11 00 p pm / K (A 20
)
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. A20
e.g. L
e.g. A20
e.g. L
Temp .
range
Temp .
coefficient
Band
alloy
0 = Factory settings
9 PC-CONFIGURATION
TEMP. COEFFICIENT
!
0
0
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1
Device ID .selectable
00 = factory default
0...F
0...F
ETH ERCAT Device ID
0
0
F
F
E
E
D
D
CC
B
B
A
A
9
9
8
8
7
7
6
6
5
5
44
3
3
2
2
1
1
0x00XX

Startup and operation
Page 18 RES-5012 Version 2
7.2.4 Configuration of the alarm relay
If the switch is set to "Alarm relay de-energized at alarm / PC CONFIGURATION", you can select more alarm
output configurations in the ROPEX visualization software (section 8.12 "USB interface for visualization soft-
ware ROPEXvisual®" on page 48).
7.3 Replacing and burning in the heatsealing band
7.3.1 Burning in the heatsealing band
The heatsealing band is a key component in the control loop because it is not only a heating element but also a
sensor. The geometry of the heatsealing band is too complex to be discussed at length here. We shall therefore
only refer to a few of the most important physical and electrical properties.
The measuring principle used for this system requires a heatsealing band alloy with a suitable temperature coef-
ficient TCR. Too low a TCR leads to oscillation or uncontrolled heating.
If a heatsealing band with a higher TCR is used, the controller must be calibrated for it.
The first time the heatsealing band is heated to approximately 200…250 °C, the standard alloy undergoes a once-
only resistance change (burn-in effect). The cold resistance of the heatsealing band is reduced by approximately
2…3%. However, this at first glance slight resistance change results in a zero point error of 20…30 °C. The zero
point must therefore be corrected after a few heating cycles, i.e. the AUTOCAL function must be run 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 occur if the heatsealing band has already been thermally pretreated
by the manufacturer.
An overheated or burned-out heatsealing band must no longer be used because the temperature
coefficient has been irreversibly altered.
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.
7.3.2 Replacing the heatsealing band
The supply voltage (all poles) must be disconnected from the RESISTRON® temperature controller in order to
replace the heatsealing band.
The heatsealing band must be replaced in accordance with the instructions provided by the manu-
facturer.
0
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENER GIZED
(AT ALARM)
DE-ENERGIZED
A
larm relay contact
opened by alarm/
PC-CONFIGURATION
A
larm relay contact
closed by alarm.
(factory setting)
!
!

Startup and operation
Version 2 RES-5012 Page 19
Each time the heatsealing band is replaced, you must calibrate the zero point with the AUTOCAL function while
the band (and the environment, i.e. silicone, PTFE cover, sealing bar etc.) is still cold in order to compensate pro-
duction-related resistance tolerances.
If a new heating element is used, the above-described procedure for burning in must be performed.
7.4 Startup procedure
Please also refer to section 2 "General information" on page 3 and section 3 "Use" on page 7.
Mounting, installation and startup may only be performed by authorized persons who have received
suitable instruction and are familiar with the associated risks and warranty provisions.
7.4.1 Initial startup
Condition: The device must be correctly installed and connected (section 6 "Mounting and installation" on
page 8).
Proceed as follows to start up the controller for the first time:
1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
2. Link the ESI file into the EtherCAT® master (section 8.3), then select the required parameters, make the con-
nections and start the communication.
3. Make sure that the higher-level controller does not send values not equal to zero to the temperature controller.
4. Switch on the line voltage and the 24 VDC supply (the order is arbitrary).
5. When the voltage is switched on, the yellow "AUTOCAL" LED lights up for approximately 0.3 seconds to indi-
cate that the controller is being powered up correctly. As long as the EtherCAT® communication is not active,
neither the "ECAT RUN" LED nor the "ECAT ERROR" LED light up.
If the red "ALARM" LED lights up for 0.3…1.5 seconds when the voltage is switched on in addition
to the yellow "AUTOCAL" LED, the configuration of this controller has been changed in the visual-
ization software (section 8.12 "USB interface for visualization software ROPEXvisual®" on page 48). In
order to avoid malfunctions, please check the controller configuration before continuing the startup pro-
cedure.
6. The green "ECAT_RUN" LED lights up to indicate an active EtherCAT® communication.
7. One of the following states then appears:
8. Activate the AUTOCAL function while the heatsealing band is still cold by setting the AC bit (AUTOCAL) in the
EtherCAT® protocol (section 8.4 "Communication protocol" on page 24). The yellow "AUTOCAL" LED lights
up for the duration of the calibration process (approx. 10…15 seconds). The AA bit (AUTOCAL active) is addi-
tionally set and a voltage of approximately 0 VDC appears at the actual value output (terminals 17+18). If an
ATR-x is connected, it indicates 0…3 °C.
After the zero point has been calibrated, the "AUTOCAL" LED goes out and a voltage of 0.66 VDC (300 °C
range) or 0.4 VDC (500 °C range) appears at the actual value output. If an ATR-x is connected, it must be set
to "Z".
If the zero point was not calibrated successfully, the AL bit (alarm active) is set and the red "ALARM" LED blinks
"ALARM" LED "OUTPUT" LED ACTION
OFF Short impulses every 1.2 s Go to step 8
BLINKS fast (4 Hz) OFF Go to step 8
LIT continuously OFF Error diagnosis (section 8.19)
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!

Startup and operation
Page 20 RES-5012 Version 2
slowly (1 Hz). In this case the controller configuration is incorrect (section 7.2 "Device configuration" on
page 16, ROPEX Application Report). Repeat the calibration after correcting the controller configuration.
9. After the zero point has been successfully calibrated, specify a defined temperature by means of the EtherCAT®
protocol (set point) and set the ST bit. The RA bit (control active) is then activated and the "HEAT" LED lights
up. The heating and control process can be observed at the actual value output.
The controller is functioning correctly if the temperature (which corresponds to the signal change at the analog
output or the actual value in the EtherCAT® protocol) is a regular curve, in other words it must not jump abruptly,
fluctuate, or temporarily deviate in the wrong direction. This kind of behavior would indicate that the UR mea-
surement cable was laid incorrectly.
If an error code is displayed, proceed as described in section 8.19 "Error messages" on page 50.
10.Burn in the heatsealing band (section 7.3 "Replacing and burning in the heatsealing band" on page 18) and
run the AUTOCAL function again.
7.4.2 Restart after replacing the heatsealing band
To replace the heatsealing band, proceed as described in section 7.3 "Replacing and burning in the heatsealing
band" on page 18.
Always use a heatsealing band with the correct alloy, dimensions, and copper plating in order to
avoid malfunctions and overheating.
Continue with section 7.4, steps 3 to 10.
!