RESISTRON

RES-403

Operating
Instructions

Important features

• Automatic zero calibration (AUTOCAL)

• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of October 2005)
• Automatic phase angle compensation (AUTOCOMP, as of October 2005)
• Automatic frequency adjustment
• Set point selection with potentiometer
• 0…10VDC analog output for ACTUAL temperature
• Activated with contact or 24VDC signal
• Alarm function with fault diagnosis
• Heatsealing band alloy and temperature range selectable
Version 1
24.7.20

ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: info@ropex.de

Adolf-Heim-Str. 4 Fax: +49 (0)7142-7776-211 Internet: https://ropex.de
74321 Bietigheim-Bissingen (Germany) Data subject to change
Contents
1 General information .................. 3 6 Controller functions . . . . . . . . . . . . . . . . . 20
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3 6.1 Indicators and controls . . . . . . . . . . . 21
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 3 6.2 Temperature setting (set point selection)
1.3 Heatsealing band ................ 3 22
1.4 Impulse transformer .............. 4 6.3 Temperature indication (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5 Current transformer PEX-W4/-W5 . . . . 4
6.4 Automatic zero calibration (AUTOCAL) .
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
25
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 4
6.5 "START" signal (HEAT) . . . . . . . . . . . 26
1.8 Transportation . . . . . . . . . . . . . . . . . . . 4
6.6 Measuring impulse duration
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5 (as of October 2005) . . . . . . . . . . . . . 28
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.7 Automatic phase angle
compensation (AUTOCOMP)
3 Principle of operation . . . . . . . . . . . . . . . . . 7
(as of October 2005) . . . . . . . . . . . . . 28
4 Traits of the controller ................ 7 6.8 Temperature diagnosis
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (as of October 2005) . . . . . . . . . . . . . 30
5.1 Installation procedure . . . . . . . . . . . . . 8 6.9 Heatup timeout
5.2 Installation steps . . . . . . . . . . . . . . . . . 9 (as of October 2005) . . . . . . . . . . . . . 32

5.3 Power supply . . . . . . . . . . . . . . . . . . . 10 6.10 Diagnostic interface/visualization software

(as of October 2005) . . . . . . . . . . . . . 32
5.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 11
6.11 System monitoring/alarm output . . . . 33
5.5 Current transformer PEX-W4/-W5 . . . 11
6.12 Error messages . . . . . . . . . . . . . . . . . 34
5.6 Wiring diagram (Standard) . . . . . . . . 13
6.13 Fault areas and causes . . . . . . . . . . . 39
5.7 Wiring diagram with booster
connection (MOD 26) . . . . . . . . . . . . 14 7 Factory settings . . . . . . . . . . . . . . . . . . . . . 40
5.8 Wiring diagram with "Temp- 8 Technical data . . . . . . . . . . . . . . . . . . . . . . 42
erature reached" signal (MOD 40)
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 44
or „Temp. OK“ signal (MOD 46) . . . . 15
5.9 Startup and operation . . . . . . . . . . . . 16 10 Modifications (MODs) . . . . . . . . . . . . . . . . 44
5.10 View of the controller . . . . . . . . . . . . . 16 11 How to order . . . . . . . . . . . . . . . . . . . . . . . . 46
5.11 Controller configuration . . . . . . . . . . . 16 12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.12 Replacing and "burning in" the heat-
sealing band . . . . . . . . . . . . . . . . . . . 18
5.13 Startup procedure . . . . . . . . . . . . . . . 19

Page 2 RES-403 Version 1

General information

1 General information
This RESISTRON® temperature controller is manufactured according to EN 61010-1. In the course of its manu-
facture it passed through quality assurance, whereby it was subjected to extensive inspections and tests. As a
result of this, the product left our factory in perfect condition.
Please carefully read through the operating manual before using the RESISTRON® temperature controller. Keep
the operating manual for later reference and make sure that information and functions important for the user are
available.
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 Copyright

All contents, in particular texts, photographs and graphics, are protected by copyright. All rights, including to rep-
lication, publication, editing and translation, are reserved.

1.2 Intended use

RESISTRON® temperature controllers may only be used for heating and temperature control of heatsealing bands
which are expressly approved for them, and providing the regulations, notes and warnings contained in these
instructions are observed.
In case of non-observance 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. This is the personal responsibility of the
user.

1.3 Heatsealing band

The use of suitable heatsealing bands is a basic prerequisite for reliable and safe operation of the system.
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:
–4 –1 –1
TCR = 10x10 K or K or ppm/K
e.g. Alloy A20: TCR = 1100 ppm/K
LEX3500: TCR = 3500 ppm/K
Vacodil: TCR = 1100 ppm/K
The RESISTRON® temperature controller must be set and coded according to the temperature coefficient of the
heatsealing band.
The temperature coefficient must be taken from the ROPEX application report and must be set accordingly.

The use of incorrect alloys with a too low temperature coefficient and incorrect coding of the
! RESISTRON® temperature controller leads to uncontrolled heating of the heatsealing band, which
will ultimately burn out!

The original heatsealing bands must be clearly identified by means of suitable markings as well as the connector
geometry, length, or other means to ensure that replacement bands are identical.

Version 1 RES-403 Page 3

 General information

1.4 Impulse transformer

A suitable impulse transformer is necessary in order to guarantee trouble-free operation of the control loop. This
transformer must be designed according to EN 61558 or UL 5058 (isolating transformer with reinforced insulation)
and have a one section bobbin. When the impulse transformer is installed, suitable touch protection must be
provided in accordance with the national installation regulations for electrical equipment. In addition to this, water,
cleaning solutions and conductive fluids must be prevented from seeping into the transformer.
Incorrect installation of the impulse transformer impairs electrical safety.

1.5 Current transformer PEX-W4/-W5

The current transformer supplied with the RESISTRON® temperature controller is an integral part of the control
system.
Only the original ROPEX PEX-W4 or PEX-W5 current transformer may be used. Other transformers may cause
the equipment to malfunction.
The current transformer may only be operated if it is correctly connected to the RESISTRON® temperature
controller (see section "Startup and operation"). The relevant safety instructions contained in section "Power
supply", must be observed. External monitoring modules can be used in order to additionally increase operating
safety. They are not included in the scope of supply of the standard control system and are described in a separate
document.

1.6 Line filter

ROPEX provides line filters in different power classes. The ROPEX application report lists the suitable line filter
which can be ordered accordingly.
The use of an original ROPEX line filter is mandatory in order to comply with the directives mentioned in section
"DECLARATION OF CONFORMITY" on page 6. This device must be installed and connected according to the
instructions contained in section "Power supply" as well as the separate documentation enclosed with the line
filter.

1.7 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 con-
troller can be removed with dry compressed air.

Dust deposits and dirt from liquids result in a loss of function. Accordingly, installation in a switch
! cabinet or terminal cabined with IP54 is recommended.

1.8 Transportation

Store and transport the device in its original carton.

After transport, perform a visual inspection for possible damage.

Page 4 RES-403 Version 1

General information

1.9 Disposal

This device is subject to Directive 2012/19/EU concerning the reduction of the increasing amount of
waste electrical and electronic equipment and the disposal of such waste in an environmentally
sound way.
To guarantee proper disposal and / or the recover of reusable material, please take the device to a
designated municipal collection point and observe local regulations.
Careless, uncontrolled disposal can cause damage to the environment and human health. By
ensuring that your product is disposed of or recycled in a responsible way, you can help protect the
environment and human health.

This device must not be disposed of as residual waste!

!

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 General information

DECLARATION OF CONFORMITY

We hereby declare that the following device has been developed and manufactured in conformance with the direc-
tives cited below:

Designation: RESISTRON temperature controller with accessories

Type: RES-403 with line filter and current transformer

Operating principle: Impulse sealing of films and plastics

Compliant with following standards and directives:

EN 61010-1 Safety requirements for electrical equipment, control, and laboratory use

2014/35/EU low voltage directive

2014/30/EU electromagnetic compatibility directive

2011/65/EU RoHS directive

Note:

This declaration of conformity certifies that the device/electronic itself complies with the above-mentioned direc-
tives. The CE mark on the device/electronic does not relieve the machinery manufacturer of his duty to verify the
conformity of the completely installed, wired and operationally ready system in the machine with the EMC directive.

Comments:

RESISTRON/CIRUS temperature controllers are not independently operable devices. They are used by the
machinery manufacturer to form a sealing system by adding EMC-relevant components such as filters, transfor-
mers, heatsealing bands and wiring. The final configuration may vary significantly in terms of performance and
physical dimensions. All information provided by us in connection with the line filter is merely intended as a guide
and is based on a typical measuring setup. It serves to demonstrate that compliance with the EMC directive can
be achieved by using a line filter that is suitable for the overall system. The line filter and current transformer must,
however, be determined on the basis of the respective application. We also wish to point out that the transformer
which is used must be designed in accordance with VDE 0551/EN 61558 or UL 5058 for safety reasons.

July 12, 2020

J. Kühner (CEO)

ROPEX Industrie-Elektronik GmbH

Adolf-Heim-Str. 4
74321 Bietigheim-Bissingen (Germany)

Page 6 RES-403 Version 1

Application

2 Application
This RESISTRON® temperature controller is an integral part of the "Series 400", the outstanding feature of which
is its microprocessor technology. All RESISTRON temperature controllers are used to control the temperature of
heating elements (heatsealing bands, beaded bands, cutting wires, heatsealing blades, solder elements etc.), as
required in a variety of heatsealing processes.
The controller is most commonly used for impulse-heatsealing PE films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
• etc.

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 dis-
played 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® temper-
ature controller.
The control loop is closed: ACTUAL temperature = SET temperature. Even minute thermal loads on the heat-
sealing band are detected and can be corrected quickly and precisely.
A highly high response thermo-electric control loop is formed which is highly accurate 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 allows optimum adaptation to the load and to the required
dynamic range despite the exceptionally compact dimensions of the controller.

4 Traits of the controller

• 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 con-
trolled system.
• High precision thanks to further improved control accuracy and linearization of the heatsealing band character-
istic.
• High flexibility: The AUTORANGE function (as of October 2005) covers a secondary voltage range from 0.4V
to 120V and a current range from 30A to 500A.
• Automatic adjustment to the line frequency in the range from 47Hz…63Hz.
• Increased protection against dangerous conditions, such as overheating of the heatsealing band.
The ACTUAL temperature of the heatsealing band is supplied to an analog 0…10VDC output. The real heat-
sealing band temperature can thus be displayed on an external temperature indicator (e.g. ATR-x).
The RESISTRON® temperature controller RES-403 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.

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 Installation

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, LEX3500 etc.) and set to the required temperature range (0…300°C, 0…500°C etc.).
The compact design of the RESISTRON® temperature controller RES-403 and the plug-in connections make this
controller easy to install.

5 Installation
 See also section 1 "General information" 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.

5.1 Installation procedure

Proceed as follows to install the RESISTRON® temperature controller RES-403:

1. Switch off the line voltage and verify that the circuit is de-energized.
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
RESISTRON® temperature controller in the range from 47Hz…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 8 "Technical data" on page 42 must be allowed between them.
4. Wire the system in accordance with the instructions in section 5.3 "Power supply" on page 10, section 5.6
"Wiring diagram (Standard)" on page 13 and the ROPEX Application Report. The information provided in
section 5.2 "Installation steps" on page 9 must also be heeded additionally.

Check the tightness of all the system connections, including the terminals for the impulse trans-
! former windings.

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

Page 8 RES-403 Version 1

Installation

5.2 Installation steps

Use heatseal bands with No

Heatseal element suitable temperature coefficient push-on
with coppered ends connectors

Heatsealing band R= f (T)

No additional Connect UR measuring

F resistance wires directly to
in secondary Note heatsealing band ends
circuit number
Sufficient wire
cross-section A of turns Twisted
Current transformer
PEX-W2/-W3 Current measuring
U1 (prim.) wires IR
U2 (sec.)
Line
Temperature Line filter
Avoid long meter
LF-xx480
cables ATR-x
Note
direction
of rotation
Impulse
transformer Note Digital
Dimension polarity Controller potentiometer
transformer correctly PD-x
- Secondary voltage
- Power Configure
- Duty cycle DIP switches
20mm clearance if several correctly
controllers installed on (up to Sept. 2005)
one top hat rail

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 Installation

5.3 Power supply

LINE
L1 (L1)
N (L2) Line
GND/
Earth
Over-current protection
Double-pole circuit-breaker or fuses,
ON Kc
( ROPEX Application Report)
Short-circuit protection only. RESISTRON® temper-
I> I> ! ature controller not protected.
OFF
3
Ka Relay Ka
For "HEAT ON - OFF" function (all-pole) or
"EMERGENCY STOP".
Line filter
LINE The filter type and size must be determined according to
FILTER
the load, the transformer and the machine wiring
( ROPEX Application Report).
Short wires Do not run the filter supply wires (line side) parallel
3
UR
! to the filter output wires (load side).
ROPEX
temperature RESISTRON® temperature controller
IR controller
Relay Kb
Kb Load break (all-pole), e.g. in combination with the alarm
output of the temp. controller (ROPEX recommendation).
When using a series resistor RV-....-1 the relay Kb
! shall be installed.
U1 3
Impulse Transformer
PRIM.
Designed according to EN 61558 (isolating transformer
with reinforced insulation). Connect core to ground.
Use transformers with a one section bobbin. The
! power, duty cycle and voltage values must be deter-
U2
2 mined individually according to the application ( ROPEX
SEC.
Application Report and "Accessories" leaflet for impulse
1
transformers).
2

Wiring
The wire cross-sections depend on the application
( ROPEX Application Report).

R
 Wires must always be twisted (min. 20 turns/meter).
 These wires must be twisted (min. 20 turns/meter)
if several control loops are laid together ("crosstalk").
 Twisting (min. 20 turns/meter) is recommended to
improve EMC.

Page 10 RES-403 Version 1

Installation

5.4 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 distur-
bances.

The use of a suitable line filter is part of the standards conformity and a prerequisite of the CE mark.
!
ROPEX line filters are specially optimized for use in RESISTRON control loops. Providing that they are installed
and wired correctly, they guarantee compliance with the EMC limit values.
You can find the exact specification of the line filter in the ROPEX Application Report calculated for your particular
heatsealing application.
For more technical information:  "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 5.3 "Power supply" on page 10 must be observed.
Example drawing for LF-06480:

Large cross-section
wire to ground

max. 1 m

PE

LINE ROPEX
temperature
controller

Do not lay parallel Mounting plate (galvanized)

Large cross-section Large frame contact surface
wire to ground

5.5 Current transformer PEX-W4/-W5

The PEX-W4/-W5 current transformer supplied with the RESISTRON® temperature controller is an integral part
of the control system. The current transformer may only be operated if it is connected to the temperature controller
correctly ( section 5.3 "Power supply" on page 10).

Version 1 RES-403 Page 11

 Installation

5.5.1 PEX-W4

24 75 14
23 28

terminal
wires

60
12

39
26
14

terminal
block

Snap-on for DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022)

5.5.2 PEX-W5

Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022).

Page 12 RES-403 Version 1

Installation

5.6 Wiring diagram (Standard)

NOTE: Line filter LF-xx480

1
AUTOCAL button
also provided on RES-403 LINE
controller (also with MOD 01) 2

AUTOCAL
8
with 24VDC signal

6
ALARM
OUTPUT
max. 30V/0,2A 5
Contact closed or 3
opened by ALARM
START (HEAT) (see configuration) 4
12
with 24VDC signal U1
prim.

GND 13 Impuls
transformer
Ground
U2
for 24VDC signals. sec.
Must be grounded
externally to prevent
electrostatic
charging! 7 Heat-
UR R sealing
0V 9 band
18 (Internal ground) twisted
No external
START (HEAT) grounding allowed!
with contact 10
IR
15 up to 11
_
production Current transformer
ATR date
°C September 2005
+
ANALOG 14 0V
OUTPUT (Internal ground)
+0...10VDC No external
Cable shielded grounding allowed!
cw

16
2K 0V
(Internnal ground)
17
SET POINT No external
POTENTIOMETER grounding allowed!
PD-3 or PD-5

Version 1 RES-403 Page 13

 Installation

5.7 Wiring diagram with booster connection (MOD 26)

NOTE: Line filter LF-xx480

1
AUTOCAL button
also provided on RES-403 LINE
controller (also with MOD 01) 2
Booster
AUTOCAL 3 1
8 20
with 24VDC signal
IN OUT
19
6 4 2
ALARM
OUTPUT
max. 30V/0,2A 5
Contact closed or 3 NC
opened by ALARM
START (HEAT) (see configuration) 4 NC
12
with 24VDC signal U1
prim.

GND 13 Impuls
transformer
Ground
U2
for 24VDC signals. sec.
Must be grounded
externally to prevent
electrostatic
charging! 7 Heat-
UR R sealing
0V 9 band
18 (Internal ground) twisted
No external
START (HEAT) grounding allowed!
with contact 10
IR
15 up to 11
_
production Current transformer
ATR date
°C September 2005
+
ANALOG 14 0V
OUTPUT (Internal ground)
+0...10VDC No external
Cable shielded grounding allowed!
cw

16
2K 0V
(Internnal ground)
17
SET POINT No external
POTENTIOMETER grounding allowed!
PD-3 or PD-5

Page 14 RES-403 Version 1

Installation

1 ALARM
HEAT
2
OUTPUT
AUTOCAL
3
4

19 20
BOOSTER

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

MOD 26 cannot be used in combination with MOD 40 ("Temperature OK" signal) manufactured up
! to September 2005.

5.8 Wiring diagram with "Temp-

erature reached" signal (MOD 40)
or „Temp. OK“ signal (MOD 46)

+24VDC +24VDC
RES- 403
1

ALARM
HEAT
2

+ OUTPUT
AUTOCAL
Imax. 50mA
3
4

GND GND

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

MOD 40 cannot be used in combination with MOD 26 (booster connection) manufactured prior to
! September 2005.

MOD 46 cannot be used in combination with MOD 40.

!

Version 1 RES-403 Page 15

 Installation

5.9 Startup and operation

5.10 View of the controller

Button for
LEDs AUTOCAL function

Coding switches and

plug-in jumpers

Terminals

Typenschild

Wiring diagramm

5.11 Controller configuration

The controller must be switched off in order to configure the coding switches and plug-in jumpers.
!
5.11.1 Configuration of the DIP switches for secondary voltage and current

Automatic configuration (AUTORANGE)

(as of October 2005)

The secondary voltage and current ranges are automatically configured by the automatic calibration function
(AUTOCAL). The voltage is configured in the range from 0.4VAC to 120VAC and the current in the range from
30A to 500A. If the voltage and/or the current is outside the permissible range, an detailed error message appears
on the controller ( see section 6.12 "Error messages" on page 34).

Configuration with coding switches

(up to September 2005)

Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to the correct position
for your application.

Page 16 RES-403 Version 1

Installation

You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated for your par-
ticular application.

1-10 OFF

Factory settings
ON 1 2 3 4 5
SWITCH

U2 ( V )
ON

3
U2 DIP switch I2 DIP switch
12345

4
1 2 3 4 5
1...10V ON OFF OFF 30...100A OFF OFF
OFF

ON

6...60V OFF ON OFF 60...200A ON OFF

20...120V OFF OFF ON 120...400A ON ON

If the secondary current I2 is less than 30A, the secondary high-current wire must be laid twice (or several times)
through the PEX-W3 or PEX-W4 current transformer ( ROPEX Application Report).

2x

5.11.2 Configuration of the rotary coding switch for the temperature range and alloy

Switch Temp. Temp. Band

position range coefficient alloy
0 300°C 1100ppm/K e.g. A20
1 300°C 780ppm/K e.g. L
4 500°C 1100ppm/K e.g. A20
5 500°C 780ppm/K e.g. L
8 300°C 3500ppm/K SWITCH POS. TEMP. RANGE
0 300°C
ALLOY
1100ppm/K (A20)
1 300°C 780ppm/K (L)
9 PC-CONFIGURATION 0 4
5
500°C
500°C
1100ppm/K (A20)
780ppm/K (L)
1
789

2 34

8 300°C 3500ppm/K
6

9 PC CONFIGURATION
0
5
1
789

2 34

0 = Factory settings
6

The settings for a temperature coefficient of 780ppm (switch position 1 and 5) are only available on controllers
manufactured as of October 2003.
If the switch is set to "9" (as of October 2005), more temperature ranges and alloys can be selected by means of
the ROPEX visualization software ( see section 6.10 "Diagnostic interface/visualization software (as of October
2005)" on page 32).

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 Installation

5.11.3 Configuration of the alarm relay

Alarm relay contact DE-ENERGIZED / PC

CONFIGURATION
opened by alarm/ AT ALARM
ENERGIZED
ALARM OUTPUT
PC-CONFIGURATION.
Alarm relay contact
0
closed by alarm.

789
1
2 34
(factory setting)

6
5

If the plug-jumper is not inserted - or if it is incorrectly inserted - an error message appears when
! the controller is switched on ( section 6.12 "Error messages" on page 34).

If the "Alarm output opened by alarm/PC CONFIGURATION" position is selected (as of October 2005), the
behavior of the alarm output can be configured in more detail by means of the ROPEX visualization software
( see section 6.10 "Diagnostic interface/visualization software (as of October 2005)" on page 32).

5.12 Replacing and "burning in" the heatsealing band

5.12.1 "Burning in" the heatsealing band

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. 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 corrected after a few heating cycles, i.e. the AUTOCAL function must be repeated.
The burn-in effect described here does not occur if the heatsealing band has already been thermally pretreated
by the manufacturer.

An overheated or burned-out heatsealing band must no longer be used because the TCR has been
! altered irreversibly.

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.

Page 18 RES-403 Version 1

Installation

5.12.2 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 manu-
! facturer.

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.

5.13 Startup procedure

Please also refer to section 1 "General information" on page 3 and section 2 "Application" on page 7.

Installation and startup may only be performed by technically trained, skilled persons who are
! familiar with the associated risks and warranty provisions.

5.13.1 Initial startup

Prerequisites: The controller must be correctly installed and connected ( section 5 "Installation" on page 8).
Proceed as follows to start up the controller for the first time:
1. Switch off the line voltage and verify that all circuits are de-energized.
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…63Hz.
3. In the case of controllers manufactured up to September 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 5.11
"Controller configuration" on page 16).
4. Make sure that no START signal is activated.
5. Switch on the line voltage.
6. When the voltage is switched on, the yellow "AUTOCAL" LED lights up for approximately 0.3 seconds to indi-
cate 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
( section 6.10 "Diagnostic interface/visualization software (as of October 2005)" on page 32). In order to
avoid malfunctions, please check the controller configuration before continuing the startup procedure.

7. One of the following states then appears:

"ALARM" "OUTPUT"
ACTION
LED LED

OFF Short pulses Go to 7

every 1.2s

Version 1 RES-403 Page 19

 Controller functions

"ALARM" "OUTPUT"
ACTION
LED LED

BLINKS fast OFF Go to 7

(4Hz)

Lit OFF Fault diagnosis

Continuously ( sec. 6.12)

Activate the AUTOCAL function while the heatsealing band is still cold (either with the manual button on the
controller or by applying an external signal to terminals 8+13). The yellow "AUTOCAL" LED lights up the dura-
tion of the calibration process (approx. 10…15s). A voltage of app. 0VDC appears at the same time at the
actual value output (terminals 14+15). 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 0.66VDC (300°C
range) or 0.4VDC (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 ( section 5.11 "Controller configuration" on page 16 and ROPEX
Application Report). Repeat the calibration after the controller has been configured correctly.
8. When the zero point has been calibrated successfully, set a defined temperature on the set point potentiometer
and activate 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) has a harmonious motion, in other words it must not jump abruptly, fluctuate or deviate temporarily in
the wrong direction. This kind of behavior would indicate that the UR measuring wires have been wired incor-
rectly.
If an error message is displayed, please proceed as described in section 6.12 "Error messages" on page 34.
9. Burn in the heatsealing band ( section 5.12 "Replacing and "burning in" the heatsealing band" on page 18)
and repeat the AUTOCAL function.

The controller is now

ready

5.13.2 Restart after replacing the heatsealing band

To replace the heatsealing band, proceed as described in section 5.12 "Replacing and "burning in" the heatsealing
band" on page 18.

Always use a heatsealing band with the correct alloy, dimensions and copper-plating in order to
! avoid malfunctions and overheating.

Continue with section 5.13.1 steps 4 to 9.

6 Controller functions
See also section 5.6 "Wiring diagram (Standard)" on page 13.

Page 20 RES-403 Version 1

Controller functions

6.1 Indicators and controls

Manufactured as of October 2005

Red LED, lights up or blinks to indicate ALARM.

1

ALARM
HEAT Yellow LED, lit during heating phase.
2

OUTPUT
AUTOCAL
3

Green LED, indicates pulses in measure-

ment mode. In control mode, luminous
4

intensity is proportional to heating current.

Yellow LED, remains lit for duration

RESISTRON of AUTOCAL process.
12 13 14 15 16 17 18
5 6 7 8 9 10 11

RES- 403
Temperature
controller Button for manual activation of AUTOCAL
function (zero calibration). Do not press
ROPEX
Tel:+49(0)7142-7776-0
unless heatsealing band is cold.

Made in Germany

Manufactured up to September 2005

AUTOCAL
Button for manual activation of AUTOCAL
function (zero calibration). Do not press
1

unless heatsealing band is cold.

2

Yellow LED, remains lit for duration

3

OUTPUT

HEAT
of AUTOCAL process.
4

ALARM
Green LED, indicates pulses in measure-
ment mode. In control mode, luminous
! intensity is proportional to heating current.
12 13 14 15 16 17 18
5 6 7 8 9 10 11

Yellow LED, lit during heating phase.

RESISTRON
μP-Controller
Red LED, lights up or blinks to indicate ALARM.

ROPEX
INDUSTRIE - ELEKTRONIK
.

Version 1 RES-403 Page 21

 Controller functions

In addition to the functions shown in the diagram above, various controller operating states are indicated by the
LEDs. These states are described in detail in the table below:

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

RESET active,
AUTOCAL START and AUTOCAL AUTOCAL requested, but
AUTOCAL executing
(yellow) functions are locked function disabled
(as of October 2005)

HEAT START requested,

— START executing
(yellow) but function disabled

OUTPUT
In control mode the luminous intensity is proportional to the heating current.
(green)

ALARM Configuration error, Controller calibrated incor-

Fault,  section 6.12
(red) AUTOCAL not possible rectly, run AUTOCAL

6.2 Temperature setting (set point selection)

The heatsealing temperature is set by means of a 2kΩ potentiometer at terminals 16+17. The connecting wires
between the controller and the potentiometer must be shielded ( section 5.6 "Wiring diagram (Standard)" on
page 13).

RES-403
Set point 17
selection 3
cw

input
2
2K
1
0V 16
Cable shielded

e.g. PD-3
Potentiometer P03
with 3
digital dial KD 1
2

Setting range:
0Ω  0°C
2kΩ  300°C (PD-3) or 500°C (PD-5)
(depending on the controller configuration).
The relationship between the potentiometer setting and the SET temperature is linear.

The terminals 16+17 are not potenial-free and might have the potential of the secondary voltage of
! the impulse transformer.

Page 22 RES-403 Version 1

Controller functions

For the terminals of the external potentiometer touch voltage protection must be installed.
!
External grounding is not allowed. If this warning is ignored, the controller will be damaged by frame
! currents.

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

6.3 Temperature indication (actual value output)

The RES-403 supplies an analog 0…10VDC signal, which is proportional to the real ACTUAL temperature, at
terminals 14+15.

RES-403
Actual value max. 5mA
R=33Ohm
output 14
0...10VDC

0V 15

0...10VDC
+

Temperature
meter
e.g. ATR-3

Voltage values:
0VDC  0°C
10VDC  300°C (ATR-3) or 500°C (ATR-5)
(depending on the controller configuration)

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 Controller functions

The relationship between the change in the output voltage and the ACTUAL temperature is linear.

°C 0 - 300°C range
Temperature T

300
270
240
210
180
150
120
90
60

20°C

1 2 3 4 5 6 7 89 10
0.66V Voltage U VDC
"ZERO"

°C 0 - 500°C range
Temperature T

500
450
400
350
300
250
200
150
100

20°C
1 2 3 4 5 6 7 89 10
0.4V Voltage U VDC
"ZERO"

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 indicator (size, scaling, dynamic response) are ideally
suited to this application and this instrument should therefore always be used ( section 10 "Modifications
(MODs)" on page 44).
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 indicator moreover permits disturbances in the control loop (loose connections, contacting or wiring prob-
lems) as well as any line disturbances to be observed extremely effectively and interpreted accordingly. The same
applies if mutual interference occurs between several neighboring control loops.

This output is not potential-free and might have the potential of the secondary voltage of the
! impulse transformer.

Page 24 RES-403 Version 1

Controller functions

External grounding is not allowed. If this warning is ignored, the controller will be damaged by frame
! currents.

For the terminals of the external temperature meter touch voltage protection must be installed.
!
If an alarm is signaled, the analog output at terminals 14+15 is used to display a selective error message
( section 6.12 "Error messages" on page 34).

6.4 Automatic zero calibration (AUTOCAL)

Because of 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).

You should always wait for the heatsealing band and the bar to cool down (to ambient temperature)
! before activating the AUTOCAL function.

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 ( section 6.10 "Diagnostic interface/visualization software (as of
October 2005)" on page 32). 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 soft-
ware. The initial temperature for this setting can be specified in the +3…+40°C range via the set point potentiom-
eter (terminals 16+17;  section 6.2 "Temperature setting (set point selection)" on page 22). The value selected
at the set point potentiometer must be present when the "AUTOCAL" function is activated.
If the specified value is too high (greater than 40°C) or if the selected value varies, an error message appears
(error codes 115 and 116;  section 6.12 "Error messages" on page 34).

24VDC
RES- 403
AUTOCAL
8
max. 6mA

GND
13

HIGH: 12VDC AUTOCAL

LOW: 2VDC

0,1...5s

Version 1 RES-403 Page 25

 Controller functions

The AUTOCAL function is activated either by means of a 24VDC pulse at terminals 8+13 or by pressing the
AUTOCAL button on the controller.

The automatic calibration process takes about 10…15 seconds. 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 (ter-
minals 14+15) is 0…3°C (corresponds to app. 0 VDC) during this process.
If the temperature of the heatsealing band varies on controllers manufactured as of October 2005, the "AUTOCAL"
function is executed a maximum of three times. If the function still cannot be terminated successfully, an error
message appears ( section 6.12 "Error messages" on page 34).

You should always wait for the heatsealing band and the bar to cool down (to ambient temperature)
! before activating the AUTOCAL function.

Reasons for disabled AUTOCAL function:

1. The AUTOCAL function cannot be activated until 10 seconds after the controller is switched on. If you attempt
to activate it sooner, it will not function.
2. The AUTOCAL function is not activated if the heatsealing band is cooling down at a rate of more than 0.1K/
sec. If the control signal is activated, the function is activated automatically providing the cooling rate has fallen
below the above mentioned value.
3. If the "START" signal (24VDC) is active, the AUTOCAL function is not executed ("HEAT" LED lit).
4. AUTOCAL cannot be activated if error codes 101…103, 201…203, 801 or 9xx (up to September 2005: error
codes 1…3, 5…7) occur at start-up. AUTOCAL cannot be activated with error codes 201…203, 801 or 9xx (up
to September 2005: error codes 5…7). If the controller has operated correctly, at least one time, after start-up
( section 6.12 "Error messages" on page 34).

If the AUTOCAL function is disabled and if you attempt to activate it then the "AUTOCAL" LED
! blinks.

6.5 "START" signal (HEAT)

When the "START" signal is activated, the controller-internal 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.
The "HEAT" LED on the front panel of the RES-403 is lit continuously for the duration of the heating phase.
The "START" signal can be activated in two ways:

Page 26 RES-403 Version 1

Controller functions

• By means of a 24VDC signal at terminals 12+13

24VDC
START RES- 403
(HEAT)
12
max. 6mA

GND
13

HIGH: 12VDC

START
(HEAT)
LOW: 2VDC

or
• By means of a control contact at terminals 15+18

max.
5mA RES- 403
18
START
(HEAT)
with
contact
15 0V

The "START" signal is disabled as long as the AUTOCAL function is executing ("AUTOCAL" LED lit, "HEAT" LED
blinks).

The terminals 15+18 are not potenial-free and might have the potential of the secondary voltage of
! the impulse transformer.

For the terminals of the control contact touch voltage protection must be installed.
!
External grounding is not allowed. If this warning is ignored, the controller will be damaged by frame
! currents.

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 ("HEAT" LED blinks).
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 September 2005: error codes 8…12) ( section 6.12 "Error mes-
sages" on page 34). The heatsealing band is no longer heated up.

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 Controller functions

6.6 Measuring impulse duration

(as of October 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 1.7ms for certain applications ( ROPEX
Application Report).
This parameter can only be set by means of the ROPEX visualization software ( section 6.10 "Diagnostic inter-
face/visualization software (as of October 2005)" on page 32).

6.7 Automatic phase angle

compensation (AUTOCOMP)
(as of October 2005)

It may be necessary to compensate the phase angle displacement between the UR and IR measuring signals in
certain heatsealing applications ( ROPEX Application Report). The "AUTOCOMP" function is provided for this
purpose.
The "AUTOCOMP" function must be activated in the ROPEX visualization software ( section 6.10 "Diagnostic
interface/visualization software (as of October 2005)" on page 32).
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 ( section 6.4 "Automatic zero
calibration (AUTOCAL)" on page 25) 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 2.0s. The second
"AUTOCAL" function only takes around 2.0s and incorporates the "AUTOCOMP" function.
If the interval following a successful "AUTOCAL" function is longer than 2.0s, the display returns to the home
position without executing the „AUTOCOMP“ function.

Page 28 RES-403 Version 1

Controller functions

AUTOCAL <2.0s
signal
24VDC "AC" "AP"

0
t

Function
AUTOCOMP

AUTOCAL
0
t
"AUTOCAL"
LED
lit

OFF
t

"OUTPUT"
LED
lit

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.approx. 0VDC).
3. „AUTO“
(as of software revision 108)
With this setting the „AUTOCOMP“ function is activated automatically after the "AUTOCAL" function has been
successfully executed.

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 Controller functions

AUTOCAL
signal
24VDC „AC“

0
t

Function
AUTOCOMP

AUTOCAL
0
t
„AUTOCAL“
LED
lit

OFF
t

„OUTPUT“
LED
lit

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.approx. 0VDC).

6.8 Temperature diagnosis

(as of October 2005)

An additional temperature diagnosis can be activated in the ROPEX visualization software ( section 6.10 "Diag-
nostic interface/visualization software (as of October 2005)" on page 32). The RES-403 checks whether the
ACTUAL temperature is within a settable tolerance band ("OK" window) on either side of the SET temperature.
The lower ( Δϑ lower ) and upper ( Δϑ upper ) tolerance band limits are configured in the factory to -10K and +10K.
These values can be set independently of one another in the ROPEX visualization software.
If the actual temperature is inside the specified tolerance band when the "START" signal is activated, the temper-
ature 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 relay is switched ( section 6.12 "Error messages" on page 34).

Page 30 RES-403 Version 1

Controller functions

Actual value
Set+ Δϑ upper

Set

Set+ Δϑ lower

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 relay is switched.
An additional delay time (0…9.9s) can be set in the ROPEX visualization software. The first time the lower toler-
ance 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 suppressed, e.g. if the temperature drops tem-
porarily 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 and the
delay time are identical to those for the "Temperature OK" signal (MOD 46).

Version 1 RES-403 Page 31

 Controller functions

6.9 Heatup timeout

(as of October 2005)

An additional heatup timeout can be activated in the ROPEX visualization software ( section 6.10 "Diagnostic
interface/visualization software (as of October 2005)" on page 32).
This timeout starts when the START signal is activated. The RES-403 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 relay is switched ( section 6.12 "Error messages" on
page 34).

Actual value

Set
95% of Set

Timeout

Time
Heatup time Alarm
304

6.10 Diagnostic interface/visualization software (as of October 2005)

An interface with a 6-pole Modular Jack (RJ-12) is provided for system diagnostics and process visualization. This
interface allows a data connection to be set up to the ROPEX visualization software using the ROPEX communi-
cation interface CI-USB-1.
DIAG

0
789
1
2 34
6

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.

Page 32 RES-403 Version 1

Controller functions

6.11 System monitoring/alarm output

To increase operating safety and to avoid faulty heatsealing, this controller incorporates special hardware and
software features that facilitate selective fault detection and diagnosis. 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

three states:

1. Blinks fast (4Hz)

The AUTOCAL function should be executed (error codes 104…106, 211, 302, 303; up to September 2005:
error codes 8+9).
2. Blinks slowly (1Hz)
The system configuration is incorrect and the zero calibration (AUTOCAL function) was unsuccessful
( section 5.11 "Controller configuration" on page 16). It corresponds to error codes 110…114 (up to Sep-
tember 2005: error codes 10…12).
3. Lit continuously:
This indicates that a fault is preventing the controller from being started (error codes 101…103, 107, 108,
201…203, 307, 308, 801, 9xx; up to September 2005: error codes 1…7).
As a rule, it refers to an external wiring fault.

B.) Alarm relay (relay contact terminals 5+6):

This contact is set in the factory as follows:

• OPEN in operating states A.1) and A.2), but closed if a "START" signal is activated in one of these states.
• CLOSED in operating state A.3)
If the alarm relay is configured opposite to the factory setting ( section 5.11.3 "Configuration of the alarm relay"
on page 18), these states are reversed.

C.) Error code output via the 0…10VDC analog

output (terminals 14+15):

Since a temperature indication is no longer necessary if a fault occurs, the analog output is used to dis-
play error messages in the event of an alarm.

13 voltage levels (up to September 2005: 12 voltage levels) are offered for this purpose in the 0…10VDC range,
each of which is assigned an error code ( section 6.12 "Error messages" on page 34).
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 September 2005: error codes 8…12), the signal at the analog output jumps back
and forth at 1Hz between the voltage value which corresponds to this error and the end of the scale (10VDC, 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.

An alarm can only be reset by switching the controller off and then on again.
!
Invalid error messages may appear when the controller is switched off owing to the undefined oper-
! ating state. This must be taken into account when they are evaluated by the higher-level controller
(e.g. a PLC) in order to avoid false alarms.

Version 1 RES-403 Page 33

 Controller functions

6.12 Error messages

The table below shows how the analog voltage values correspond with the faults that have occurred. It also
describes the fault and the required corrective action.
The error messages are listed in two separate tables for controllers "up to September 2005" and "as of October
2005". The block diagram in section 6.13 "Fault areas and causes" on page 39 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
October 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 ( section 6.10 "Diagnostic interface/visualization
software (as of October 2005)" on page 32) to facilitate troubleshooting.

If the actual value output is evaluated in order to identify an error message - in the higher-level con-
! troller, for instance - the tolerance window must be adjusted to prevent it from being incorrectly
interpreted. Please note the tolerances of the actual value output ( section 8 "Technical data" on
page 42).

Page 34 RES-403 Version 1

Controller functions

Part 1 of 3: Error messages as of October 2005 (faults)

NOTE: The error messages shown here are output as faults (constant error voltage at actual value output,
alarm LED lit continuously, alarm relay energized).

Act. val.
Action if machine
Error output Action if machine
Cause already operated, HS
code voltage started for first time
band not changed
[V]

101 0.66 No current signal Fault area  Fault area 

102 1.33 No voltage signal Fault area  Fault area 

103 2.00 No current / voltage signals Fault area  Fault areas 

107 Temperature step, down Fault areas  Fault areas 
108 Temperature step, up ("loose contact") ("loose contact")

307
2.66
308 Temperature too high / low
- -
309 ( section 6.8)

310

No line frequency / line fre-

201
quency fluctuates

Line frequency too high /

202 3.33 Check power supply Check power supply
fluctuates

Line frequency too low /

203
fluctuates

Heatup time too long

304 4.00 Perform RESET Perform RESET
( section 6.9)

901 No line voltage / sync signal Replace device Replace device

913 Triac defective Replace device Replace device

914

915 4.66 Internal fault, device defective Replace device Replace device

916

917 Jumper for alarm output incor-

Check jumper Check jumper
918 rect

Version 1 RES-403 Page 35

 Controller functions

Part 2 of 3: Error messages as of October 2005 (warnings)

NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth
between two values, alarm LED blinks, alarm relay de-energized). When the "START" signal is activated, the
warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm
LED lit continuously, alarm relay energized).

Act. val.
Action if machine
Error output Action if machine
Cause already operated, HS
code voltage started for first time
band not changed
[V]

Current signal incorrect,

104 incorrect impulse transformer
specification

Voltage signal incorrect, Perform AUTOCAL ,

105 incorrect impulse transformer check transformer specifi-
specification cation,
fault areas
Current and voltage signals
incorrect,
106
5.33 incorrect impulse transformer Fault areas 
 10  specification ("loose contact")
Temperature too low,
calibration not performed,
302
loose contact, Perform AUTOCAL
ambient temp. fluctuates and / or
Temperature too high, fault areas 
calibration not performed, ("loose contact")
303
loose contact,
ambient temp. fluctuates

6.00
211 Data error Perform AUTOCAL Perform AUTOCAL
 10 

Page 36 RES-403 Version 1

Controller functions

Part 3 of 3: Error messages as of October 2005 (warnings)

NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth
between two values, alarm LED blinks, alarm relay de-energized). When the "START" signal is activated, the
warning changes to a fault (actual value output no longer jumps back and forth, see bold italic values, alarm
LED lit continuously, alarm relay energized).

Act. val.
Action if machine
Error output Action if machine
Cause already operated, HS
code voltage started for first time
band not changed
[V]

6.66 Current signal incorrect, Fault area , Fault areas 

111
 10  no calibration possible check configuration ("loose contact")

7.33 Voltage signal incorrect, Fault area , Fault areas 

112
 10  no calibration possible check configuration ("loose contact")

Current / voltage signals incor-

8.00 Fault area , Fault areas 
113 rect,
 10  check configuration ("loose contact")
no calibration possible

Perform AUTOCAL Perform AUTOCAL

Temperature fluctuates, and / or and / or
114
no calibration possible fault areas  fault areas 
("loose contact") ("loose contact")
8.66 Perform AUTOCAL with Perform AUTOCAL with
Ext. calibration temp. too high,
115  10  ext. calibration tempera- ext. calibration tempera-
no calibration possible
ture ≤40°C ture ≤40°C

Ext. calibration temp. fluctu- Perform AUTOCAL with Perform AUTOCAL with
116 ates, stable ext. calibration stable ext. calibration
no calibration possible temperature temperature

Version 1 RES-403 Page 37

 Error messages up to September 2005

Page 38
Error Act. value Temp. Temp. ALARM STATUS Action Action if machine
output ; 300°C 500°C of alarm relay Cause if machine started already operating,
code LED
Voltage [V] [°C] [°C] (factory set.) for first time HS-band not chang.
1 0.66 20 33 IR signal missing Fault area  Fault area 

2 1.33 40 66 UR signal missing Fault area  Fault area 

3 2.00 60 100 UR and IR signals missing Fault area  Fault areas 

Fault areas  Fault areas 

4 2.66 80 133 Temperature step
Lit (loose contact) (loose contact)
Closed
Continuously
Frequency fluctuation,
5 3.33 100 166 Check power supply Check power supply
inadmissible line frequency

6 4.00 120 200 Internal fault Run RESET Run RESET

Internal fault,
7 4.66 140 233 Replace controller Replace controller
controller defective

RES-403
5.33 160 266 UR and/or IR signal
8 Run AUTOCAL Fault areas 
 10  300 500 Blinks incorrect
fast Open,
6.00 180 300 (4Hz)
9 does not close Data error Run AUTOCAL ---
 10  300 500
until "START"
6.66 200 333 signal IR signal incorrect, Fault area ,
10 ---
 10  300 500 (voltage value calibration not possible check configuration
Blinks at analog
7.33 220 365 output then UR signal incorrect, Fault area ,
11 slowly ---
 10  300 500 no longer calibration not possible check configuration
(1Hz)
changes)
8.00 240 400 UR and IR signals incorrect, Fault areas ,
12 ---
 10  300 500 calibration not possible check configuration
Controller functions

Version 1
Controller functions

6.13 Fault areas and causes

5 1 2 2 9

6 3
Temperature
4 controller
HARDWARE
9

123 45
8 I2 8
UR
7
1 U2 7
IR
8

The table below explains the possible fault causes.

Fault area Explanation Possible causes

Load circuit interrupted after UR - Wire break, heatsealing band break

pickoff point - Contact to heatsealing band defective

Current transformer signal - IR measuring wires from current transformer interrupted
interrupted

- Wire break, triac in controller defective

Primary circuit interrupted
- Primary winding of impulse transformer interrupted

Secondary circuit interrupted - Wire break
before UR pickoff point - Secondary winding of impulse transformer interrupted

 UR signal missing - Measuring wires interrupted

- Heatsealing band partially bypassed by conducting part

 Partial short-circuit (delta R)
(clamp, opposite heatsealing bar etc.)

- Wire break, heatsealing band break

 Parallel circuit interrupted
- Contact to heatsealing band defective

- Heatsealing band installed incorrectly, insulation at

 Total short-circuit heatsealing bar ends missing or incorrectly installed
- Conducting part bypasses heatsealing band completely

- Up to September 2005: DIP switches 1 - 3 configured

incorrectly (U2 range)
 UR signal incorrect
- As of October 2005: U2 outside permissible range
from 0.4…120VAC

Version 1 RES-403 Page 39

 Factory settings

Fault area Explanation Possible causes

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

incorrectly (I2 range)
IR signal incorrect
- As of October 2005: I2 outside permissible range
 from 30…500A

Turns through current transformer - Check number of turns (two or more turns required for
incorrect currents < 30A)

- Hardware fault (replace controller)

 Internal controller fault - Plug-in jumper for alarm output not connected or
incorrectly connected

7 Factory settings
The RESISTRON® temperature controller RES-403 is configured in the factory as follows:

DIP switches U2 = 6…60VAC

for OFF I2 = 30…100A
secondary voltage
U2 and current I2 DIP switches: 2 ON
(up to September ON 1 2 3 4 5 1, 3, 4, 5 OFF
2005)
These switches are automatically set by
the AUTORANGE function on all
controllers manufactured as of October
2005.

Rotary coding switch Heatsealing band alloy: Alloy A20

for Temperature range: 300°C
heatsealing band alloy Maximum temperature: 300°C
and SWITCH POS.
0
1
temperature range 0 4
5
Rotary coding switch: "0" position
12
789

8 300°C
34
6

9
5

Plug-in jumper Cobtact closes by alarm

for
alarm relay
SWITCH POS.
0
1
0 4
5
1
789

2 34

8 300°C
6

9
5

Automatic phase AUTOCOMP: OFF

angle compensation
(AUTOCOMP)
[X]

Page 40 RES-403 Version 1

Factory settings

Measuring impuse Measuring impulse length: 1,7ms

duration

[X]

„Temp. OK“ signal Tolerance band: -10K…+10K

(as of October 2005:
With MOD 46 only)
[X]

Temperature Temperature diagnosis: OFF

diagnosis

[X]

Heatup timeout Heatup timeout: OFF

[X]

[X] As of October 2005:

With ROPEX visualization software only.

Version 1 RES-403 Page 41

 Technical data

8 Technical data
Type of construction Housing for installation in the electrical cabinet
Snaps onto a standard top hat rail (DIN TS35 rail, 35 mm) acc. to DIN EN 50022
Dimensions: 90 x 75mm; height: 135mm (incl. terminals)

Line voltage All controllers manufactured as of October 2005:

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

All controllers manufactured as of January 2004 up to September 2005:

115VAC version: 115VAC -15%…120VAC +10% (equivalent to 98…132VAC)
230VAC version: 230VAC -15%…240VAC +10% (equivalent to 196…264VAC)
400VAC version: 400VAC -15%…415VAC +10% (equivalent to 340…456VAC)

All controllers manufactured up to December 2003:

115VAC, 230VAC or 400VAC, tolerance: +10% / -15%

depending on version selected ( section 11 "How to order" on page 46)

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

Heatsealing band All controllers manufactured as of October 2005:

type and temperature The temperature range and temperature coefficient settings can also be specified
range by means of the ROPEX visualization software ( section 6.10 "Diagnostic
interface/visualization software (as of October 2005)" on page 32) in addition to
the rotary coding switch (see below):
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)

Five different ranges can be set on the controller with a rotary coding switch:
Temperature coefficient 1100ppm, 0…300°C (e.g. Alloy A20), default
Temperature coefficient 780ppm, 0…300°C (e.g. Alloy L)
Temperature coefficient 1100ppm, 0…500°C (e.g. Alloy A20)
Temperature coefficient 780ppm, 0…500°C (e.g. Alloy L)
Temperature coefficient 3500ppm, 0…300°C (e.g. LEX3500)

The settings for a temperature coefficient of 780ppm are only available on control-
lers manufactured as of October 2003.

Set point selection With an external PD-3 or PD-5 precision potentiometer (R = 2kΩ)
Terminals 16+17 0…2kΩ, equivalent to 0…300°C or 0…500°C

Analog output 0…10VDC, Imax = 5mA

(actual value) Equivalent to 0…300°C or 0…500°C
Terminals 14+15 Accuracy: ±1% add. 50mV

Digital logic levels LOW (0V): 0…2VDC

Terminals 8, 12, 13 HIGH (24VDC): 12…30VDC (max. current input 6mA)
Reverse polarity-protected

Page 42 RES-403 Version 1

Technical data

Digital logic levels Umax = 30VDC

„Temp. reached“ Imax = 50mA
signal UON < 2V (saturation voltage)
(MOD 40)
or "Temp. OK" signal
(MOD 46)

Alarm relay Umax = 30V (DC/AC), Imax = 0.2A, potential-free

Maximum load Imax = 5A (duty cycle = 100%)

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

Power dissipation max. 20W

Ambient +5…+45°C
temperature

Degree of protection IP20

Installation If several controllers are installed on one top hat

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

The moving clip required for fastening must be

facing down for mounting on a horizontal top hat
rail.

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

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

Housing material Plastic, polycarbonate, UL-94-V0

Connecting cables Rigid or flexible; 0.2…2.5mm² (AWG 24…12)

Type / cross-sections Plug-in

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.

Version 1 RES-403 Page 43

 Dimensions

9 Dimensions

135.0
113.0
75.0 90.0

10 Modifications (MODs)
Owing to its universal design, the RESISTRON® temperature controller RES-403 is suitable for a very wide range
of heatsealing applications.
Various modifications (MODs) are available for the RESISTRON® temperature controller RES-403 for imple-
menting special applications.
The modifications described here are just a few of the large number available. Separate documents are supplied
for all modifications.
The modifications must be ordered separately.

MOD 01
Amplifier for low secondary voltages (UR = 0.25…16VAC). This modification is necessary, for example, for very
short or low-resistance heatsealing bands.

MOD 26
Additional terminal for connecting an external switching amplifier (booster). This modification is necessary for high
primary currents (continuous current > 5A, pulsed current > 25A).

Page 44 RES-403 Version 1

Modifications (MODs)

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
! September 2005.

MOD 46 (as of October 2005)

Additional terminal for "Temperature OK" signal. If this modification is installed, the RES-403 checks whether the
ACTUAL temperature is within a settable tolerance band ("OK" window) on either side of the SET temperature.
The lower ( Δϑ lower ) and upper ( Δϑ upper ) tolerance band limits are configured in the factory to -10K and +10K.
These values can be set independently of one another in the ROPEX visualization software ( section 6.10
"Diagnostic interface/visualization software (as of October 2005)" on page 32).
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):

Actual value
Set+ Δϑ upper

Set

Set+ Δϑ lower

Time
Signal
„Temp. OK“
Conductive
Not conduct.
Time

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).

Version 1 RES-403 Page 45

 How to order

11 How to order
Pictures exemplary.

Contr. RES - 403 / . . . VAC

115: Power supply 115VAC, P/N 740301
230: Power supply 230VAC, P/N 740302
400: Power supply 400VAC, P/N 740303
Scope of supply: Controller includes connector plug-in
parts (without current transformer)

Modification MOD . . (optional, if required)

e.g.
01: MOD 01, P/N 800001 (Amplifier for low voltage)
26: MOD 26, P/N 800026 (Booster connection)
40: MOD 40, P/N 800040 ("Temp. reached" signal)
46: MOD 46, P/N 800046 ("Temp. OK" signal)

Please indicate the article numbers of the controller and the required modifications
(optional) in all orders,
e.g. RES-403/400VAC + MOD 26
(controller for 400VAC power supply with booster connection)
P/N 740303 + 800026 must be ordered

Current transformer PEX-W4

P/N 885106

Line filter LF- . . 480

06: Continuous current 6A, 480VAC, P/N 885500
35: Continuous current 35A, 480VAC, P/N 885506

Impulse transformer
See ROPEX Application Report
for design and ordering information

Communiction interface CI-USB-1

P/N 885650

Potentiometer PD- .
3: For 300°C range, P/N 881103
5: For 500°C range, P/N 881105
Scope of supply: Potentiometer with digital dial

Temp. meter ATR- .

3: 300°C range, P/N 882130
5: 500°C range, P/N 882150

Page 46 RES-403 Version 1

How to order

Booster B- . . .
075415: Max. pulse load 75A, 415VAC, P/N 885302
100400: Max. pulse load 100A, 400VAC, P/N 885304

For more accessories: "Accessories" leaflet

Version 1 RES-403 Page 47

 Index

12 Index
A Installation 8, 43
Actual value output 23 Installation procedure 8
Alarm output 33 Installation regulations 8
Alarm relay 18, 43
Alloy 17, 20 L
Ambient temperature 43 Line filter 4, 10, 11, 46
Application 7 Line frequency 7, 42
Application Report 8, 11, 17 Line voltage 42
AUTOCAL 7, 20, 25
AUTOCOMP 28
M
Automatic phase angle compensation 28
Maintenance 4
Automatic zero calibration 7, 20, 25
Measuring impulse duration 28
AUTOTUNE 7
Modifications 14, 15, 44, 46
MODs 14, 15, 44, 46
B
Booster 14, 44, 47
O
Burning in the heatsealing band 18, 20
Over-current protection 10
Overheating of heatsealing band 7
C
Circuit-breaker 10
P
CI-USB-1 32, 46
PEX-W4 46
Communication interface 32, 46
PEX-W4/-W5 4, 11
Controller configuration 16
Phase angle compensation 28
Controls 21
Potentiometer 22, 46
Current transformer 11, 46
Power dissipation 43
Power supply 10, 46
D Principle of operation 7
Degree of protection 43
Diagnostic interface 32
R
Dimensions 44
Replacing the heatsealing band 19, 20
DIP switches 16
Disposal 5
S
Secondary current I2 16
E
Secondary voltage U2 16
Error messages 34
Set point potentiometer 22
External switching amplifier 14
Set point selection 22, 42
Signal „Temperatur erreicht“ 45
F "START" signal 20, 26
Factory settings 40 Startup 16
Fault areas 39 System diagnostics 32
Fault diagnosis 7 System monitoring 33
Fuse 10
T
H TCR 3, 18
HEAT 20, 26 Technical data 42
Heatsealing band type 42 Temperature coefficient 3, 18
Heatup timeout 32 Temperature control 7
How to order 46 Temperature diagnosis 30
Temperature indication 23, 24
I Temperature meter 46
Impulse heatsealing method 7 Temperature OK signal 15
Impulse transformer 10, 46 Temperature range 17, 42

Page 48 RES-403 Version 1

Index

Temperature reached signal 15, 45 V

Temperature setting 22 View of the controller 16
Transformer 4, 10, 46 Visualization software 32
Transportation 4
Type of construction 42
W
Wiring 8, 10
Wiring diagram 13, 14

Version 1 RES-403 Page 49