Toss ROPEX RESISTRON RES-407 User manual

19.11.07
RESISTRON
RES-407 GB
Important features
• Microprocessor technology
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of April 2005)
• Automatic phase angle compensation (AUTOCOMP, as of April 2005)
• Automatic frequency adjustment
• Large current and voltage range
• Electrically isolated analog input for set point selection with potentiometer or 0…10VDC
• Electrically isolated 0…10VDC analog output for ACTUAL temperature
• 24VDC control signals for START, AUTOCAL and RESET with electrical isolation
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable as standard (as of June 2003)
Operating
Instructions
Exclusive Sales and Service:
www.tossheatseal.com
Toss Machine Components, Inc.
539 S. Main Street, Nazareth. PA 18064
Phone [phone] Fax [phone]
E-Mail: [email protected]
Exclusive Sales and Service:
www.tossheatseal.com
Toss Machine Components, Inc.
539 S. Main Street, Nazareth. PA 18064
Phone [phone] Fax [phone]
E-Mail: [email protected]

Page 2 RES-407
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 . . . . . . . . . . . . . . . . . . . . . . 10
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.1 Installation procedure . . . . . . . . . . . . 12
8.2 Installation steps . . . . . . . . . . . . . . . . 13
8.3 Power supply . . . . . . . . . . . . . . . . . . . 14
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 15
8.5 Current transformer PEX-W3 . . . . . . 15
8.6 Auxiliary voltage . . . . . . . . . . . . . . . . 16
8.7 Wiring diagram (standard) . . . . . . . . . 16
8.8 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 17
8.9 Wiring diagram with "Temp-
erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46) . . . . 18
9 Startup and operation . . . . . . . . . . . . . . . . 19
9.1 View of the controller . . . . . . . . . . . . . 19
9.2 Controller configuration . . . . . . . . . . . 19
9.3 Heatsealing band . . . . . . . . . . . . . . . . 21
9.4 Startup procedure . . . . . . . . . . . . . . . 22
10 Controller functions . . . . . . . . . . . . . . . . . 24
10.1 Indicators and controls . . . . . . . . . . . 24
10.2 Temperature setting
(set point selection) . . . . . . . . . . . . . . 25
10.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 26
10.4 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 27
10.5 "START" signal (HEAT) . . . . . . . . . . . 28
10.6 "RESET" signal . . . . . . . . . . . . . . . . . 28
10.7 Measuring impulse duration
(as of April 2005) . . . . . . . . . . . . . . . . 29
10.8 Automatic phase angle
compensation (AUTOCOMP)
(as of April 2005) . . . . . . . . . . . . . . . . 29
10.9 Temperature diagnosis
(as of April 2005) . . . . . . . . . . . . . . . . 30
10.10 Heatup timeout
(as of April 2005) . . . . . . . . . . . . . . . . 31
10.11 Diagnostic interface/visualization software
(as of April 2005) . . . . . . . . . . . . . . . . 31
10.12 System monitoring/alarm output . . . . 31
10.13 Error messages . . . . . . . . . . . . . . . . . 32
10.14 Fault areas and causes . . . . . . . . . . . 37
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 38
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 39
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 40
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Safety and warning notes
RES-407 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 bobbin. 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-407
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
RESISTRON 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 heatsealing processes.
The controller is most commonly used for impulse-
heatsealing PE and PP films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•L-sealers
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-407 Page 5
•etc.
The use of RESISTRON temperature controllers
results in:
• Repeatable quality of the heatseals under any
conditions
• 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
temperature-sensitive, is monitored 50x per second
(60x at 60Hz) by measuring the current and voltage.
The temperature calculated with the help of these
measurements is displayed and compared with the set
point.
The primary voltage of the impulse transformer is
adjusted 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
RESISTRON temperature controller.
The control loop is closed: ACTUAL temperature = SET
temperature. Even minute thermal loads on the
heatsealing band are detected and can be corrected
quickly and precisely.
The thermoelectric control loop which is formed has a
highly dynamic response because purely electrical
variables are measured at a high sampling rate. A very
wide secondary current range can be controlled with
only minimal power loss - a considerable advantage -
because power is controlled on the primary side of the
transformer. 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 controller 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 with one another.
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-407
4 Description of the controller
The microprocessor technology endows the
RESISTRON temperature controller RES-407 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
April 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 to 63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The electrically isolated analog interfaces for the
temperature set point and the actual temperature
(0-10VDC) allow the temperature to be set either
directly on the machine PLC or by means of an external
potentiometer (PD-x).
Similarly, the real heatsealing band temperature can be
visualized either on the display of the machine PLC or
on an external temperature meter (ATR-x).
The RESISTRON temperature controller RES-407
features 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
immunity, 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 A20, NOREX etc.) and set the required
temperature range (0...300°C, 0...500°C etc.) on all
controllers manufactured as of June 2003.
An external 24VDC auxiliary voltage is required to
supply the isolating amplifiers and optocouplers. The
compact design of the RESISTRON temperature
controller RES-407 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-407. 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.

Accessories and modifications
RES-407 Page 7
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON
temperature controller RES-407 is suitable for a very
wide range of heatsealing applications.
Various modifications (MODs) are offered for the
RESISTRON temperature controller RES-407 for
implementing special applications.
The modifications described here are just a few of the
large number available. Separate documents are
supplied 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
heatsealing bands.
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
display corresponds to the SET heatsealing temperature in °C.
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/-W3 current transformer.

Accessories and modifications
Page 8 RES-407
MOD 21
Inverts the alarm signal (terminal 18). If an alarm is
signaled, the alarm output is switched to open condition
(LOW). If the controller does not report an alarm, a
24VDC voltage level (HIGH) is output at terminal 18.
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).
MOD 37 (until May 2003)
Additional rotary coding switch for the heatsealing band
alloy and the temperature range. Various heatsealing
band alloys (e.g. Alloy-20, NOREX) and temperature
ranges (e.g. 300°C, 500°C) can be selected.
This modification is supplied as standard
with all controllers manufactured as of June
2003 (ª
ªª
ªsection 9.2.2 "Configuration of the rotary
coding switch for the temperature range and alloy
(as of June 2003)" on page 20).
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 March 2005.
!
Switch
position
Temp.
range
Temp.
coefficient
Band
alloy
0
5
1
2
3
4
6
7
8
9
0
5
1
2
3
4
6
7
8
9
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
0 = Factory settings
SWITCH POS.
1
0
4
5
8
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
ALLOY
780ppm/K
1100ppm/K
(L)
(A20)
1100ppm/K (A20)
780ppm/K
3500ppm/K
(L)
(NOREX)
!

Accessories and modifications
RES-407 Page 9
MOD 46 (as of April 2005)
Additional terminal for "Temperature OK" signal. If this
modification is installed, the RES-407 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 10.11 "Diagnostic
interface/visualization software (as of April 2005)" on
page 31).
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
Page 10 RES-407
6 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm) acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)
Line voltage All controllers manufactured as of April 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 March 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 the controller version (ªsection 13 "How to order" on page 40)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Auxiliary voltage
Terminals 12+13
24VDC, +20%, -10%, reverse polarity-protected
Current input (up to March 2005): max. 50mA
(as of April 2005): max. 1.0A
Heatsealing band
type and temperature
range
All controllers manufactured as of April 2005:
The temperature range and temperature coefficient settings can also be specified
by means of the ROPEX visualization software (ªsection 10.11 "Diagnostic
interface/visualization software (as of April 2005)" on page 31) 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)
All controllers manufactured as of June 2003:
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)
All controllers manufactured up to May 2003:
Default value 300°C, Alloy-20
The temperature range and alloy are selectable with MOD 37.
Analog input
(set point)
Terminals 16+14
0…10VDC, Imax = 5mA, electrically isolated
Equivalent to 0…300°C or 0…500°C
or with an external PD-3 or PD-5 precision potentiometer (R = 2kohms)
0…2kohms equivalent to 0…300°C or 0…500°C
Analog output
(actual value)
Terminals 17+14
0…10VDC, Imax = 5mA, electrically isolated
Equivalent to 0…300°C or 0…500°C
Accuracy: ±1% add. 50mV

Technical data
RES-407 Page 11
Reference voltage +10VDC / ±5%, Imax =5mA
Digital logic levels
Terminals 5, 6, 7
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected
Switching output for
"Temp. OK" signal
(MOD 40)
Umax =30VDC
Imax =50mA
UON < 2V (saturation voltage)
Alarm output UON < 3V (saturation voltage), electrically isolated,
short-circuit proof
Up to March 2005: Imax =40mA
As of April 2005: Imax =200mA
As of April 2005, the output can also be inverted by means of a plug-in jumper.
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
mounting 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…2.5 mm² (AWG 24…12)
Plug-in connectors
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
Page 12 RES-407
7 Dimensions
8 Installation
ªSee also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON
temperature controller RES-407:
1. Switch off the line voltage and verify that all circuits
are deenergized.
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
automatically detected by the temperature controller
in the range from 47Hz to 63 Hz.
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 10 must be allowed between them.
4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 14,
section 8.6 "Auxiliary voltage" on page 16 and the
ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 13 must be heeded additionally.
Check the tightness of all the system
connections, 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
RES-407 Page 13
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 March 2005)

Installation
Page 14 RES-407
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
50/60Hz
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
determined 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
RES-407 Page 15
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
control 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
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: ª"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 8.3 "Power
supply" on page 14 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
controller correctly (ªsection 8.3 "Power supply" on
page 14).
!!
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
Page 16 RES-407
8.6 Auxiliary voltage
Since the inputs and outputs of the RES-407 are
electrically isolated, a 24VDC auxiliary voltage must be
applied to terminals 12+13. The auxiliary voltage has a
maximum current input of 1,0A and it is also protected
against reverse polarity.
8.7 Wiring diagram (standard)
GND
GND
+24VDC
14
12
7
6
5
4
3
2
1
U
REF
+10VDC
16
17
15
13
18
=
=
Auxiliary
supply
16
15
14
cw
2K
OPTION:
SET POINT
POTENTIOMETER
PD-3 or PD-5
RES-407
(also with MOD 01)
Impulse
transformer
LINE
Line filter LF-xx480
prim.
U1
RESET
with 24VDC signal
START (HEAT)
with 24VDC signal
AUTOCAL
with 24VDC signal
ALARM
OUTPUT
+24VDC
ANALOG
OUTPUT
(real temperatur)
+0...10VDC
ANALOG
INPUT
(set point)
+0...10VDC
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
R
9
8
UR
Current transformer
PEX-W2/-W3
Heat-
sealing
band
sec.
Twisted
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
U2
up to
production
date
March 2005
11
10
IR

Installation
RES-407 Page 17
8.8 Wiring diagram with booster
connection (MOD 26)
RESET
with 24VDC signal
START (HEAT)
with 24VDC signal
AUTOCAL
with 24VDC signal
ALARM
OUTPUT
+24VDC
GND
GND
+24VDC
14
12
7
6
5
U
REF
+10VDC
16
17
15
13
18
ANALOG
OUTPUT
(real temperature)
+0...10VDC
ANALOG
INPUT
(set point)
+0...10VDC
=
=
Auxiliary
supply
R
9
8
UR
Booster
NC
NC
2
24
IN OUT
1
13
4
3
16
15
14
cw
2K
OPTION:
SET POINT
POTENTIOMETER
PD-3 or PD-5
Current transformer
PEX-W2/-W3
Impulse
transformer
Heat-
sealing
band
LINE
Line filter LF-xx480
sec.
Twisted
0V
(Internal ground)
No external
grounding allowed!
0V
(Internal ground)
No external
grounding allowed!
U2
prim.
U1
RES-407
(also with MOD 01)
Ground
for 24VDC signals.
Must be grounded
externally to prevent
electrostatic
charging!
up tol
production
date
March 2005
20
19
11
10
IR

Installation
Page 18 RES-407
MOD 26 cannot be used in combination with
MOD 40 ("Temperature OK" signal)
manufactured up to March 2005.
8.9 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 March 2005.
MOD 46 cannot be used in combination with
MOD 40.
BOOSTER
19 20
4
3
2
1
Additional terminals
in housing cover
for MOD 26 (booster connection)
AUTOCAL
OUTPUT
HEAT
ALARM
!
+
RES- 407
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
! !

Startup and operation
RES-407 Page 19
9 Startup and operation
9.1 View of the controller
9.2 Controller configuration
The controller must be switched off in order
to configure the coding switches and the
plug-in jumpers.
9.2.1 Configuration of the DIP switches
for secondary voltage and current
Automatic configuration (AUTORANGE)
(as of April 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 10.13 "Error messages" on page 32).
Configuration with coding switches
(up to March 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.
Te r m in a l s
Wiring diagram
LEDs
Coding switches and
plug-in jumpers
Nameplate
!
!

Startup and operation
Page 20 RES-407
If the secondary current I2is less than 30 A, the
PEX-W2 or PEX-W3 current transformer must have
two turns (ªROPEX Application Report).
9.2.2 Configuration of the rotary coding
switch for the temperature range
and alloy (as of June 2003)
This configuration is supplied as standard
with all controllers manufactured as of June
2003. The settings are only possible on older
controllers in conjunction with MOD 37 (ª
ªª
ªsection
"MOD 37 (until May 2003)" on page 8).
If the switch is set to "9" (as of April 2005), more
temperature ranges and alloys can be selected by
means of the ROPEX visualization software (ªsee
section 10.11 "Diagnostic interface/visualization
software (as of April 2005)" on page 31).
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
!