Toss ROPEX RESISTRON RES-407 Operating Instructions Manual

RESISTRON

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www.tossheatseal.com

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www.tossheatseal.com

GB

RES-407

Operating

Instructions

Important features

• Microprocessor technology

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)

• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of April 2005)

• Automatic phase angle compensation (AUTOCOMP, as of April 2005)

• Automatic frequency adjustment

• Large current and voltage range

• Electrically isolated analog input for set point selection with potentiometer or 0…10 VDC

• Electrically isolated 0…10VDC analog output for ACTUAL temperature

• 24VDC control signals for START, AUTOCAL and RESET with electrical isolation

• Alarm function with fault diagnosis

• Heatsealing band alloy and temperature range selectable as standard (as of June 2003)

19.11.07

Toss Machine Components, Inc.

Toss Machine Components, Inc.
539 S. Main Street, Nazareth. PA 18064

539 S. Main Street, Nazareth. PA 18064
Phone [phone] Fax [phone]

Phone [phone] Fax [phone]

E-Mail: [e-mail]

E-Mail: [e-mail]

Contents

1 Safety and warning notes . . . . . . . . . . . . . . 3

1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Heatsealing band . . . . . . . . . . . . . . . . 3

1.3 Impulse transformer . . . . . . . . . . . . . . 3

1.4 Current transformer PEX-W2/-W3 . . . . 3

1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4

1.6 Warranty provisions . . . . . . . . . . . . . . . 4

1.7 Standards / CE marking . . . . . . . . . . . 4

2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Principle of operation . . . . . . . . . . . . . . . . . 5

4 Description of the controller . . . . . . . . . . . 6

5 Accessories and modifications . . . . . . . . . 6

5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 6

5.2 Modifications (MODs) . . . . . . . . . . . . . 7

6 Technical data . . . . . . . . . . . . . . . . . . . . . . 10

7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 12

8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 12

8.1 Installation procedure . . . . . . . . . . . . 12

8.2 Installation steps . . . . . . . . . . . . . . . . 13

8.3 Power supply . . . . . . . . . . . . . . . . . . . 14

8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 15

8.5 Current transformer PEX-W3 . . . . . . 15

8.6 Auxiliary voltage . . . . . . . . . . . . . . . . 16

8.7 Wiring diagram (standard) . . . . . . . . . 16

8.8 Wiring diagram with booster

connection (MOD 26) . . . . . . . . . . . . 17

8.9 Wiring diagram with "Temp­erature reached" signal (MOD 40)

or „Temp. OK“ signal (MOD 46) . . . . 18

9 Startup and operation . . . . . . . . . . . . . . . . 19

9.1 View of the controller . . . . . . . . . . . . . 19

9.2 Controller configuration . . . . . . . . . . . 19

9.3 Heatsealing band . . . . . . . . . . . . . . . . 21

9.4 Startup procedure . . . . . . . . . . . . . . . 22

10 Controller functions . . . . . . . . . . . . . . . . . 24

10.1 Indicators and controls . . . . . . . . . . . 24

10.2 Temperature setting

(set point selection) . . . . . . . . . . . . . . 25

10.3 Temperature indication (actual value

output) . . . . . . . . . . . . . . . . . . . . . . . . 26

10.4 Automatic zero calibration

(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 27

10.5 "START" signal (HEAT) . . . . . . . . . . . 28

10.6 "RESET" signal . . . . . . . . . . . . . . . . . 28

10.7 Measuring impulse duration

(as of April 2005) . . . . . . . . . . . . . . . . 29

10.8 Automatic phase angle
compensation (AUTOCOMP)

(as of April 2005) . . . . . . . . . . . . . . . . 29

10.9 Temperature diagnosis

(as of April 2005) . . . . . . . . . . . . . . . . 30

10.10 Heatup timeout

(as of April 2005) . . . . . . . . . . . . . . . . 31

10.11 Diagnostic interface/visualization software

(as of April 2005) . . . . . . . . . . . . . . . . 31

10.12 System monitoring/alarm output . . . . 31

10.13 Error messages . . . . . . . . . . . . . . . . . 32

10.14 Fault areas and causes . . . . . . . . . . . 37

11 Factory settings . . . . . . . . . . . . . . . . . . . . . 38

12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 39

13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 40

14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Page 2 RES-407

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 a too low

!

temperature coefficient and incorrect coding
of the RESISTRON temperature controller lead to
uncontrolled heating and ultimately to burn-out of
the heatsealing band!

The heatsealing bands that were originally supplied
must be identified by detail specification, part number
or some other means that will assure that replacement
bands are identical.

1.3 Impulse transformer

A suitable impulse transformer is necessary to ensure
that the control loop functions perfectly. This
transformer must be designed according to VDE 0570/
EN 61558 (isolating transformer with reinforced
insulation) and have a one section bobbin. When the
impulse transformer is installed, suitable shock
protection must be provided in accordance with the
national installation regulations for electrical
equipment. In addition, water, cleaning solutions and
conductive fluids must be prevented from seeping into
the transformer.

Incorrect installation of the impulse

!

transformer impairs electrical safety.

1.2 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-407 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 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

Application

operating safety. They are not included in the scope of
supply of the standard control system and are
described in a separate document.

1.5 Line filter

The use of an original ROPEX line filter is mandatory in
order to comply with the standards and provisions
mentioned in section 1.7 "Standards / CE marking" on
page 4. This device must be installed and connected
according to the instructions contained in section 8.3,
"Power supply" as well as the separate documentation
enclosed with the line filter.

1.6 Warranty provisions

The statutory provisions for warranties apply for a
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory.
Devices that have been damaged due to faulty
connections, dropping, electrical overloading, natural
wear, incorrect or negligent handling, chemical
influences or mechanical overloading as well as
devices that have been modified, relabeled or
otherwise altered by the customer, for example in an
attempt to repair them or install additional components,
are excluded from the warranty.
Warranty claims must be examined in the factory and
approved by ROPEX.

1.7 Standards / CE marking

The controller described here complies with the
following standards, provisions and directives:

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-407

The controller is most commonly used for impulse­heatsealing PE and PP films in:

• Vertical and horizontal f/f/s machines

• Pouch, filling and sealing machines

• Film wrapping machines

• Pouch-making machines

• Group packaging machines

•L-sealers

Principle of operation

•etc.

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 controller play a significant
role in enhancing the performance of modern
machines. However, the full benefit can only be
obtained from the advanced technology offered by this
control system if all the system components, in other
words the heatsealing band, the impulse transformer,
the wiring, the timing signals and the controller itself,
are compatible with one another.

We will be pleased to

contribute our many

years of experience

towards optimizing your

heatsealing system.

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-407 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-407 with
previously unattainable capabilities:

• Very simple operation thanks to AUTOCAL, the
automatic zero calibration function.

• Good dynamic response of the control system
thanks to AUTOTUNE, which adapts automatically
to the controlled system.

• High precision thanks to further improved control
accuracy and linearization of the heatsealing band
characteristic.

• High flexibility: The AUTORANGE function (as of
April 2005) covers a secondary voltage range from

0.4V to 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 electrically isolated analog interfaces for the
temperature set point and the actual temperature
(0-10VDC) allow the temperature to be set either

directly on the machine PLC or by means of an external
potentiometer (PD-x).
Similarly, the real heatsealing band temperature can be
visualized either on the display of the machine PLC or
on an external temperature meter (ATR-x).
The RESISTRON temperature controller RES-407
features an integrated fault diagnosis function, which
tests both the external system (heatsealing band,
wiring etc.) and the internal electronics and outputs a
selective error message in case of a fault.
To increase operational safety and interference
immunity, all 24VDC logic signals are electrically
isolated from the controller and the heating circuit.
Coding switches on the temperature controller itself
can be used to adapt to different heatsealing band
alloys (Alloy A20, NOREX etc.) and set the required
temperature range (0...300 °C, 0...500°C etc.) on all
controllers manufactured as of June 2003.
An external 24VDC auxiliary voltage is required to
supply the isolating amplifiers and optocouplers. The
compact design of the RESISTRON temperature
controller RES-407 and the plug-in connections make
this controller easy to install.

5 Accessories and modifications

A wide range of compatible accessories and peripheral
devices are available for the RESISTRON temperature
controller RES-407. They allow it to be optimally
adapted to your specific heatsealing application and to
your plant's design and operating philosophy.

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.

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-407

Accessories and modifications

Designed according to VDE 0570/EN 61558 with a one-section bobbin.

Set point potentiometer PD-x

Front panel-mounting version for setting the required SET heatsealing temperature
of the RESISTRON temperature controller. The number which appears on the
display corresponds to the SET heatsealing temperature in °C.

Line filter

Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.

Impulse transformer

Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
(ª ROPEX Application Report).

Communication interface CI-USB-1

Interface for connecting a RESISTRON temperature controller with 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).

Monitoring current transformer

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

5.2 Modifications (MODs)

Owing to its universal design, the RESISTRON
temperature controller RES-407 is suitable for a very
wide range of heatsealing applications.
Various modifications (MODs) are offered for the
RESISTRON temperature controller RES-407 for
implementing special applications.

The modifications described here are just a few of the
large number available. Separate documents are
supplied for all modifications.

MOD 01

Amplifier for low secondary voltages

= 0.25…16VAC). This modification is necessary,

(U

R

for example, for very short or low-resistance
heatsealing bands.

RES-407 Page 7

Accessories and modifications

MOD 21

Inverts the alarm signal (terminal 18). If an alarm is
signaled, the alarm output is switched to open condition
(LOW). If the controller does not report an alarm, a
24VDC voltage level (HIGH) is output at terminal 18.

MOD 26

Additional terminal for connecting an external switching
amplifier (booster). This modification is necessary for
high primary currents (continuous current > 5 A, pulsed
current > 25A).

Switch

position

0
1
4
5
8

0 = Factory settings

Te mp .

range

300°C
300°C
500°C
500°C
300°C

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

MOD 37 (until May 2003)

Additional rotary coding switch for the heatsealing band
alloy and the temperature range. Various heatsealing
band alloys (e.g. Alloy-20, NOREX) and temperature
ranges (e.g. 300 °C, 500°C) can be selected.

This modification is supplied as standard

!

with all controllers manufactured as of June

2003 (ªªªª section 9.2.2 "Configuration of the rotary
coding switch for the temperature range and alloy
(as of June 2003)" on page 20).

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)

MOD 40

Additional terminal for "Temperature reached" signal.
This output signal is activated when the ACTUAL
temperature of the heatsealing band exceeds 95 % of
the SET heatsealing temperature. It can be used to

monitor the process, for example, or to control the
closure of the heatsealing bars.

MOD 40 cannot be used in combination with

!

MOD 26 (booster connection) manufactured

prior to March 2005.

Page 8 RES-407

Accessories and modifications

MOD 46 (as of April 2005)

Additional terminal for "Temperature OK" signal. If this
modification is installed, the RES-407 checks whether
the ACTUAL temperature is within a settable tolerance
band ("OK" window) on either side of the SET
temperature. The lower ( ) and upper
( ) tolerance band limits are configured in the

∆ϑ

upper

factory to -10 K and +10 K. These values can be set
independently of one another in the ROPEX
visualization software (ª section 10.11 "Diagnostic
interface/visualization software (as of April 2005)" on
page 31).
If the actual temperature is inside the specified
tolerance band when the "START" signal is activated,
the output signal is activated as well (see graph below):

Set+∆ϑ

upper

Set

Set+∆ϑ

lower

∆ϑ

lower

Actual value

If the actual temperature leaves the tolerance band, the
output signal is deactivated again. The output signal
then remains deactivated, even if the actual tempera­ture subsequently returns to the tolerance band.
It is thus possible to check - as part of the monitoring
concept, for instance - whether the output signal is still
active at the end of the heatsealing process, in other
words whether the actual temperature has remained
within the defined tolerance band throughout the entire
process.
The output signal is not deactivated again until the next
"START" signal is activated or until an alarm is
signaled.

MOD 46 ("Temperature OK" signal) cannot be

!

used in combination with MOD 40

("Temperature reached" signal).

Signal
„Temp. OK“

Conductive

Not conduct.

Time

Time

RES-407 Page 9

6 Technical data

Type of construction Housing for installation in the electrical cabinet

Snaps onto a standard top hat rail (DIN TS35 rail, 35mm) acc. to DIN EN 50022
Dimensions: 90 x 75 mm; height: 135 mm (incl. terminals)

Line voltage All controllers manufactured as of April 2005:

115VAC version: 110VAC -15 %…120VAC +10% (equivalent to 94…132 VAC)
230VAC version: 220VAC -15 %…240VAC +10% (equivalent to 187…264 VAC)
400VAC version: 380VAC -15 %…415VAC +10% (equivalent to 323…456 VAC)

All controllers manufactured as of January 2004 up to March 2005:
115VAC version: 115VAC -15 %…120VAC +10% (equivalent to 98…132 VAC)
230VAC version: 230VAC -15 %…240VAC +10% (equivalent to 196…264 VAC)
400VAC version: 400VAC -15 %…415VAC +10% (equivalent to 340…456 VAC)

All controllers manufactured up to December 2003:
115VAC, 230 VAC or 400VAC, tolerance: +10% / -15 %

Technical data

Depending on the controller version (ª section 13 "How to order" on page 40)

Line frequency 47…63Hz, automatic adjustment to frequencies in this range

Auxiliary voltage

Terminals 12+13

Heatsealing band
type and temperature
range

24VDC, +20%, -10%, reverse polarity-protected
Current input (up to March 2005): max. 50mA

(as of April 2005): max. 1.0A

All controllers manufactured as of April 2005:
The temperature range and temperature coefficient settings can also be specified
by means of the ROPEX visualization software (ª section 10.11 "Diagnostic
interface/visualization software (as of April 2005)" on page 31) in addition to the
rotary coding switch (see below):

Temperature range: 200°C, 300 °C, 400°C or 500 °C
Temperature coefficient: 400…4000 ppm (variable setting range)

All controllers manufactured as of June 2003:
Five different ranges can be set on the controller with a rotary coding switch:

Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20), default
Temperature coefficient 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)

All controllers manufactured up to May 2003:
Default value 300°C, Alloy-20
The temperature range and alloy are selectable with MOD 37.

Analog input

(set point)
Terminals 16+14

Analog output

(actual value)
Terminals 17+14

Page 10 RES-407

0…10VDC, I
Equivalent to 0…300 °C or 0…500°C
or with an external PD-3 or PD-5 precision potentiometer (R = 2 kohms)
0…2kohms equivalent to 0…300 °C or 0…500°C

0…10VDC, I
Equivalent to 0…300 °C or 0…500°C
Accuracy: ±1% add. 50mV

= 5mA, electrically isolated

max

= 5mA, electrically isolated

max

Technical data

Reference voltage +10VDC / ±5 %, I

Digital logic levels

Terminals 5, 6, 7

LOW (0V): 0…2VDC, electrically isolated
HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected

Switching output for
"Temp. OK" signal
(MOD 40)

Alarm output U

=30VDC

U

max

=50mA

I

max

U

< 2V (saturation voltage)

ON

< 3V (saturation voltage), electrically isolated,

ON

short-circuit proof
Up to March 2005: I
As of April 2005: I
As of April 2005, the output can also be inverted by means of a plug-in jumper.

Maximum load

(primary current of

= 5A (duty cycle = 100%)

I

max

= 25A (duty cycle = 20 %)

I

max

impulse transformer)

Power dissipation max. 20W

Ambient

+5…+45°C

temperature

Degree of protection IP20

max

=5mA

max

max

=40mA
=200mA

Installation If several controllers are installed on one top hat rail

(DIN TS35 rail), a clearance of at least 20mm should
be allowed between them.

The moving clip required for fastening must be facing
down for mounting on a horizontal top hat rail.

End holders to mechanical fix the controller must be fitted at both ends for
mounting on a vertical top hat rail.

Weight Approx. 0.7 kg (incl. connector plug-in parts)

Housing material Plastic, polycarbonate, UL-90-V0

Connecting cables

Type / cross-sections

Rigid or flexible; 0.2…2.5mm² (AWG 24…12)
Plug-in connectors

If ferrules are used, they must be crimped in accordance

!

with DIN 46228 and IEC/EN 60947-1.

This is essential for proper electrical contact in the terminals.

RES-407 Page 11

7 Dimensions

Dimensions

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-407:

1. Switch off the line voltage and verify that all circuits

are deenergized.

2. The supply voltage specified on the nameplate of

the RESISTRON temperature controller must be
identical to the line voltage that is present in the
plant or machine. The line frequency is

automatically detected by the temperature controller
in the range from 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 10 must be allowed between them.

4. Wire the system in accordance with the instructions
in section 8.3 "Power supply" on page 14,
section 8.6 "Auxiliary voltage" on page 16 and the
ROPEX Application Report. The information
provided in section 8.2 "Installation steps" on
page 13 must be heeded additionally.

Check the tightness of all the system

!

connections, including the terminals for the

impulse transformer windings.

5. Make sure that the wiring conforms to the relevant
national and international installation regulations.

Page 12 RES-407

Installation

8.2 Installation steps

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

Note

direction

of rotation

Digital
potentiometer
PD-x

Configure

DIP switches

correctly

(up to March 2005)

RES-407 Page 13

8.3 Power supply

Installation

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
50/60Hz

Circuit breaker

Double-pole, C characteristic
(ª ROPEX Application Report)

I

>

3

Kb

3

2

Short-circuit protection only.

!

RESISTRON temperature controller not protected.

Relay Ka

For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".

Line filter

The filter type and size must be determined according to
the load, the transformer and the machine wiring
(ª ROPEX Application Report).

Do not run the filter supply wires (line side) parallel

!

to the filter output wires (load side).

RESISTRON temperature controller belonging to the
4xx Series.

Relay Kb

Load break (all-pole), e.g. in combination with the alarm
output of the temperature controller.

When using a series resistor RV-....-1 the relay Kb

!

shall be installed.

Impulse Transformer

Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.

Use transformers with a one section bobbin. The

!

power, duty cycle and voltage values must be

determined individually according to the application
(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.

Page 14 RES-407

Installation

8.4 Line filter

To comply with EMC directives – corresponding to
EN 50081-1 and EN 50082-2 – RESISTRON control
loops must be operated with line filters.
These filters damp the reaction of the phase-angle
control on the line and protect the controller against line
disturbances.

The use of a suitable line filter is part of the

!

standards conformity and a prerequisite of

the CE mark.

ROPEX line filters are specially optimized for use in
RESISTRON control loops. Providing that they are

Large cross-section
wire to ground

PE

LINE

installed and wired correctly, they guarantee
compliance with the EMC limit values.
You can find the exact specification of the line filter in
the ROPEX Application Report calculated for your
particular heatsealing application.
For more technical information: ª "Line filter"
documentation.

It is permissible to supply several

!

RESISTRON control loops with a single line
filter, providing the total current does not exceed
the maximum current of the filter.

The wiring instructions contained in section 8.3 "Power
supply" on page 14 must be observed.

max. 1m

ROPEX

temperature

controller

Do not lay parallel

Large cross-section
wire to ground

Large frame contact surface

8.5 Current transformer PEX-W3

The PEX-W3 current transformer supplied with the
RESISTRON temperature controller is an integral part

24

23

terminal

wires

60

39

26

14

Mounting plate (galvanized)

of the control system. The current transformer may only
be operated if it is connected to the temperature
controller correctly (ª section 8.3 "Power supply" on
page 14).

28

75

12

14

terminal

block

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

RES-407 Page 15

Installation

8.6 Auxiliary voltage

Since the inputs and outputs of the RES-407 are
electrically isolated, a 24VDC auxiliary voltage must be
applied to terminals 12+13. The auxiliary voltage has a

RES-407

AUTOCAL

with 24VDC signal

START (HEAT)

with 24VDC signal

RESET

with 24VDC signal

5

6

7

(also with MOD 01)

maximum current input of 1,0A and it is also protected
against reverse polarity.

8.7 Wiring diagram (standard)

Line filter LF-xx480

1

LINE

2

3

4

U

1

prim.

GND

Ground

for 24VDC signals.

Must be grounded

externally to prevent

electrostatic

charging!

GND

Auxiliary

supply

+24VDC

ANALOG

INPUT

(set point)

+0...10VDC

ANALOG

OUTPUT

(real temperatur)

+0...10VDC

14

13

12

16

17

0V

(Internal ground)

No external

grounding allowed!

up to

production

date

March 2005

0V

(Internal ground)

No external

grounding allowed!

Impulse

transformer

8

U

R

9

10

11

Twi sted

I

R

Current transformer

PEX-W2/-W3

U

2

sec.

Heat-

R

sealing

band

ALARM

OUTPUT

+24VDC

U

REF

+10VDC

Page 16 RES-407

18

15

=

=

OPTION:

SET POINT

POTENTIOMETER

PD-3 or PD-5

2K

cw

14

16

15

Installation

8.8 Wiring diagram with booster
connection (MOD 26)

RES-407

AUTOCAL

with 24VDC signal

START (HEAT)

with 24VDC signal

RESET

with 24VDC signal

5

6

7

(also with MOD 01)

1

2

Booster

20

IN OUT

19

NC

3

4

NC

Line filter LF-xx480

13

24

U

1

prim.

LINE

GND

Ground

for 24VDC signals.

Must be grounded

externally to prevent

electrostatic

charging!

GND

Auxiliary

supply

+24VDC

ANALOG

INPUT

(set point)

+0...10VDC

ANALOG

OUTPUT

(real temperature)

+0...10VDC

14

13

12

16

17

0V

(Internal ground)

No external

grounding allowed!

up tol

production

date

March 2005

0V

(Internal ground)

No external

grounding allowed!

Impulse

transformer

8

U

R

9

10

11

Twi sted

I

R

Current transformer

PEX-W2/-W3

U

2

sec.

Heat-

R

sealing

band

ALARM

OUTPUT

+24VDC

U

REF

+10VDC

18

15

OPTION:

SET POINT

=

=

RES-407 Page 17

POTENTIOMETER

PD-3 or PD-5

2K

cw

14

16

15

1

2

3

4

Additional terminals
in housing cover
for MOD 26 (booster connection)

ALARM
HEAT
OUTPUT
AUTOCAL

BOOSTER

Installation

MOD 26 cannot be used in combination with

!

MOD 40 ("Temperature OK" signal)

manufactured up to March 2005.

19 20

8.9 Wiring diagram with "Temp­erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46)

+24VDC

+24VDC

RES- 407

+

I

max. 50mA

GND GND

MOD 40 cannot be used in combination with

! !

MOD 26 (booster connection) manufactured

prior to March 2005.

1

2

3

4

Additional terminals
in housing cover
for MOD 40 (”Temp. reached” signal)
or MOD 46 (”Temp. OK” signal)

MOD 46 cannot be used in combination with
MOD 40.

ALARM
HEAT
OUTPUT
AUTOCAL

Page 18 RES-407

Startup and operation

9 Startup and operation

9.1 View of the controller

Te rm in al s

Wiring diagram

LEDs

Nameplate

9.2 Controller configuration

The controller must be switched off in order

!

to configure the coding switches and the

plug-in jumpers.

9.2.1 Configuration of the DIP switches for secondary voltage and current

Automatic configuration (AUTORANGE)
(as of April 2005)

The secondary voltage and current ranges are
automatically configured by the automatic calibration
function (AUTOCAL). The voltage is configured in the
range from 0.4 VAC to 120VAC and the current in the
range from 30 A to 500A. If the voltage and/or the

Coding switches and
plug-in jumpers

current is outside the permissible range, a detailed
error message appears on the controller (ª see
section 10.13 "Error messages" on page 32).

Configuration with coding switches
(up to March 2005)

Set the DIP switches for matching the secondary
voltage U
position for your application.

!

Report calculated for your particular application.

and the secondary current I2 to the correct

2

You can find the exact configuration of the
DIP switches in the ROPEX Application

RES-407 Page 19

Startup and operation

F

F

O

1-10

)

V

2

ON

U (

3
4

SWITCH

5
4
3
2
1

F
F

O

N
O

O

2

1

N

U

2

1...10V

6...60V

20...120V

If the secondary current I2 is less than 30 A, the
PEX-W2 or PEX-W3 current transformer must have
two turns (ª ROPEX Application Report).

2x

Factory settings

4

5

3

DIP switch DIP switch

12

OFF

ON

OFF

OFF

ON

OFF

3

OFF

OFF

ON

I

2

30...100A

60...200A

120...400A

4

OFF

ON

ON

5

OFF

OFF

ON

9.2.2 Configuration of the rotary coding
switch for the temperature range
and alloy (as of June 2003)

Switch

position

0
1
4
5
8

9 PC-CONFIGURATION

0 = Factory settings

This configuration is supplied as standard

!

with all controllers manufactured as of June

2003. The settings are only possible on older

controllers in conjunction with MOD 37 (ªªªª section
"MOD 37 (until May 2003)" on page 8).

Te mp .

range

300°C
300°C
500°C
500°C
300°C

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
4
5
8

9

TEMP. RANGE

300°C
300°C
500°C
500°C
300°C

PC CONFIGURATION

SWITCH POS.

0

1

9

2

8

3

7

4

6

5

ALLOY

1100ppm/K

780ppm/K

1100ppm/K (A20)

780ppm/K

3500ppm/K

(A20)

(L)

(L)

(NOREX)

If the switch is set to "9" (as of April 2005), more
temperature ranges and alloys can be selected by
means of the ROPEX visualization software (ª see
section 10.11 "Diagnostic interface/visualization
software (as of April 2005)" on page 31).

Page 20 RES-407

Startup and operation

9.2.3 Configuration of the alarm output

(as of April 2005)

Alarm output opened
(HIGH) by alarm/
PC-CONFIGURATION.

Alarm output closed
(LOW) by alarm.
(factory setting)

If the plug-jumper is not inserted - or if it is

!

incorrectly inserted - an error message

appears when the controller is switched on
(ªªªª section 10.13 "Error messages" on page 32).

If the "Alarm output opened by alarm/PC
CONFIGURATION" position is selected (as of April

2005), the behavior of the alarm output can be

configured in more detail by means of the ROPEX
visualization software (ª see section 10.11
"Diagnostic interface/visualization software (as of April

2005)" on page 31).

DE-ENERGIZED / PC
AT ALARM
ENERGIZED

0

1

9

2

8

3

7

4

6

5

CONFIGURATION
ALARM OUTPUT

corrected after a few heating cycles (ª section 9.3.2
"Burning in the heatsealing band" on page 21).
One very important design feature is the copper or
silver-plating of the heatsealing band ends. Cold ends
allow the temperature to be controlled accurately and
increase the life of the teflon coating and the
heatsealing band.

An overheated or burned-out heatsealing

!

band must no longer be used because the

TCR has been altered irreversibly.

9.3.2 Burning in the heatsealing band

9.3 Heatsealing band

9.3.1 General

The heatsealing band is a key component in the control
loop, since it is both a heating element and a sensor.
The geometry of the heatsealing band is too complex to
be discussed at length here. We shall therefore only
refer to a few of the most important physical and
electrical properties:
The measuring principle applied for this system
necessitates a heatsealing band alloy with a suitable
temperature coefficient TCR, i.e. one whose resistance
increases as the temperature rises.
Too low a TCR leads to oscillation or uncontrolled
heating.
When heatsealing bands with a higher TCR are used,
the controller must be calibrated for this.
The first time the heatsealing band is heated to
approximately 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 approximately 2…3 %. However, this at first
glance slight resistance change results in a zero point
error of 20…30°C. The zero point must therefore be

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.
When the "AUTOCAL" function has finished, the
controller 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 heatsealing band has now been burned in and the
change in the alloy stabilized.
The burn-in effect described here does not occur if the
heatsealing band has already been thermally
pretreated by the manufacturer.

9.3.3 Replacing the heatsealing band

All power supply leads must be disconnected from the
RESISTRON temperature controller in order to replace
the heatsealing band.

The heatsealing band must be replaced in

!

accordance with the instructions provided by

the manufacturer.

RES-407 Page 21

Startup and operation

Each time the heatsealing band is replaced, the zero
point must be calibrated with the AUTOCAL function
while the band is still cold, in order to compensate
production-related resistance tolerances. The burn-in
procedure described above should be performed for all
new heatsealing bands.

9.4 Startup procedure

Please also refer to section 1 "Safety and warning
notes" on page 3 and section 2 "Application" on
page 4.

Installation and startup may only be

!

performed by technically trained, skilled
persons who are familiar with the associated risks
and warranty provisions.

9.4.1 Initial startup

Prerequisites: The controller must be correctly installed
and connected (ª section 8 "Installation" on page 12).
Proceed as follows to start up the controller for the first
time:

1. Switch off the line voltage and verify that all circuits

are deenergized.

2. 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
frequency is automatically detected by the
temperature controller in the range from 47 to 63 Hz.

3. In the case of controllers manufactured up to March

2005, the settings of the DIP switches on the
controller are indicated in the ROPEX Application
Report and depend on the heatsealing band that is
used (section 9.2 "Controller configuration" on
page 19).

4. Make sure that no START signal is present.

5. Apply the auxiliary voltage (24VDC).

6. Switch on the line voltage.

7. When the voltage is switched on, the yellow

"AUTOCAL" LED lights up for approximately

0.3 seconds to indicate that the controller is being
powered up correctly.

As of SW-Revision 106:

!

If the red "ALARM" LED lights up for 0.3s in
addition to the yellow "AUTOCAL" LED when the
voltage is switched on, the configuration of this
controller has been changed in the visualization
software (ªªªª section 10.11 "Diagnostic interface/
visualization software (as of April 2005)" on
page 31). In order to avoid malfunctions, please
check the controller configuration before
continuing the startup procedure.

8. One of the following states then appears:

"ALARM"

LED

OFF Short pulses

BLINKS fast
(4Hz)

Lit
continuously

9. Activate the AUTOCAL function while the

heatsealing band is still cold (terminals 5+14). The
yellow "AUTOCAL" LED lights up for the duration of
the calibration process (approx. 10…15s). A
voltage of app. 0 V appears at the same time at the
actual value output (terminals 17+14). If an ATR-x is
connected, it indicates 0…3°C.
When the zero point has been calibrated, the
"AUTOCAL" LED goes out and a voltage of 0.66 V
(300°C range) or 0.4 V (500°C range) appears at
the actual value output instead. If an ATR-x is
connected, it must be set to "Z".
If the zero point has not been calibrated
successfully, the red "ALARM" LED blinks slowly
(1Hz). In this case the controller configuration is
incorrect (ª section 9.2 "Controller configuration"
on page 19 and ROPEX Application Report).
Repeat the calibration after the controller has been
configured correctly.

10.When the zero point has been calibrated

successfully, set a defined temperature at the set
point input (terminal 16) and apply the "START"
signal (HEAT). The "HEAT" LED then lights up. The
heating and control process can be observed at the
actual value output:
The controller is functioning correctly if the
temperature (which corresponds to the signal
change at the analog output) follows a harmonious

"OUTPUT"

LED

every 1.2 s

OFF Go to 9

OFF Fault diagnosis

ACTION

Go to 9

(ª section 10.1

3)

Page 22 RES-407

Startup and operation

curve, in other words it must not jump abruptly,
fluctuate or deviate temporarily in the wrong
direction. This kind of behavior would indicate that

measuring wires have been laid incorrectly.

the U

R

If an error message is displayed, please proceed as
described in section 10.13 "Error messages" on
page 32.

11.Burn in the heatsealing band (ª section 9.3.2

"Burning in the heatsealing band" on page 21) and
repeat the AUTOCAL function.

The controller is now

ready

9.4.2 Restart after replacing the

heatsealing band

To replace the heatsealing band, proceed as described
in section 9.3.2 "Burning in the heatsealing band" on
page 21 .

Always use a heatsealing band with the

!

correct alloy, dimensions and copper-plating
in order to avoid malfunctions and overheating.

Continue with section 9.4.1, steps 4 to 11.

RES-407 Page 23

10 Controller functions

See also section 8.6 "Auxiliary voltage" on page 16.

10.1 Indicators and controls

Manufactured as of April 2005

Controller functions

1

2

3

ALARM
HEAT
OUTPUT
AUTOCAL

4

RESISTRON

RES- 407

Temperature

controller

5
6

7

8

ROPEX

Tel:[phone]

9

1
0

11

Made in Germany

Manufactured up to March 2005

1

2

3

4

POWER ON

AUTOCAL

OUTPUT

HEAT

ALARM

12 13 14 1516 17 18

Red LED, lights up or blinks to indicate ALARM.

Yellow LED, lit during heating phase.

Green LED, indicates pulses in measure-

ment mode. In control mode, luminous

intensity is proportional to heating current.

Yellow LED, remains lit for duration

of AUTOCAL process.

Green LED, lit continuously when

power supply is on.

Yellow LED, remains lit for duration

of AUTOCAL process.

Green LED, indicates pulses in measure-

ment mode. In control mode, luminous

intensity is proportional to heating current.

!

5

12 13 14 1516 17 18

6

RESISTRON

µP-Controller

7

8

Red LED, lights up or blinks to indicate ALARM.

9

1

ROPEX

INDUSTRIE - ELEKTRONIK

.

0

11

Page 24 RES-407

Yellow LED, lit during heating phase.

Controller functions

In addition to the functions shown in the diagram
above, various controller operating states are indicated

LED Blinks slowly (1 Hz) Blinks fast (4Hz) Lit continuously

RESET active,

AUTOCAL

(yellow)

HEAT

(yellow)

OUTPUT

(green)

ALARM

(red)

START and AUTOCAL

functions are locked

(as of April 2005)

—

In control mode the luminous intensity is proportional to the heating current.

Configuration error,

AUTOCAL not possible

10.2 Temperature setting (set point selection)

by the LEDs. These states are described in detail in the
table below:

AUTOCAL requested, but

function is locked
(as of April 2005)

HEAT requested,

but function is locked

(as of April 2005)

Controller calibrated

incorrectly, run AUTOCAL

• By connecting a 2 kohm potentiometer to
terminals 14…16:

AUTOCAL executing

START executing

Fault, ª section 10.13

The heatsealing temperature of the RES-407 can be
set in two ways:

• By applying a 0…10VDC voltage to the analog input
terminals 16 + 14:

RES-407

+

+

0…10VDC

-

The relationship between the applied voltage and the
SET temperature is linear.
Setting range:
0VDC Æ 0°C
10VDC Æ 300 °C or 500°C

(depending on the contr. configuration)
Please refer to section 10.3 "Temperature indication
(actual value output)" on page 26 for a circuit diagram.

16

14

GND

13

RES-407

15

U

10VDC

16

IN 0…10VDC

14

13

REF

3

1

2

±5%)

CW

2K

GND

Potentiometer with
digital dial PD-x

15

14

16

In order to be able to select the set point with a
potentiometer, the controller makes a +10 VDC (
reference voltage available at terminal 15.
The relationship between the potentiometer setting and
the SET temperature is linear.
The connecting wires between the controller and the
potentiometer must be shielded.

RES-407 Page 25

Controller functions

V

If a ROPEX PD-x precision potentiometer is used, the
SET temperature can be adjusted exactly with the help
of the digital display in the window of the dial. The
number which appears on the display corresponds to
the SET temperature in °C.
The set point that is selected for the heatsealing
temperature must be greater than 40°C. If not, the
heatsealing band will not be heated up when the
"START" signal is activated.

If a potentiometer is not connected or if 0VDC

!

is applied to the set point input, the set point
is assumed to be zero. When you connect the
potentiometer, please note the direction of
rotation!

10.3 Temperature indication (actual

value output)

The RES-407 supplies an analog 0…10VDC signal,
which is proportional to the real ACTUAL temperature,
at terminals 17+14.

RES-407

Actual value
output
0…10VDC

+

33ohms

max. 5mA

17

GND

14

°C

T

300

e
r

u

270

t
a

r

240

e
p

210

m
e
T

180

150

120

20°C

°C

T

500

e
r

u

450

t
a

r

400

e
p

350

m
e
T

300

250

200

150

100

90

60

0.66V

"ZERO"

0 - 300°C range

12345678910

oltage U

VDC

0 - 500°C range

13

-

Temperature

meter

e.g. ATR-x

Voltage values:
0VDC Æ 0°C
10VDC Æ 300 °C or 500°C

(depending on the contr. configuration)
The relationship between the change in the output
voltage and the ACTUAL temperature is linear.

Page 26 RES-407

0…10VDC

+

An indicating instrument can be connected to this
output in order to visualize the temperature of the
heatsealing band.
The characteristics of the ROPEX ATR-x temperature
meter (size, scaling, dynamic response) are ideally
suited to this application and this instrument should
therefore always be used (ª section 5 "Accessories
and modifications" on page 6).
It not only facilitates SET-ACTUAL comparisons, but
also enables other criteria such as the heating rate, set
point reached within the specified time, cooling of the
heatsealing band etc. to be evaluated.
This meter moreover permits disturbances in the
control loop (loose connections, contacting or wiring
problems) as well as any line disturbances to be

20°C

12345678910

0.4V

"ZERO"

Voltage U

VDC

Controller functions

observed extremely effectively and interpreted
accordingly. The same applies if mutual interference
occurs between several neighboring control loops.

If an alarm is signaled, this analog output is

!

used to display a selective error message

(ªªªª section 10.13 "Error messages" on page 32).

10.4 Automatic zero calibration

(AUTOCAL)

Owing to the automatic zero calibration (AUTOCAL)
function, there is no need to adjust the zero point man­ually on the controller. This function matches the con­troller to the current and voltage signals that are pre­sent in the system. The zero point is calibrated in the
factory to the initial temperature (ambient temperature,
20°C).

Variable initial temperature:
On controllers manufactured as of April 2005, the initial
temperature for the "AUTOCAL" function can be set in
the 0…+40°C range in the visualization software
(ª section 10.11 "Diagnostic interface/visualization
software (as of April 2005)" on page 31). This setting is
remembered if the controller is switched off and then on
again.
As of SW Revision 107, the "External calibration tem­perature" setting can also be selected in the visualiza­tion software. The initial temperature for this setting can
be specified in the +3…+40°C range via the analog
input (terminals 16+14) (ª section 10.2 "Temperature
setting (set point selection)" on page 25). The value
selected at the analog input must be present when the
"AUTOCAL" function is activated.
If the specified temperature is too high (greater than
40°C) or if the selected value varies, an error message
appears (error codes 115 and 116; ª section 10.13
"Error messages" on page 32).

The "AUTOCAL" function is activated by means of a
24VDC pulse at terminals 5+14.

24VDC

AUTOCAL

+

-

HIGH:

LOW:

The automatic calibration process takes around
10…15seconds. The heatsealing band is not heated
during this process.
The yellow LED on the front panel lights up when the
"AUTOCAL" function is active. The actual value output
(terminals 14+17) is 0…3°C (corresponds to app.
0 VDC).
If the temperature of the heatsealing band varies on
controllers manufactured as of April 2005, the
"AUTOCAL" function is executed a maximum of three
times. If the function still cannot be terminated
successfully, an error message appears
(ª section 10.13 "Error messages" on page 32).

!

temperature) before activating the "AUTOCAL"
function.

max. 6mA

GND

14

13

≥ 12VDC

≤ 2VDC

You should always wait for the heatsealing
band and the bar to cool down (to ambient

RES-407

5

AUTOCAL

0.1…5s

Reasons for disabled "AUTOCAL" function:

1. The "AUTOCAL" function cannot be activated until
10seconds after the controller is switched on. If you
attempt to activate it sooner, it will not work.

2. The "AUTOCAL" function cannot be not activated if
the heatsealing band cools down at a rate of more
than 0.1K/ s. If the control signal is activated, the
function is executed automatically providing the
cooling rate has fallen below the above-mentioned
value.

RES-407 Page 27

Controller functions

3. If the "START" signal (24VDC) is active, the
"AUTOCAL" function is not executed ("HEAT" LED
lit).

4. If the "RESET" signal (24VDC) is active, the
"AUTOCAL" function is not executed.

5. The "AUTOCAL" function cannot be activated if
error codes 101…103, 201…203, 801 or 9xx (up to
March 2005: error codes 1…3, 5…7) occur on
startup (ª section 10.13 "Error messages" on
page 32). If the controller has already operated
correctly - at least once - after starting up, the
"AUTOCAL" function cannot be activated with error
codes 201…203, 801 or 9xx (up to March 2005:
error codes 5…7).

10.5 "START" signal (HEAT)

When the "START" signal is activated, the controller­internal set/actual comparison is enabled and the
heatsealing band is heated up to the SET temperature.
It remains at this temperature until the signal is
deactivated again.
The "HEAT" LED on the front panel of the RES-407 is
lit continuously for the duration of the heating phase.
The "START" signal is activated by means of a 24VDC
signal at terminals 6+14.

The set point that is selected for the heatsealing
temperature must be greater than 40°C. If not, the
heatsealing band will not be heated up.
The alarm output is switched if the "START" signal is
activated while an error message is indicating error
codes 104…106, 111…114, 211, 302 or 303 (up to
March 2005: error codes 8…12) (ª section 10.13
"Error messages" on page 32). The heatsealing band is
no longer heated up.

10.6 "RESET" signal

The RESISTRON temperature controller RES-407 can
be reset by means of an external "RESET" signal at
terminals 7+14). As a result:

• A heatsealing cycle is aborted if one is in progress

• No more measuring impulses are generated

• An error message is reset if one is present
(Note: The error message is not reset until the

"RESET" signal is deactivated)

24VDC

RESET

+

max. 6mA

RES-407

7

24VDC

START

+

-

HIGH: ≥ 12VDC

LOW:

!

„RESET“ signal is active.

(HEAT)

max. 6mA

GND

14

13

≤ 2VDC

The "START" signal is disabled as long as the
"AUTOCAL" function is executing or the

RES-407

6

START (HEAT)

-

HIGH:

≤ 2VDC

LOW:

As of SW revision 103, the controller actual value
output changes to 0…3 °C (i.e. approximately 0 VDC)
while the "RESET" signal is being activated. This may
be interpreted by the higher-level controller (e.g. a
PLC) as feedback.
The "AUTOCAL" function is not aborted if the "RESET"
signal is activated while it is still executing.

GND

≥ 12VDC

14

13

RESET

>0.1s

Page 28 RES-407

Controller functions

The controller performs an internal

!

initialization run lasting approximately
500ms after the "RESET" signal is deactivated. The
next heatsealing process cannot be started until it
has finished.

If a contactor Kb is used to deactivate the

!

control loop (ªªªª section 8.3 "Power supply"
on page 14), it must be energized again 50ms at the
latest after the "RESET" signal is deactivated. If it is
energized too late, an error message will be output
by the controller.

10.7 Measuring impulse duration

(as of April 2005)

The length of the measuring impulses generated by the
controller can be set with the parameter. It may be
necessary to set a measuring impulse that is longer
than the default 1.7 ms for certain applications
(ª ROPEX Application Report).

This parameter can only be set by means of

!

the ROPEX visualization software
(ª section 10.11 "Diagnostic interface/
visualization software (as of April 2005)" on
page 31).

If the interval between the two "AUTOCAL"
functions is longer than 2.0 s, "AUTOCAL" is
executed normally again the second time.

AUTOCAL
signal

24VDC

0

Function

AUTOCAL

0

"AUTOCAL"
LED

lit

off

"OUTPUT"
LED

lit

<2.0s

AUTOCOMP

t

t

t

10.8 Automatic phase angle

compensation (AUTOCOMP)
(as of April 2005)

It may be necessary to compensate the phase angle
displacement between the U
signals for special heatsealing applications (ª ROPEX
Application Report). The "AUTOCOMP" function is
provided for this purpose. The following settings are
possible:

1. „OFF" (Factory settings)

The „AUTOCOMP“ function is deactivated.

2. „ON“

The „AUTOCOMP“ function is executed whenever
the "AUTOCAL" function (ª section 10.4
"Automatic zero calibration (AUTOCAL)" on
page 27) is run twice in quick succession. The
interval between the end of the first "AUTOCAL"
function and the start of the second "AUTOCAL"
must be shorter than 2.0 s. The second "AUTOCAL"
function only takes around 2.0s and incorporates
the "AUTOCOMP" function.

and IR measuring

R

off

t

The "OUTPUT" LED blinks repeatedly when the
"AUTOCOMP" function is executed and the actual
value output (terminals 17+14) is set to 0…3 °C (i.e.
app. 0 VDC).

3. „AUTO“

(as of software revision 108)

With this setting the „AUTOCOMP“ function is acti­vated automatically after the "AUTOCAL" function
has been successfully executed.

RES-407 Page 29

Controller functions

AUTOCAL
signal

24VDC

Function

„AUTOCAL“
LED

lit

OFF

„OUTPUT“
LED

lit

temperature. The lower ( ) and upper
( ) tolerance band limits are configured in the

∆ϑ

upper

„AC“

0

t

AUTOCOMP

AUTOCAL

0

t

t

factory to -10 K and +10K. These values can be set
independently of one another in the ROPEX
visualization software.
If the actual temperature is inside the specified
tolerance band when the "START" signal is activated,
the temperature diagnosis is activated as well. If the
ACTUAL temperature leaves the tolerance band, the
corresponding error code (307 or 308) is indicated and
the alarm output is switched (ª section 10.13 "Error
messages" on page 32).

Set+∆ϑ

Set+∆ϑ

upper

Set

lower

∆ϑ

lower

Actual value

OFF

The "OUTPUT" LED blinks repeatedly when the
"AUTOCOMP" function is executed and the actual
value output (terminals 17+14) is set to 0…3 °C (i.e.
app. 0 VDC).

The "AUTOCOMP" function must be

!

activated in the ROPEX visualization
software (ª section 10.11 "Diagnostic interface/
visualization software (as of April 2005)" on
page 31) (default setting: AUTOCOMP off).

t

10.9 Temperature diagnosis

(as of April 2005)

An additional temperature diagnosis can be activated in
the ROPEX visualization software (ª section 10.11
"Diagnostic interface/visualization software (as of April

2005)" on page 31). The RES-407 checks whether the
ACTUAL temperature is within a settable tolerance
band ("OK" window) on either side of the SET

Time

Alarm

307

If the temperature diagnosis is not activated by the time
the "START" signal is deactivated (i.e. if the ACTUAL
temperature does not exceed the upper or lower
tolerance band limit), the corresponding error code
(309, 310) is indicated and the alarm output is
switched.
An additional delay time (0…9.9 s) can be set in the
ROPEX visualization software. The first time the lower
tolerance band limit is exceeded, the temperature
diagnosis is not activated until the parameterized delay
time has elapsed. The temperature diagnosis function
can thus be explicitly deactivated, e.g. if the
temperature drops temporarily owing to the closure of
the sealing jaws.

The values that can be set in the ROPEX

!

visualization software for the upper and
lower tolerance band are identical to those for the
"Temperature OK" signal (MOD 46).

Page 30 RES-407

Controller functions

A

10.10 Heatup timeout (as of April 2005)

An additional heatup timeout can be activated in the
ROPEX visualization software (ª section 10.11
"Diagnostic interface/visualization software (as of April

2005)" on page 31).

This timeout starts when the START signal is activated.
The RES-407 then monitors the time required for the
ACTUAL temperature to reach 95% of the SET
temperature. If this time is longer than the
parameterized time, the corresponding error code
(304) is indicated and the alarm output is switched
(ª section 10.13 "Error messages" on page 32).

Actual value

Set

95% of Set

Only a ROPEX comunication interface is

!

allowed to be connected to the diagnostic
interface. Connecting another device (e.g. a
telephone cable) could result in malfunctions or
damage to the controller.

The ROPEX visualization software is described in a
separate document.

10.12 System monitoring/alarm output

To increase operating safety and to avoid faulty
heatsealing, this controller incorporates special
hardware and software features that facilitate fault
diagnosis and selective error messages. Both the
external wiring and the internal system are monitored.
These features assist the operator in identifying the
cause of abnormal operations.
A system fault is reported or differentiated by means of
the following indications:

A.) Red "ALARM" LED on the controller with

three states:

Timeout

1. Blinks fast (4 Hz):

The "AUTOCAL" function should be executed (error

Heatup time Alarm

Time

304

codes 104…106, 211, 302, 303; up to March 2005:
error codes 8+9).

2. Blinks slowly (1 Hz):

The system configuration is incorrect and the zero
calibration ("AUTOCAL" function) was unsuccessful

10.11 Diagnostic interface/visualization software (as of April 2005)

(ª section 9.2 "Controller configuration" on
page 19). It corresponds to error codes 110…114
(up to March 2005: error codes 10…12).

An interface with a 6-pole Western socket is provided
for systemdiagnostics and process visualization. This
interface allows a data connection to be set up to the
ROPEX visualization software using the ROPEX
communication interface CI-USB-1.

3. Lit continuously:
A fault is preventing the controller from being started
(error codes 101…103, 107, 108, 201…203, 307,
308, 801, 9xx; up to March 2005: error codes 1…7).
Also in instances 1 and 2 if the "START" signal is
activated simultaneously.
As a rule, it refers to an external wiring fault.

DI

G

B.) Alarm output signal on the controller

(terminals 12+18):

0

1

9

2

8

3

7

4

6

5

This logic output is set in the factory as follows:

• LOW (OPEN) in operating states A.1) and A.2), but
high (closed) if a "START" signal is activated in one
of these states.

• HIGH (CLOSED) in operating state A.3)

RES-407 Page 31

Controller functions

If the alarm relay is configured opposite to the factory
setting (ª section 9.2.3 "Configuration of the alarm
output (as of April 2005)" on page 21), these states are
reversed.

C.) Error code output via the 0 to 10 V DC

actual value output (terminals 17+14):

Since a temperature indication is no longer necessary
if a fault occurs, the actual value output is used to
display error messages in the event of an alarm.
13 voltage levels (up to March 2005: 12 voltage levels)
are offered for this purpose in the 0…10VDC range,
each of which is assigned an error code
(ª section 10.13 "Error messages" on page 32).
If a state that requires "AUTOCAL" occurs - or if the
controller configuration is not correct - (error codes
104…106, 111…114, 211, 302, 303; up to March 2005:
error codes 8…12), the actual value output jumps back
and forth at 1 Hz between the voltage value which
corresponds to this error and the end of the scale (10 V
DC, i.e. 300 °C or 500 °C). If the "START" signal is
activated in one of these states, the voltage value does
not change any more.
Selective fault detection and indication can thus be
implemented simply and inexpensively using the
analog input of a PLC with a corresponding error
message (ª section 10.13 "Error messages" on
page 32).

An alarm can only be reset by applying a

!

"RESET" signal or by switching the

controller off and then on again.

If an error message is reset using the

!

"RESET" signal, the "RESET" signal must be

deactivated first.

Invalid error messages may appear when the

!

controller is switched off owing to the
undefined operating state. This must be taken into
account when they are evaluated by the higher­level controller (e.g. a PLC) in order to avoid false
alarms.

10.13 Error messages

The table below shows how the analog voltage values
that appear at the actual value output correspond to the
faults that have occurred. It also describes each fault
and the required corrective action.
The error messages are listed in two separate tables for
controllers "up to March 2005" and "as of April 2005".
The block diagram in section 10.14 "Fault areas and
causes" on page 37 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
April 2005. The error messages are differentiated even
more finely in the controller. The error codes described
below can be displayed with the ROPEX visualization
software (ª section 10.11 "Diagnostic interface/
visualization software (as of April 2005)" on page 31) to
facilitate troubleshooting.

If the actual value output is evaluated in order

!

to identify an error message - in the higher­level controller, for instance - the tolerance window
must be adjusted to prevent it from being
incorrectly interpreted. Please note the tolerances
of the actual value output (ªªªª section 6 "Technical
data" on page 10).

Page 32 RES-407

Controller functions

Action if machine

already operating,

HS band not chang.

c

Fault area

Fault area e

Fault area dk

Fault area fgh

Check

(loose contact)

Check power supply

Run RESET

Replace controller

Replace controller

Replace controller

Replace controller

Replace controller

plug-in jumper

Action

if machine started

Cause

STATUS

of alarm outp.

for first time

(factory set.)

c

Fault area

signal missing

R

I

e

Fault area

signal missing

R

U

d

Fault area

signals missing

R

and I

R

U

fgh

Fault area

Temperature step, down

(loose contact)

Temperature step, up

Temperature too low/high

(ª section 10.9)

Replace controller

Int. faut, contr. defective

Check

plug-in jumper

output wrong

Plug-in jumper for alarm

Check

power supply

Frequency fluctuation,

inadmissible line frequency

HIGH

Run RESET

Replace controller

Replace controller

Replace controller

Replace controller

(ª section 10.10)

Heatup time too long

Triac defective

Int. faut, contr. defective

Int. faut, contr. defective

Int. faut, contr. defective

Part 1 of 3: Error messages as of April 2005

LED

ALARM

Temp.

500°C

Tem p .

300°C

output;

Act. value

code

Error

[°C]

[°C]

Volta ge [V]

33

20

0.66

(101)

1

66

40

1.33

(102)

2

100

60

2.00

(103)

3

Lit

uously

contin-

133

80

2.66

(107)

(108)

(307)

(308)

(309)

(310)

4

RES-407 Page 33

166

100

3.33

(201)

(202)

5

200

120

4.00

(203)

(304)

(901)

6

233

140

4.66

(913)

(914)

(915)

(916)

(917)

(918)

7

Action if machine

already operating,

HS band not chang.

fgh

Fault area

Controller functions

---

(loose contact)

Action

STATUS

if machine started

Cause

of alarm outp.

for first time

(factory set.)

ij

fgh

and/or

of transformer,

Check specification

Fault area

signals

R

Run AUTOCAL,

Run AUTOCAL

incorrect,

signals incorrect,

R

I

incorrect specification of

signals incorrect,

impulse-transformer

R

U

incorrect specification of

and/or I

R

impulse-transformer

U

LOW

Warning:

Fault:

incorrect specification of

impulse-transformer

HIGH

(voltage value

Temperature too low,

formed, loose contact,

AUTOCAL wasn’t per-

at actual

value output

then no longer

ambient temp. fluctuates

changes)

fault area

temperature too high,

(loose contact)

Run AUTOCAL

Data error

formed, loose contact,

AUTOCAL wasn’t per-

ambient temp. fluctuates

LED

ALARM

Temp.

500°C

Tem p .

300°C

[°C]

[°C]

Blinks

Warning:

alarm LED blinks; alarm output is LOW). When the "START" signal is activated, the warning changes to a fault

output;

Volt. [V]

Act. value

(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm output is HIGH).

NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;

code

(104)

Error

(105)

Part 2 of 3: Error messages as of April 2005

Page 34 RES-407

fast

(4Hz)

¯266«

ª500®

¯160«

ª300®

¯5.33«

ª 10 ®

(106)

8

Lit

Fault:

uously

contin-

¯300«

ª500®

¯180«

ª300®

¯6.00«

ª 10 ®

(302)

(303)

(211)

9

Controller functions

Action if machine

already operating,

Action

if machine started

Cause

HS band not chang.

for first time

---

j,

Fault area

signal incorrect,

R

I

check configuration

calibration not possible

---

i,

Fault area

signal incorrect,

R

U

check configuration

calibration not possible

ij,

Fault area

signals incorrect,

R

and I

R

U

---

check configuration

calibration not possible

Ext. calibration

temperature too high,

calibration not possible

Temperature fluctuates,

calibration not possible

Ext. calibration

temperature fluctuates

calibration not possible

STATUS

of alarm outp.

ALARM

Tem p .

500°C

Tem p .

300°C

(factory set.)

LED

[°C]

[°C]

¯333«

¯200«

ª500®

ª300®

¯366«

¯220«

ª500®

ª300®

LOW

Warning:

Warning:

¯400«

¯240«

Fault:

HIGH

at actual

(voltage value

Lit

Fault:

(1Hz)

Blinks

slowly

ª500®

ª300®

value output

contin-

¯433«

¯260«

changes)

then no longer

uously

ª500®

ª300®

alarm LED blinks; alarm output is LOW). When the "START" signal is activated, the warning changes to a fault

output;

Volt. [V]

¯6.66«

ª 10 ®

¯7.33«

ª 10 ®

¯8.00«

(actual value output no longer jumps back and forth, see bold italic values; alarm LED lit continuously; alarm output is HIGH).

Act. value

ª 10 ®

¯8.66«

ª 10 ®

NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;

(111)

code

Error

Part 3 of 3: Error messages as of April 2005

10

(112)

11

(113)

12

(114)

(115)

(116)

13

RES-407 Page 35

Controller functions

Action if machine

already operating,

Action

if machine started

Cause

HS-band not chang.

for first time

c

Fault area

c

Fault area

signal missing

R

I

Fault area e

Fault area e

signal missing
U

fgh

Fault areas dk

(loose contact)

Fault areas

Check power supply

Run RESET

Replace controller

fgh

Fault area d

signals missing

R

R

and I

R

U

(loose contact)

Fault areas

Check power supply

Temperature step

Frequency fluctuation,

Run RESET

Replace controller

Internal fault

Internal fault,

inadmissible line frequency

fgh

---

Fault areas

Run AUTOCAL

signal

R

incorrect

and/or I

R

controller defective

U

Run AUTOCAL

Data error

---

j,

Fault area

signal incorrect,

R

I

---

i,

Fault area

check configuration

signal incorrect,

R

U

calibration not possible

---

ij,

Fault areas

check configuration

calibration not possible

check configuration

signals incorrect,

R

and I

calibration not possible

R

U

STATUS

of alarm outp.

LED

ALARM

HIGH

(factory set.)

Lit

Blinks

LOW,

fast

(4Hz)

gets HIGH

signal

with"START"

at analog

(voltage value

Blinks

output then

slowly

no longer

changes)

(1Hz)

Continuously

33

66

40

1.33

2

100

60

2.00

3

[°C]

Tem p .

500°C

20

[°C]

Temp.

300°C

0.66

output ;

Act. value

Voltage [V]

1

code

Error

Error messages up to March 2005

133

80

2.66

4

166

100

3.33

5

200

120

4.00

6

233

140

4.66

7

¯266«

¯160«

¯5.33«

¯300«

ª500®

¯180«

ª300®

¯6.00«

ª 10 ®

8

¯333«

ª500®

¯200«

ª300®

ª 10 ®

¯6.66«

9

10

ª500®

ª300®

ª 10 ®

¯365«

¯220«

¯7.33«

11

ª500®

ª300®

ª 10 ®

¯400«

¯240«

¯8.00«

ª500®

ª300®

ª 10 ®

12

Page 36 RES-407

Controller functions

10.14 Fault areas and causes

1229

5

6

3

Temperature

4

8

1

The table below explains the possible fault causes.

Fault area Explanation Possible causes

Load circuit interrupted after U

pickoff point

- Wire break, heatsealing band break

R

- Contact to heatsealing band defective

UR

IR

controller

HARDWARE

8

7

c

PEX-W2/-W3 current transformer
signal interrupted

Primary circuit interrupted

measuring wires from current transformer interrupted

- I

R

- Wire break, triac in controller defective

- Primary winding of impulse transformer interrupted

d

Secondary circuit interrupted
before U

pickoff point

R

- Wire break

- Secondary winding of impulse transformer interrupted

9

45

I2

8

32

U2

1

7

e

f

g

h

i

U

signal missing

R

Partial short-circuit (delta R)

Parallel circuit interrupted

Total short-circuit

U

signal incorrect

R

- Measuring wires interrupted

- Heatsealing band partially bypassed by conducting part
(clamp, opposite heatsealing bar etc.)

- Wire break, heatsealing band break

- Contact to heatsealing band defective

- Heatsealing band installed incorrectly, insulation at
heatsealing bar ends missing or incorrectly installed

- Conducting part bypasses heatsealing band completely

- Up to March 2005: DIP switches 1 - 3 configured incorrectly
(U

range)

2

- As of April 2005: U

0.4…120VAC

RES-407 Page 37

outside permissible range from

2

Fault area Explanation Possible causes

- Up to March 2005: DIP switches 4 + 5 configured

incorrectly

(I

range)

2

- As of April 2005: I

outside permissible range from

2

j

signal incorrect

I

R

30…500A

Factory settings

Turns through PEX-W2/-W3
current transformer incorrect

- Check number of turns (two or more turns required for
currents < 30 A)

- Hardware fault (replace controller)

k

Internal controller fault

- Plug-in jumper for alarm output not connected or
incorrectly connected

11 Factory settings

The RESISTRON temperature controller RES-407 is
configured in the factory as follows:

DIP switches

F

F

for
secondary voltage

and current I

U

2

2

(up to March 2005)

O

2

4

1

O

N

3

U

=6…60VAC

2

=30…100A

I

2

DIP switches: 2 ON

5

1, 3, 4, 5 OFF

These switches are automatically set by
the AUTORANGE function on all
controllers manufactured as of April 2005.

Rotary coding switch
for
heatsealing band alloy
and
temperature range
(as of June 2003)

Plug-in jumper
for
alarm output
(as of April 2005)

Automatic phase
angle compensation
(AUTOCOMP)
[X]

Heatsealing band alloy: Alloy A20
Temperature range: 300°C
Maximum temperature: 300°C

SWITCH POS.

0
1

0

1

9

2

8

3

7

4

6

5

4
5
8

300°C

9

Rotary coding switch: "0" position

Output closes (HIGH) by alarm

SWITCH POS.

0
1

0

1

9

2

8

3

7

4

6

5

4
5
8

300°C

9

AUTOCOMP: OFF

Page 38 RES-407

Maintenance

Measuring impuse
duration

[X]

„Temp. OK“ signal
(as of April 2005:

With MOD 46 only

[X]

Temperature
diagnosis

[X]

Heatup timeout

[X]

[X] As of April 2005:
With ROPEX visualization software only.

Measuring impulse length: 1,7ms

Tolerance band: -10 K…+10K

Temperature diagnosis: OFF

Heatup timeout: OFF

12 Maintenance

The controller requires no special maintenance.
Regular inspection and/or tightening of the terminals –
including the terminals for the winding connections on

the impulse transformer – is recommended. Dust
deposits on the controller can be removed with dry
compressed air.

RES-407 Page 39

13 How to order

Contr. RES - 407 / . . . VAC

Scope of supply: Controller includes connector plug-in parts

Modification MOD . . (optional, if required)

Please indicate the article numbers of the controller and the required modifications
(optional) in all orders,

How to order

115: Power supply 115 VAC, Art. No. 740701
230: Power supply 230 VAC, Art. No. 740702
400: Power supply 400 VAC, Art. No. 740703

(without current transformer)

e.g.

01: MOD 01, Art. No. 800001 (amplifier for low voltage)
26: MOD 26, Art. No. 800026 (booster connection)
40: MOD 40, Art. No. 800040 ("Temperature OK" signal)

e.g. RES-407/400 VAC + MOD 26

(controller for 400 VAC power supply with booster connection)
Art. Nos. 740703 + 800026 must be ordered

Current transformer PEX-W3

Art. No. 885105

Line filter LF- . . 480

06: Continuous current 6 A, 480VAC, Art. No. 885500
35: Continuous current 35 A, 480VAC, Art. No. 885506

Impulse transformer

See ROPEX Application Report
for design and ordering information

Communiction interface CI-USB-1

Art. No. 885650

Potentiometer PD- .

3: For 300°C range, Art. No. 881103
5: For 500°C range, Art. No. 881105

Scope of supply: Potentiometer with digital dial

Temp. meter ATR- .

3: 300°C range, Art. No. 882130
5: 500°C range, Art. No. 882150

Page 40 RES-407

How to order

Booster B- . . . 400

For more accessories: ª"Accessories" leaflet

075: Max. pulse load 75A, 400 VAC, Art. No. 885301
100: Max. pulse load 100 A, 400VAC, Art. No. 885304

RES-407 Page 41

14 Index

Index

A

Accessories 6
Actual value output 26
Alarm output 11
Alarm relay 21
Alloy 20
Ambient temperature 11
Analog input 10
Analog output 10
Analog temperature meter 6
Application 4
Application Report 12
AUTOCAL 6
AUTOCOMP 29
Automatic phase angle compensation 29
Automatic zero calibration 6
AUTOTUNE 6
Auxiliary voltage 10

, 23

, 31

, 15, 19

, 22, 27

, 22, 27

, 16

B

Booster 7, 8, 41
Burning in the heatsealing band 21

, 23

C

Circuit breaker 14
CI-USB-1 7
Communication interface 7
Controller configuration 19
Controls 24
Current transformer 7

, 31, 40

, 31, 40

, 15, 40

I

Impulse heatsealing method 4
Impulse transformer 7
Installation 11
Installation procedure 12
Installation regulations 12

, 12

, 14, 40

L

Line filter 7, 14, 15, 40
Line frequency 6
Line voltage 10

, 10

, 40

M

Maintenance 39
Measuring impulse duration 29
Modifications 7
MODs 7
Monitoring current transformer 7

, 17, 18, 40

, 17, 18, 40

O

Overheating of heatsealing band 6

P

PEX-W2/-W3 3
PEX-W3 15
Phase angle compensation 29
Potentiometer 7
Power dissipation 11
Power supply 14
Principle of operation 5

, 40

, 25, 40

D

Degree of protection 11
Diagnostic interface 31
Digital temperature meter 6
Dimensions 12
DIP switches 19

E

Error messages 32
External switching amplifier 7

F

Factory settings 38
Fault areas 37
Fault diagnosis 6

R

Reasons for locked "AUTOCAL" function 27
Reference voltage 11
Replacing the heatsealing band 21
"RESET" signal 28

S

Secondary current I219
Secondary voltage U
Set point potentiometer 7
Set point selection 10
Signal „Temperatur erreicht“ 9
"START" signal 22
Startup 19
System diagnostics 31
System monitoring 31

H

HEAT 22, 28
Heatsealing band type 10
Heatup timeout 31
How to order 40

Page 42 RES-407

T

TCR 3, 21
Technical data 10
Temperature coefficient 3

2

, 28

, 23

19

, 25

, 25

, 21

Index

Temperature control 4
Temperature diagnosis 30
Temperature meter 6
Temperature OK signal 11
Temperature range 10
Temperature reached signal 8
Temperature setting 25
Transformer 3
Type of construction 10

, 7, 14, 40

, 26, 40

, 18

, 20

, 18

V

View of the controller 19
Visualization software 31

W

Wiring 12, 14
Wiring diagram 16

RES-407 Page 43