Toss ROPEX RESISTRON RES-403 User manual

Industrie-Elektronik GmbH Tel: [phone] E-Mail: [email protected]
Gansäcker 21 Fax: [phone] Internet: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
26.6.06
RESISTRON
RES-403 GB
Important features
• Microprocessor technology
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of October 2005)
• Automatic phase angle compensation (AUTOCOMP, as of October 2005)
• Automatic frequency adjustment
• Large current and voltage range
• Set point selection with potentiometer
• 0…10VDC analog output for ACTUAL temperature
• Activated with contact or 24VDC signal
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
Operating
Instructions

Page 2 RES-403
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Heatsealing band . . . . . . . . . . . . . . . . 3
1.3 Impulse transformer . . . . . . . . . . . . . . 3
1.4 Current transformer PEX-W2/-W3 . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 7
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Installation procedure . . . . . . . . . . . . 11
8.2 Installation steps . . . . . . . . . . . . . . . . 12
8.3 Power supply . . . . . . . . . . . . . . . . . . . 13
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 14
8.5 Current transformer PEX-W3 . . . . . . 14
8.6 Wiring diagram (Standard) . . . . . . . . 15
8.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 16
8.8 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46) . . . . 17
8.9 Startup and operation . . . . . . . . . . . . 18
8.10 View of the controller . . . . . . . . . . . . . 18
8.11 Controller configuration . . . . . . . . . . . 18
8.12 Replacing and "burning in" the heat-
sealing band . . . . . . . . . . . . . . . . . . . 20
8.13 Startup procedure . . . . . . . . . . . . . . . 21
9 Controller functions . . . . . . . . . . . . . . . . . 23
9.1 Indicators and controls . . . . . . . . . . . 23
9.2 Temperature setting
(set point selection) . . . . . . . . . . . . . . 24
9.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 25
9.4 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 26
9.5 "START" signal (HEAT) . . . . . . . . . . . 27
9.6 Measuring impulse duration
(as of October 2005) . . . . . . . . . . . . . 28
9.7 Automatic phase angle
compensation (AUTOCOMP)
(as of October 2005) . . . . . . . . . . . . . 28
9.8 Temperature diagnosis
(as of October 2005) . . . . . . . . . . . . . 29
9.9 Heatup timeout
(as of October 2005) . . . . . . . . . . . . . 29
9.10 Diagnostic interface/visualization software
(as of October 2005) . . . . . . . . . . . . . 30
9.11 System monitoring/alarm output . . . . 30
9.12 Error messages . . . . . . . . . . . . . . . . . 31
9.13 Fault areas and causes . . . . . . . . . . . 36
10 Factory settings . . . . . . . . . . . . . . . . . . . . . 37
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 38
12 How to order . . . . . . . . . . . . . . . . . . . . . . . . 39
13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Safety and warning notes
RES-403 Page 3
1 Safety and warning notes
This RESISTRON temperature controller is
manufactured according to DIN EN 61010-1. In the
course of its manufacture it passed through quality
assurance, whereby it was subjected to extensive
inspections and tests.
It left the factory in perfect condition.
The recommendations and warning notes contained in
these operating instructions must be complied with, in
order to guarantee safe operation.
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational
safety. Installation and maintenance may only be
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
1.1 Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance 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.
Ensuring such compliance is the personal
responsibility of the user.
1.2 Heatsealing band
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands.
The resistance of the heatsealing band which
is used must have a positive minimum
temperature coefficient in order to guarantee
trouble-free operation of the RESISTRON
temperature controller.
The temperature coefficient must be specified as
follows:
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
The RESISTRON temperature controller must be set
and coded according to the temperature coefficient of
the heatsealing band.
The use of incorrect alloys with a too low
temperature coefficient and incorrect coding
of the RESISTRON temperature controller lead to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by detail specification, part number
or some other means that will assure that replacement
bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one section bobin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.
Incorrect installation of the impulse
transformer impairs electrical safety.
1.4 Current transformer PEX-W2/-W3
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2 or PEX-W3
current transformer may be used. Other
transformers may cause the equipment to
malfunction.
The current transformer may only be operated if it is
connected to the RESISTRON temperature controller
correctly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
"Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
!
!
TCR 10 4– ×10 K 1– ≥
!
!
!

Application
Page 4 RES-403
operating safety. They are not included in the scope of
supply of the standard control system and are
described in a separate document.
1.5 Line filter
The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.
1.6 Warranty provisions
The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.
1.7 Standards / CE marking
The controller described here complies with the
following standards, provisions and directives:
Compliance with these standards and provisions is only
guaranteed if original accessories and/or peripheral
components approved by ROPEX are used. If not, then
the equipment is operated on the user's own
responsibility.
The CE marking on the controller confirms that the
device itself complies with the above-mentioned
standards.
It does not imply, however, that the overall system also
fulfils these standards.
It is the responsibility of the machine manufacturer and
of the user to verify the completely installed, wired and
operationally ready system in the machine with regard
to its conformity with the safety provisions and the EMC
directive (see also section 8.3, "Power supply"). If
peripheral components (e.g. the transformer or the line
filter) from other manufacturers are used, no functional
guarantee can be provided by ROPEX.
2 Application
This RESISTRON temperature controller is an integral
part of the "Series 400", the outstanding feature of
which is its microprocessor technology. All RESIS-
TRON temperature controllers are used to control the
temperature of heating elements (heatsealing bands,
beaded bands, cutting wires, heatsealing blades,
solder elements etc.), as required in a variety of heat-
sealing processes.
The controller is most commonly used for impulse-
heatsealing PE films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•etc.
DIN EN 61010-1
(VDE 0411-1)
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
DIN EN 60204-1 Electrical equipment of machines
(machinery directive)
EN 50081-1 EMC interference emissions
according to EN 55011, group 1,
class B
EN 50082-2 EMC interference immunity:
ESDs, RF radiation, bursts, surges.

Principle of operation
RES-403 Page 5
The use of RESISTRON temperature controllers
results in:
• Repeatable quality of the heatseals under any con-
ditions
• Increased machine capacity
• Extended life of the heatsealing bands and teflon
coatings
• Simple operation and control of the sealing process
3 Principle of operation
The resistance of the heatsealing band, which is tem-
perature-sensitive, is monitored 50x per second (60x at
60Hz) by measuring the current and voltage. The tem-
perature calculated with the help of these measure-
ments is displayed and compared with the set point.
The primary voltage of the impulse transformer is adju-
sted by phase-angle control, if the measured values
deviate from the set point. The resulting change in the
current through the heatsealing band leads to a change
in the band temperature and thus also its resistance.
This change is measured and evaluated by the RESIS-
TRON temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the heat-
sealing band are detected and can be corrected quickly
and precisely.
A highly high response thermo-electric control loop is
formed which is highly accurate because purely elec-
trical variables are measured at a high sampling rate. A
high secondary current can be controlled because
power is controlled on the primary side of the trans-
former. This allows optimum adaptation to the load and
to the required dynamic range despite the exceptionally
compact dimensions of the controller.
PLEASE NOTE!
RESISTRON temperature controllers play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible and interrelated.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
R=f(T)
+
_
Set point
Start
Indicators
and
controls
or
bus interface
Actual value
LINE
RESISTRON controller
Heatsealing band R = f (T)
Current
transformer
Impulse transformer
UR IR
prim.
U1
sec.
U2

Description of the controller
Page 6 RES-403
4 Description of the controller
The microprocessor technology endows the RESIS-
TRON temperature controller RES-403 with previously
unattainable capabilities:
• Very simple operation thanks to AUTOCAL, the
automatic zero calibration function.
• Good dynamic response of the control system
thanks to AUTOTUNE, which adapts automatically
to the controlled system.
• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.
• High flexibility: The AUTORANGE function (as of
October 2005) covers a secondary voltage range
from 0.4V to 120V and a current range from 30A to
500A.
• Automatic adjustment to the line frequency in the
range from 47Hz…63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The ACTUAL temperature of the heatsealing band is
supplied to an analog 0…10VDC output. The real heat-
sealing band temperature can thus be displayed on an
external temperature indicator (e.g. ATR-x).
The RESISTRON temperature controller RES-403 fea-
tures an integrated fault diagnosis function, which tests
both the external system (heatsealing band, wiring etc.)
and the internal electronics and outputs a selective
error message in case of a fault.
To increase operational safety and interference immu-
nity, all 24VDC logic signals are electrically isolated
from the controller and the heating circuit.
Coding switches on the temperature controller itself
can be used to adapt to different heatsealing band
alloys (Alloy-20, NOREX etc.) and set to the required
temperature range (0…300°C, 0…500°C etc.).
The compact design of the RESISTRON temperature
controller RES-403 and the plug-in connections make
this controller easy to install.
5 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the RESISTRON temperature
controller RES-403. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.
5.1 Accessories
The products described below are only a few of the
wide range of accessories available for RESISTRON
temperature controllers (ª"Accessories" leaflet).
Analog temperature meter ATR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Analog indication of the ACTUAL temperature of the heatsealing band in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
in impulse mode.
Digital temperature meter DTR-x
For front panel mounting or mounting on a top hat rail (DIN TS35 rail).
Digital indication of the ACTUAL temperature of the heatsealing band in °C, with
HOLD function.
Set point potentiometer PD-x
Front panel mounting version for setting the required SET heatsealing temperature
of the RESISTRON temperature controller. The number which appears on the dis-
play corresponds to the SET heatsealing temperature in °C.

Accessories and modifications
RES-403 Page 7
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON tempe-
rature controller RES-403 is suitable for a very wide
range of heatsealing applications.
Various modifications (MODs) are available for the
RESISTRON temperature controller RES-403 for
implementing special applications.
The modifications described here are just a few of the
large number available. Separate documents are sup-
plied for all modifications.
MOD 01
Amplifier for low secondary voltages
(UR= 0.25…16VAC). This modification is necessary,
for example, for very short or low-resistance heat-
sealing bands.
MOD 26
Additional terminal for connecting an external switching
amplifier (booster). This modification is necessary for
high primary currents (continuous current > 5A, pulsed
current > 25A).
Line filter
Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer
Designed according to VDE 0570/EN 61558 with a one section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application (ªROPEX Application Report).
Communication interface CI-USB-1
Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL tempe-
ratures in real time.
Booster
External switching amplifier, necessary for high primary currents (continuous
current > 5A, pulsed current > 25A).
Monitoring current transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2 current transformer.

Accessories and modifications
Page 8 RES-403
MOD 40
Additional terminal for "Temperature reached" signal.
This output signal is activated when the ACTUAL
temperature of the heatsealing band exceeds 95 % of
the SET heatsealing temperature. It can be used to
monitor the process, for example, or to control the
closure of the heatsealing bars.
MOD 40 cannot be used in combination with
MOD 26 (booster connection) manufactured
prior to September 2005.
MOD 46 (as of October 2005)
Additional terminal for "Temperature OK" signal. If this
modification is installed, the RES-403 checks whether
the ACTUAL temperature is within a settable tolerance
band ("OK" window) on either side of the SET
temperature. The lower ( ) and upper
( ) tolerance band limits are configured in the
factory to -10K and +10K. These values can be set
independently of one another in the ROPEX
visualization software (ªsection 9.10 "Diagnostic
interface/visualization software (as of October 2005)"
on page 30).
If the actual temperature is inside the specified
tolerance band when the "START" signal is activated,
the output signal is activated as well (see graph below):
If the actual temperature leaves the tolerance band, the
output signal is deactivated again. The output signal
then remains deactivated, even if the actual tempera-
ture subsequently returns to the tolerance band.
It is thus possible to check - as part of the monitoring
concept, for instance - whether the output signal is still
active at the end of the heatsealing process, in other
words whether the actual temperature has remained
within the defined tolerance band throughout the entire
process.
The output signal is not deactivated again until the next
"START" signal is activated or until an alarm is
signaled.
MOD 46 ("Temperature OK" signal) cannot be
used in combination with MOD 40
("Temperature reached" signal).
!
∆ϑlower
∆ϑupper
Set
Signal
Set+∆ϑlower
Set+∆ϑupper
Actual value
Time
Time
Not conduct.
Conductive
„Temp. OK“
!

Technical data
RES-403 Page 9
6 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35 mm) acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Line voltage All controllers manufactured as of October 2005:
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
230VAC version: 220VAC -15%…240VAC +10% (equivalent to 187…264VAC)
400VAC version: 380VAC -15%…415VAC +10% (equivalent to 323…456VAC)
All controllers manufactured as of January 2004 up to September 2005:
115VAC version: 115VAC -15%…120VAC +10% (equivalent to 98…132VAC)
230VAC version: 230VAC -15%…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15%…415VAC +10% (equivalent to 340…456VAC)
All controllers manufactured up to December 2003:
115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on version selected (ªsection 12 "How to order" on page 39)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
All controllers manufactured as of October 2005:
The temperature range and temperature coefficient settings can also be specified
by means of the ROPEX visualization software (ªsection 9.10 "Diagnostic
interface/visualization software (as of October 2005)" on page 30) in addition to
the rotary coding switch (see below):
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Five different ranges can be set on the controller with a rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy-A20), default
Temperature coefficient 780ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy-A20)
Temperature coefficient 780ppm, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm, 0…300°C (e.g. NOREX)
The settings for a temperature coefficient of 780ppm are only available on control-
lers manufactured as of October 2003.
Set point selection
Terminals 16+17
With an external PD-3 or PD-5 precision potentiometer (R = 2kΩ)
0…2kΩ, equivalent to 0…300°C or 0…500°C
Analog output
(actual value)
Terminals 14+15
0…10VDC, Imax = 5mA
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% add. 50mV
Digital logic levels
Terminals 8, 12, 13
LOW (0V): 0…2VDC
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected
Digital logic levels
„Temp. OK“ signal
(MOD 40)
Umax =30VDC
Imax =50mA
UON < 2V (saturation voltage)

Technical data
Page 10 RES-403
Alarm relay Umax =50VDC,I
max = 0.2A, potential-free
Maximum load
(primary current of
impulse
transformer)
Imax = 5A (duty cycle = 100%)
Imax = 25A (duty cycle = 20%)
Power dissipation max. 20W
Ambient
temperature
+5…+45°C
Degree of protection IP20
Installation If several controllers are installed on one top hat
rail (DIN TS35 rail), a clearance of at least 20mm
should be allowed between them.
The moving clip required for fastening must be
facing down for mounting on a horizontal top hat
rail.
End holders to mechanical fix the controller must be fitted at both ends for moun-
ting on a vertical top hat rail.
Weight Approx. 0.7kg (incl. connector plug-in parts)
Housing material Plastic, polycarbonate, UL-90-V0
Connecting cables
Type / cross-sections
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in
If ferrules are used, they must be crimped in accordance
with DIN 46228 and IEC/EN 60947-1.
This is essential for proper electrical contact in the terminals.
!

Dimensions
RES-403 Page 11
7 Dimensions
8 Installation
ªSee also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be per-
formed by technically trained, skilled per-
sons who are familiar with the associated risks and
warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON tempera-
ture controller RES-403:
1. Switch off the line voltage and verify that the circuit
is de-energized.
2. The supply voltage specified on the nameplate of
the RESISTRON temperature controller must be
identical to the line voltage that is present in the
plant or machine. The line frequency is automati-
cally detected by the RESISTRON temperature
controller in the range from 47Hz…63Hz.
3. Install the RESISTRON temperature controller in
the electrical cabinet on a standard top hat rail (DIN
TS35 rail, according to DIN EN 50022). If several
controllers are installed on one top hat rail, the
minimum clearance specified in section 6 "Technical
data" on page 9 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 13,
section 8.6 "Wiring diagram (Standard)" on page 15
and the ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 12 must also be heeded additionally.
Check the tightness of all the system connec-
tions, including the terminals for the impulse
transformer windings.
5. Make sure that the wiring conforms to the relevant
national and international installation regulations.
75.0 90.0
113.0
135.0
!
!

Installation
Page 12 RES-403
8.2 Installation steps
Line
Impulse
transformer
Current transformer
PEX-W2/-W3
U (prim.)
1
Heatsealing band R= f (T)
U (sec.)
2
A
F
Controller
Temperature
meter
ATR-x
Digital
potentiometer
PD-x
Avoid long
cables
Heatseal element
with coppered ends
Use heatseal bands with
suitable temperature coefficient
20mm clearance if several
controllers installed on
one top hat rail
Note
polarity
No additional
resistance
in secondary
circuit
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
Configure
DIP switches
correctly
Sufficient wire
cross-section
No
push-on
connectors
Twisted
Current measuring
wires IR
R
Connect U measuring
wires directly to
heatsealing band ends
Line filter
LF-xx480
Note
direction
of rotation
Note
number
of turns
(up to Sept. 2005)

Installation
RES-403 Page 13
8.3 Power supply
ROPEX
temperature
controller
UR
IR
R
PRIM.
U1
Kb
Ka
SEC.
U2
LINE
I > I >
GND/
Earth
N(L2)
L1 (L1)
LINE
FILTER
ON
OFF
K1
3
3
3
1
Short wires
2
2
Line
115VAC, 230VAC, 400VAC
Circuit breaker
Double-pole, C characteristic
(ªROPEX Application Report)
Short-circuit protection only.
RESISTRON temperature 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
(ªROPEX Application Report).
Do not run the filter supply wires (line side) parallel
to the filter output wires (load side).
!
RESISTRON temperature controller belonging to the
4xx Series.
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
When using a series resistor RV-....-1 the relay Kb
shall be installed.
!
Impulse Transformer
Designed according to VDE 0570/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 (ªROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
!
Wiring
The wire cross-sections depend on the application
(ªROPEX Application Report).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
Secondary circuit: min. 4.0mm², max. 25mm²
cThese wires must always be twisted (>20/m)
dThese wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
eTwisting (>20/m) is recommended to improve EMC.

Installation
Page 14 RES-403
8.4 Line filter
To comply with EMC directives – corresponding to
EN 50081-1 and EN 50082-2 – RESISTRON control
loops must be operated with line filters.
These filters damp the reaction of the phase-angle con-
trol on the line and protect the controller against line
disturbances.
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 com-
pliance with the EMC limit values.
You can find the exact specification of the line filter in
the ROPEX Application Report calculated for your par-
ticular heatsealing application.
For more technical information: ª"Line filter" docu-
mentation.
It is permissible to supply several RESIS-
TRON control loops with a single line filter,
providing the total current does not exceed the
maximum current of the filter.
The wiring instructions contained in section 8.3 "Power
supply" on page 13 must be observed.
8.5 Current transformer PEX-W3
The PEX-W3 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 con-
troller correctly (ªsection 8.3 "Power supply" on
page 13).
!!
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. 1m
ROPEX
temperature
controller
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
terminal
block
terminal
wires
14
60
24 75 14
23 28
26
39
12

Installation
RES-403 Page 15
8.6 Wiring diagram (Standard)
R
IR
UR
START (HEAT)
with
24VDC signal
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
AUTOCAL
with 24VDC signal
NOTE:
AUTOCAL button
also provided on
controller
ALARM
OUTPUT
max. 50V/0,2A
RES-403
(also with MOD 01)
GND 13
12
5
6
8
Contact closed or
opened by ALARM
(see configuration)
11
9
10
7
START (HEAT)
with contact
14
15
18
17
16
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
Cable shielded
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
2
1
4
3
Current transformer
PEX-W2/-W3
twisted
Impuls
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
U2
prim.
U1
0V
(Internnal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
until
productions
date
09.05

Installation
Page 16 RES-403
8.7 Wiring diagram with booster
connection (MOD 26)
START (HEAT)
with 24VDC signal
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
AUTOCAL
with 24VDC signal
NOTE:
AUTOCAL button
also provided on
controller
ALARM
OUTPUT
max. 50V/0,2A
RES-403
(also with MOD 01)
GND 13
12
5
6
8
Contact closed or
opened by ALARM
(see configuration)
0V
(Internnal ground)
No external
grounding allowed!
R
Current transformer
PEX-W2/-W3
Impuls
transformer
11
9
10
7
IR
UR
Heat-
sealing
band
START (HEAT)
with contact
14
15
18
17
16
cw
2K
SET POINT
POTENTIOMETER
PD-3 or PD-5
Cable shielded
°C
ATR
_
+
ANALOG
OUTPUT
+0...10VDC
LINE
Booster
NC
NC
2
24
IN OUT
1
13
Line filter LF-xx480
4
3
sec.
U2
prim.
U1
twisted
20
19
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
until
productions
date
09.05

Installation
RES-403 Page 17
MOD 26 cannot be used in combination with
MOD 40 ("Temperature OK" signal)
manufactured up to September 2005.
8.8 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46)
MOD 40 cannot be used in combination with
MOD 26 (booster connection) manufactured
prior to September 2005.
MOD 46 cannot be used in combination with
MOD 40.
Additional terminals
in housing cover
for MOD 26 (Booster connection)
BOOSTER
19 20
4
3
2
1
A
UTOCAL
OUTPUT
HEAT
ALARM
!
+
RES- 403
I max. 50mA
+24VDC
GND GND
+24VDC
4
3
2
1
Additional terminals
in housing cover
for MOD 40 (”Temp. reached” signal)
or MOD 46 (”Temp. OK” signal)
AUTOCAL
OUTPUT
HEAT
ALARM
! !

Installation
Page 18 RES-403
8.9 Startup and operation
8.10 View of the controller
8.11 Controller configuration
The controller must be switched off in order
to configure the coding switches and plug-in
jumpers.
8.11.1 Configuration of the DIP switches
for secondary voltage and current
Automatic configuration (AUTORANGE)
(as of October 2005)
The secondary voltage and current ranges are
automatically configured by the automatic calibration
function (AUTOCAL). The voltage is configured in the
range from 0.4VAC to 120VAC and the current in the
range from 30A to 500A. If the voltage and/or the
current is outside the permissible range, a detailed
error message appears on the controller (ªsee
section 9.12 "Error messages" on page 31).
Configuration with coding switches
(up to September 2005)
Set the DIP switches for matching the secondary
voltage U2and the secondary current I2to the correct
position for your application.
You can find the exact configuration of the
DIP switches in the ROPEX Application
Report calculated for your particular application.
Terminals
Wiring diagramm
LEDs
Button for
Nameplate
AUTOCAL function
Coding switches and
plug-in jumpers
!
!

Installation
RES-403 Page 19
If the secondary current I2is less than 30A, the
PEX-W2 or PEX-W3 current transformer must have
two turns (ªROPEX Application Report).
8.11.2 Configuration of the rotary coding
switch for the temperature range
and alloy
The settings for a temperature coefficient of
780ppm (switch position 1 and 5) are only
available on controllers manufactured as of
October 2003.
If the switch is set to "9" (as of October 2005), more
temperature ranges and alloys can be selected by
means of the ROPEX visualization software (ªsee
section 9.10 "Diagnostic interface/visualization soft-
ware (as of October 2005)" on page 30).
3
2
145
ON
OFF
1...10V
6...60V
20...120V
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
30...100A
60...200A
120...400A
OFF
ON
ON
OFF
OFF
ON
DIP switch DIP switch
12
U
2
I
2
345
3
2
145
4
3
ON
OFF
U (V)
2
1-10
SWITCH
ON
Factory settings
2x
0
5
1
2
3
4
6
7
8
9
0
5
1
2
3
4
6
7
8
9
Switch
position
0
1
4
5
8
300°C
300°C
500°C
500°C
300°C
1100ppm/K
780ppm/K
1100ppm/K
780ppm/K
3500ppm/K
e.g. Alloy-20
e.g. Alloy L
e.g. Alloy-20
e.g. Alloy L
e.g. NOREX
Temp.
range
Temp.
coefficient
Band
alloy
0 = Factory settings
SWITCH POS.
1
0
4
5
8
9
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
PC CONFIGURATION
ALLOY
780ppm/K
1100ppm/K
(L)
(A20)
1100ppm/K (A20)
780ppm/K
3500ppm/K
(L)
(NOREX)
9 PC-CONFIGURATION
!

Installation
Page 20 RES-403
8.11.3 Configuration of the alarm relay
If the plug-jumper is not inserted - or if it is
incorrectly inserted - an error message
appears when the controller is switched on
(ª
ªª
ªsection 9.12 "Error messages" on page 31).
If the "Alarm output opened by alarm/PC CONFIGURA-
TION" position is selected (as of October 2005), the
behavior of the alarm output can be configured in more
detail by means of the ROPEX visualization software
(ªsee section 9.10 "Diagnostic interface/visualization
software (as of October 2005)" on page 30).
8.12 Replacing and "burning in" the
heatsealing band
8.12.1 "Burning in" the heatsealing band
The heatsealing band is a key component in the control
loop, since it is both a heating element and 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 elec-
trical properties:
The measuring principle applied for this system neces-
sitates a heatsealing band alloy with a suitable tempe-
rature coefficient TCR. Too low a TCR leads to oscilla-
tion or uncontrolled heating.
When heatsealing bands with a higher TCR are used,
the controller must be calibrated for this.
The first time the heatsealing band is heated to appro-
ximately 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 appro-
ximately 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 repeated.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally pret-
reated by the manufacturer.
An overheated or burned-out heatsealing
band must no longer be used because the
TCR has been altered irreversibly.
One very important design feature is the copper or
silver-plating of the heatsealing band ends. Cold ends
allow the temperature to be controlled accurately and
increase the life of the teflon coating and the heat-
sealing band.
0
5
1
2
3
4
6
7
8
9
Alarm relay contact
opened by alarm/
PC-CONFIGURATION.
Alarm relay contact
closed by alarm.
(factory setting)
CONFIGURATION
ALARM OUTPUT
DE-ENERGIZED / PC
AT ALARM
ENERGIZED
!
!