Ropex RESISTRON RES-408 Operating Instruction
RESISTRON
GB
RES-408
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)
26.6.06
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
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) . . . . . . . . . . . . . 8
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
7 Controller/terminal compatibility . . . . . . . 11
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 12
9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.1 Installation procedure . . . . . . . . . . . . 13
9.2 Installation steps . . . . . . . . . . . . . . . . 14
9.3 Power supply . . . . . . . . . . . . . . . . . . . 15
9.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 16
9.5 Current transformer PEX-W3 . . . . . . 16
9.6 Wiring diagram (standard) . . . . . . . . . 17
9.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 18
11 Controller functions . . . . . . . . . . . . . . . . . 24
11.1 Indicators and controls . . . . . . . . . . . 24
11.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 27
11.3 Navigation in the menus . . . . . . . . . . 27
11.4 Menu structure . . . . . . . . . . . . . . . . . . 28
11.5 Menu steps . . . . . . . . . . . . . . . . . . . . 29
11.6 Temperature setting
(set point selection) . . . . . . . . . . . . . . 31
11.7 Temperature indication / actual value
output . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.8 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 32
11.9 Heating to the heatsealing
temperature (HEAT) . . . . . . . . . . . . . 33
11.10 "PREHEAT" signal . . . . . . . . . . . . . . . 34
11.11 Hold mode . . . . . . . . . . . . . . . . . . . . . 34
11.12 Measuring impulse duration (as of
June 2006) . . . . . . . . . . . . . . . . . . . . . 35
11.13 Automatic phase compensation (AUTO-
COMP) (as of June 2006) . . . . . . . . . 35
11.14 Temperature diagnosis
(as of June 2006) . . . . . . . . . . . . . . . . 36
11.15 Heatup timeout
(as of June 2006) . . . . . . . . . . . . . . . . 37
11.16 Diagnostic interface / visualization soft-
ware (as of June 2006) . . . . . . . . . . . 37
11.17 System monitoring / alarm output . . . 37
11.18 Error messages . . . . . . . . . . . . . . . . . 38
11.19 Fault areas and causes . . . . . . . . . . . 43
10 Startup and operation . . . . . . . . . . . . . . . . 19
10.1 View of the controller . . . . . . . . . . . . . 19
10.2 Controller configuration . . . . . . . . . . . 20
10.3 Heatsealing band . . . . . . . . . . . . . . . 21
10.4 Startup procedure . . . . . . . . . . . . . . . 22
Page 2 RES-408
12 Factory settings . . . . . . . . . . . . . . . . . . . . . 44
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 45
14 How to order . . . . . . . . . . . . . . . . . . . . . . . . 46
15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Safety and warning notes
1 Safety and warning notes
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 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.
The RESISTRON-Temperaturreglers 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-Temperaturreglers lead to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by detail specification, part number
or some other means that will assure that replacement
bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced insulation) and have a one section bobin. When the impulse
transformer is installed, suitable shock protection must
be provided in accordance with the national installation
regulations for electrical equipment. In addition, water,
cleaning solutions and conductive fluids must be prevented from seeping into the transformer.
Incorrect installation of the impulse trans-
!
former impairs electrical safety.
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 troublefree operation of the RESISTRON-Temperaturregler.
The temperature coefficient must be specified as follows:
TCR 104–×10 K
≥
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
1–
RES-408 Page 3
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-Temperaturregler 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
operating safety. They are not included in the scope of
Application
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:
DIN EN 61010-1
(VDE 0411-1)
DIN EN 60204-1 Electrical equipment of machines
EN 50081-1 EMC interference emissions accor-
EN 50082-2 EMC interference immunity:
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.
Safety provisions for electrical
measuring, control and laboratory
devices (low voltage directive).
Overvoltage category III, pollution
severity 2, safety class II.
(machinery directive)
ding to EN 55011, group 1, class B
ESDs, RF radiation, bursts, surges.
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 impulseheatsealing PE and PP films in:
• Vertical and horizontal f/f/s machines
Page 4 RES-408
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•L-sealers
•etc.
Principle of operation
The use of RESISTRON temperature controllers
results in:
• Repeatable quality of the heatseals under any conditions
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
• Increased machine capacity
• Extended life of the heatsealing bands and teflon
coatings
• Simple operation and control of the sealing process
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 controllers play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Heatsealing band R = f (T)
U
2
sec.
Impulse transformer
Current
transformer
U
1
prim.
RESISTRON controller
URI
R
R=f(T)
LINE
_
+
Actual value
Start
Set point
RES-408 Page 5
Indicators
and
controls
or
bus interface
4 Description of the controller
Description of the controller
The microprocessor technology endows the RES-408
RESISTRON temperature controller 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
June 2006) covers a secondary voltage range from
0.4V to 120 V and a current range from 30 A to
500A.
• Automatic adjustment to the line frequency in the
range from 47 Hz to 63Hz.
• Increased protection against dangerous conditions,
such as overheating of the heatsealing band.
The temperature can be set on the separate T-408-1
(or T-400) operator terminal.
The real heatsealing band temperature is also visualized on the operator terminal.
The RES-408 RESISTRON temperature controller 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 24 VDC logic signals are electrically isolated
from the controller and the heating circuit.
Coding switches on the temperature controller itself
can be used to adapt to different heatsealing band
alloys (Alloy 20, NOREX etc.) and set the required temperature range (0...300 °C, 0...500°C etc.) on all controllers manufactured as of June 2006.
The compact design of the RES-408 RESISTRON temperature controller 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 RES-408 RESISTRON
temperature controller. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.
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.
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).
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
(ª 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 displaying setting and configuration data, and for recording SET and ACTUAL temperatures 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
5.2 Modifications (MODs)
Owing to its universal design, the RES-408 RESISTRON temperature controller is suitable for a very wide
range of heatsealing applications.
Various modifications (MODs) are offered for the
RES-408 RESISTRON temperature controller for
implementing special applications.
The modifications described here are just a few of the
large number available. Separate documentation is
supplied for all modifications.
MOD 37 (up to May 2006)
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.
MOD 01
Amplifier for low secondary voltages
(U
= 0.25…16 VAC). This modification is necessary,
R
for example, for very short or low-resistance heatsealing bands.
MOD 26
Additional terminal for connecting an external switching
amplifier (booster). This modification is necessary for
high primary currents (continuous current > 5 A, pulsed
current > 25A).
This modification is supplied as standard
!
with all controllers manufactured as of
June 2006 (ªªªª section 10.2.2 "Configuration of the
rotary coding switch for the temperature range and
alloy (as of June 2006)" on page 21).
Switch
position
0
1
4
5
8
Te mp .
range
300°C
300°C
500°C
500°C
300°C
0 = Factory settings
Te mp .
coefficient
1100ppm/K
780ppm/K
1100ppm/K
780ppm/K
3500ppm/K
Band
alloy
e.g. Alloy-20
e.g. Alloy L
e.g. Alloy-20
e.g. Alloy L
e.g. NOREX
0
1
9
2
8
3
7
4
6
5
0
1
9
8
7
4
6
5
SWITCH POS.
2
3
0
1
4
5
8
TEMP. RANGE
300°C
300°C
500°C
500°C
300°C
ALLOY
1100ppm/K
1100ppm/K (A20)
3500ppm/K
780ppm/K
780ppm/K
(A20)
(L)
(L)
(NOREX)
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 75 mm; height: 135 mm (incl. terminals)
Terminal: Housing for installation in the electrical cabinet
Dimensions (W x H): 96 x 48 mm; depth: 55 mm (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…264 VAC)
400VAC version: 380VAC -15 %…415VAC +10% (equivalent to 323…456 VAC)
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…264 VAC)
400VAC version: 400VAC -15 %…415VAC +10% (equivalent to 340…456 VAC)
Controllers manufactured up to December 2003:
115VAC, 230 VAC or 400VAC, tolerance: +10% / -15 %
depending on device version (ª section 14 "How to order" on page 46)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band
type and temperature
range
Controllers manufactured as of June 2006:
The temperature range and temperature coefficient settings can also be specified
in the ROPEX visualization software (ª section 11.16 "Diagnostic interface /
visualization software (as of June 2006)" on page 37) in addition to using the
rotary coding switch (see below):
Temperature range: 200 °C, 300°C, 400 °C or 500°C
Temperature coefficient: 400…4000 ppm (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 780 ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780 ppm, 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
(actual value)
Terminals 17+18
Digital logic levels
Terminals 5+7
0…10VDC, I
Equivalent to 0…300 °C or 0…500°C
Accuracy: ±1 % plus 50 mV
LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30V DC (max. current input 6mA)
Reverse polarity-protected
max
=5mA
RES-408 Page 9
Technical data
Alarm relay
Terminals 12, 13, 14
Maximum load
(primary current of
U
=50VDC, I
max
= 0.2A, changeover contact, potential-free
max
Can be inverted by means of a plug-in jumper
I
= 5A (duty cycle = 100%)
max
I
= 25A (duty cycle = 20 %)
max
impulse transformer)
Power loss max. 22W
Ambient
+5…+45°C
temperature
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 mounting on a vertical top hat rail.
Weight Controller: Approx. 0.7 kg (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 connecting cables
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
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
All RES-408 RESISTRON temperature controllers
manufactured as of June 2006 are supplied as an
upgraded version.
Among other things, the data transfer between the controller and the terminal has been modified. These
changes were necessitated by the new European
RoHS/WEEE Directives. Lead has now been banned
from some of the electronic components used in our
products.
As a result, all RES-408 controllers manufac-
!
tured up to May 2006 can only be operated
with a T-400 terminal. Controllers manufactured as
of June 2006 can only be operated with a T-408-1.
Malfunctions or damage may otherwise occur.
This has no effect on temperature control or on the
external PLC control signals.
RES-408 controllers manufactured as of
!
June 2006 are fully electrically compatible
with the old version (as far as the PLC control
signals are concerned).
Please pay attention to the controller and terminal versions when ordering spare parts. The controller may
have to be exchanged together with the terminal. Refer
to the compatibility table below:
New version (as of June 2006):
Controller type Art. No. Compatible with
RES-408/115VAC 740841
RES-408/230VAC 740842
RES-408/400VAC 740843
Terminal T-408-1
Art. No. 885441
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
RES-408-0-3/400VAC 740803 or 740833
RES-408-0-5/xxxVAC 740805, 740806, 740807, 740835, 740836 or 740837
RES-408-1-x/xxxVAC 740811, 740812, 740813, 740815, 740816 or 740817
Terminal T-400
Art. No. 885440
RES-408 Page 11
8 Dimensions
RES-408 controller
Dimensions
135.0
113.0
75.0 90.0
T-400 or T-408-1 terminal
panel cutout
+0.8
- 0 - 0
92 x 45
+0.6
96.0
90.0
front panel
o 5mm
48.0
42.0
outline dimensions front frame
Page 12 RES-408
9.0 55.0
56.0
Installation
9 Installation
ª See also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be per-
!
formed by technically trained, skilled persons who are familiar with the associated risks and
warranty provisions.
9.1 Installation procedure
Proceed as follows to install the RES-408 RESISTRON
temperature controller:
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 47 Hz to 63Hz.
3. Install the RESISTRON temperature controller in
the electrical cabinet on a standard top hat rail (DIN
TS35 rail according to DIN EN 50022). If several
controllers are installed on one top hat rail, the
minimum clearance specified in section 6 "Technical
data" on page 9 must be allowed between them.
4. Install the terminal in the front panel cutout. It is
fastened by means of four clips which snap onto the
side of the terminal housing.
5. Connect the controller and terminal together with
the cable provided for this purpose.
Controllers manufactured up to May 2006 are
!
only allowed to be operated with a T-400 terminal. Controllers manufactured as of June 2006
can only be operated with a T-408-1. Malfunctions
or damage may otherwise occur (ªªªª section 7 "Controller/terminal compatibility" on page 11).
6. Wire the system in accordance with the instructions
in section 9.3 "Power supply" on page 15 and the
ROPEX Application Report. The information provided in section 9.2 "Installation steps" on page 14
must be heeded additionally.
Check the tightness of all system connec-
!
tions, including the terminals for the impulse
transformer winding wires.
7. Make sure that the wiring conforms to the relevant
national and international installation regulations.
RES-408 Page 13
9.2 Installation steps
Installation
Heatseal element
with coppered ends
Sufficient wire
cross-section
Avoid long
cables
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
F
U (sec.)
2
Heatsealing band R= f (T)
No additional
resistance
in secondary
circuit
A
Impulse
transformer
Use heatseal bands with
suitable temperature coefficient
Note
number
of turns
Current transformer
U (prim.)
1
20mm clearance if several
controllers installed on
PEX-W2/-W3
Temperature
meter
ATR -x
Note
polarity
one top hat rail
Controller
No
push-on
connectors
Connect U measuring
heatsealing band ends
Twi sted
Current measuring
R
wires directly to
wires I
R
Line
Line filter
LF-xx480
Termin al
Configure
DIP switches
correctly
(up to May 2006)
Page 14 RES-408
Installation
9.3 Power supply
L1
(L1)
N(L2)
GND/
Earth
ON
OFF
Short wires
1
LINE
Ka
U
K1
I
2
R
R
I
>
3
LINE
FILTER
ROPEX
temperature
controller
U
1
PRIM.
U
2
SEC.
R
Line
115VAC, 230 VAC, 400VAC
Circuit breaker
Double-pole, C characteristic
(ª ROPEX Application Report)
I
>
3
Kb
3
2
Short-circuit protection only.
!
RESISTRON-Temperaturreglers 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
(ª ROPEX Application Report).
Do not run the filter supply wires (line side) parallel
!
to the filter output wires (load side).
RESISTRON-Temperaturregler belonging to the 4xx
Series.
Relay Kb
Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.
When using a series resistor RV-....-1 the relay Kb
!
shall be installed.
Impulse Transformer
Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.
Use transformers with a one section bobbin. The
!
power, duty cycle and voltage values must be deter-
mined individually according to the application (ª ROPEX
Application Report and "Accessories" leaflet for impulse
transformers).
Wiring
The wire cross-sections depend on the application
(ª ROPEX Application Report).
Guide values:
Primary circuit: min. 1.5mm², max. 2.5 mm²
Secondary circuit: min. 4.0 mm², max. 25 mm²
c These wires must always be twisted (>20/m)
d These wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
e Twisting (>20/m) is recommended to improve EMC.
RES-408 Page 15
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