This RESISTRON-Temperaturregler 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 contain... more
Instructions > Technology
Published on: 2015-11-05
Pages: 483

RESISTRON RES-408 GB Operating Instructions Important features Microprocessor technology Separate terminal for operation and display

Automatic zero calibration (AUTOCAL) Automatic optimization (AUTOTUNE) Automatic configuration of the secondary voltage and current ranges (AUTORANGE, as of May 2006) Automatic phase angle compensation (AUTOCOMP, as of June 2006) Automatic frequency adjustment Wide current and voltage range 0…10VDC analog output for ACTUAL temperature 24VDC control signals for START and PREHEAT with electrical isolation Alarm function with fault diagnosis Heatsealing band alloy and temperature range selectable as standard (as of June 2006)

5.1.09 Industrie-Elektronik GmbH Tel: +49/(0)7142/7776-0 E-Mail: info@ropex.de Gansäcker 21 Fax: +49/(0)7142/7776-19 Internet: www.ropex.de D-74321-Bietigheim-Bissingen (Germany) Data subject to change

Contents 1 Safety and warning notes . . . . . . . . . . ....3 11 Controller functions . . . . . . . . . . . . . . . . . 24 1.1 Use . . . . . . . . . . . . . . . . . . . . . . . ....3 11.1 Indicators and controls . . . . . . . . . . . 24 1.2 Heatsealing band . . . . . . . . . . . . ....3 11.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 27 1.3 Impulse transformer . . . . . . . . . .

....3 11.3 Navigation in the menus . . . . . . . . . . 27 1.4 Current transformer PEX-W2/-W3 ....3 11.4 Menu structure . . . . . . . . . . . . . . . . . . 28 1.5 Line filter . . . . . . . . . . . . . . . . . . . ....4 11.5 Menu steps . . . . . . . . . . . . . . . . . . . . 29 1.6 Warranty provisions . . . . . . . . . . . ....4 11.6 Temperature setting

1.7 Standards / CE marking . . . . . . . ....4 (set point selection) . . . . . . . . . . . . . . 31 2 Application 4 11.7 Temperature indication / actual value ...................... .... output 31 3 Principle of operation 5 ....................... ..

............. .... 11.8 Automatic zero calibration 4 Description of the controller . . . . . . . ....6 (AUTOCAL) . . . . . . . . . . . . . . . . . . . . 32 5 Accessories and modifications 6 11.9 Heating to the heatsealing

..... .... temperature (HEAT) 33 5.1 Accessories 6 ........... .. ................. .... 11.10 "PREHEAT" signal 34 5.2 Modifications (MODs) 8

............. .. ......... .... 11.11 Hold mode 34 6 Technical data 9 ................... .. ................... .... 11.12 Temperature unit

7 Controller/terminal compatibility . . . . . . . 11 Celsius / Fahrenheit 8 Dimensions 12 (as of controller SW revision 106 ..................... ... and terminal SW revision 103) . . . . . 35 9 Installation 13

....................... .. 11.13 Measuring impulse duration (as of 9.1 Installation procedure . . . . . . . . . . . . 13 June 2006) . . . . . . . . . . . . . . . . . . . . . 36 9.2 Installation steps . . . . . . . . . . . . . . . . 14 11.14 Automatic phase compensation (AUTO- 9.3 Power supply . . . . . . . . . . . . . . . . .

. . 15 COMP) (as of June 2006) . . . . . . . . . 36 9.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 16 11.15 Temperature diagnosis 37 9.5 Current transformer PEX-W3 16 (as of June 2006) . . . . . . . . . . . . . . .. .... .. 11.16 Heatup timeout

9.6 Wiring diagram (standard) 17 ....... .. (as of June 2006) 38 9.7 Wiring diagram with booster .............. ..

11.17 Communication error between connection (MOD 26) 18 .......... .. the controller and the terminal 10 Startup and operation 19 ..............

.. (as of June 2006) . . . . . . . . . . . . . . . . 38 10.1 View of the controller . . . . . . . . . . . . . 19 11.18 Undervoltage detection 10.2 Controller configuration . . . . . . . . . . . 20 (as of June 2006) . . . . . . . . . . . . . . . . 38 10.3 Heatsealing band . . . . . . . . . . . . . . . 21 11.19 Diagnostic interface / visualization soft-

10.4 Startup procedure 22 ware (as of June 2006) . . . . . . . . . . . 39 ............. .. 11.20 System monitoring / alarm output . . . 39

11.21 Error messages . . . . . . . . . . . . . . . . . 40 11.22 Fault areas and causes . . . . . . . . . . . 45 12 Factory settings . . . . . . . . . . . . . . . . . . . . . 46 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 47

14 How to order . . . . . . . . . . . . . . . . . . . . . . . . 48 15 Index ............................ . . 50 Page 2 RES-408

Safety and warning notes The recommen dations and warning notes 1 contained in these operating Safety instruction and s must be complied warni with, in order to ng guarantee notes safe operation. This The device RESISTR can be ON- operated Temperatu within the rregler is limits manufactu indicated red in the according "Technical to DIN EN Data" 61010-1. without In the impairing course of its its operationa manufactu l safety. re it Installation passed and through maintenan quality ce may assurance, only be whereby it performed was by subjected technically to trained, extensive skilled inspection persons s and who are tests. familiar with the associated It left the risks and factory in warranty perfect provisions. condition.

-Temperat urreglers lead to uncontroll ed heating and ultimately The to burn- RESISTR out of ON- Temperatu rreglers must be the set and heatsealin coded g band! according to the temperatur e The coefficient heatsealin of the g bands heatsealin that were g band. originally supplied must be identified The use by detail of specificati incorrect on, part alloys number or with a too some other ! means low that will temperatu assure re that coefficien replaceme t and nt bands incorrect are coding of identical. the RESISTR ON 1.3 Impulse transformer 1.1 Use A suitable impulse transformer is necessary to ensure

RESISTRON temperature controllers may only be used that the control loop functions perfectly. This for heating and temperature control of heatsealing transformer must be designed according to VDE 0570/ bands which are expressly suitable for them, and EN 61558 (isolating transformer with reinforced providing the regulations, notes and warnings insulation) and have a one section bobbin. When the contained in these instructions are complied with. impulse transformer is installed, suitable shock

protection must be provided in accordance with the In case of non-compliance or use contrary to national installation regulations for electrical the intended purpose, there is a risk that equipment. In addition, water, cleaning solutions and Heatsea ling safety will be band impaired or that the heatsealin A basic g band, prerequisit electrical e for wiring, reliable transform and safe er etc. will operation overheat. of the Ensuring system is such the use of complian suitable ce is the heatsealin personal g bands. responsib ility of the user. The resistanc e of the heatsealin g band

prevented ! from which seeping is used into the must transforme have a r. positive minimum temperatu re ! coefficien t in order Incorrect to installatio guarantee n of the trouble- impulse free operation of the RESISTR ON- transform er impairs electrical Temperat safety. urregler. The temperatur e coefficient Current must be transfor specified mer as follows: PEX- W2/-W3 TCR 10 10 –4 –1 K The current transforme r supplied e.g. Alloy- with the 20: RESISTR ON TCR = temperatur 1100 e ppm/K controller NOREX: is an integral TCR = part of the 3500 control ppm/K system. conductive Only the fluids must original be ROPEX

PEX-W2 or ON- Temperatu ! rregler PEX-W3 correctly current (see transform section 9, er may be used. "Startup Other and transform operation") ers may . The cause the relevant equipment safety to instruction s contained in section malfuncti 8.3, on. "Power supply", must be The obeyed. current External transforme monitoring r may only modules be can be operated if used in it is order to connected additionall to the y increase RESISTR RES-408 Page 3

Application operating safety. They are not included in the scope of Standards / CE marking supply of the standard control system and are described in a separate document. The controller described here complies with the following standards, provisions and directives: Line filter DIN EN 61010-1 Safety provisions for electrical (VDE 0411-1) measuring, control and laboratory The use of an original ROPEX line filter is mandatory in order to comply with the standards and provisions devices (low voltage directive). Overvoltage category III, mentioned in section 1.7 "Standards / CE marking" on pollution severity 2, safety class II. 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. DIN EN 60204-1 Electrical equipment of machines (machinery directive) EN 50081-1 EMC interference emissions according to Warranty provisions EN 55011, group 1, class B The statutory provisions for warranties apply for a EN 50082-2 EMC interference immunity: ESDs, RF period of 12 months following the delivery date. radiation, bursts, surges. All devices are tested and calibrated in the factory. Devices that have been damaged due to faulty connections, dropping, electrical overloading, natural Compliance with these standards and provisions is wear, incorrect or negligent handling, chemical only guaranteed if original accessories and/or influences or mechanical overloading as well as peripheral components approved by ROPEX are devices that have been modified, relabeled or used. If not, then the equipment is operated on the otherwise altered by the customer, for example in an user's own responsibility. attempt to repair them or install additional components, are excluded from the warranty. The CE marking on the controller confirms that the device itself complies with the above-mentioned Warranty claims must be examined in the factory and standards. approved by ROPEX. 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. The controller is most 2 commonly used for impulse-heatsealing PE Application and PP films in: Vertical and horizontal This RESISTRON f/f/s machines temperature controller is an integral part of the "series 400", the outstanding feature of Pouch, filling and sealing which is its machines microprocessor technology. All RESISTRON temperature controllers Film wrapping machines are used to con-trol the temperature of heating elements (heatsealing Pouch-making machines bands, beaded bands, cutting wires, heatsealing blades, solder elements etc.), as required in a Group packaging variety of heatsealing machines processes. L-sealers Page 4 RES-408

Principle of operation Increase d etc. machine capacity The use of Extende RESIST d life of RON the temperat heatseal ure ing controlle bands rs and results teflon in: coatings Repeata Simple ble operation quality and of the control of heatseal the s under sealing any con- process ditions 3 Principle of operation is monitore The d 50x per resistanc second e of the (60x at heatseali 60Hz) by ng band, measurin which is g the tem- current perature- and sensitive, voltage.

The tem- evaluate perature d by the calculate RESIST d with RON the help temperat of these ure measure controlle -ments is r. displaye d and compare d with The the set control point. loop is closed: ACTUAL The temperat primary ure = voltage SET of the temperat impulse ure. transfor Even mer is minute adju- thermal sted by loads on phase- the angle heatse- control if aling the band are measure detected d values and can deviate be from the correcte set d quickly point. and The precisely resulting . change The in the thermoel current ectric through control the loop heatseal which is ing band formed leads to has a a highly change dynamic in the response band because temperat purely ure and electrical thus variables also its are measure resistan d at a ce. This high change sampling is rate. A measure very d and wide

secondar RESIST y current RON range temperat can be ure controlle controlle d with rs play a only significa minimal nt role in power enhanci loss - a ng the consider perform able advantag ance of e- modern because machine power is s. controlle However d on the , the full primary benefit side of can only the be obtained from the advance d Heatseali technolo ng band gy R = f (T) offered by this control system if transfor all the mer. system This compon allows ents, in optimum other adaptati words on to the the load and heatseal to the ing required band, dynamic the range impulse despite transfor the mer, the exceptio wiring, nally the compact timing dimensi signals ons of and the the controlle controlle r itself, r. are compati ble with PLEAS one E another. NOTE!

We ence will be toward please s d to optimi contri zing bute your our heatse many aling years syste of m. experi RESISTRON controller

Current IR UR Actual value

R=f(T) U2 transformer


Start and sec. U1 controls

_ or


+ Set point bus interface

Impulse transformer


RES-408 Page 5

Description of the controller 4 Description of the controller The microprocessor technology endows the RES-408 The temperature can be set on the separate T-408-1 RESISTRON temperature controller with previously (or T-400) operator terminal. unattainable capabilities: The real heatsealing band temperature is also visua- lized on the operator terminal. Very simple operation thanks to AUTOCAL, the The RES-408 RESISTRON temperature controller automatic zero calibration function. 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. Good dynamic response of the control system thanks to AUTOTUNE, which adapts automatically to the controlled system. To increase operational safety and interference immu- nity, all 24VDC logic signals are electrically isolated from the controller and the heating circuit. High precision thanks to further improved control accuracy and linearization of the heatsealing band characteristic. Coding switches on the temperature controller itself can be used to adapt to different heatsealing band alloys (Alloy 20, NOREX etc.) and set the required High flexibility: The AUTORANGE function (as of June tem-perature range (0...300°C, 0...500°C etc.) on all 2006) covers a secondary voltage range from 0.4V to con-trollers manufactured as of June 2006. 120V and a current range from 30A to 500A. The compact design of the RES-408 RESISTRON Automatic adjustment to the line frequency in the tem-perature controller and the plug-in connections range from 47Hz to 63Hz. make this controller easy to install. Increased protection against dangerous conditions, such as overheating of the heatsealing band. 5 Accessories and modifications A wide range of compatible accessories and peripheral

5.1 Accessories devices are available for the RES-408 RESISTRON temperature controller. They allow it to be optimally The products described below are only a few of the adapted to your specific heatsealing application and to wide range of accessories available for RESISTRON your plant's design and operating philosophy. temperature controllers ("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. Line filter Essential in order to ensure CE conformity. Optimized for the RESISTRON temperature controller. Page 6 RES-408

Accessories and modifications 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 ( ROPEX Application Report). CI-USB-1 communication interface Interface for connecting a RESISTRON temperature controller with a diagnostic interface (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). Monitoringcurrent transformer

For detecting frame short-circuits on the heatsealing band. Used as an alternative to the standard PEX-W2/-W3 current transformer.

RES-408 Page 7

Accessories and modifications Modificati ons (MODs) MOD 37 Owing to its universal (up to May design, the 2006) RES-408 RESISTRON temperature Additional controller is rotary coding suitable for a switch for the very wide heatsealing range of band alloy heatsealing and the applications. temperature range. Various heatsealing Various band alloys modifications (e.g. Alloy 20, (MODs) are NOREX) and offered for temperature the RES-408 ranges (e.g. RESISTRON 300°C, temperature 500°C) can controller for be selected. implementing special applications. The modifications MOD 01 described here are just a few of the Amplifier for large number low available. secondary Separate documentatio voltages (UR n is supplied = 0.25… for all 16VAC). This modifications modification . is necessary, for example, for very short

or low- ! resistance heatse-aling This bands. modification is MOD 26 supplied as standard Additional terminal for connecting an external with switching all amplifier controllers (booster). This manufacture modification d as of is necessary for high primary currents June 2006 (continuous current > 5A, ( section pulsed 10.2.2 current > "Configurati 25A). on of the rotary coding switch for the temperature range and alloy (as of June 2006)" on page 21). 3 0 position 7 4 range 5 1 6 coefficie 5 nt 5 7 0 8 3 300°C 3 5 4 1100pp m/K 0 1 a

2 8 4 9 3 0 S T A 0 3 1 ( 7 1 3 7 ( 4 6 5 1 5 ( 5 5 7 ( 8 3 3 1

Page 8 RES-408

Technical data 6 Technical data Type of construction Controller: 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) Terminal: Housing for installation in the electrical cabinet

Dimensions (W x H): 96 x 48mm; depth: 55mm (excl. connector) Line voltage Controllers manufactured as of June 2006: 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) Controllers manufactured between January 2004 and May 2006: 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) Controllers manufactured up to December 2003: 115VAC, 230VAC or 400VAC, tolerance: +10% / -15%

depending on device version ( section 14 "How to order" on page 48) Line frequency 47…63Hz, automatic adjustment to frequencies in this range Heatsealing band Controllers manufactured as of June 2006: type and temperature The temperature range and temperature coefficient settings can also be specified range in the ROPEX visualization software ( section 11.19 "Diagnostic interface / visualization software (as of June 2006)" on page 39) in addition to using 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 the 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) Controllers manufactured up to May 2006: Default value 300°C, Alloy 20 The temperature range and alloy can be selected with MOD 37. Analog output 0…10VDC, Imax = 5mA (actual value)

Equivalent to 0…300°C or 0…500°C Terminals 17+18 Accuracy: ±1% plus 50mV Digital logic levels LOW (0V): 0…2VDC, electrically isolated Terminals 5+7 HIGH (24VDC): 12…30V DC (max. current input 6mA) Reverse polarity-protected RES-408 Page 9

Technical data Alarm relay Umax = 50V (DC/AC), Imax = 0.2A, changeover contact, potential-free Terminals 12, 13, 14 Can be inverted by means of a plug-in jumper Maximum load Imax = 5A (duty cycle = 100%) (primary current of

Imax = 25A (duty cycle = 20%) impulse transformer)

Power loss max. 22W

Ambient +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 mechanically fix the controller must be fitted at both ends for moun- ting on a vertical top hat rail.

Weight Controller: Approx. 0.7kg (incl. connector plug-in parts) Terminal: Approx. 0.15kg

Housing material Controller: Plastic, polycarbonate, UL-90-V0 Terminal: Black plastic, type Noryl SE1 GFN2

Controller connec- Rigid or flexible; 0.2…2.5mm² (AWG 24…12) ting cables with plug-in connections Type / cross-sections 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.

Page 10 RES-408

Controller/terminal compatibility 7 Controller/terminal compatibility This has no effect on temperature control or on the All RES-408 RESISTRON external PLC control signals. temperature controllers manufactured as of June 2006 are supplied as an upgraded version. ! RES-408 Among other things, the data controllers transfer between the con-troller and the terminal has been manufactured as of modified. These changes were necessitated by the new European RoHS/WEEE Directives. Lead has now been banned from some of the June 2006 electronic components used in our products. are fully electrically compatible As a result, all RES-408 ! with the old version (as far controllers manufac- tured as the PLC control signals up to May 2006 can only be are concerned). operated with a T-400 terminal. Controllers manufactured as of June Please pay attention to the 2006 can only be operated controller and terminal ver- with a T-408-1. sions when ordering spare parts. The controller may have to be exchanged together with Malfunctions or damage may the terminal. Refer to the otherwise occur. compatibility table below: New version (as of June 2006):

Controller type Art. No. Compatible with RES-408/115VAC 740841 Terminal T-408-1 RES-408/230VAC 740842 Art. No. 885441 RES-408/400VAC 740843

Old version (up to May 2006): Controller type Art. No. Compatible with RES-408-0-3/115VAC 740801 or 740831

RES-408-0-3/230VAC 740802 or 740832 Terminal T-400 RES-408-0-3/400VAC 740803 or 740833 Art. No. 885440 RES-408-0-5/xxxVAC 740805, 740806, 740807, 740835, 740836 or 740837 RES-408-1-x/xxxVAC 740811, 740812, 740813, 740815, 740816 or 740817

RES-408 Page 11

75.0 8 Dimensions T-400 or T-408-1 terminal RES-408 controller 96.0 panel cutout 48.0 +0.8 +0.6 92 - 0 x 45 - 0

Dimensions outline dimensions front frame 9.0 135.0 113.0

o 5mm 42.0 55.0 56.0 90.0 Page 12 RES-408 90.0 front panel

Installation ma y onl y be 9 per - In st al la for me ti d o by n tec hni call y  trai Se ne e d, als skil o led sec tion per 1 - "Sa fety and war nin g not es" on pag e 3. ! Ins tall ati on an d sta rtu p

so SIS ns TR wh ON o tem are per fa atu mil re iar con wit troll h er: the ass Swi oci tch ate off d the ris line ks volt an age d and wa veri rra fy nty that pro all visi circ on uits s. are dee ner giz ed. In Th st e sup all ply ati volt on age pr spe oc cifi ed ed on ur the e na me plat e of Pro the cee RE d SIS as TR foll ON ow tem s to per inst atu all re the con RE troll S- er 408 mu RE

st Inst be all ide the ntic RE al SIS to TR the ON tem line per volt atur age e that con is troll pre er sen in t in the the ele pla ctri nt cal or cab ma inet chi on ne. a Th sta e nda rd line top fre hat que rail ncy (DI is N aut TS om 35 ati- rail call acc y ordi det ng ect to ed DIN by EN the 500 tem 22). per If atu sev eral re con con troll troll ers er are in inst the alle ran d ge on fro one m top 47 hat Hz rail, to the 63 Hz.

by me ans of fou r clip s min imu whi m ch cle sna ara p nce ont spe o cifi the ed sid in e of sec the tion ter 6 min "Te al chn hou ical sin dat g. a" on pag e9 Co mu nne st ct be the allo con we troll d bet er we and en ter the min m. al tog eth er Inst wit all h the the ter cab min le al pro in vid the ed fro for nt this pan pur el pos cut e. out. It is fast ene Co d ntr oll

ers T- ma 408 nuf -1. act Mal ure fun d cti up on to s Ma or y da 200 ma 6 ge are ma y ! oth er onl wis y e all oc ow cur ed ( to sec be tio op n7 era "C ted on- wit ha T- 400 trol ter- ler/ mi ter nal mi . nal Co co ntr mp oll ati ers bili ma ty" nuf on act pa ure ge d 11) as . of Ju ne Wir 200 e 6 the ca sys n tem onl in y acc be ord op anc era e ted wit wit h ha the

inst y. ruct ion s in Che sec ck tion the 9.3 tigh "Po tne wer ss of sup all ply" sys on tem pag con e nec 15 ! and - the tion RO s, incl PE udi X ng Ap the plic ter atio min n als for Re the por imp t. uls Th e e info rm tra atio nsf n or pro me - r vid win ed din in g sec wir tion es. 9.2 "In stal lati Ma on ke ste sur ps" e on that pag the e wiri 14 ng mu con st for be ms hee to ded the add rele itio van nall t

nati inst ona alla l tion and reg inte ulat rna ion tion s. al

RES-408 Page 13

A of turns cross-section Installation steps Use heatseal bands with Heatseal element suitable temperature coefficient with coppered ends Current transformer U2(sec.) Heatsealing band R= f (T) U1(prim.) PEX-W2/-W3 F No additional resistance in secondary Note Sufficient wire circuit number

Installation eral cont rolle rs Dim inst ensi alle on d on one pola top rity hat Con rail troll er No tran Ter sfor min mer al corr push-on connectors ectl y Sec ond ary volt Con age figur e Pow DIP Connect UR measuring wires directly to heatsealing band ends er swit che Dut s Twisted y corr cycl ectl e y (up Current measuring wires IR to 20m May m 200 clea ATR- 6) Li ranc x e if ne sev Temperature Line Avoid long filter LF- meter xx48 0 cables Note Impulse transformer

Page 14 RES-408

Installation FILTER Short wires Power supply UR L1 (L1) LINE N (L2) GND/ Earth ON K1 I> I> OFF Ka LINE

ROPEX temperature controller I R


U1 PRIM. U2 SEC. R Line 115VAC, 230VAC, 400VAC 50/60Hz

Circuit breaker Designed according to VDE 0570/EN 61558 (isolating transformer with reinforced insulation). Connect core to Double-pole, C characteristic ( ROPEX ground. Application Report) Short-circuit protection only. ! Use transformers with a one section bobbin. The power, RESISTRON-Temperaturreglers not duty cycle and voltage values must be deter-mined protected. individually according to the application ( ROPEX Application Report and "Accessories" leaflet for impulse Relay Ka transformers). For "HEAT ON - OFF" function (all-pole) or "EMERGENCY STOP". Wiring Line filter The wire cross-sections depend on the application ( ROPEX Application Report). Guide values: The filter type and size must be determined according to the load, the transformer and the machine wiring ( ROPEX Application Report). Primary circuit: min. 1.5mm², max. 2.5mm² Do not run the filter supply wires (line side) parallel Secondary circuit: min. 4.0mm², max. 25mm² to the filter output wires (load side). These wires must always be twisted (>20/m) RESISTRON-Temperaturregler belonging to the 4xx Series. These wires must be twisted (>20/m) if several control loops are laid together ("crosstalk"). Relay Kb Twisting (>20/m) is recommended to improve EMC. 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

RES-408 Page 15

Installation Line filter installed and wired correctly, they guarantee comp- liance with the EMC limit values. You can find the exact specification of the line filter in To comply with EMC directives – corresponding to EN the ROPEX Application Report calculated for your par- 50081-1 and EN 50082- 2 – RESISTRON control ticular heatsealing application. loops must be operated with line filters. For more technical information:  "Line filter" docu- These filters damp the reaction of the phase-angle mentation. con-trol on the line and protect the controller against line disturbances. ! ! It is permissible to supply several The use of a suitable line filter is part of the standards conformity and a prerequisite of the CE mark. RESISTRON control loops with a single line ROPEX line filters are specially optimized for use in RESISTRON control loops. Providing that they are filter, providing the total current does not exceed the maximum current of the filter. The wiring instructions contained in section 9.3 "Power supply" on page 15 must be observed. Large cross-section wire to ground max. 1m PE LINE ROPEX temperature controller

wires Do not lay parallel Mounting plate (galvanized) Large cross-section Large frame contact surface wire to ground 60 12 Current of the control system. transformer PEX- The current transformer may only be operated if it 39 W3 is connected to the temperature con-troller correctly ( section 9.3 The PEX-W3 current "Power supply" on page transformer supplied with 15). the RESISTRON temperature controller is an integral part 24 28 75 14 23 26 terminal

terminal block 14

Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022) Page 16 RES-408

Installation Wiring diagram (standard) 1 Line filter LF-xx480 RES-408 LINE 2 (also with MOD 01)


with 24VDC-Signal



with 24VDC-Signal



Impulse prim.



U2 for 24VDC signals.

Must be grounded


externally to prevent

electrostatic (Internal ground) 8

Heat- charging! No external

U R R 14

grounding allowed! 9 sealing

band ALARM

twisted 12


max. 50V/0,2A up to


13 production

11 IR


Current transformer

May 2006

+ 17 0V


ATR (Internal ground)

°C 18

No external

grounding allowed!










Display- and

operation panel Up to production date March 2003 the standard output power circuit (terminals 3+4) has NO function when the booster-connection (MOD 26) is installed. As of April 2003 the terminals 3+4 are active too when the booster-connection is installed. RES-408 Page 17

Installation Wiring diagram with booster connection (MOD 26) RES-408 1

Line filter LF-xx480



(also with MOD 01)


+ 15 3 1




with 24VDC-Signal


4 NC

with 24VDC-Signal


6 Impulse




U2 for 24VDC signals.

Must be grounded

sec. externally to prevent

electrostatic (Internal ground) 8

Heat- charging! No external UR R

14 grounding allowed! 9

sealing band ALARM

twisted 12



max. 50V/0,2A

up to 10

13 production

11 IR


Current transformer

May 2006

+ 17 0V


ATR (Internal ground)

°C 18

No external

grounding allowed!









Display- and

operation panel

Up to production date March 2003 the standard output power circuit (terminals 3+4) has NO function when the booster-connection (MOD 26) is installed. As of April 2003 the terminals 3+4 are active too when the booster-connection is installed. Page 18 RES-408

Startup and operation 10 Startup and operation T-400 or T-408-1 terminal View of the controller Nameplate RES-408 controller Display Terminals Operator keys Wiring diagram

Cable connection LEDs Fixing clips (4x) Connection for terminal Nameplate Coding switches and plug-in jumpers RES-408 Page 19

Startup and operation Controller configuration side the permissible range, a detailed error message appears on the controller ( see section 11.21 "Error messages" on page 40). ! The controller must be switched off in order to configure the coding switches and plug-in Configuration with coding switches (up to May 2006) jumpers. Configuration for secondary voltage Set the DIP switches for and current matching the secondary voltage U2 and the Automatic secondary current I2 to configuration the correct position for (AUTORANGE) (as of your application. June 2006) You can find the exact The secondary voltage ! and current ranges are configuration of the DIP automa-tically configured switches in the ROPEX by the automatic Application calibration function (AUTOCAL). The voltage is configured in the range Report calculated for from 0.4VAC to 120VAC and the current in the your particular range from 30A to 500A. If application. the voltage and/or current are out- 4 1-

S D WI TC I HO N P 1 s 2 3 w ) 4 i 5 t c h 1... I 10V V 2 ON O F D OFF F I P OFF s 30 w ...100A F i ( t OFF a c c h OFF t o 6... r y 60V 2 s OFF 1 e ON t 2 OFF ti n 3 60... g 200A U s ON OFF 4 O N 1 5 20... 2 3 120V 4 5 OFF OFF OFF ON 120... U ON 400A 2

O Page 20 RES-408 N O N If the secondary current I2 is less than 30A, the PEX- W2 or PEX-W3 current transformer must have two turns ( ROPEX Application Report). 2x

Startup and operation 5 G 0 U 2 0° R C AT IO 7 N 8 0 Configuration of the rotary coding switch p for the temperature range and alloy (as of p June 2006) m /K position e. range g. Al coefficient lo y L 8 9 alloy 0 8 1 3 0 0 0° 300°C C 1100ppm/K 3 5 0 0 e.g. Alloy-20 p p m 1 /K 3 300°C 780ppm/K e. g. N O e.g. Alloy L R E X 4 7 500°C 9 1100ppm/K P C - e.g. Alloy-20 C O N FI 5

6 0 = Factory settings 0 SWITCH POS. TEMP. RANGE ALLOY 1 0 8 300°C 2 9 1100ppm/K 5 (A20) 4 1 300°C 3 780ppm/K (L) 4 5 7 500°C 4 1100ppm/K (A20) 6 5 500°C 780ppm/K (L) 300°C 3500ppm/K (NOREX) PC CONFIGURATION only possible on This older configuration controllers is set as standard on in conjunction ! with MOD all controllers 37 ( manufactured section as of June "MOD 37 2006. The settings are

(up to May 2006)" on the ROPEX visualization page 8). software ( see section 11.19 "Diagnostic interface / visualization software (as of June A If the switch is set to "9" 2006)" on page 39). A (as of June 2006), other tem-perature ranges and alloys can be selected in E 10.2.3 Configuration of the alarm relay 2006 - or if it is incorrectly inserted - an error message appears when the con-troller is switched on ( section 11.21 "Error mes- 8 Alarm relay de-energized 9 by alarm/ PC- sages" on page 40). 0 CONFIGURATION. 1 If the "Alarm relay de- Alarm relay energized by energized by alarm/PC alarm. CONFI-GURATION" position is selected (as of 2 June 2006), the behavior of the alarm output can be (factory setting) configured more finely in the ROPEX visualization software ( see 3 R E S - If the plug-in jumper is 4 ! 0 not inserted on con- 8 trollers manufactured up P to May 2006, the alarm a relay is permanently g energized (alarm con- e tact between terminals DE -ENERGIZED / PC 2 13 and 14 closed). The CONFIGURATION 1 other functions of the controller (e.g. heating the heatsealing band, AUTOCAL etc.) are not affected. If the plug-in jumper is not inserted on controllers manufactured as of June

When the "AUTOCAL" function has finished, the con- troller outputs a voltage equivalent to a temperature of 20°C at the actual value output. Adjust the set point to approximately 250°C and activate the "START" signal to heat for approximately 1 second. After recooling, the controller usually outputs an actual value of less than 20°C. Repeat the "AUTOCAL" function. The heatse-aling band has now been burned in and the change in the rature coefficient TCR, i.e. one whose resistance alloying properties stabilized. increases as the temperature rises. Too low a TCR leads to oscillation or uncontrolled hea- ting. The burn-in effect described here does not occur if the heatsealing band has already been thermally pre- treated by the manufacturer. If a heatsealing band with a higher TCR is used, the controller must be specially calibrated. Replacing the heatsealing band 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 All power supply leads must be disconnected from the appro-ximately 2…3%. However, this at first glance RESISTRON temperature controller in order to slight resistance change results in a zero point error of replace the heatsealing band. 20…30°C. The zero point must therefore be corrected after a few heating cycles ( section 10.3.2 "Burning in the heatsealing band" on page 22). One very important design feature is the copper or silver-plating of the heatsealing band ends. Cold ends allow the temperature to be controlled precisely and increase the life of the teflon coating and the heatse- aling band. ! An overheated or burned-out heatsealing band must no longer be used because the TCR has been altered irreversibly. Burning in the heatsealing band If a new heatsealing band has been used, the zero point is first of all calibrated while the band is still cold by activating the "AUTOCAL" function on the controller.

Startup and operation Prerequisites: The controller must be correctly installed and connected ( section 9 "Installation" on page 13). Proceed as follows to start up the controller for the first time: Switch off the line voltage and verify that all circuits ! are deenergized. The heatsealing band must be replaced in accordance with the instructions provided by The supply voltage specified on the nameplate of the controller must be identical to the line voltage that is present in the plant or machine. The line fre-quency is the manufacturer. automatically detected by the tempera-ture controller in the range from 47 to 63Hz. Each time the heatsealing band is replaced, the zero point must be calibrated with the AUTOCAL function In the case of controllers manufactured up to May 2006, the DIP switches on the controller must be set according while the band is still cold, in order to compensate pro- to the ROPEX Application Report and depend on the duction -related resistance tolerances. The burn -in heatsealing band that is used (section 10.2 "Controller pro-cedure described above must be performed for all configuration" on page 20). new heatsealing bands. Make sure that a START signal is not present. Startup procedure Switch on the line voltage. Please also refer to section 1 "Safety and warning notes" on page 3 and section 2 "Application" on page When the voltage is switched on, the yellow 4. "AUTOCAL" LED lights up for approximately 0.3 ! seconds on all controllers manufactured as of June 2006 to indicate that the controller is being powered Installation up correctly. and startup may only be per- formed by technically trained, skilled per- sons who are familiar with the associated risks and warranty provisions. Page 22 RES-408 Initial startup

Startup and operation OFF Short pulses ! Go to 8 Controllers manufactured as of June 2006: If the red "ALARM" LED lights up for 0.3s in addition to the yellow "AUTOCAL" LED when the every 1.2s voltage is switched on, the configuration of this controller has been changed in the visualization software ( section 11.19 "Diagnostic interface / visualization software (as of June 2006)" on page 39). In order to avoid malfunctions, please check the controller configuration before conti-nuing the startup procedure. One of the following states then appears: Controllers manufactured as of June 2006: BLINKS fast "ALARM" OFF "OUTPUT" Go to 8 ACTION (4Hz) LED LED Lit conti- OFF Fault diagnosis nuously ( section 11.21)

Short pulses Go to 8 every 1.2s Controllers manufactured up to May 2006: Alarm no. Alarm no. "OUTPUT" OFF ACTION Go to 8 104…106, 211 LED Alarm no. OFF Fault diagnosis 101…103, 107 ( section 11.21) 108, 201…203 ---

When the zero point has been calibrated suc- cessfully, select a defined SET temperature and 9xx activate the "START" signal (HEAT). The "SEAL- HEAT" LED on the terminal then lights up. The ACTUAL temperature appears on the display. The heating and control process can now be observed The controller is functioning correctly if the tempera-ture has a continuous curve, in other words it must not jump abruptly, fluctuate or deviate temporarily in the wrong direction. This kind of behavior would indicate that the UR measuring wire has been laid incorrectly. If an error message is displayed, please proceed as described in section 11.21 "Error messages" on page 40. Activate the AUTOCAL function on the T-408-1 (or T- 400) terminal while the heatsealing band is cold. "AC" 10.Burn in the heatsealing band ( section 10.3.2 blinks on the terminal display for the duration of the "Burning in the heatsealing band" on page 22) and calibration process (approx. 10…15s) (the yellow repeat the AUTOCAL function. "AUTOCAL" LED lights up as well on all con-trollers manufactured as of June 2006). A voltage of app. 0V appears at the same time at the actual value output (terminals 17+18). If an ATR-x is con-nected, it The controller is now ready indicates 0…3°C. When the zero point has been calibrated, the ter- Restart after replacing the heatse-aling band To replace the heatsealing band, proceed as described in section 10.3.2 "Burning in the heatsealing band" on page 22 . minal display returns to the home position and a voltage of 0.66V (300°C range) or 0.4V (500°C range) appears at the actual value output instead. If an ATR-x is connected, it must be set to "Z". The "AUTOCAL" ! Always use a heatsealing band with the cor- rect alloy, LED goes out again on controllers manufactured as of dimensions and copper-plating in June 2006. order to avoid malfunctions and overheating. If the zero point has not been calibrated suc-cessfully, an alarm is indicated on the terminal dis-play. In Continue with section 10.4.1, steps 4 to 10. addition, the red "ALARM" LED blinks slowly (1Hz) on all controllers manufactured as of June 2006. In this case the controller configuration is incorrect ( section 10.2 "Controller configura-tion" on page 20 and ROPEX Application Report). Repeat the calibration after the controller has been configured correctly.

RES-408 Page 23

Controller functions 11 Controller functions Indicators and controls Controllers manufactured as of June 2006 RES-408 controller Red LED, lights up or blinks to indicate ALARM. ALARM HEAT OUTPUT Yellow LED, lit during heating phase. AUTOCAL 1 2 3 4 Green LED, indicates pulses in measure-ment mode. In control mode, luminous intensity is proportional to heating current. Tel: +49(0) 5678 7142- 7776-0 RESISTRON RES- 408 9 10 Made in 12 13 14 1516 17 18 Germ any Temperature controller 11 Yellow LED, remains lit for duration of AUTOCAL process. ROPEX

In addition to the functions shown in the diagram controller LEDs. These states are described in detail above, various operating states are indicated by the in the table below: LED Blinks slowly (1Hz) Blinks fast (4Hz) Lit continuously AUTOCAL — AUTOCAL requested, but AUTOCAL executing (yellow) function is locked

HEAT — HEAT requested, START executing (yellow) but function is locked OUTPUT In control mode, luminous intensity is proportional to heating current (green)

ALARM Configuration error, Controller calibrated incor- Fault,  section 11.21 (red) AUTOCAL not possible rectly, run AUTOCAL

Page 24 RES-408

Controller functions H A N T D - 4 0 R E 8 S - E T 1 t e r m i n a l L E R D O P E d X i T s - p 4 0 l 8 a y , 1 5 c S E A h L H E A T a r a 2 c P R t e E H E A T r s 3 H O L D

Y i e v l e l o w Y e L ll E o D w : L H E e D a : t P u R n E g H E u A p T / a t c e ti m v p e . c G o r n e t e r n o L l E D t : o H o s l e d t m o t d e e m a p c e ti r v a e t u r “ e U P a ” c a t

n a d n g “ e D O W H N o ” l d k ( e > y 2 s s e f c o .) r : F s a e s t t t c i h n a g n g v e a l u e “ s E N P T r E e R s ” s k e ( y < 2 E s N e T c E . R ) : f u S n l c o ti w o n c : h S

a v a e ft e v r a a l l u a e r s m H A “ N M D E N f U u ” n k c e t y i f o o n r : a d M v a a n n u c a i l n g m t o o d n e e x R t E m S e E n T u s f t u e n p c o t r i s o w n it : c h R i e n s g e m t

e e n p u H P o r l e d s ( s > 2 ( s < e c 2 .) : s R e e c t . u ) r : n t N o e h x o t m e m p e o n s u it i s o t n

RES-408 Page 25

7 14 Controllers manufactured up to May 2006 μP-Controller 98 01 RES-408 controller 171516 ROPEX 4321 TERMINALROPEX INDUSTRIE - ELEKTRONIK 11 18 POWER ON . OUTPUT ! 5 T-400 terminal 12 ROPEX RESISTRON 6 1 SEALHEAT 13

2 PREHEAT Controller functions 3 HOLD ENTER HAND RESET Green LED, lit when power supply is ok. Green LED, indicates pulses in measure-ment mode. In control mode, luminous intensity is proportional to heating current.

LED display, 5 characters Red/Green LED: Red, during heating up Yellow LED: Green, set temp. achieved Page 26 RES-408 PREHEAT active Green LED: Hold mode active “UP” and “DOWN” keys for setting values Press (< 2 sec.): Slow change Hold (> 2 sec.): Fast change “ENTER” key ENTER function: Save values HAND function: Manual mode RESET function: Reset after alarm “MENU” key for advancing to next menu step or switching menu Press (< 2 sec.): Next menu step Hold (> 2 sec.): Return to home position

Controller functions SW revision of the con- troller for the Displa next y 1.5s (e.g.: 00.105). Power -up ROPEX T-408 mess SEALHEAT age PREHEAT A power- HOLD up messag e ENTER appears on the display HAND for appro- ximately 3 RESET seconds when the controlle r is On switche controll d on. On ers controlle manufa rs ctured manufa up to ctured May as of 2006, June the 2006, power- this up messag messag e shows e only the SW shows revision "00 of the 000". terminal for the first 1.5s (e.g.: Displa 00.105) and the y in

home Error positi mess on ages If no The settings fault are diagnos entered is on the function controlle of the r and no controll error er is messag always e is active. indicate If a fault d, the display is is in the detecte home d, it is posi- indicate tion, in d on the other display words it immedi shows ately in the the ACTUA form of L an error tempera messag ture. e ( section 11.20 ROPEX T-408 "Syste SEALHEAT m monitori ng / PREHEAT alarm output" on page HOLD 39). ENTER ROPEX T-408 SEALHEAT HAND PREHEAT RESET HOLD ENTER HAND

RESET (>2s), you can return to the home position from Navig anywhe ation re in the in the menu structur menu e, s providin ga controll er Navig alarm is ation not in active. menu In this case, s the witho Alarm ut an menu is alarm opened. A In "MENU addition " key is , you provide always d for return navigati to the ng home through position the if you various do not menu press steps. any By keys for pressin a period g this of 30s. key There is briefly no (<2s) at automat any ic return time, after you can 30s jump to from the next "AC" menu [AutoC step. By al] or pressin "AL" g the [ALarm] key for . longer

Settin indicate gs d, the terminal menu display shows the The Alarm require menu. d Some parame faults ters are can be set in acknowl the edged Settings by menu pressin ( g the section "RESE 11.4 T" key "Menu ( structur section e" on 11.20 page "Syste 28) m monitori ng / alarm ROPEX T-408 output" SEALHEAT on page 39). In this PREHEAT case, the display HOLD switche s back to the ENTER home position . HAND If the RESET fault can be rectified Navig by ation executi ng the in AUTOC menu AL s with function an , you alarm can select the "AC" If an [Auto alarm is Cal]

menu pressin step g the directly "ENTE by R" key briefly ( pressin section g the 11.8 "MENU "Autom " key atic (<2s). zero You can cali- then bration activate (AUTO the CAL)" "AUTO on page CAL" 32). function by RES-408 Page 27

Controller functions Menu structure Autocomp Power-up message Fault °C Home position AL Alarm SH Heatsealing temp. AC Autocal? PH Preheat temp. Autocal AC Page 28 Autocal? RES-408 Autocal 1) AUTOCOMP: OFF 2) AP AUTOCOMP: ON Autocomp?

Controller functions Menu steps Name Description Setting range °C Home position The current actual value appears on the terminal

display. The heatsealing band can be heated manually (to the specified heatsealing or preheat temperature) by pressing the "HAND" key. HA [HAnd] The heatsealing band can be heated manually (to Hand menu the specified heatsealing or preheat temperature)

by pressing the "HAND" key. ! This menu step is only available on con- trollers manufactured up to December 2000.

SH [SealHeat] The required heatsealing temperature (set point) Controllers manufactured Heatsealing tem- can be set with the "UP" and "DOWN" keys. up to May 2006: perature Controllers manufactured up to May 2006: 0…300°C or 0…500°C The maximum selectable set point is limited by the Controllers manufactured controller version (300°C or 500°C).

Controllers manufactured as of June 2006: as of June 2006: The maximum selectable set point is limited by the 0, 40°C…maximum tem- rotary coding switch (alloy/range) and/or the PC perature visualization software. PH

[PreHeat] The required preheat temperature (PREHEAT) can Controllers manufactured Preheat tempera- be set with the "UP" and "DOWN" keys. up to May 2006: ture Controllers manufactured up to May 2006: 0°C…set point The preheat temperature must always be lower Controllers manufactured than the selected heatsealing temperature. Controllers manufactured as of June 2006:

as of June 2006: The maximum selectable preheat temperature is 0, 40°C…maximum tem- limited by the rotary coding switch (alloy/range) perature and/or the PC visualization software. The preheat function can be deactivated by ente-ring 0°C.

RES-408 Page 29

Controller functions Name Description Setting range AC [AutoCal] The AUTOCAL function matches the controller to Controllers manufactured Automatic calibra- the current and voltage signals that are present in up to May 2006: tion AUTOCAL the system. Setting not possible The required calibration temperature can be set

with the "UP" and "DOWN" keys on controllers Controllers manufactured manufactured as of June 2006. Pressing the as of June 2006: "ENTER" key stores the set value and starts the 0…40°C "AUTOCAL" function. On controllers manufactured up to May 2006, the calibration temperature is set to a fixed value of 20°C by pressing the "ENTER" key. "AC" blinks on the display while the AUTOCAL

function is executing. When the controller has been calibrated successfully, the display switches back directly to the home position providing the "AUTO- COMP" function is deactivated. If "AUTOCOMP" is active, the display jumps to the AP step. If the controller cannot be calibrated, the AUTOCAL function is aborted and an error message is dis- played instead.

AP [AutocomP] Pressing the "ENTER" key starts the "AUTO- Automatic phase COMP" function. If the "ENTER" key is not pressed compensation within 2s, the display returns to the home position. AUTOCOMP This step is automatically displayed if the "AUTOCAL" function is successfully executed and "AUTOCOMP" is active. HO [HOld]

If Hold mode ("On") is activated, the last measured Controllers manufactured Hold mode value at the end of the heating phase is stored and up to May 2006: displayed on the terminal. On The "HOLD" LED lights up on the terminal when OFF hold mode is active. This procedure is repeated in every cycle and the displayed value is updated. Controllers manufactured Controllers manufactured as of June 2006: as of June 2006: If you select the "On2" function, the display swit- On ches back from hold mode to the actual value in real

On2 time after 2 seconds. The hold function is activated OFF again for 2 seconds at the end of the next cycle.

Page 30 RES-408

Controller functions Name Description Setting range AL [ALarm] If an alarm is indicated, the controller shows the Alarm menu Alarm menu. Some faults can be acknowledged by pressing the "RESET" key. In this case, the con-

troller switches back to the home position. If the fault can be rectified by executing the AUTOCAL function, you can select the "AC" [AutoCal] menu step directly by briefly pressing the "MENU" key (<2s). You can then activate the "AUTOCAL" function by pressing the "ENTER" key.

! This step is included in the menu struc- ture of all controllers manufactured up to May 2006. If no error message is indicated, the display shows "000". On controllers manufac- tured as of June 2006, this step only appears if an alarm is indicated.

HAND RESET Temperature setting (set point selection) The heatsealing temperature can be set on the RES- The heating and control process can thus be observed 408 controller with the setting in the "SH" [Seal-Heat] at any time. menu step. In addition, the RES-408 controller outputs an analog 0…10VDC signal, which is proportional to the real The set point selected for the heatsealing temperature ACTUAL temperature, at terminals 17+18. must be greater than 40°C. If not, the heatsealing band is not heated when the "START" signal is activated or the "HAND" key is pressed. The 1…39°C setting range is not available on controllers RES-408 manufactured as of June 2006. Temperature indication / actual value output If the display is in the home position ("°C"), the Actual value ACTUAL temperature is indicated. R=33ohm ROPEX T-408 SEALHEAT max. 5mA PREHEAT output HOLD ENTER

17 0V 18 0…10VDC

0…10VDC - + Temperature meter e.g. ATR-3 RES-408 Page 31

Controller functions 0- 300°C range Voltage values: 0VDC  0°C 10VDC  300°C or 300 500°C (depen ding on the controll er configur a- tion) The relation ship betwee urt n the 270 change in the output voltage and the ACTUA L temper ature is linear. Te °C

ra 240 Te 180 mpe 210 150

60 120 1 2 3 4 5 6 7 8 9 90 10 0.66V Voltag eU

VDC urt "ZERO" 450 Te ra °C 400 0- 500°C range 500 mpe

350 250 Te 300 200

6 7 8 150 9 10 "ZERO" Voltag eU VDC 100 1 2 3 An 4 indicati ng 5 instrum ent can

be L connect compari ed to -sons, this but also output enables in order other to criteria visualiz such as e the the temper hea-ting ature of rate, set the point heat- reached sealing within band. the specifie d time, cooling The of the charact heatsea eristics ling of the band ROPEX etc. to ATR- x be temper evaluat ature ed. meter (size, scaling, dynami This c instrum respons ent e) are moreov optimiz er ed for permits this disturba applicat nces in ion ( the section control 5 loop "Access (loose ories connect and ions, modific contacti ations" ng or on page wiring 6). problem s) as well as any line disturba nces to be moni- The tored meter extreme not only ly facilitat effectiv es SET- ely and ACTUA

interpre May ted 2006, accurat no error ely. The messag same es applies appear if at the mutual analog interfer output. ence In the occurs event of bet- an ween alarm, several the last neighbo ACTUA ring L tem- control peratur loops. e continu es to be indicate If an d at the alarm is analog signale output. d, this analog output is used This – in output addition is not to the potenti terminal al-free display and – to show a ! selectiv could e error carry messag the e on second controll ary ers voltage manufa of the ctured impuls as of e June transfo 2006 rmer. ( Extern section al 11.21 ground "Error ing is messag not es" on allowe page d. If 40). On this controll warnin ers g is manufa ignore ctured d, the up to control

ler will ally on be the damag controll ed by er. The frame "AUTO current CAL" s. function Contac mat- t ches voltage the pro- controll tection er to must the be current installe and d at the voltage termina signals ls of that are the present in the system. This externa function l can be temper activate ature d in the meter. "AC" [AutoC al] step by pressin Auto g the "ENTE matic R" key. zero calibr ation On (AUT controll OCAL ers ) manufa ctured as of June Owing 2006, to the the cur- automat rently ic zero valid calibrati initial on temper (AUTO ature CAL) (ambien function t , there temper is no ature) need to of the adjust heatsea the zero ling point bar(s) manu-

require tion is d for executi calibrati ng. The on can actual be value preset output in the (termin 0… als 40°C 17+18) range is set to using 0…3°C the (corres "UP" ponds and to "DOWN approxi " keys. mately 0 VDC) until the function The has zero ended. point is calibrat ed in the If the factory temper to 20°C. ature of The the automat heatsea ic ling calibrati band on varies process on takes controll around ers 10…15 manufa second ctured s. The as of heatsea June ling 2006, band is the not "AUTO heated. CAL" "AC" function blinks is on the execute display da while maximu the m of "AUTO three CAL" func- Page 32 RES-408

Controller functions When the "START" signal is activated, the controller- internal set/actual comparison is performed immedia- tely and the heatsealing band is heated to the SET tem-perature (the "PREHEAT" signal must be deactivated). It remains at this temperature until the signal is deacti-vated again. This process can also be started indepen-dently of the "START" signal by times. If the function still cannot be terminated suc- pressing the "HAND" key while the display is in the home position (on control-lers manufactured up to cessfully, an error message appears ( section 11.21 December 2000, the same effect can be achieved by "Error messages" on page 40). pressing the "HAND" key in the "HA" [HAnd] step). ! You should always wait for the heatsealing band and the bar to cool down (to ambient temperature) before activating the "AUTOCAL" The "START" signal is activated by applying a 24VDC function. signal at terminals 5+6. Reasons for locked AUTOCAL function: 24VDC The "AUTOCAL" function cannot be activated if the heatsealing band cools down at a rate of more than 0.1K/s. This is additionally indicated in the "AC" [AutoCal] step by the message "no1" (up to May 2006: "no"). If the "START" signal is activated, the "AUTOCAL" function is not executed. This is additionally indi-cated in the "AC" [AutoCal] step by the message "no2" (up to May 2006: "no"). Directly after the controller is powered up, the "AUTOCAL" function cannot be activated if a fault with error code 101…103, 201…203, 801, or 9xx is indicated ( section 11.21 "Error messages" on page 40). If the controller has already operated cor-rectly - a minimum of once - after powering up, the "AUTOCAL" function cannot be activated with error codes 201… 203, 801, or 9xx. START Heating to the heatsealing temperature (HEAT)

RES-408 max. 6mA (HEAT) + 5

HIGH: 12VDC START (HEAT) LOW: 2VDC ! The "START" signal is disabled as long as the "AUTOCAL" function is executing in the "AC" step. On controllers manufactured as of June 2006, the set point selected for the heatsealing temperature ("SH" [SealHeat]) step) must be greater than 40°C. If not, the heatsealing band is not heated up. The "SEALHEAT" LED on the T-400 or T-408-1 ter- minal lights up during the heating and control process until the heatsealing temperature is reached. The alarm relay is switched if the "START" signal is activated while an error message is indicating error codes 104…105, 111…113 or 211 ( section 11.21 "Error messages" on page 40). The heatsealing band is not heated. - GND ! If a "PREHEAT" signal is used, it must be 6 deactivated during the heating and control process. If not, the heatsealing band is heated to the set preheat temperature instead of the heatse- aling temperature ( section 11.10 ""PREHEAT" signal" on page 34).

RES-408 Page 33

RES-408 "PREHEAT" signal The heatsealing band can be heated to a specified pre-heat temperature with the "PREHEAT" function, in order to shorten the heating time to the selected SET temperature in time-critical applications. PREHEAT The preheat temperature is set with the "PH" [P reH eat] step in the Settings menu. The value selected for the preheat temperature must be greater than 40°C. If not, the heatsealing band is not heated when the "START" signal is activated or the "HAND" key is pressed. The 1…39°C setting range is not available on controllers manufactured as of June 2006. + The "PREHEAT" signal is activated by applying a 24VDC signal at terminals 7+6. 24VDC max. 6mA 7

- GND 6 HIGH: 12VDC PREHEAT LOW: 2VDC ! The heatsealing band is heated to the preheat temperature if the "START" and "PREHEAT" signals are active. In this case, the "PREHEAT" LED on the T-400 or T-408-1 terminal lights up.

Controller functions "START" signal 24VDC 0 "PREHEAT" signal t

24VDC 0 t

ACTUAL temperature T2 T1

t 0 T1 = Preheat temperature (PREHEAT)

T2 = Heatsealing temperature The heatsealing band is heated to the set preheat tem-perature if the "HAND" key is pressed and the "PRE-HEAT" signal is activated when the terminal display is in the home position. The "PREHEAT" LED Page 34 RES-408 then lights up. On controllers manufactured up to December 2000, the same effect can be achieved by pressing the "HAND" key in the "HA" [HAnd] step. Hold mode The behavior of the ACTUAL temperature display in the home position can be changed with the "HO" [HOld] step. The following settings are possible: "OFF" (Factory setting) If the home position is visible on the display, the real ACTUAL temperature is always indicated. "On" If the display is in the home position, the ACTUAL temperature that was valid at the end of the last heatsealing phase is always indicated as a digital value. When the controller is powered up, the real ACTUAL temperature is shown until the end of the first heating phase.

Controller functions 3. "On2" The "HOLD" LED on the terminal lights up if a tempera- This setting is available on controllers manufac- ture value is indicated in hold mode. tured as of June 2006. It causes the current ACTUAL temperature to be 11.12 Temperature unit displayed for an additional 2 seconds at the end of a heatsealing phase. This temperature is then indi- Celsius / Fahrenheit

cated again in real time until the end of the next (as of controller SW revision 106 heatsealing phase. and terminal SW revision 103) ! Hold mode only affects the value on the dis- As of controller software revision 106 AND terminal play. The ACTUAL temperature is always software revision 103 the unit for the temperature indi- indicated in real time, regardless of the setting, at cation and value selection can be switched between the actual value output. °C (Celsius) and °F (Fahrenheit). The unit is switched

The various hold modes are shown below: by pressing the „UP“ and „DOWN“ keys simultaneously when the home position is displayed. The keys must be START pressed together for 2seconds minimum. signal 24VDC ROPEX T-408 SEALHEAT


ACTUAL indication Hold OFF Hold T 0 t 0 t Hold On2 T Hold Hold On Hold T Hold

Heatsealing phase The following settings are possible: 0 „Celsius“ (Factory setting) Temperature indication and value selection in Celsius (°C). t „Fahrenheit“ Temperature indication and value selection in Fahrenheit (°F) 2s 2s Up to controller software revision 105 and/or terminal software revision 102, only Celsius (°C) can be speci- fied on the controller as the temperature unit. ! The degree unit can be changed on the con- troller without interrupting operation ! If you specify temperature indication and value selection in Fahrenheit (°F), the con- End of

troller still uses Celsius (°C) internally. Value steps are therefore possible with this function owing to the conversion from Celsius to Fahrenheit. RES-408 Page 35

Controller functions Measuring impulse duration (as of June "ENTER" key 2006) <2.0s The length of the measuring impulses generated by pressed the controller can be set with this parameter. It may be necessary to set a measuring impulse that is longer than the default 1.7ms for certain applications ( ROPEX Application Report). ! This parameter can only be set in the ROPEX visualization software ( section 11.19 "Dia-gnostic interface / visualization software (as of June 2006)" on page 39). Automatic phase compensation (AUTOCOMP) (as of June 2006) 0

t "AC" "AP"

Function vided for this lit purpose. The following settings are pos-sible: AUTOCOMP f u 1. T 2 „ „OFF" (Factory settings) O t The „AUTOCOMP“ function is activated by pressing display and the three decimal points light up conse- AUTOCAL the "ENTER" key after the "AUTOCAL" function has cutively). been successfully 0 executed ( section 11.8 If the interval following a "Auto- successful "AUTOCAL" t matic zero calibration function is longer than (AUTOCAL)" on page 2.0s, the display returns 32). to The interval after the end the home position of the "AUTOCAL" func- without executing the „AUTO- "AUTOCAL" LED tion must be less than 2.0s ("AP" appears on the COMP“ function. ter- lit The "OUTPUT" LED minal display during this blinks repeatedly when time and the three decimal the "AUTOCOMP" p function is executed and r the actual value output It may be necessary to compensate the phase O (terminals 17+18) is set points light up). The angle displacement to 0…3°C (i.e.approx. "AUTOCOMP" function " 0VDC). between the UR and IR only measuring signals in certain heatsealing applications ( ROPEX „AUTO“ takes around 2.0s ("AP" Application Report). The appears on the terminal "AUTOCOMP" function is

(as of software revision acti-vated automatically 102) after the "AUTOCAL" function has been successfully executed. With this setting the „AUTOCOMP“ function is Page 36 RES-408

Controller functions „ A „ J 0 t t

specifi ed Functi tole- on rance band when the AUTO "STA COM RT" P signal is activa ted, the tempe rature diagn osis is activa ted as well. If the ACTU AUTO AL CAL tempe rature leave s the tolera nce 0 band, the t corres pondi ng error code (307 or 308) is indica ted and „AUTOC the AL“ LED alarm relay lit is switch ed ( sectio If the n ACTU 11.21 AL "Error tempe mess rature ages" is on inside page the 40).

O „ t A S

in the ROPEX lit visualiz ation softwar e ( section OFF 11.19 "Diagn t ostic interfac e/ visualiz a-tion softwar e (as of June 2006)" on The page "OUTP 39) UT" LED blinks repeate (default dly setting: when AUTOC the OMP "AUTO off). COMP" function is execute d and the Temp actual eratur value e output diagn (termin osis als (as of 17+18) June is set to 0…3°C 2006) (i.e.app rox. 0VDC). An addition al The temper "AUTO ature COMP" diagnos functio is can n must be be activate d in the ! ROPEX acti- visualiz vated ation

softwar exceed e ( the section upper 11.19 or lower "Diagno tole- stic rance interfac band e/ limit), visualiz the ation corresp softwar onding e (as of error code (309, 310) is indicate d and the alarm relay is switche d. An addition al delay time (0..9.9s ) can be set in Ti the Alarm ROPEX me visualiz ation softwar e. The 307 first time the lower toleranc If the e band temper limit is ature exceed diagnos ed, the is is not temper activate ature d by the dia- time the gnosis "START is not " signal activate is d until deactiv the ated parame (i.e. if terized the delay ACTUA time L has temper elapsed ature . The does temper not ature

diagnos a-ture is drops function tempor can arily thus be owing selectiv to the ely closure deactiv of the ated, sealing e.g. if jaws. the temper RES-408 Page 37

out Heatup time Heatup timeout (as of June 2006) Alarm Time An additional heatup timeout can be activated in the ROPEX visualization software ( section 11.19 "Dia- gnostic interface / visualization software (as of June 2006)" on page 39). This timeout starts when the START signal is activated. The RES -408 then monitors the time required for the ACTUAL temperature to reach 95% of the SET tempe-rature. If this time is longer than the parameterized time, the corresponding error code 304 (304) is indicated and the alarm relay is switched ( section 11.21 "Error messages" on page 40). ACTUAL temp. Communication error between the controller and the terminal (as of June 2006) SET If a data communication error occurs between the T- 408 terminal and the RES-408 controller or if commu- nication is interrupted, the display on the terminal changes to indicate this (rotating segments). 95% of SET ROPEX T-408 SEALHEAT PREHEAT Time- HOLD ENTER HAND

Controller functions RESET A communication error can have the following causes: The controller and terminal are not compatible. The permissible device combinations are described in section 7 "Controller/terminal compatibility" on page 11. The connecting cable between the controller and the terminal is defective. The controller and/or terminal hardware is defective. ! Operation of the RES- 408 is not interrupted in the event of an error in communication. No error message appears and the fault relay is not active. In order to avoid malfunctions, the con- troller must be immediately switched off. Undervoltage detection (as of June 2006) Trouble-free operation of the temperature controller is guaranteed within the line voltage tolerance range specified in section 6 "Technical data" on page 9. If a line voltage which is less than the lower limit of the permissible range occurs, the controller is switched to a standby mode. No more heatsealing processes take place and no more measuring impulses are generated. The display changes to indicate this.. ROPEX T-408 SEALHEAT

PREHEAT Page 38 RES-408 HOLD ENTER HAND RESET The main menu is displayed again, and operation is resumed, when the input voltage returns to the speci- fied tolerance range. The standby mode is indicated by 0°C (corresponds to 0V) at the analog output. The alarm relay is de-ener- gized. ! Trouble-free operation of the controller is only guaranteed within the specified input voltage tolerance range. An external voltage mon- itor must be connected to prevent defective heatseals as a result of low line voltage.

Controller functions 6 Diagnostic interface / visualization software (as of June 2006) An interface with a 6-pole Western socket is provided for system diagnostics and process visualization. This interface allows a data connection to be set up to the ROPEX visualization software using the ROPEX CI- 5 USB-1 communication interface. 4 DIAG 8 9 0 1 ! Only a ROPEX communication interface is allowed to be connected to the diagnostic interface. Connecting another device (e.g. a tele- phone cable) could result in malfunctions or damage to the controller. 2 The ROPEX visualization software is described in a separate document. 3 System monitoring / alarm output 7

To increase operating safety and avoid faulty heatse- aling, this controller incorporates special hardware and software features that facilitate fault diagnosis and Blinking fast (4Hz) selective error messages. Both the external wiring and the internal system are monitored. The "AUTOCAL" function should be executed (error codes 104…106, 211, 302, 303). These features crucially support the system owner in Blinking slowly (1Hz) localizing the cause of an abnormal operating state. A system fault is reported or differentiated by means of the following indications: The system configuration is incorrect and the zero calibration (AUTOCAL function) was therefore unsuccessful ( section 10.2 "Controller configura- A.) Error message on the terminal display: tion" on page 20). This corresponds to error codes 111…114. ROPEX T-408 SEALHEAT Lit continuously: PREHEAT A fault is preventing the controller from being started up (error codes 101…103, 107, 108, 201…203, 307… 310, 801, 9xx). HOLD Also in instances 1 and 2 if the "START" signal is activated simultaneously. ENTER As a rule, this refers to an external wiring fault. HAND RESET C.) Alarm relay (relay contact terminals 12, 13, 14): The alarm relay is set in the factory as follows: The cause of a fault can be localized quickly and easily with the help of the error code that appears on the dis- DE-ENERGIZED in operating states B.1 and B.2, but energized if a "START" signal is activated in one of these states. ENERGIZED in operating state B.3. play. Please refer to section 11.21 "Error messages" on page 40 for a list of possible error codes. If the alarm relay is configured differently from the fac- tory setting ( section 10.2.3 "Configuration of the alarm relay" on page 21), these states are inverted. B.) Controllers manufactured as of June 2006: Red "ALARM" LED on the controller with three states:

D.) Controllers manufactured as of June 2006: Error code appears at the 0 to 10VDC actual value output (terminals 17+18): Since the temperature no longer needs to be indicated if a fault occurs, the actual value output is used to dis- play error codes in the event of an alarm. 13 voltage levels are offered for this purpose in the 0…10VDC range, each of which is assigned an error code ( section 11.21 "Error messages" on page 40). If a state that requires "AUTOCAL" occurs – or if the controller configuration is incorrect – (error codes 104…106, 111…114, 211, 302, 303), the actual value output jumps back and forth at 1Hz between the voltage value that corresponds to this error and the end of the scale (10VDC, i.e 300°C or 500°C). If the RES-408 Page 39

! Invalid error messages may appear when the controller is switched off owing to the unde-fined operating state. This must be taken into account when they are evaluated by the higher-level controller (e.g. a PLC) in order to avoid false "START" signal is activated in one of these states, the voltage value does not change any more. alarms. Selective fault detection and indication can thus be implemented simply and inexpensively using the analog input of a PLC with a corresponding error mes- sage ( section 11.21 "Error messages" on page 40). ! An alarm can only be reset by pressing the "RESET" key or by switching the controller off and then on again. The alarm is not reset until the key is released. ROPEX T-408 SEALHEAT PREHEAT HOLD ENTER HAND RESET

Controller functions Error messages The table below shows how the analog voltage values that appear at the actual value output are assigned to the faults that have occurred. It also describes each fault and the required corrective action. The error mes-sages are listed in two separate tables for controllers "up to May 2006" and "as of June 2006". The block dia-gram in section 11.22 "Fault areas and causes" on page 45 permits each fault to be cleared quickly and efficiently. 13 voltage levels for fault diagnostics appear at the actual value output of all controllers manufactured as of June 2006. The error messages are differentiated even more finely in the controller. The error codes described below can be displayed in the ROPEX visualization software ( section 11.19 "Diagnostic interface / visua-lization software (as of June 2006)" on page 39) to faci-litate troubleshooting. ! If the actual value output is evaluated in order to identify an error message - in the higher-level controller, for instance - the tolerance window must be adjusted to prevent it from being incor-rectly interpreted. Please note the tolerances of the actual value output ( section 6 "Technical data" on page 9). Page 40 RES-408

41 RES-408 P a rt 1 o f 3 : E rr o r m e s s a g e s a Page s o

f J u n e o 2 ut 0 p 0 ut 6 ; 3 0 0° C 5 0 0° C of al Error ar Act. value m re Temp. la y Temp. ALARM if STATUS m Cause a c Action hi n Action if machine e

st ar te d al re a d Voltage [V] y [°C] o p [°C] er at in g, (factory set.) for first time c HS band not chang. o d e 1 L E (1 D 0 1) 0. 6 6

20 33 IR si gn al mi ss in g 2 F au lt (102) ar ea 1.33 3  40 F 66 (1 au 0 lt 3) ar ea 2.  0 UR signal missing 0 Fault area  6 0 Fault area  1 0 0

U R (1 an 0 d 8) IR si gn al s mi ss in g F Te au m lt p ar er ea (107) at  ur e F st au e lt p, ar u ea p  (l  o Temperature step, down os e Fault area  co nt Fault area  ac t)

(l 2.66 o os 80 (3 e 0 133 9) co nt ac t) Lit (  se cti o (308) n 1 1. 1 5) Temperature too low/high 4 (3 1 (3 0) 0 7)

Fr e q u e nc y flu ct u ati o n, C h ec k C h ec k p o w er co 5 su nti p n- pl E (201) y ne 3.33 rgi ze 100 d 166 uously

(2 inadmissible line frequency 0 2) power supply (203) 6

(3 Run RESET 0 4) 4. 0 0 1 2 0 2 0 0 H ( section 11.16) ea tu p ti m e to o lo ng R un R E S E (9 T 0 1)

R e pl ac e co (913) nt ro lle Int r . R fa e ut, pl co ac ntr e . co de Triac defective nt fe ro cti Replace controller lle ve Replace controller r R ep la 7 ce co nt rol (9 (914) ler 1 5) R ep 4. la 6 ce 6 co nt 1 rol 4 ler 0 Int. faut, contr. defective

2 3 3 (916) Int . fa ut, co ntr . de Int. faut, contr. defective fe cti Replace controller ve Replace controller R ep la ce co nt rol ler R ep la ce (9 co 1 nt 7) rol ler

Pl output wrong ug -in plug-in jumper ju plug-in jumper m pe r fo r al ar m C he ck C he ck (9 1 8) Controller functions

P RES-408 3 a 0 g 0 e ° 4 Part 2 of 3: Error messages as of June 2006 C 2 5 0 NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values; alarm LED blinks; alarm 0 relay is de-energized). When the "START" signal is activated, the warning changes to a fault ° (actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is energized. C o f Error a l Act. value a r Temp. m Temp. r ALARM e l STATUS a y Cause Action i Action if machine f m a c h i n output; e

st ar te d al re a d Volt. [V] y [°C] o p [°C] er at in g, (factory set.) for first time c HS band not chang. o d e L E D ( 1 0 4 )

incorrect specification of IR si gn al s in R co u rr n ec t, A U T O C A L , impulse-transformer

Check specification U R si gn al s i in m co p rr u ec l t, s e - t r a n s Warning: f o incorrect specification of r (1 of transformer, m 05 e ) r

De-Energized W ar ni ng : B li n k s F au lt ar ea  

5.33 160 266 fast incorrect, U R an Fault area  d/ or IR si gn al s  10  300 8 500 (4Hz) (1 Fault: 06 ) incorrect specification of (loose contact) F a

ult : (voltage value E ne rgi ze d im p ul se - tr T a e ns m fo p r e m r er a t u r e t o o l o w ,

AUTOCAL wasn’t per- Lit f o at (302) r ac m tu e al d , l o o s contin- e value output c o n t a c t , R u n

A U T O C A L f a u l t a r e a  changes)  ambient temp. fluctuates  u o and/or us ly th e n n o lo n g er

AUTOCAL wasn’t per- (loose contact) te m pe ra tu re to o hi gh , formed, loose contact, (3 03 ) a m

bi 9 e nt te (211) m p. 6.00 flu ct 180 u at 300 es Data error Run AUTOCAL ---  10  300 500

Controller functions

4 3 RES-408 P a rt 3 o f 3 : E rr o r m e s s a g e s a s o f J u n Page e 2

0 l value output jumps back and forth between two values; alarm LED blinks; alarm relay is de-energized). When the "START" signal is activated, the warning changes to a fault 0 6 (actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm relay is energized). c o d N Error e O T Act. value E: Th Temp. e sp Temp. ec ALARM ifi L ed STATUS E er D ro Cause r m Action es sa Action if machine ge s ar e ini tia output; lly 300°C ou tp 500°C ut as V w ol ar of alarm relay t. ni [V ng ] s (a if machine started [° ct C ua already operating, ]

[° C] 1 0 (f ac to (1 ry 11 se ) t.)  6. 6 fo 6 r  fir st  ti 2 m 0 e 0  H S  b 3 a 3 n 3 d  n ot c h W a ar n ni g. n g: I si g n

al Warning: in co rr R ec t, check configuration F Bli au nks lt ar ea  , ---  1 1 (1 1 De-Energized 2) 10  calibration not possible  7.  3 30 3 0     2 50 2 0 0  

 3 6 6 10 1  2 sl 300 o 500 wl (1 y (1Hz) 1 F 3) Energized au  lt: calibration not possible 8. U check configuration 0 0 R  si gn  al 2 in 4 co 0 rr  ec t,  4 F 0 au 0 lt  ar ea F  a , ult : --- (voltage value U R

an at actual d IR si gn al s in v co al rr u ec e t, o ut F p au ut  lt ar 10  ea  300  500 , Lit --- calibration not possible check configuration

co nti n- 8.66 260 433  1 0 Temperature fluctuates,   3 0 0  13  5 0 th (114) 0 en  no lo ng ch er a n uously g es )

ca lib ra tio n no t po ss ibl e (C o nt ro lle r in LL LLL 0 0 0 OFF De-Energized Line voltage too low

(  K ap . 11 .1 8) 8 8 8 8 8 C o nt ro lle r o p er at e s st in an d db e y) p e

nd en tly of te r mi na l ( Kap. 11.17) C o m m un ic ati on segments) er ro r (r ot ati ng

Controller functions

44Page Error codes up to May 2006


Cause Action Action if machine

code of alarm relay

if machine started already operating, (factory setting)

for first time HS band not chang. 101 IR signal missing

Fault area  Fault area  102 UR signal missing Fault area  Fault area 

103 UR and IR signals missing Fault area  Fault areas 


Temperature step Fault areas  Fault areas  108 (loose contact) (loose contact)


201 Frequency fluctuation,


Check power supply Check power supply inadmissible line frequency



801 Internal fault Run RESET Run RESET

Internal fault, 408 9xx

Replace controller Replace controller controller defective

104 UR and/or IR signal

105 Run AUTOCAL Fault areas  106


AC De-energized,

211 will be energized with

Data error Run AUTOCAL ---

"START" signal

IR signal incorrect, Fault area , 111 (voltage value ---

at actual value output calibration not possible check configuration

then no longer Controller

U signal incorrect, Fault area , 112 changes)

R ---

check configuration calibration not possible

113 U R and I R signals incorrect, Fault areas , --- functions

check configuration

calibration not possible

Controller functions Fault areas and causes 6 Temperaturregler HARDWARE I2 UR U2 7 123 45 IR The table below explains the possible fault causes. Fault area Explanation Possible causes

Load circuit interrupted after UR - Wire break, heatsealing band break  pickoff point - Contacting to heatsealing band defective PEX-W2/-W3 current transformer - IR measuring wires from current transformer interrupted signal interrupted

Primary circuit interrupted - Wire break, triac in controller defective - Primary winding of impulse transformer interrupted  Secondary circuit interrupted - Wire break before UR pickoff point - Secondary winding of impulse transformer interrupted 

UR signal missing - Measuring wire interrupted  Partial short-circuit (delta R) - Heatsealing band partially bypassed by conducting part (clamp, opposite heatsealing bar etc.)  Parallel circuit interrupted - Wire break, heatsealing band break - Contacting to heatsealing band defective

- Heatsealing band installed incorrectly, insulation at heatse-  Total short-circuit aling bar ends missing or incorrectly installed - Conducting part bypasses heatsealing band completely - Up to May 2006: DIP switches 1 - 3 configured incorrectly 

UR signal incorrect (U2 range) - As of June 2006: U2 outside permissible range from 0.4…120VAC RES-408 Page 45

Factory settings Fault area Explanation Possible causes - Up to May 2006: DIP switches 4 + 5 configured incorrectly IR signal incorrect (I2 range) - As of June 2006: I2 outside permissible range from 

30…500A Turns through PEX-W2/-W3 cur- - Check number of turns (two or more turns required for rent transformer incorrect currents < 30A)  - Hardware fault (replace controller) Internal controller fault - Plug-in jumper for alarm output not connected or incorrectly

connected U2 and current I2 12 Factory settings ON 12345 The RES-408 RESISTRON temperature controller is configured in the factory as follows: (up to May 2006) DIP switches OFF for secondary voltage Rotary coding switch

1 for 9 0 1 4 heatsealing band alloy (as of June 2006) 8 2 5 and 3 8 SWITCH POS. 7 0 6 temperature range

0 5 4 9 1 9 0 1 4 8 2 5 Plug-in jumper for alarm relay 3 8 7 SWITCH POS.

U2 = 6…60VAC 6 5 I2 = 30…100A 4 DIP switches:2 ON 9 1, 3, 4, 5 OFF These switches are automatically set by the AUTORANGE function on all control- lers manufactured as of June 2006. Heatsealing band alloy: Alloy A20 Temperature range: 300°C Maximum temperature: 300°C Rotary coding switch: "0" position Relay closed by alarm Temperature unit (as of controller SW revision 106 AND terminal SW revision 103) Temperature unit: Celsius

Page 46 RES-408

Maintenance Automatic AUTOCOMP: OFF phase compensation (AUTOCOMP) [X] Measuring impulse Measuring impulse duration: 1.7ms duration [X] Temperature Temperature diagnosis: OFF diagnosis [X] Heatup Heatup timeout: OFF timeout

[X] [X] As of June 2006: Only in ROPEX visualization software 13 Maintenance The controller requires no special maintenance. the impulse transformer – is recommended. Dust Regular inspection and/or tightening of the terminals – depo-sits on the controller can be removed with dry including the terminals for the winding connections on com-pressed air.

RES-408 Page 47

How to order 14 How to order Controller RES - 408 / . . . V AC 115: Line voltage 115VAC, Art. No. 740841 230: Line voltage 230VAC, Art. No. 740842 400: Line voltage 400VAC, Art. No. 740843 Scope of supply: Controller includes connector plug-in parts (without terminal and current transformer) Terminal T-408-1 Art. No. 885441 Scope of supply: Terminal with fixing clips Sub-D connecting cable 2m: Art. No. 884202 5m: Art. No. 884205 10m: Art. No. 884210 Modification MOD . . (optional, if required) e.g. 01: MOD 01, Art. No. 800001 (amplifier for low voltage) 26: MOD 26, Art. No. 800026 (booster connection) Please indicate the article numbers of the controller and the required modifications in all orders, e.g. RES-408/400VAC + MOD 26

(controller for 400VAC power supply with booster connection) Art. Nos. 740843 + 800026 must be ordered Current transformer PEX-W3 Art. No. 885105 Line filter LF- . . 480 06: Continuous current 6A, 480VAC, Art. No. 885500 35: Continuous current 35A, 480VAC, Art. No. 885506 Impulse transformer See ROPEX Application Report for design and ordering information Communication interface CI-USB-1 Art. No. 885650

Page 48 RES-408

How to order Temperature meter ATR- . 3: 300°C range, Art. No. 882130 5: 500°C range, Art. No. 882150 Booster B- . . . 400 075: Max. pulse load 75A, 400VAC, Art. No. 885301 100: Max. pulse load 100A, 400VAC, Art. No. 885304 For more accessories: "Accessories" leaflet

RES-408 Page 49

Ambient temperature 10 Analog input 15 9 Index Analog output A 9 Analog temperature meter 6 Accessories Application 4 6 13, 16, 20 Application Report Actual value output 31 AUTOCAL 6, 23, 32 Alarm output 39 AUTOCOMP 36 Alarm relay 10, 21 Automatic phase compensation 36 Automatic zero calibration 6, 23, 32 AUTOTUNE 6 Alloy B 21, 23 Booster 7, 8, 49 Burning in heatsealing band 22, 23

Controls C 24 Celsius °C 7, 16, 48 35 Current transformer D Circuit breaker 15 CI-USB-1 7, 39, 48 Degree of protection 10 Diagnostic interface Communication error 39 38 7, 39, 48 Communication interface Digital temperature meter 6 Dimensions 12 Controller configuration 20

F DIP switches 20 Display 27 Factory settings 46 Fahrenheit °F E 35 Fault areas 45 Error messages 40 Fault diagnosis 6 External switching amplifier 7

Index H 23, 33 Heatsealing temperature 33 Heatup timeout HEAT 38 How to order 48 I Impulse heatsealing method 4 Heatsealing band type 9 Impulse transformer 7, 15, 48 Installation Page 50 10, 13 Installation procedure 13 Installation regulations 13

L 6, 15, 16, 48 Measuring impulse duration 36 Line filter Modifications 8, 18, 48 MODs 8, 18, 48 Line frequency 6, 9 Monitoring current transformer 7 Line voltage 9, 48 O Overheating of heatsealing band 6 M P PEX-W2/-W3 3 PEX-W3 16, 48 Maintenance Phase compensation 47 36 Power loss 10 Power supply Manual mode 15 31, 34

Startup "PREHEAT" signal 19 34 Preheating 34 Principle of operation System diagnostics 5 39 R System monitoring Replacing heatsealing band 22, 23 39 S T 3, 22 Secondary current I2 20 Secondary voltage U2 TCR 20 Set point selection 31 Standby mode 38 RES-408 "START" signal 23, 33

Index Temperature unit 35 Technical data Transformer 3, 7, 15, 48 9 Type of construction 3, 21 9 Temperature coefficient Temperature control 4 37, 38 U Temperature diagnosis Undervoltage detection 38 V Temperature indication 6, 31 View of the controller 19 Temperature meter Visualization software 32, 49 39 Temperature range W 9, 21 Wiring 13, 15 Temperature setting Wiring diagram 17 31

RES-408 Page 51

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