RESISTRON
GB
RES-409
Operating
instructions
Important features
• Microprocessor technology
• Complete control via CAN-Bus interface
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic frequency adjustment
• Large current and voltage range
• 0…10VDC analog output for ACTUAL temperature
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
9.7.04
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 . . . . . . . 3
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Warranty provisions . . . . . . . . . . . . . . . 4
1.7 Standards / CE marking . . . . . . . . . . . 4
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Principle of operation . . . . . . . . . . . . . . . . . 5
4 Description of the controller . . . . . . . . . . . 6
5 Accessories and modifications . . . . . . . . . 6
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6
5.2 Modifications (MODs) . . . . . . . . . . . . . 7
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 8
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.1 Installation procedure . . . . . . . . . . . . . 9
8.2 Installation steps . . . . . . . . . . . . . . . . 10
8.3 Power supply . . . . . . . . . . . . . . . . . . . 11
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12
8.5 Current transformer PEX-W2 . . . . . . 12
8.6 Wiring diagram (standard) . . . . . . . . . 13
8.7 Wiring diagram with booster connection
(MOD 26) . . . . . . . . . . . . . . . . . . . . . . 14
9 Startup and operation . . . . . . . . . . . . . . . . 15
9.1 View of the controller . . . . . . . . . . . . . 15
9.2 Controller configuration . . . . . . . . . . . 15
9.3 Heatsealing band . . . . . . . . . . . . . . . . 18
9.4 Startup procedure . . . . . . . . . . . . . . . 19
10 Controller functions . . . . . . . . . . . . . . . . . 20
10.1 Indicators and controls . . . . . . . . . . . 20
10.2 CAN protocol . . . . . . . . . . . . . . . . . . . 20
10.3 Receiving CAN messages . . . . . . . . . 21
10.4 Sending CAN messages . . . . . . . . . . 24
10.5 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 25
10.6 System monitoring/alarm output . . . . 27
10.7 Error messages . . . . . . . . . . . . . . . . . 27
10.8 Fault areas and causes . . . . . . . . . . . 29
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 30
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 30
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 31
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Page 2 RES-409
Safety and warning notes
1 Safety and warning notes
This RESISTRON temperature controller is
manufactured according to DIN EN 61010-1. In the
course of its manufacture it passed through quality
assurance, whereby it was subjected to extensive
inspections and tests.
It left the factory in perfect condition.
The recommendations and warning notes contained in
these operating instructions must be complied with, in
order to guarantee safe operation.
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational
safety. Installation and maintenance may only be
performed by technically trained, skilled persons who
are familiar with the associated risks and warranty
provisions.
1.1 Use
RESISTRON temperature controllers may only be used
for heating and temperature control of heatsealing
bands which are expressly suitable for them, and
providing the regulations, notes and warnings
contained in these instructions are complied with.
In case of non-compliance or use contrary to
!
the intended purpose, there is a risk that
safety will be impaired or that the heatsealing band,
electrical wiring, transformer etc. will overheat.
Ensuring such compliance is the personal
responsibility of the user.
The RESISTRON temperature controller must be set
and coded according to the temperature coefficient of
the heatsealing band.
The use of incorrect alloys with too low a
!
temperature coefficient and incorrect coding
of the RESISTRON temperature controller leads to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!
The heatsealing bands that were originally supplied
must be identified by their detailed specification, part
number or some other means to ensure that all
replacement bands are identical.
1.3 Impulse transformer
A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one-section bobbin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.
Incorrect installation of the impulse
!
transformer impairs electrical safety.
1.2 Heatsealing band
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands.
The resistance of the heatsealing band which
!
is used must have a positive minimum
temperature coefficient in order to guarantee
trouble-free operation of the RESISTRON
temperature controller.
The temperature coefficient must be specified as
follows:
TCR 104–×10 K
≥
e.g. Alloy-20: TCR = 1100 ppm/K
NOREX: TCR = 3500 ppm/K
1–
RES-409 Page 3
1.4 Current transformer PEX-W2
The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W2 current
!
transformer may be used. Other transformers
may cause the equipment to malfunction.
The current transformer may only be operated if it is
connected to the RESISTRON temperature controller
correctly (see section 9, "Startup and operation"). The
relevant safety instructions contained in section 8.3,
"Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
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
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)
according 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.
Page 4 RES-409
The controller is most commonly used for impulseheatsealing PE films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
•etc.
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 high
secondary current can be controlled because power is
controlled on the primary side of the transformer. This
• Increased machine capacity
• Extended life of the heatsealing bands and teflon
coatings
• Simple operation and control of the sealing process
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 and interrelated.
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-409 Page 5
Indicators
and
controls
or
bus interface
4 Description of the controller
Description of the controller
The microprocessor technology endows the
RESISTRON temperature controller RES-409 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 secondary voltage range from 1 V
to 120V is covered with only 3 DIP switches, with
2 DIP switches for the current range from 30 A to
400A.
• 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 RESISTRON temperature controller RES-409 is
equipped with a CAN-Bus interface. This interface can
be used to control all the controller functions and
interrogate controller information.
The ACTUAL temperature of the heatsealing band is
supplied to the CAN-Bus interface and to an analog
0 to 10V DC output. The real heatsealing band
temperature can thus be displayed on an external
temperature meter (e.g. ATR-x).
The RES-409 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 CAN-Bus signals are electrically isolated
from the controller and the heating circuit.
Either coding switches on the temperature controller
itself or the CAN-Bus interface 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.).
The compact design of the RESISTRON temperature
controller RES-409 and the plug-in connections make
this controller easy to install.
5 Accessories and modifications
A wide range of compatible accessories and peripheral
devices are available for the RESISTRON temperature
controller RES-409. 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 LF-xx480
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-409
Accessories and modifications
Impulse transformer ITR-x
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).
Booster B-xxx400
External switching amplifier, necessary for high primary currents (continuous
current > 5 A, pulsed current > 25 A).
Monitoring current transformer MSW-1
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2 current transformer.
5.2 Modifications (MODs)
Owing to its universal design, the RESISTRON
temperature controller RES-409 is suitable for a very
wide range of heatsealing applications.
Two modifications (MOD) are available for the
RESISTRON temperature controller RES-409 for
implementing special applications.
MOD 01
Amplifier for low secondary voltages
(U
= 0.25…16VAC). 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).
RES-409 Page 7
6 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35mm) acc. to DIN EN 50022
Dimensions: 90 x 75 mm; height: 135mm (incl. terminals)
Line voltage All controllers manufactured as of January 2004:
115VAC version: 115VAC -15 %…120VAC +10% (equivalent to 98…132 VAC)
230VAC version: 230VAC -15 %…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15 %…415VAC +10% (equivalent to 340…456VAC)
All controllers manufactured up to December 2003:
115VAC, 230 VAC or 400VAC, tolerance: +10% / -15 %
depending on device version (ª section 13 "How to order" on page 31)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
CAN interface Baud rates: 10kBaud; 50 kBaud; 125kBaud; 205 kBaud;
250kBaud; 500 kBaud; 800kBaud; 1 MBaud
2 x 3-pole M8 circular connector acc. to IEC 947-5-2
Technical data
Heatsealing band
type and temperature
range
Six ranges selectable via the CAN interface:
Temperature coefficient 1100ppm, 0…200°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…400°C (e.g. Alloy A20)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 3500ppm, 0…200 °C (e.g. NOREX)
Temperature coefficient 3500ppm, 0…300 °C (e.g. NOREX)
Analog output
(actual value)
0…10V DC, Imax = 5 mA
Equivalent to 0…300 °C or 0…500°C
Terminals 17+18
Alarm relay
U
max
=50VDC, I
= 0.2A, changeover contact, potential-free
max
Terminals 12, 13, 14
Maximum load
(primary current of
= 5A (duty cycle = 100%)
I
max
= 25A (duty cycle = 20 %)
I
max
impulse
transformer)
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.
Weight Approx. 0.7 kg (incl. connector plug-in parts)
Page 8 RES-409
Dimensions
Housing material Plastic, UL-94-1, self-extinguishing
Connecting cables
Type / cross-sections
7 Dimensions
Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors
135.0
113.0
75.0 90.0
8 Installation
ª See also section 1 "Safety and warning notes" on
page 3.
Installation and startup may only be
!
performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON
temperature controller RES-409:
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 8 must be allowed between them.
RES-409 Page 9
Installation
4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 11,
section 8.6 "Wiring diagram (standard)" on page 13
and the ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 10 must be heeded additionally.
5. Connect the RESISTRON temperature controller to
the CAN master using a cable according to
IEC 947-5-2.
8.2 Installation steps
Use heatseal bands with
Heatseal element
with coppered ends
suitable temperature coefficient
Heatsealing band R= f (T)
Check the tightness of all the system
!
connections, including the terminals for the
impulse transformer windings.
6. Make sure that the wiring conforms to the relevant
national and international installation regulations.
No
push-on
connectors
Sufficient wire
cross-section
Avoid long
cables
Dimension
transformer correctly
- Secondary voltage
- Power
- Duty cycle
F
U (sec.)
2
No additional
resistance
in secondary
circuit
A
Impulse
transformer
Note
number
of turns
Current transformer
U (prim.)
1
20mm clearance if several
controllers installed on
PEX-W2
Temperature
meter
ATR -x
Note
polarity
one top hat rail
Controller
Connect U measuring
heatsealing band ends
Twi sted
Current measuring
R
wires directly to
wires I
R
Line
Line filter
LF-xx480
Note
direction
of rotation
Digital
potentiometer
PD-x
Configure
DIP switches
correctly
Page 10 RES-409
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