Ropex RESISTRON RES-5027 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 1
RESISTRON
RES-5027
Important features
• 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
• Temperature OK output
• Analogue input for setpoint specification with potentiometer or 0…10 VDC
• Analogue output 0…10 VDC for ACTUAL temperature
• 24 VDC control signals for START, AUTOCAL, RESET and CH-1, e.g. constant setting degree
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Micro-USB interface for ROPEXvisual®
• cULus approval
Operating
Instructions

Page 2 RES-5027 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 Maintenance . . . . . . . . . . . . . . . . . . . . 4
2.8 Transportation . . . . . . . . . . . . . . . . . . . 5
2.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
3Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Functional principle . . . . . . . . . . . . . . . . . . 7
5 Controller features . . . . . . . . . . . . . . . . . . . 7
6 Mounting and Installation . . . . . . . . . . . . . . 8
6.1 Installation sequence . . . . . . . . . . . . . . 8
6.2 Installation notes . . . . . . . . . . . . . . . . 10
6.3 Power supply . . . . . . . . . . . . . . . . . . . 11
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12
6.5 Current transformer PEX-W4/-W5 . . . 12
6.6 Supply voltage . . . . . . . . . . . . . . . . . . 14
6.7 Connection diagram (standard) . . . . . 14
6.8 Connection diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 15
7 Commissioning and operation . . . . . . . . . 16
7.1 Device view . . . . . . . . . . . . . . . . . . . . 16
7.2 Device configuration . . . . . . . . . . . . . 16
7.3 Changing and burning in the heating
element . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Commissioning rules . . . . . . . . . . . . . 18
8 Device functions . . . . . . . . . . . . . . . . . . . . 20
8.1 Display and operating elements . . . . 20
8.2 Temperature setting (setpoint
specification) . . . . . . . . . . . . . . . . . . . 21
8.3 Temperature display (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4 Autom. zeroing (AUTOCAL) . . . . . . . 23
8.5 START signal (HEAT) . . . . . . . . . . . . 24
8.6 RESET signal . . . . . . . . . . . . . . . . . . 25
8.7 CH-1 signal . . . . . . . . . . . . . . . . . . . . 26
8.8 Measurement impulse duration . . . . . 26
8.9 Automatic phase correction
(AUTOCOMP) . . . . . . . . . . . . . . . . . . 27
8.10 Temperature diagnosis . . . . . . . . . . . 28
8.11 “Temperature reached” or “Temperature
OK” signal . . . . . . . . . . . . . . . . . . . . . 29
8.12 Heat-up time monitoring . . . . . . . . . . 31
8.13 Booster connection . . . . . . . . . . . . . . 32
8.14 USB interface for visualisation software
ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 32
8.15 AUX interface . . . . . . . . . . . . . . . . . . 33
8.16 Data storage for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 33
8.17 Integrated clock (date and time) . . . . 33
8.18 System monitoring/alarm output . . . . 33
8.19 Error messages . . . . . . . . . . . . . . . . . 34
8.20 Error ranges and causes . . . . . . . . . . 39
9Factory settings. . . . . . . . . . . . . . . . . . . . . 40
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 42
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 44
12 Modifications (MODs) . . . . . . . . . . . . . . . . 44
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 45
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Revision list
Version 1 RES-5027 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.
Version Change
1 • Creation of documentation
TCR 10x10 4– K1– or K 1– or ppm/K=

General information
Page 4 RES-5027 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 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 1 RES-5027 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-5027 Version 1
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-5027 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 1 RES-5027 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 RES-5027. 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 Controller features
The analogue interfaces for temperature setpoint and temperature actual value 0…10 VDC, which are electrically
isolated from the heating circuit, permit temperature setting directly from the machine control or also through an
external potentiometer (PD-x).

Mounting and Installation
Page 8 RES-5027 Version 1
The real heating element temperature can also be visualised on a machine controller display or an external display
instrument (ATR-x).
The RESISTRON® temperature controller RES-5027 has an integrated error diagnosis that checks both the
external system (heating element, wiring, etc.) and the internal electronics and puts out a differentiated error mes-
sage in case of malfunction.
To increase operational security and immunity to interference, all 24VDC logic signals and 0-10VDC analogue
signals are electrically isolated from the heating circuit.
Adjustment for different heating element alloys (alloy A20, etc.) and setting of the temperature range to be used
(0…300°C, 0…500°C, etc.) can be performed through coding switches on the temperature controller itself.
An external voltage supply of 24VDC is required for the controller. The compact design of the RESISTRON® tem-
perature controller RES-5027 as well as the plug-in connecting terminals 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
• High control dynamics through AUTOTUNE, automatic adjustment to the controlled system
• High flexibility: A secondary voltage range of 0.4V to 120V and a current range of 30A to 500A are covered
through the AUTORANGE function
• 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®
• Error diagnosis
• Booster output available for connecting a switching amplifier
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 RES-5027:
1. Switch off network voltage; verify that no voltage is present.
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 42 must be maintained.
3. Wiring of the system in accordance with the regulations in section 6.3 "Power supply" on page 11, section 6.6
"Supply voltage" on page 14 and the ROPEX Application Report. The specifications in section 6.2 "Installation
notes" on page 10 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)
!
!

Mounting and Installation
Version 1 RES-5027 Page 9
- 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.
Check all connection terminals of the system – including the terminals for the coil wires on the
impulse transformer – that they are seated firmly.
6. Check the wiring in accordance with the applicable national and international installation and setup stipulations.
!

Mounting and Installation
Page 10 RES-5027 Version 1
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
Version 1 RES-5027 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® 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
Page 12 RES-5027 Version 1
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 1 RES-5027 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-5027 Version 1
6.6 Supply voltage
To provide power to the RES-5027, voltage of 24 VDC must be applied to the terminals 12+13. The maximum cur-
rent draw is 1.0 A. The supply voltage input is protected against faulty polarisation.
6.7 Connection diagram (standard)
RES-5027
(also with MOD 01)
4
3
2
1
U1
22
21
BOOSTER
14
12
7
6
5
16
17
15
13
18
=
=
20
19
RESET
24 signal VDC
START HEAT ( )
24 signal VDC
Protective con-
ductor connection
AUTOCAL
24 signal VDC
ALARM OUTPUT
+24 VDC
PE
+24 VDC
REFERENCE
VOLTAGE
OUTPUT U
REF
+10 VDC
ANALOG OUTPUT
(actual value)
+0...10 VDC
ANALOG INPUT
(setpoint)
+0...10 VDC
24 VDC POWER
SUPPLY
GND
TEMP OK.
OUTPUT
+24 VDC
CH-1
24 signal VDC
R
Current transformer
Impulse
transformer
sec.
IR
UR
U2
prim.
U1
twisted
9
8
11
10
Heat-
sealing
band
Line f r
ilte
LINE

Mounting and Installation
Version 1 RES-5027 Page 15
6.8 Connection diagram with booster connection
R
Current transformer
Impulse
transformer
sec.
IR
UR
U2
Booster
24
IN OUT
13
prim.
U1
twisted
RESET
24 signal VDC
START HEAT ( )
24 signal VDC
Protective con-
ductor connection
AUTOCAL
24 signalVDC
ALARM OUTPUT
+24 VDC
RES-5027
(also with 01)MOD
PE
+24 VDC
14
12
7
6
5
9
8
4
3
2
1
REFERENCE
VOLTAGE
OUTPUT U
REF
+10 VDC
16
17
15
13
18
=
=
ANALOG OUTPUT
(actual value)
+0...10 VDC
ANALOG INPUT
(setpoint)
+0...10 VDC
11
10
24 VDC POWER
SUPPLY
22
21
GND
20
19
TEMP OK
.
OUTPUT
+24 VDC
CH-1
24 signal VDC
Heat-
sealing
band
LINE
Line filter
twisted
Max. length 1 m

Commissioning and operation
Page 16 RES-5027 Version 1
7 Commissioning and operation
7.1 Device view
7.2 Device configuration
The controller must be switched off to configure the coding switch of the slide switch.
7.2.1 Configuration 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 34).
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
!
2x

Commissioning and operation
Version 1 RES-5027 Page 17
7.2.2 Configuration of the rotary coding switch for temperature range and alloy
This configuration is available as standard.
When the switch position “9” is selected, additional temperature ranges and alloys can be set through the ROPEX
visualisation software (see section 8.14 "USB interface for visualisation software ROPEXvisual®" on page 32).
7.2.3 Configuration of the alarm output
When the “Alarm output 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 8.14 "USB inter-
face for visualisation software ROPEXvisual®" on page 32).
7.3 Changing and burning in the 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, ie an increase in resistance with temperature. A TCR that is too small results in vibrating 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
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
5
1
2
3
4
6
7
8
9
AUX
CONFIGURATION
ALARM OUTPUT
ENERGI ZED
(AT ALARM)
DE-ENERGIZED
Alarm output opened
by alarm/
PC-CONFIGURATION
Alarm output closed
by alarm.
(factory setting)

Commissioning and operation
Page 18 RES-5027 Version 1
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.
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.
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, the AUTOCAL function must be performed with a cold heating element (and
cold surroundings: i.e. silicone, PTFE cover, sealing bar, among others) to compensate for production-related tol-
erances of the heating element resistance. With a new heating element, 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 7.
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 8).
Proceed as follows when starting up the controller for the first time:
1. Switch off network voltage; verify that no voltage is present.
2. Set the coding switch on the device in accordance with the ROPEX application report and the heating element
used (section 7.2 "Device configuration" on page 16).
3. Check that there is no START signal present.
4. Apply auxiliary voltage (24 VDC).
5. Switching on the network voltage.
6. After the voltage is switched on, the yellow “AUTOCAL” LED lights up for about 0.3 sec. and displays the cor-
rect 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
0.3 sec, the configuration with the visualisation software has been changed for this controller
(section 8.14 "USB interface for visualisation software ROPEXvisual®" on page 32). The controller’s
configuration must be checked to avoid malfunctions before continuing with commissioning.
!
!
!
!
!

Commissioning and operation
Version 1 RES-5027 Page 19
7. The following statuses can then result:
8. With a cold heating element, activate the AUTOCAL function (terminal 5+13). The yellow “AUTOCAL” LED
lights up for the duration of the calibration process (approx. 10…15 seconds). During this process, a voltage of
approx. 0 V is output at the actual value output (terminal 17+13). A connected ATR-x shows 0…3 °C.
After zeroing is completed, the “AUTOCAL” LED goes out, and a voltage of 0.66 V (in 300 °C range) or 0.4 V
(in 500 °C range) is set at the actual value output. A connected ATR x must be on the “Z” marking.
If zeroing was not performed correctly, the red “ALARM” LED flashes slowly (1 Hz). Then configuration of the
controller is not correct (section 7.2 "Device configuration" on page 16, ROPEX application report). After
device configuration is correct, perform zeroing again.
9. After successful zeroing, specify a defined temperature at the setpoint value input (terminal 16) and apply the
START signal (HEAT). “HEAT” LED then lights up. 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) is steady, that is,
does not jump, oscillate or even go briefly in the wrong direction. Such behaviour indicates an incorrect place-
ment of the UR measurement line.
When an error message is issued, proceed according to section 8.19 "Error messages" on page 34.
10.Burning in the heating element (section 7.3.1 "Burning in the 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 7.3.1 "Burning in the 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. 7.4.1 item 3 to item 10.
“ALARM” LED “OUTPUT” LED MEASURE
OFF Short pulses every 1.2 sec. Continue with item 8
FLASHES quickly (4 Hz) OFF Continue with item 8
Permanently ON OFF Error diagnosis (Chap. 8.19)
!

Device functions
Page 20 RES-5027 Version 1
8 Device functions
See also section 6.6 "Supply voltage" on page 14.
8.1 Display and operating elements
The LEDs display additional operating statuses of the controller besides the functions in the above illustration.
These are shown in detail in the following table:
LED Flashes slowly (1 Hz) Flashes quickly (4 Hz) On permanently
AUTOCAL
(yellow)
RESET active,
START and AUTOCAL
function are blocked.
AUTOCAL requested, but
function is blocked. AUTOCAL is carried out
HEAT
(yellow) —HEAT requested,
But function is blocked START is carried out
OUTPUT
(green) In control operation, the light intensity is proportional to the heating current.
ALARM
(red)
Configuration error,
AUTOCAL not possible
Controller incorrectly cali-
brated, carry out
AUTOCAL
Error, chap. 8.19
12 13 14 15 16 17 18
9
8
6
5
10
11
7
4
3
2
1
Visual
AC
HEAT
OUTPUT
ALARM
CH-1
TEMP OK
.
µC POWER
24 V
POWER
www. .deROPEX
Made in Germany
RES-5027
!
PROCESS CONTROL
EQUIPMENT
E464680
CH-1
TEMP OK.
(Yellow )LED
(Green )LED
µC POWER
24 V POWER
(Green )LED
(Green )LED
Lit if the input signal CH-1 is
active.
Lit if the actual temperature is
within the monitoring band.
Lit if internal µC power supply
is OK.
Lit if external 24 V power
supply is present.
1
22
21
20
19
AUTOCAL
(Yellow )LED
(Yellow )LED
(Red )LED
HEAT
OUTPUT
ALARM
(Green )LED
Lit during heating phase.
Lit while AUTOCAL process is
executing.
Indicates pulses in
measurement mode. In control
mode, luminous intensity is
proportional to heating current.
Lit or blinking to indicate fault.