RES-420 - Control Tempe

RESISTRON
GB
RES-420
Operating
Instructions
Important features
• Microprocessor technology
• LC display (green), 4 lines, 20 characters, (multilingual)
Alternatively:
VF display (blue), 4 lines, 20 characters, (multilingual)
• Automatic zero calibration (AUTOCAL)
• Automatic optimization (AUTOTUNE)
• Automatic configuration of the secondary voltage and current ranges
(AUTORANGE, as of software revision 100)
• Automatic phase angle compensation (AUTOCOMP, as of software revision 100)
• Automatic frequency adjustment
• Large current and voltage range
• Booster connection as standard
• Heatsealing band alloy and temperature range selectable
• Alarm function with fault diagnosis
Identical design to and compatible with RES-210, -211, -220, -221

12.1.09
Industrie-Elektronik GmbH Tel: +49/(0)7142/7776-0 E-Mail: info@ropex.de

Gansäcker 21 Fax: +49/(0)7142/7776-19 Internet: www.ropex.de
D-74321-Bietigheim-Bissingen (Germany) Data subject to change
Contents
1 Safety and warning notes . . . . . . . . . . . . . . 3 10 Controller functions . . . . . . . . . . . . . . . . . 24
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10.1 Indicators and controls . . . . . . . . . . . 24
1.2 Heatsealing band ................ 3 10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Impulse transformer .............. 3 10.3 Navigation in the menus . . . . . . . . . . 26
1.4 Current transformer PEX-W2/-W3 . . . . 3 10.4 Menu structure . . . . . . . . . . . . . . . . . . 28
1.5 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4 10.5 Two-digit numbering system
1.6 Warranty provisions . . . . . . . . . . . . . . . 4 up to software revision 027 . . . . . . . . 30
1.7 Standards / CE marking . . . . . . . . . . . 4 10.6 Menu steps . . . . . . . . . . . . . . . . . . . . 31
10.7 Temperature setting (set point
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
selection) . . . . . . . . . . . . . . . . . . . . . . 35
3 Principle of operation . . . . . . . . . . . . . . . . . 5 10.8 Temperature indication . . . . . . . . . . . 35
4 Description of the controller ........... 6 10.9 Automatic zero calibration
(AUTOCAL) . . . . . . . . . . . . . . . . . . . . 35
5 Accessories and modifications . . . . . . . . . 7
10.10 "START" signal (HEAT) . . . . . . . . . . . 35
5.1 Accessories . . . . . . . . . . . . . . . . . . . . . 7
10.11 Cycle counter . . . . . . . . . . . . . . . . . . . 36
5.2 Modifications (MODs) . . . . . . . . . . . . . 8
10.12 Hold mode . . . . . . . . . . . . . . . . . . . . . 36
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . 9
10.13 Measuring impulse duration
7 Dimensions/front panel cutout . . . . . . . . . 11 (as of software revision 026) . . . . . . . 37
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 12 10.14 Automatic phase angle
8.1 Installation procedure . . . . . . . . . . . . 12 compensation (AUTOCOMP)
(as of software revision 100) . . . . . . . 37
8.2 Installation steps . . . . . . . . . . . . . . . . 13
10.15 Locking the "HAND" key
8.3 Power supply . . . . . . . . . . . . . . . . . . . 14
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 15
10.16 Temperature unit
8.5 Current transformer PEX-W3 . . . . . . 15 Celsius / Fahrenheit
8.6 Wiring diagram (standard) . . . . . . . . . 16 (as of software revision 106) . . . . . . . 38
8.7 Wiring diagram with booster 10.17 Disabling the Configuration menu . . . 38
connection . . . . . . . . . . . . . . . . . . . . . 17 10.18 Setting the display brightness
9 Startup and operation . . . . . . . . . . . . . . . . 18 (VF display only) . . . . . . . . . . . . . . . . 39
9.1 Front view of the controller . . . . . . . . 18 10.19 Undervoltage detection . . . . . . . . . . . 39
9.2 Rear view of the controller . . . . . . . . . 18 10.20 Diagnostic interface/visualization software
9.3 Controller configuration . . . . . . . . . . . 19
10.21 Booster connection . . . . . . . . . . . . . . 40
9.4 Heatsealing band . . . . . . . . . . . . . . . 22
10.22 System monitoring/alarm output . . . . 40
9.5 Startup procedure . . . . . . . . . . . . . . . 23
10.23 Error messages . . . . . . . . . . . . . . . . . 40
10.24 Fault areas and causes . . . . . . . . . . . 44
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 46
11.1 Customer settings
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 47
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 48
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Page 2 RES-420
Safety and warning notes
1 Safety and warning notes

This RESISTRON temperature controller is The RESISTRON temperature controller must be set
manufactured according to DIN EN 61010-1. In the and coded according to the temperature coefficient of
course of its manufacture it passed through quality the heatsealing band.
assurance, whereby it was subjected to extensive
inspections and tests. The use of incorrect alloys with a too low
It left the factory in perfect condition. ! temperature coefficient and incorrect coding
The recommendations and warning notes contained in of the RESISTRON temperature controller lead to
these operating instructions must be complied with, in uncontrolled heating and ultimately to burn-out of
order to guarantee safe operation. the heatsealing band!
The device can be operated within the limits indicated
in the "Technical Data" without impairing its operational The heatsealing bands that were originally supplied
safety. Installation and maintenance may only be must be identified by detail specification, part number
performed by technically trained, skilled persons who or some other means that will assure that replacement
are familiar with the associated risks and warranty bands are identical.
provisions.
1.3 Impulse transformer

1.1 Use
A suitable impulse transformer is necessary to ensure
RESISTRON temperature controllers may only be used that the control loop functions perfectly. This
for heating and temperature control of heatsealing transformer must be designed according to VDE 0570/
bands which are expressly suitable for them, and EN 61558 (isolating transformer with reinforced
providing the regulations, notes and warnings insulation) and have a one section bobbin. When the
contained in these instructions are complied with. impulse transformer is installed, suitable shock
protection must be provided in accordance with the
In case of non-compliance or use contrary to national installation regulations for electrical
! the intended purpose, there is a risk that equipment. In addition, water, cleaning solutions and
safety will be impaired or that the heatsealing band, conductive fluids must be prevented from seeping into
electrical wiring, transformer etc. will overheat. the transformer.
Ensuring such compliance is the personal
responsibility of the user. Incorrect installation of the impulse
! transformer impairs electrical safety.
1.2 Heatsealing band

1.4 Current transformer PEX-W2/-W3
A basic prerequisite for reliable and safe operation of
the system is the use of suitable heatsealing bands. The current transformer supplied with the RESISTRON
temperature controller is an integral part of the control
The resistance of the heatsealing band which system.
! is used must have a positive minimum
temperature coefficient in order to guarantee Only the original ROPEX PEX-W2 or PEX-W3
trouble-free operation of the RESISTRON ! current transformer may be used. Other
temperature controller. transformers may cause the equipment to
malfunction.
The temperature coefficient must be specified as
follows: The current transformer may only be operated if it is
–4 –1 connected to the RESISTRON temperature controller
TCR  10 10 K
correctly (see section 9, "Startup and operation"). The
e.g. Alloy-20: TCR = 1100 ppm/K relevant safety instructions contained in section 8.3,
NOREX: TCR = 3500 ppm/K "Power supply", must be obeyed. External monitoring
modules can be used in order to additionally increase
RES-420 Page 3
Application
operating safety. They are not included in the scope of 1.7 Standards / CE marking
supply of the standard control system and are
described in a separate document. The controller described here complies with the
following standards, provisions and directives:
1.5 Line filter DIN EN 61010-1 Safety provisions for electrical

(VDE 0411-1) measuring, control and laboratory
The use of an original ROPEX line filter is mandatory in devices (low voltage directive).
order to comply with the standards and provisions Overvoltage category III, pollution
mentioned in section 1.7 "Standards / CE marking" on severity 2, safety class II.
page 4. This device must be installed and connected
according to the instructions contained in section 8.3, DIN EN 60204-1 Electrical equipment of machines
"Power supply" as well as the separate documentation (machinery directive)
enclosed with the line filter. EN 50081-1 EMC interference emissions
according to EN 55011, group 1,
class B
1.6 Warranty provisions
EN 50082-2 EMC interference immunity:
The statutory provisions for warranties apply for a ESDs, RF radiation, bursts, surges.
period of 12 months following the delivery date.
All devices are tested and calibrated in the factory. Compliance with these standards and provisions is only
Devices that have been damaged due to faulty guaranteed if original accessories and/or peripheral
connections, dropping, electrical overloading, natural components approved by ROPEX are used. If not, then
wear, incorrect or negligent handling, chemical the equipment is operated on the user's own
influences or mechanical overloading as well as responsibility.
devices that have been modified, relabeled or The CE marking on the controller confirms that the
otherwise altered by the customer, for example in an device itself complies with the above-mentioned
attempt to repair them or install additional components, standards.
are excluded from the warranty. It does not imply, however, that the overall system also
Warranty claims must be examined in the factory and fulfils these standards.
approved by ROPEX. 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.
2 Application
This RESISTRON temperature controller is an integral The controller is most commonly used for impulse-
part of the "series 400", the outstanding feature of heatsealing PE and PP films in:
which is its microprocessor technology. All
• Vertical and horizontal f/f/s machines
RESISTRON temperature controllers are used to con-
trol the temperature of heating elements (heatsealing • Pouch, filling and sealing machines
bands, beaded bands, cutting wires, heatsealing • Film wrapping machines
blades, solder elements etc.), as required in a variety of
• Pouch-making machines
heatsealing processes.
• Group packaging machines
• L-sealers
Page 4 RES-420
Principle of operation
• etc. • Increased machine capacity

The use of RESISTRON temperature controllers • Extended life of the heatsealing bands and teflon
results in: coatings
• Repeatable quality of the heatseals under any con- • Simple operation and control of the sealing process
ditions
3 Principle of operation
The resistance of the heatsealing band, which is tem- to the load and to the required dynamic range despite
perature-sensitive, is monitored 50x per second (60x at the exceptionally compact dimensions of the controller.
60Hz) by measuring the current and voltage. The tem-
perature calculated with the help of these measure- PLEASE NOTE!
ments is displayed and compared with the set point.
The primary voltage of the impulse transformer is adju- RESISTRON temperature controllers play a significant
sted by phase-angle control if the measured values role in enhancing the performance of modern
deviate from the set point. The resulting change in the machines. However, the full benefit can only be
current through the heatsealing band leads to a change obtained from the advanced technology offered by this
in the band temperature and thus also its resistance. control system if all the system components, in other
This change is measured and evaluated by the words the heatsealing band, the impulse transformer,
RESISTRON temperature controller. the wiring, the timing signals and the controller itself,
The control loop is closed: ACTUAL temperature = SET are compatible with one another.
temperature. Even minute thermal loads on the heatse-
aling band are detected and can be corrected quickly
and precisely.
We will be pleased to
The thermoelectric control loop which is formed has a contribute our many
highly dynamic response because purely electrical years of experience
variables are measured at a high sampling rate. A high towards optimizing your
secondary current can be controlled with only minimal heatsealing system.
power loss because power is controlled on the primary
side of the transformer. This allows optimum adaptation
Heatsealing band R = f (T)
RESISTRON controller
IR UR Actual value
Current
transformer R=f(T)
Indicators
U2 and
sec. Start
U1 controls
_
prim. or
+ Set point bus interface
Impulse transformer
LINE
RES-420 Page 5
Description of the controller
4 Description of the controller

The microprocessor technology endows the are available as an option. Various display languages
RESISTRON temperature controller RES-420 with pre- can be selected.
viously unattainable capabilities: The real heatsealing band temperature is visualized on
the display both as a digital number in °C and in the
• Very simple operation thanks to AUTOCAL, the
form of a dynamic bar.
automatic zero calibration function.
The RESISTRON temperature controller RES-420 also
• Good dynamic response of the control system features an integrated fault diagnosis function, which
thanks to AUTOTUNE, which adapts automatically tests both the external system (heatsealing band,
to the controlled system. wiring etc.) and the internal electronics and outputs a
• High precision thanks to further improved control selective error message in case of a fault.
accuracy and linearization of the heatsealing band To increase operational safety and interference immu-
characteristic. nity, all 24VDC logic signals are electrically isolated
• High flexibility: The AUTORANGE function (as of from the controller and the heating circuit.
software revision 100) covers a secondary voltage The menu in the temperature controller itself can be
range from 0.4V to 120V and a current range from used to adapt to different heatsealing band alloys
30A to 500A. (Alloy-20, NOREX etc.) and set the required tempera-
ture range (0…300°C, 0…500°C etc.).
• Automatic adjustment to the line frequency in the
range from 47Hz to 63Hz. The RESISTRON temperature controller RES-420 is
designed for installation in a front panel cutout. The
• Increased protection against dangerous conditions, compact design and the plug-in connections make this
such as overheating of the heatsealing band. controller easy to install.
The process data is represented on an LC display with
4 lines and 20 characters. Devices with a VF display
Page 6 RES-420
Accessories and modifications
5 Accessories and modifications

A wide range of compatible accessories and peripheral 5.1 Accessories
devices are available for the RESISTRON temperature
controller RES-420. They allow it to be optimally The products described below are only a few of the
adapted to your specific heatsealing application and to wide range of accessories available for RESISTRON
your plant's design and operating philosophy. temperature controllers ("Accessories" leaflet).
Line filter LF-xx480

Essential in order to ensure CE conformity.
Optimized for the RESISTRON temperature controller.
Impulse transformer ITR-x

Designed according to VDE 0570/EN 61558 with a one-section bobbin.
Optimized for impulse operation with RESISTRON temperature controllers.
Specified according to the heatsealing application
( ROPEX Application Report).
Communication interface CI-USB-1

Interface for connecting a RESISTRON temperature controller with diagnostic inter-
face (DIAG) to the PC (USB port). Associated PC visualization software for dis-
playing setting and configuration data, and for recording SET and ACTUAL tempe-
ratures in real time.
Booster B-xxx400
External switching amplifier, necessary for high primary currents
(continuous current > 5A, pulsed current > 25A).
Monitoringcurrent transformer
For detecting frame short-circuits on the heatsealing band.
Used as an alternative to the standard PEX-W2/-W3 current transformer.
Transparent front cover TFA-1

For increasing the degree of protection on the front of the controller to IP65.
Also facilitates applications in the food technology sector (GMP).
RES-420 Page 7
Accessories and modifications
Adapter for top hat rail mounting, HS-Adapter-01

For mounting the RESISTRON temperature controller RES-420 on a top hat rail
(DIN TS35). Allows the controller to be installed in the electrical cabinet, for instance,
where it is only accessible to authorized persons.
Lockable door TUER-S/K-1

Transparent door (with lock) for mounting on the bezel of the controller. The display
is clearly legible at all times. The keyboard can only be operated, however, by autho-
rized persons in possession of a key.
Measurement cable UML-1

Twisted measurement cable for the UR voltage measurement.
Trailing cable, halogen and silicone-free.
5.2 Modifications (MODs) MOD 33

(Software revision 010 or higher)
Owing to its universal design, the RESISTRON tempe-
Important heatsealing process data can be output and
rature controller RES-420 is suitable for a very wide
logged via a serial RS232 interface ( MOD 33" docu-
range of heatsealing applications.
mentation).
Modifications (MOD) are available for the RESISTRON
temperature controller RES-420 for implementing spe-
This modification is only recommended for
cial applications. ! existing applications. The PC visualization
software ( section 10.20 "Diagnostic interface/
MOD 01 visualization software (as of software
Amplifier for low secondary voltages revision 100)" on page 39) should be used for all
(UR = 0.25…16VAC). This modification is necessary, new applications.
for example, for very short or low-resistance heatse-
aling bands.
Page 8 RES-420
Technical data
6 Technical data
Type of construction Housing for front panel mounting
Dimensions (W x H): 144 x 72mm; depth: 161mm (incl. terminals)
Line voltage All controller manufactured as of December 2005

(as of software revision 100):
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
All controllers manufactured as of January 2004 up to November 2005

(up to software revision 027):
All controllers manufactured up to December 2003:

115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version ( Kap. 13 „How to order“ auf Seite 48)
Line frequency 47…63Hz, automatic adjustment to frequencies in this range
Heatsealing band As of software revision 100:

type and temperature The temperature range and temperature coefficient can be set independently of
range one another in the Configuration menu:
Temperature range: 200°C, 300°C, 400°C or 500°C
Temperature coefficient: 400…4000ppm (variable setting range)
Up to software revision 027:

Several different ranges can be selected on the controller in the Configuration
menu:
Temperature coefficient 410ppm, 0…300°C (SW revision 021 or higher)
Temperature coefficient 780ppm (e.g. Alloy L)
0…200°C, 0…300°C, 0…400°C, 0…500°C
(SW revision 011 or higher)
Temperature coefficient 1100ppm (e.g. Alloy 20):
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 3500ppm (e.g. NOREX):
0…200°C, 0…300°C
Set point selection Via the Settings menu in the controller
Digital logic levels LOW (0V): 0…2VDC

Terminals 3, 4 HIGH (24VDC): 12…30VDC (max. current input 6mA)
Electrically isolated, reverse polarity-protected
RES-420 Page 9
Technical data
START with contact Switching threshold: 3.5VDC, Umax = 5VDC, Imax = 5mA
Terminals 2+7
Alarm relay Contact, potential-free, Umax = 50V (DC/AC), Imax = 0.2A

Terminals 5+6
Maximum load Imax = 5A (duty cycle = 100%)

(primary current of Imax = 25A (duty cycle = 20%)
impulse transformer)
Power dissipation max. 25W
Display LC display (green), 4 lines, 20 characters, alternatively:

VF display (blue), 4 lines, 20 characters
Ambient temperature +5…+45°C
Degree of protection Front: IP42 (IP65 with transparent front cover, Art. No. 887000)
Back: IP20
Installation Installed in front panel cutout with (W x H) 138(+-0.2) x 68(+-0.2) mm

Fastened with clips
Weight Approx. 1.0kg (incl. connector plug-in parts)
Housing material Black plastic, type Noryl SE1 GFN2
Connecting cable Rigid or flexible; 0.2…2.5mm² (AWG 24…12)

Type / cross-sections 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.
Page 10 RES-420
Dimensions/front panel cutout
7 Dimensions/front panel cutout
panel cutout outline dimensions

front frame
±0.2 ±0.2
138 x 68
rubber seal mounting clamp
66
72
terminal blocks
front frame front panel terminal wires

9 132 29
DIP-switch
to select
U2, I2
136
144
RES-420 Page 11
Installation
8 Installation
 See also Kap. 1 „Safety and warning notes“ auf cally detected by the temperature controller in the
Seite 3. range from 47Hz to 63Hz.
3. Install the RESISTRON temperature controller in
Installation and startup may only be per- the front panel cutout. It is fastened by means of two
! formed by technically trained, skilled per- clips which snap onto the side of the controller
sons who are familiar with the associated risks and housing.
warranty provisions.
4. Wire the system in accordance with the instructions
in Kap. 8.3 „Power supply“ auf Seite 14, Kap. 8.6
„Wiring diagram (standard)“ auf Seite 16 and the
8.1 Installation procedure ROPEX Application Report. The information pro-
vided in Kap. 8.2 „Installation steps“ auf Seite 13
Proceed as follows to install the RESISTRON tempera-
must be heeded additionally.
ture controller RES-420:
1. Switch off the line voltage and verify that all circuits Check the tightness of all the system connec-
are deenergized. ! tions, including the terminals for the impulse
2. The supply voltage specified on the nameplate of transformer windings.
the RESISTRON temperature controller must be
identical to the line voltage that is present in the 5. Make sure that the wiring conforms to the relevant
plant or machine. The line frequency is automati- national and international installation regulations.
Page 12 RES-420
Installation
8.2 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
Line filter
Avoid long LF-xx480
cables
OPTION:
Temperature
meter
Impulse ATR-x
transformer
Dimension
transformer correctly Controller
- Secondary voltage
Note
- Power
polarity
- Duty cycle Configure
DIP switches
correctly
(up to SW-Rev. 027)
RES-420 Page 13
Installation
8.3 Power supply
LINE Line
L1 (L1)
N (L2) 115VAC, 230VAC, 400VAC
GND/ 50/60Hz
Earth
Circuit breaker
Double-pole, C characteristic
ON K1
( ROPEX Application Report)
Short-circuit protection only.
I> I> ! RESISTRON temperature 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
Short wires Do not run the filter supply wires (line side) parallel
3 ! to the filter output wires (load side).
UR ROPEX
temperature RESISTRON temperature controller belonging to the
IR controller 4xx Series.
Relay Kb
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.
U1 3
Impulse Transformer
PRIM.
Designed according to VDE 0570/EN 61558 (isolating
transformer with reinforced insulation). Connect core to
ground.
Use transformers with a one section bobbin. The
2
U2 ! power, duty cycle and voltage values must be deter-
SEC.
mined individually according to the application ( ROPEX
1
Application Report and "Accessories" leaflet for impulse
2
transformers).
Wiring
The wire cross-sections depend on the application
Guide values:
Primary circuit: min. 1.5mm², max. 2.5mm²
R Secondary circuit: min. 4.0mm², max. 25mm²
 These wires must always be twisted (>20/m)
 These wires must be twisted (>20/m) if several control
loops are laid together ("crosstalk").
 Twisting (>20/m) is recommended to improve EMC.
Page 14 RES-420
Installation
8.4 Line filter installed and wired correctly, they guarantee comp-
liance with the EMC limit values.
To comply with EMC directives – corresponding to You can find the exact specification of the line filter in
EN 50081-1 and EN 50082-2 – RESISTRON control the ROPEX Application Report calculated for your par-
loops must be operated with line filters. ticular heatsealing application.
These filters damp the reaction of the phase-angle con- For more technical information:  "Line filter" docu-
trol on the line and protect the controller against line mentation.
disturbances.
It is permissible to supply several
The use of a suitable line filter is part of the ! RESISTRON control loops with a single line
! standards conformity and a prerequisite of filter, providing the total current does not exceed
the CE mark. the maximum current of the filter.
ROPEX line filters are specially optimized for use in The wiring instructions contained in section 8.3 "Power
RESISTRON control loops. Providing that they are supply" on page 14 must be observed.
Large cross-section
wire to ground
max. 1m
PE
LINE ROPEX
temperature
controller
Do not lay parallel Mounting plate (galvanized)

Large cross-section Large frame contact surface
wire to ground
8.5 Current transformer PEX-W3 of the control system. The current transformer may only
be operated if it is connected to the temperature con-
The PEX-W3 current transformer supplied with the troller correctly ( section 8.3 "Power supply" on
RESISTRON temperature controller is an integral part page 14).
24 75 14
23 28
terminal
wires
60
12
39
26
14
terminal
block
Snap-on for DIN-rail 35 x 7,5mm or 35 x 15mm (DIN EN 50022)
RES-420 Page 15
Installation
8.6 Wiring diagram (standard)

14
RES-420 LINE
(also with MOD 01) 15
1 +
2 0V
6 13
ALARM
OUTPUT
max. 50V/0.2A 12
5
Contact closed or U1
opened by ALARM prim.
(see configuration)
Impulse
transformer
U2
sec.
11 Heat-
0V UR R sealing
(Internnal ground) 10 twisted
band
START (HEAT)
3 No external
with 24VDC signal
grounding allowed!
9
IR
GND 4 8
Current transformer
Ground PEX-W2/-W3
for 24VDC signals.
Must be grounded
externally to prevent up to 0V (Internal ground)
electrostatic production data Terminal 2
charging! November 2005
START (HEAT)
7 with contact
0V
(Internnal ground)
No external
grounding allowed!
Page 16 RES-420
Installation
8.7 Wiring diagram with booster

connection

14
RES-420 LINE
(also with MOD 01) 15
Booster
3 1
+ 1
IN OUT
0V
2
4 2
6 13 NC
ALARM
OUTPUT
max. 50V/0.2A 12 NC
5
Contact closed or U1
opened by ALARM prim.
(see configuration)
Impulse
transformer
U2
sec.
11 Heat-
0V UR R sealing
(Internnal ground) 10 band
START (HEAT) twisted
3 No external
with 24VDC signal
grounding allowed!
9
IR
GND 4 8
Current transformer
Ground PEX-W2/-W3
for 24VDC signals.
Must be grounded
externally to prevent up to 0V (Internal ground)
electrostatic production data Terminal 2
charging! November 2005
START (HEAT)
7 with contact
0V
(Internnal ground)
No external
grounding allowed!
RES-420 Page 17
Startup and operation
9 Startup and operation
9.1 Front view of the controller
Terminals
Wiring diagram Operator keys
Diagnostic interface
Nameplate (on rear of controller)
Clips
Display
9.2 Rear view of the controller
As of software revision 100:
Printed wiring diagram
ROPEX RES- 420

(only with filter)
U2 U1
R SEC. PRIM.
N (L1)
AUTO U R 0,4 - 120V FILTER L1 (L2)
(PE)
CONTACT
START RANGE I2 30 - 500A

START
BOOSTER 24VDC ALARM

0V UR
GND IR 12 13 14 15
DIAG
1 2 3 4 5 6 7 8 9 10 11
50V / 0,2A
Terminals Diagnostic interface Terminals
Page 18 RES-420
Up to software revision 027:
Printed wiring diagram
DIP-SWITCH
ON 1 2 3 42 5 I (A)
OFF OFF 30 - 100
ROPEX RES- 420 U2 ( V ) 1-10 6-60 20-120 ON OFF 60 - 200
ON ON 120 - 400 (only with filter)
N (L1)
U U
R FILTER L1 (L2)
START 24VDC
SEC. PRIM. (PE)

BOOSTER
START
ALARM
0V GND
IR UR 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 DIP-SWITCH
OFF
1 2 3 4 5 ON
12345
50V / 0,2A
Terminals DIP switches Terminals
9.3 Controller configuration tion (AUTOCAL). The voltage is configured in the range
from 0.4VAC to 120VAC and the current in the range
The possible controller configurations are explained in from 30A to 500A. If the voltage and/or the current is
the following sections. Proceed as described in outside the permissible range, a detailed error mes-
Kap. 9.5.1 „Initial startup“ auf Seite 23 to start up the sage appears on the controller ( s. section 10.24
controller for the first time. "Fault areas and causes" on page 44).
9.3.1 Configuration of the DIP switches Configuration with coding switches

for secondary voltage and current (up to software revision 027)
The controller must be switched off in order Set the DIP switches for matching the secondary
! to configure the DIP switches. voltage U2 and the secondary current I2 to the correct
position for your application.
Automatic configuration (AUTORANGE)
(as of software revision 100) You can find the exact configuration of the
!
DIP switches in the ROPEX Application
The secondary voltage and current ranges are auto- Report calculated for your particular application.
matically configured by the automatic calibration func-
RES-420 Page 19
OFF
Factory settings
Rear view ON 1 2 3 4 5
of the controller
UR U2 DIP switch I2 DIP switch

10 11 DIP-SWITCH
1 2 3 4 5
10 11 OFF
1...10V ON OFF OFF 30...100A OFF OFF
1 2 3 4 5 ON
12345 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 If the controller settings are unknown when it
PEX-W2/W3 current transformer must have two turns ! is started up for the first time, the factory set-
( ROPEX Application Report). tings must be restored in order to prevent malfunc-
tions.
9.3.4 Configuration of the alloy and the

temperature range
(up to software revision 027)
2x
These parameters are set with step 22 in the Configu-
ration menu:
9.3.2 Setting the language Several different ranges can be selected:
The menu language can be changed on the controller 1. Temperature coefficient 410ppm, 0…300°C
without interrupting operation. It is set with step 20 in (software revision 021 or higher)
the Configuration menu: 2. Temperature coefficient 460ppm, 0…300°C
The following settings are possible: (software revision 019 or higher)
English, German, Italian 3. Temperature coefficient 510ppm, 0…300°C
Software revision 015 or higher also: (software revision 019 or higher)
French, Spanish, Dutch, Danish, Finnish, Swedish,
4. Temperature coefficient 570ppm, 0…300°C
Greek, Turkish.
(software revision 019 or higher)
Software revision 024 or higher also: Portuguese.
The language which is selected in this menu (software revision 019 or higher)
! remains set even if the factory settings are 6. Temperature coefficient 700ppm, 0…300°C
restored (step 202 [21] in the Configuration menu). (software revision 019 or higher)
As of software revision 103, the language (e.g. Alloy L, software revision 011 or higher)
! setting with step 202 can still be changed
even if the Configuration menu is disabled .
(e.g. Alloy L, software revision 011 or higher)
9.3.3 Restoring the factory settings 9. Temperature coefficient 780ppm, 0…400°C
The internal controller settings can be reset to the fac-
10.Temperature coefficient 780ppm, 0…500°C
tory settings with step 202 [21] in the Configuration
menu. Only the language setting (step 201 [20] in the
Configuration menu) remains unchanged. 11. Temperature coefficient 870ppm, 0…300°C
Please refer to section 11 "Factory settings" on (software revision 019 or higher)
page 46 for more information about the factory settings. 12.Temperature coefficient 980ppm, 0…300°C
Page 20 RES-420
(software revision 019 or higher) The setting can be 200°C, 300°C (Factory setting),
13.Temperature coefficient 1100ppm, 0…200°C 400°C or 500°C.
(e.g. Alloy-20)
14.Temperature coefficient 1100ppm, 0…300°C 9.3.7 Temperature diagnosis
(Factory settings) (as of software revision 100)
(e.g. Alloy-20) The temperature diagnosis function can be activated by
15.Temperature coefficient 1100ppm, 0…400°C means of step 217 in the Configuration menu. The
(e.g. Alloy-20) RES-420 then checks whether the ACTUAL tempera-
16.Temperature coefficient 1100ppm, 0…500°C ture is inside a specifiable tolerance band ("OK"
(e.g. Alloy-20) window) on either side of the SET temperature. The
lower (  lower ) and upper (  upper ) limits of the tole-
17.Temperature coefficient 3500ppm, 0…200°C
rance band can be changed independently of one ano-
(e.g. NOREX)
ther by means of steps 207 [24] + 208 [25] (factory set-
18.Temperature coefficient 3500ppm, 0…300°C ting: -10K or +10K).
(e.g. NOREX) If the ACTUAL temperature is inside the specified toler-
ance band when the "START" signal is activated, the
9.3.5 Configuration of the alloy temperature diagnosis is also activated. If the ACTUAL
(Temperature coefficient) temperature leaves the tolerance band, the corre-
(as of software revision 100) sponding error code (307, 308) is indicated and the
fault output is switched ( section 10.24 "Fault areas
The heatsealing band alloy (and the temperature coef-
and causes" on page 44).
ficient respectively) can be set with steps 203 and 204
in the Configuration menu.
In step 203 predefined values for the alloy (and the Actual value
temperature coefficient repsecitvely) are available: Set+  upper
1. Temperature coefficient 780ppm Set
(e.g. Alloy-L)
2. Temperature coefficient 1100ppm Set+  lower
(Factory setting)
(e.g. Alloy-20)
3. Temperature coefficient 1400ppm
(e.g. ROPEX CIRUS system)
4. Temperature coefficient 1700ppm
(e.g. ROPEX CIRUS system)
5. Temperature coefficient 3500ppm Time
Error code
(e.g. NOREX) 307
6. Temperature coefficient „variable“
Further settings in step 204. If the temperature diagnosis is not activated by the time
In step 204 the temperature coefficent can be set in the "START" signal is deactivated (i.e. if the ACTUAL
a range of 400…4000 ppm individually for the used temperature does not exceed the upper or lower tole-
heatsealing band then. rance band limit), the corresponding error code
(309, 310) is indicated and the fault relay is switched.
Step 204 in the Configuration menu is avai- If the temperature diagnosis function is activated, an
! lable when step 203 is set to "variable" only. additional delay time of 0 to 9.9s can be parameterized
for the temperature timeout with step 218 in the Confi-
9.3.6 Configuration of the temperature guration menu. The first time the lower tolerance band
range limit is exceeded, the temperature diagnosis is not acti-
(as of software revision 100) vated until the parameterized delay time has elapsed.
The temperature diagnosis function can thus be expli-
The temperature range can be set with steps 205 in the citly deactivated, e.g. if the temperature drops tempora-
Configuration menu. rily owing to the closure of the sealing jaws.
RES-420 Page 21
9.3.8 Heatup timeout Too low a TCR leads to oscillation or uncontrolled hea-
(as of software revision 100) ting.
When heatsealing bands with a higher TCR are used,
The heatup timeout can be parameterized with the controller must be calibrated for this.
step 219 in the Configuration menu ("0" = OFF). The first time the heatsealing band is heated to appro-
This timeout starts when the START signal is activated. ximately 200…250°C, the standard alloy undergoes a
The RES-420 then monitors the time required for the once-only resistance change (burn-in effect). The cold
ACTUAL temperature to reach 95% of the SET temper- resistance of the heatsealing band is reduced by appro-
ature. If this time is longer than the parameterized time, ximately 2…3%. However, this at first glance slight
the corresponding error code (304) is indicated and the resistance change results in a zero point error of
fault relay is switched ( section 10.24 "Fault areas 20…30°C. The zero point must therefore be corrected
and causes" on page 44). after a few heating cycles ( chap. 9.4.2 „Burning in
the heatsealing band“, page 22).
Actual value 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
Set increase the life of the teflon coating and the heatse-
95% of Set aling band.
An overheated or burned-out heatsealing

! band must no longer be used because the
TCR has been altered irreversibly.
Timeout
9.4.2 Burning in the heatsealing band
If a new heatsealing band has been used, the zero
Time
Heatup time Error code point is first of all calibrated while the band is still cold
304 by activating the "AUTOCAL" function on the controller.
When the "AUTOCAL" function has finished, the con-
9.3.9 Configuration of the alarm relay troller outputs the preselected calibration temperature
(default value: 20°C). Adjust the set point to approxi-
The alarm relay is set with step 215 [25] in the Configu- mately 250°C and press the "HAND" key (display in
ration menu. home position) to heat for approximately 1 second.
There are two possible settings: After recooling, the controller usually indicates a value
1. "Normal" less than 20°C. Repeat the "AUTOCAL" function. The
Alarm relay contact closed by a fault heatsealing band has now been burned in and the
2. "Inverse" change in the alloy properties stabilized.
Alarm relay contact opened by a fault The burn-in effect described here does not occur if the
heatsealing band has already been thermally pre-
treated by the manufacturer.
9.4 Heatsealing band
9.4.3 Replacing the heatsealing band
9.4.1 General All power supply leads must be disconnected from the
The heatsealing band is a key component in the control RESISTRON temperature controller in order to replace
loop, since it is both a heating element and a sensor. the heatsealing band.
The geometry of the heatsealing band is too complex to
be discussed at length here. We shall therefore only The heatsealing band must be replaced in
refer to a few of the most important physical and elec-
! accordance with the instructions provided by
trical properties: the manufacturer.
The measuring principle applied for this system neces-
Each time the heatsealing band is replaced, the zero
sitates a heatsealing band alloy with a suitable tempe-
point must be calibrated with the AUTOCAL function
rature coefficient TCR, i.e. one whose resistance
while the band is still cold, in order to compensate pro-
increases as the temperature rises.
Page 22 RES-420
duction-related resistance tolerances. The burn-in pro- 7. One of the following states then appears:
cedure described above must be performed for all new
heatsealing bands. DISPLAY ACTION
Main menu Go to 8
9.5 Startup procedure Error message with error codes Go to 8
104…106, 111…113, 211
Please also refer to Kap. 1 „Safety and warning notes“
auf Seite 3 and Kap. 2 „Application“ auf Seite 4. Error message with error codes Fault diagnosis
101…103, 107, 108, ( 10.24)
Installation and startup may only be per- 201…203, 801, 9xx
! formed by technically trained, skilled per-
sons who are familiar with the associated risks and 8. Set the controller configuration as described in
warranty provisions. Kap. 9.3 „Controller configuration“ auf Seite 19. The
following settings are always required:
9.5.1 Initial startup
Prerequisites: The controller must be correctly installed Step in Confi-
Setting
and connected ( Kap. 8 „Installation“ auf Seite 12). guration menu
The possible settings are described in detail in
chap. 9.3 „Controller configuration“, page 19 and Language 201 [20]
chap. 10 „Controller functions“, page 24. Restore factory settings 202 [21]
The essential controller configurations are described
below: Temperature range and heatse- 203, 204, 205
aling band alloy [22]
1. Switch off the line voltage and verify that all circuits
are deenergized.
9. Activate the AUTOCAL function while the heatse-
2. The supply voltage specified on the nameplate of
aling band is still cold (with step 7 in the Settings
the controller must be identical to the line voltage
menu). The progress of the calibration process is
that is present in the plant or machine. The line fre-
indicated by a counter on the display (approx.
quency is automatically detected by the tempera-
10…15s).
ture controller in the range from 47 to 63Hz.
When the zero point has been calibrated, the dis-
3. In case of controllers up to software revision 027, play is reset to the home position and 20°C is indi-
the setting of the DIP switches on the controller are cated as the actual value.
indicated in the ROPEX Application report and If the zero has not been calibrated successfully, an
depend on the heatsealing band (section 9.3 "Con- erro message indicates error codes 104…106, 211.
troller configuration" on page 19). In this case the controller configuration is incorrect
4. Make sure that a START signal is not present. ( Kap. 9.3 „Controller configuration“ auf Seite 19
5. Switch on the line voltage. and ROPEX Application Report). Repeat the zero
point calibration after the controller has been confi-
6. A power-up message appears on the display for
gured correctly.
approximately 2 seconds when the controller is
switched on to indicate that it has been started up 10.When the zero point has been calibrated suc-
correctly. cessfully, the main menu appears on the display
again. Then specify a defined temperature (heatse-
aling temperature) with step 1 in the Settings menu
and activate the "START" signal (HEAT). Alterna-
tively, a heatsealing process can be started by pres-
sing the "HAND" key (display in home position). The
indication of the ACTUAL temperature on the dis-
play (digital value and dynamic bar) permits the hea-
ting and control process to be monitored.
The controller is functioning correctly if the tempera-
ture indicated on the display has a continuous
RES-420 Page 23
Controller functions
curve, in other words it must not jump abruptly, fluc- 11. Burn in the heatsealing band ( Kap. 9.4 „Heatse-
tuate or deviate temporarily in the wrong direction. aling band“ auf Seite 22) and repeat the AUTOCAL
This kind of behavior would indicate that the UR function.
measuring wire has been laid incorrectly.
If an error code is displayed, please proceed as
described in section 10.24 "Fault areas and causes" The controller is now
on page 44. ready
9.5.2 Restart after replacing the heatse- Always use a heatsealing band with the cor-
aling band ! rect alloy, dimensions and copper-plating in
order to avoid malfunctions and overheating.
To replace the heatsealing band, proceed as described
in Kap. 9.4 „Heatsealing band“ auf Seite 22. Continue with section 9.5.1, steps 9 and 10.
10 Controller functions
See also Kap. 8.6 „Wiring diagram (standard)“ auf
Seite 16.
10.1 Indicators and controls
"MENU" key for advancing to next menu step

or switching menu
< 1 sec. Press: Next menu step
1-2 sec. Press: Return to previous position
RESISTRON RES-4
(as of SW-Revision 100):
> 2 sec. Press (Hold):
ENTER
HAND
Return to home position
RESET
"ENTER" key
ENTER function: Save values
ROPEX HAND function: Manual mode
RESET function: Reset after alarm
"UP" and "DOWN" keys for setting values

Press (< 2 sec.): Slow change
Hold (> 2 sec.): Fast change
LC display, 4 lines, multilingual

optional:
VF display, 4 lines, multilingual
Page 24 RES-420
10.2 Display This message also includes details of the software ver-
sion.
10.2.1 Power-up message
A power-up message appears on the display for appro-
ximately 2 seconds when the controller is switched on.
Company name
(optional: customer-specific)
Software ID number
Controller type (RES-420)
10.2.2 Display in home position tion, in other words it indicates the SET temperature as
a digital value and the ACTUAL temperature as a digital
If no settings are entered on the controller and no error value and a dynamic bar.
message are present, the display is in the home posi-
Specified heatsealing Measured ACTUAL

temperature temperature
(SET temperature)
ACTUAL temperature
as a dynamic bar
10.2.3 Settings/Configuration menus

The required parameters are set on two menu levels:
the Settings (control) menu and the Configuration
menu ( Kap. 10.4 „Menu structure“ auf Seite 28).
Menu level: Position in menu

Settings or Configuration menu (menu step)
(Configuration menu shown here)
Menu contents
(max. 3 lines)
RES-420 Page 25
10.2.4 Error messages immediately in the form of an error message

( Kap. 10.22 „System monitoring/alarm output“ auf
The fault diagnosis function of the controller is always Seite 40).
active. If a fault is detected, it is indicated on the display
Alarm indication
Fault description
and error code
Prompt to press
"RESET" key
10.3 Navigation in the menus structure, providing a controller alarm is not active. In
this case, the Alarm menu is opened instead.
10.3.1 Navigation in menus without a fault If the display is in the home position or an alarm is indi-
cated and you press the "MENU" key for longer than
A "MENU" key is provided for navigating through the 2s, you are taken directly to the configuration level
various menu steps and levels. By pressing this key (starting at step 201 [20]).
briefly (<1s) at any time, you can jump to the next menu In addition, you always return to the home position if
step. As of software revision 100, you can also jump to you do not press any keys for a period of 30s. There is
the previous menu step by pressing the "MENU" key for no automatic return after 30s from "AUTOCAL" or
1-2s. By pressing the key for longer (>2s), you can "Alarm".
return to the home position from anywhere in the menu
Settings Configuration
Home position 201 Language
>2s >2s
or
automatically
after 30s
<1s <1s
101 Heatsealing temp. 202 Factory settings
>2s >2s
or or
automatically automatically
after 30s after 30s
Page 26 RES-420
10.3.2 Navigation in menus with a fault can then activate the "AUTOCAL" function by pressing
the "ENTER" key ( section 10.9 "Automatic zero cali-
If an alarm is signaled, the controller switches to the bration (AUTOCAL)" on page 35).
Alarm menu. Some faults can be acknowledged by If you press the "MENU" key for longer than 2s in the
pressing the "RESET" key ( Kap. 10.22 „System
Alarm menu, you are taken directly to the configuration
monitoring/alarm output“ auf Seite 40). In this case, the level (starting at step 201 [20]). You can return from the
controller switches back to the home position. Configuration menu to the Alarm menu either by pres-
If the fault can be rectified by executing the AUTOCAL
sing the "MENU" key for longer than 2s or by not pres-
function, you can select the "AUTOCAL" menu step sing any keys for 30s.
directly by briefly pressing the "MENU" key (<2s). You
Fault
ENTER
HAND Alarm 201 Language
RESET
>2s >2s
or
automatically
Home position after 30s
<1s <1s
ENTER
107 Autocal? HAND 202 Factory settings
RESET
>2s
Autocal or
automatically
End of after 30s
Autocal
RES-420 Page 27
10.4 Menu structure
Settings Configuration
Power-up message
Home position 201 Language

3) AUTOCOMP: OFF
4) AUTOCOMP: ON
101 Heatsealing temp. 202 Factory settings
5) TCR variable
6) TCR not variable
102 Preheating temp. 203 Alloy
1) 2) 5) 6)
103 Starting delay 204 Temp. coefficient
104 Sealing time 205 Temperature range
105 Cooling value 206 Max. temperature
106 Hold mode 207 Set point reached
107 Autocal? 208 Set point exceeded
Autocal 209 Time control

3) 4) 1) 2)
210 Cooling mode
108 Autocomp? 211 Start of sealing time
Autocomp 212 Relay K1 function
213 Lock "HAND" key
214 Cycles
Fault
215 Alarm relay
Alarm 216 Analog output
107 Autocal? 217 Temp. diagnosis
Autocal 218 Temp. diag. delay
Continued on next page
Page 28 RES-420
Configuration
Continued from previous page
219 Heatup timeout
220 Meas. imp. length
221 Autocomp
222 "Output 1"
225 Temperature unit
Back to home position
RES-420 Page 29
10.5 Two-digit numbering system revision 027. Three-digit numbers were introduced in
up to software revision 027 software revision 100 to improve the clarity of the menu
structure.
A system of one and two-digit numbers was used for The table below compares the two numbering systems:
the Settings and Configuration menus up to software
Numbering Numbering
Menu Menu steps up to software as of software
revision 027 revision 100
Settings menu Heatsealing temperature 1 101
Hold mode 2 106
AUTOCAL 3 107
Configuration menu Language 20 201
Factory settings 21 202
Alloy / TCR 22 203, 204
Maximim temperature 23 206
Cycles 24 214
Alarm relay 25 215
Measuring pulse length 26 220
All number sor menu steps not listed above The new, three-digit menu step numbers are
! are only available as of software revision 100 ! described first in all relevant sections of this
and are described in chap. 9 „Startup and opera- document. The older, two-digit numbers are indi-
tion“, page 18 (and section 10.4 "Menu structure" cated afterwards in square brackets (e.g.
on page 28 respectively). step 201 [20]).
Page 30 RES-420
10.6 Menu steps
No. Name Description Setting range
Home position The specified set value and the current actual value
are displayed in digital form. The actual value is also
represented as a dynamic bar.
If time control (step 209 [26]) is active, the heatse-
aling time and the cooling value are also displayed.
The heatsealing band can be heated manually (to
the specified heatsealing temperature) by pressing
the "HAND" key.
101 Heatsealing The required heatsealing temperature (set point) Depends on setting of
[1] temperature can be set with the "UP" and "DOWN" keys. The step 205 [22]:
maximum selectable set point can be limited with 0, 40°C…maximum tem-
step 203 [22] (alloy/range) and step 204 [23] (max. perature (step 206 [23])
temperature). The set point is indicated in the home
position.
106 Hold mode If the "Hold" function is activated, the last measured ON
[2] value at the end of the heating phase is stored and OFF
displayed. 2s
The "ACT" (actual value) information in the home
position is replaced by "Hold". This procedure is
repeated for every cycle and the displayed value is
updated. The word "Hold" is invisible for 100ms
before the value is updated.
If you select the "2 second hold" function, the dis-
play changes back from hold mode to the actual
value in real time after 2 seconds. The hold function
is then activated again for 2 seconds at the end of
the next cycle.
107 Autocal The AUTOCAL function matches the controller to 0…40°C

[3] the current and voltage signals that are present in
the system.
The required calibration temperature can be set
with the "UP" and "DOWN" keys. Pressing the
"ENTER" key stores the set value and starts the
"AUTOCAL" function.
The word "- Calibration -" appears on the display
while the AUTOCAL function is executing and a
counter counts down from 15 to 0. When the con-
troller has been calibrated successfully, the display
switches back directly to the home position pro-
viding the "AUTOCOMP" function is deactivated. If
"AUTOCOMP" is active, the display jumps to
step 108.
If the controller cannot be calibrated, the AUTOCAL
function is aborted and an error message is dis-
played instead.
RES-420 Page 31
108 Autocomp Pressing the "ENTER" key starts the "AUTOCOMP"

function. If the "ENTER" key is not pressed within
2s, the display returns to the home position.
The home position is automatically displayed if the
"AUTOCAL" function is successfully executed and
"AUTOCOMP" is active.
201 Language The desired display language can be selected with English
[20] this menu step. German
Italian
Software revision 015 or
higher also:
French, Spanish, Dutch,
Danish, Finnish, Swedish,
Greek, Turkish.
Software revision 024 or
higher also: Portuguese.
202 Factory settings The controller can be reset to the factory settings by
[21] pressing the "ENTER" key ( section 11 "Factory
settings" on page 46).
In addition, as of software revision 100:

The "UP" and "DOWN" keys can be used to select
whether
• The controller should be reset to the ROPEX fac-

tory settings
• The current configuration should be specified as

the default setting
• The controller should be reset to a previously

specified default setting
Page 32 RES-420
22 Alloy/range This step in the Configuration menu is (Availability depends on

! available up to software revision 027 only. software revision)
TCR 410ppm, 300°C
Various heatsealing band alloys and temperature TCR 460ppm, 300°C
ranges can be selected here. TCR 510ppm, 300°C
The corresponding characteristic for the controller TCR 570ppm, 300°C
parameters is calculated on the basis of this setting. TCR 630ppm, 300°C
TCR 700ppm, 300°C
Please be very careful to select the heat- TCR 780ppm, 200°C
! sealing band material with the correct TCR 780ppm, 300°C
alloy. TCR 780ppm, 400°C
TCR 780ppm, 500°C
The temperature range setting permits the con- TCR 870ppm, 300°C
troller to be matched to the required operating TCR 980ppm, 300°C
range. This also determines the scale for the bar TCR 1100ppm, 200°C
display. TCR 1100ppm, 300°C
TCR 1100ppm, 400°C
TCR 1100ppm, 500°C
TCR 3500ppm, 200°C
TCR 3500ppm, 300°C
203 Alloy Various heatsealing band alloys can be selected (Availability depends on
here. software revision)
The corresponding characteristic for the controller TCR 780ppm
parameters is calculated on the basis of this setting. TCR 1100ppm
TCR 3500ppm
Please be very careful to select the heat- variable
! sealing band material with the correct
alloy.
204 Temperature If you selected "Variable" with step 203, you can 400…4000ppm
coefficient specify the temperature coefficient of the heatse-
aling band material here in 10ppm increments using
the "UP" and "DOWN" keys.
205 Temperature range Various temperature ranges can be selected here. 200°C
The temperature range setting permits the con- 300°C
troller to be matched to the required operating 400°C
range. This also determines the scale for the bar 500°C
display.
206 Maximum This menu item specifies the maximum selectable 0 to max. temperature
[23] temperature set point (step 101 [1]) within the range defined by range (step 205 [22])
step 205 [22].
213 Lock of "HAND" key You can specify here whether or not the heatsealing ON,
band can be heated in the home position by pres- OFF
sing the "HAND" key.
214 Cycle counter The number of heating impulses (not manual Reset with "ENTER" key
[24] impulses) is counted and displayed with this menu
step. The counter can be reset either by pressing
the "ENTER" key or by restoring the factory set-
tings.
RES-420 Page 33
215 Alarm relay This menu step permits the switching characteri-
[25] stics of the alarm relay to be configured.
• Normal: The alarm relay output (terminals 5+6) Normal

operates as an NO contact in the event of a fault.
• Inverse: The alarm relay output (terminals 5+6) Inverse

operates as an NC contact in the event of a fault.
217 Temperature If this value is set to "ON" and the actual tempera- OFF
diagnosis ture leaves the tolerance band (steps 207, 208), a ON
fault signal indicating error code 307/308 is output.
218 Temperature This delay time starts when the actual temperature 0…99.9s
diagnosis enters the tolerance band. The temperature timeout
delay time and fault output are not activated until after the
delay time has elapsed.
This step can only be selected if the temperature
diagnosis function (step 217) is active.
219 Heatup timeout If the actual temperature is outside the tolerance OFF, 0…99.9s
band when the specified time elapses (after the
"START" signal has been activated), a fault signal
indicating error code 304 is output.
220 Measuring impulse The length of the measuring impulse can be 1.7…3.0ms
[26] length changed here. This function is only available with a
few special applications (MOD 1).
221 Autocomp Activates the „AUTOCOMP“ function OFF,

ON
225 Temperature unit Unit for temperature display and input values Celsius
Fahrenheit
Page 34 RES-420
10.7 Temperature setting (set point The automatic calibration process takes around
selection) 10…15 seconds. The heatsealing band is not heated
until the calibration process has finished.
The heatsealing temperature can be set on the The message "- Calibration - Please wait..." appears
RES-420 controller by means of the setting in menu on the display while the "AUTOCAL" function is execu-
step 101 [1]. ting and a counter counts down from 13 to 0.
The maximum value of the setting range is

! limited either by the maximum value speci-
fied with step 206 [23] in the Configuration menu or
by the heatsealing band type/temperature range set
with step 205 [22].
The set point that is selected for the heatsealing tempe- If the temperature of the heatsealing band varies on
rature must be greater than 40°C. If not, the heatse- controllers as of software revision 100, the "AUTOCAL"
aling band will not be heated up when the "START" function is executed a maximum of three times. If the
signal is activated or the "HAND" key is pressed. function still cannot be terminated successfully, an
The set heatsealing temperature is displayed in the error message appears ( section 10.24 "Fault areas
main menu once it has been entered. and causes" on page 44).
You should always wait for the heatsealing

! band and the bar to cool down (to ambient
10.8 Temperature indication
temperature) before activating the "AUTOCAL"
function.
If the display is in the home position, the ACTUAL tem-
perature is indicated there as a digital value and as a
Reasons for disabled AUTOCAL function:
dynamic bar.
1. The "AUTOCAL" function cannot be activated if the
heatsealing band cools down at a rate of more than
0.1K/second. This is additionally indicated with
step 107 [3] in the Settings menu by the message
"Heatsealing band still hot! Please wait...".
2. If the "START" signal (24VDC or contact) is acti-
vated, the AUTOCAL function is not executed. As of
The heating and control process can thus be monitored software revision 024 this is additionally indicated
at any time. with step 107 [3] in the Settings menu by the mes-
sage „Autocal locked ! (START-Sig. active)“.
3. Directly after the controller is powered up, the
10.9 Automatic zero calibration AUTOCAL function cannot be activated if a fault
(AUTOCAL) with error code 101…103, 201…203, 801 or 9xx
occurs ( section 10.24 "Fault areas and causes"
Owing to the automatic zero calibration (AUTOCAL) on page 44). If the controller has already operated
function, there is no need to adjust the zero point manu- correctly - a minimum of once - after powering up,
ally on the controller. The "AUTOCAL" function mat- the AUTOCAL function cannot be activated with
ches the controller to the current and voltage signals error codes 201…203, 801 or 9xx.
that are present in the system.
You can activate this function by selecting step 107 [3]
in the Settings menu and then pressing the "ENTER" 10.10 "START" signal (HEAT)
key. The initial temperature (ambient temperature) of
the heatsealing bar(s) which is currently valid for cali- When the "START" signal is activated, the controller-
bration can be set beforehand in the 0…40°C range internal set/actual comparison is enabled immediately
using the "UP" and "DOWN" keys. and the heatsealing band is heated up to the SET tem-
The zero point is calibrated in the factory to 20°C. perature. It remains at this temperature until the signal
is deactivated again. This process can also be started
RES-420 Page 35
independently of the "START" signal by pressing the codes 104…105, 111…113 or 211 ( section 10.24
"ENTER" key ("HAND" function) while the main menu "Fault areas and causes" on page 44). The heatsealing
is displayed. band is likewise not heated.
The "START" signal can be activated in two ways:
• By means of a 24VDC signal at terminals 3+4.
10.11 Cycle counter
24VDC
START
(HEAT)
RES-420 Each activation of the "START" signal during operation
is detected by a cycle counter integrated in the con-
+ 3 troller. Actuations of the "HAND" key are not counted.
max. 6mA
The counter reading can be displayed with
step 214 [24] in the Configuration menu.
The cycle counter is reset to 0 if the "ENTER" key is
GND pressed or if the maximum count of 999.999.999 cycles
- 4 is exceeded.
HIGH: 12VDC 10.12 Hold mode
The behavior of the digital indication of the ACTUAL

START (HEAT) temperature in the home position can be changed with
LOW:  2VDC step 106 [2] in the Settings menu. The following set-
tings are possible:
1. "OFF" (Factory setting)
• By means of a control contact at terminals 2+7
If the main menu is visible on the display, the real
ACTUAL temperature is always indicated.
max.
5mA RES-420 2. "ON"
If the display is in the home position, the ACTUAL
7 temperature that was valid at the end of the last
START
heatsealing phase is always indicated as a digital
(HEAT)
value. When the controller is switched on, the real
with
ACTUAL temperature is indicated until the end of
contact
the first heating phase.
2 0V
3. "2 s"
It causes the current ACTUAL temperature to be
displayed as a digital value for an additional
The "START" signal is disabled as long as the 2 seconds at the end of a heatsealing phase. This
!
AUTOCAL function is executing in the Set- temperature is then indicated again in real time until
tings menu (with step 107 [3]). the end of the next heating phase.
The set point that is selected for the heatsealing tempe- Hold mode only affects the digital value on
rature (step 101 [1] in the Settings menu) must be ! the display. The ACTUAL temperature in real
greater than 40°C. If not, the heatsealing band will not time is always indicated, regardless of the setting,
be heated up. by the dynamic bar.
The alarm relay is switched if the "START" signal is
activated while an error message is indicating error
Page 36 RES-420
The various hold modes are shown below: step 220 [26]. It may be necessary to set a measuring
impulse that is longer than the default 1.7ms for certain
START applications ( ROPEX Application Report).
signal
24VDC
10.14 Automatic phase angle

0 compensation (AUTOCOMP)
ACTUAL t (as of software revision 100)
temp.
T It may be necessary to compensate the phase angle
displacement between the UR and IR measuring
signals in certain heatsealing applications ( ROPEX
0 Application Report). The "AUTOCOMP" function is pro-
t
ACTUAL indication vided for this purpose. It can be parameterized with
step 221 as followed:
Hold OFF 1. „OFF" (Factory setting)
T The „AUTOCOMP“ function is deactivated.
2. „ON“
0 The „AUTOCOMP“ function is activated by pressing
t the "ENTER" key after the "AUTOCAL" function has
Hold ON Hold Hold been successfully executed ( section 10.9 "Auto-
T matic zero calibration (AUTOCAL)" on page 35).
The interval after the end of the "AUTOCAL" func-
tion must be less than 2.0s ("Start AUTOCOMP?
0 Start with ENTER" appears on the display during
t
this time). The subsequent "AUTOCOMP" function
Hold 2 s Hold Hold
T is executed in approximately 2.0s ("- AUTOCOMP -
Please wait…" appears on the display during this
time).
0 If the interval following the successful execution of
t the "AUTOCAL" function is longer than 2.0s, the dis-
2s 2s
play returns to the home position and the "AUTO-
End of COMP" function is not executed.The actual value
heating phase
„ENTER“ key <2.0s
The word "Hold" appears on the display if a tempera- pressed
ture value is indicated in hold mode. It disappears for „AC“ „AP“
approximately 100ms whenever the hold value is
updated.
0
t
Function
AUTOCOMP
AUTOCAL
0
t
10.13 Measuring impulse duration
(as of software revision 026)
output is set to 0…3°C (i.e. approx. 0 VDC) when
The length of the measuring impulses generated by the the "AUTOCOMP" function is executed.
controller can be set with this parameter by means of
RES-420 Page 37
3. „AUTO“ 2. „Fahrenheit“
(as of software revision 105) Temperature indication and value selection in
With this setting the „AUTOCOMP“ function is acti- Fahrenheit (°F)
vated automatically after the "AUTOCAL" function Up to software revision 105 only Celsius (°C) can be
has been successfully executed. specified on the controller as the temperature unit.
„ENTER“ key The degree unit can be changed on the con-

pressed ! troller without interrupting operation
„AC“
If you specify temperature indication and
0
! value selection in Fahrenheit (°F), the con-
t troller still uses Celsius (°C) internally. Value steps
are therefore possible with this function owing to
Function the conversion from Celsius to Fahrenheit.
AUTOCOMP
AUTOCAL 10.17 Disabling the Configuration menu

0
t
It is possible to disable all changes to values/parame-
ters in the Configuration menu. This prevents the con-
10.15 Locking the "HAND" key troller configuration from being tampered with by unau-
thorized persons.
The Configuration menu can be disabled or enabled by
pressing the "MENU" key for 2.0seconds while the
The "HAND" key function can be configured with
power-up message is displayed (after switching on the
step 213 in the Configuration meun when the display is
controller,  section 10.2.1 "Power-up message" on
in home position.
page 25). The display then shows a message confir-
This prevents the heatsealing bands from beeing
ming that the disable function is active for 3.0seconds
heated if the "HAND" key is pressed inadvertenly.
before returning to the home position.
The following settings are possible:
1. Lock „OFF“ (Factory setting)
Pressing the "HAND" key while the display is in the
home position starts amanual heating process. The
heatsealing band is heated as long as the "HAND"
key remains pressed.
2. Lock „ON“
The same message is also displayed for 5.0seconds
The "HAND" key is locked when the display is in the
when you open the Configuration menu to indicate that
home position, in other words it has no function.
this menu is disabled.
You can still display all steps, values and

10.16 Temperature unit ! parameters even if the Configuration menu is
Celsius / Fahrenheit disabled. You are no longer allowed to enter or
(as of software revision 106) change values, however.
As of software revision 106 the unit for the temperature As of software revision 103 the language in
indication and value selection can be switched between ! menu pos. 201 can be changed while the con-
°C (Celsius) and °F (Fahrenheit). It can be paramete- figuration menu is locked ( section 9.3.2 "Setting
rized with step 225 as followed: the language" on page 20).
1. „Celsius“ (Factory setting)
Temperature indication and value selection in The Configuration menu remains disabled until the
Celsius (°C). disable function is canceled again. To do so, repeat the
above procedure (press the "MENU" key for
Page 38 RES-420
2.0seconds while the power-up message is displayed). The main menu is displayed again, and operation is
The display then shows a message confirming that the resumed, when the input voltage returns to the speci-
disable function has been canceled. fied tolerance range.
The alarm relay (terminals 5+6) is only switched by an
undervoltage condition in controllers up to and inclu-
ding software revision 008. The alarm relay in control-
lers with a higher software revision number is not swit-
ched if an undervoltage condition occurs.
Trouble-free operation of the controller is

In the factory setting the Configuration menu is not ! only guaranteed within the specified input
disabled.
voltage tolerance range. An external voltage
monitor must be connected to prevent defective
heatseals as a result of low line voltage.
10.18 Setting the display brightness
(VF display only)
10.20 Diagnostic interface/visualization
software
If the display is in the home position, the brightness of
the VF display (blue) can be set in 4 steps (25%, 50%,
75%, 100%) with the "UP" and "DOWN" keys.
An interface with a 6-pole Western socket is provided
The factory setting is 75%.
for systemdiagnostics and process visualization. This
interface allows a data connection to be set up to the
ROPEX visualization software using the ROPEX com-
munication interface CI-USB-1.
IR UR 12
DIAG
8 9 10 11
The life of the VF display can be prolonged by reducing

the brightness.
10.19 Undervoltage detection
Trouble-free operation of the temperature controller is Back view of the controller

guaranteed within the line voltage tolerance range spe-
cified in section 6 "Technical data" on page 9. Only a ROPEX comunication interface is
If a line voltage which is less than the lower limit of the ! allowed to be connected to the diagnostic
permissible range occurs, the controller is switched to interface. Connecting another device (e.g. a tele-
a standby mode. No more heatsealing processes take phone cable) could result in malfunctions or
place and no more measuring impulses are generated. damage to the controller.
The display changes to indicate this.
The ROPEX visualization software is described in a
separate document.
RES-420 Page 39
10.21 Booster connection This contact is set in the factory as follows:

• OPEN if error code 104…106, 111…113 or 211 is
The RES-420 controller has a connection for an displayed. The contact closes, however, if a
external switching amplifier (booster) as standard. This "START" signal is activated in this state.
connection (at terminals 1+2) is necessary for high pri-
• CLOSED if error code 101…103, 107, 108,
mary currents (continuous current > 5A, pulsed
201…203, 801 or 9xx appears.
current > 25A). The switching amplifier should be con-
nected as described in section 8.7 "Wiring diagram with If the alarm relay is configured differently from the fac-
booster connection" on page 17. No settings are tory setting ( section 9.3.9 "Configuration of the alarm
required in the menu. relay" on page 22), these states are inverted.
An error message can only be reset by pres-

10.22 System monitoring/alarm output ! sing the "RESET" key or by switching the
controller off and then on again.
To increase operating safety and to avoid faulty heatse-
aling, the 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 crucially support the system owner in
localizing the cause of an abnormal operating state.
A system fault is reported or differentiated by means of
the following elements.
Invalid error messages may appear when the
! controller is switched off owing to the unde-
A.) Error message on the display:
fined operating state. This must be taken into
account when they are evaluated by the higher-
level controller (e.g. a PLC) in order to avoid false
alarms.
10.23 Error messages

The cause of a fault can be localized quickly and easily
The table below describes each fault and the required
with the help of the error code that appears on the dis-
corrective action. The block diagram in section 10.24
play. Please refer to section 10.24 "Fault areas and
"Fault areas and causes" on page 44 permits each fault
causes" on page 44 for a list of the possible error
to be cleared quickly and efficiently
codes.
The error codes described below can also be displayed
B.) Alarm relay (relay contact, terminals 5+6): in the ROPEX visualization software ( section 10.20
"Diagnostic interface/visualization software (as of soft-
ware revision 100)" on page 39) to facilitate troubles-
hooting.
Page 40 RES-420
Part 1 of 3:
STATUS Action Action if machine

Error
of alarm relay Cause if machine started already operating,
code
(factory set.) for first time HS band not chang.
1 101 IR signal missing Fault area  Fault area 
2 102 UR signal missing Fault area  Fault area 
3 103 UR and IR signals missing Fault area  Fault area 
107 Temperature step, down Fault area  Fault area 
108 Temperature step, up (loose contact) (loose contact)
4 307
308 Temperature too low/high
309 ( section 9.3.7)
RES-420
310
Closed
201
Frequency fluctuation, Check
5 202 Check power supply
inadmissible line frequency power supply
203
Heatup time too long
6 304 Run RESET Run RESET
( section 9.3.8)
901 Int. faut, contr. defective Replace controller Replace controller

913 Triac defective Replace controller Replace controller
7 915 Int. faut, contr. defective Replace controller Replace controller
917 Plug-in jumper for alarm Check Check

918 relay wrong plug-in jumper plug-in jumper
Page 41
Part 2 of 3:
Page 42
NOTE: The specified error messages are initially output as warnings (alarm relay is open)
When the "START" signal is activated, the warning changes to a fault
(alarm relay is closed).

Error
code
IR signals incorrect,
104 incorrect specification of
impulse-transformer
Run AUTOCAL,
UR signals incorrect,
Check specification
105 incorrect specification of
Warning: of transformer,
impulse-transformer
Open Fault area 
RES-420
UR and/or IR signals
incorrect, Fault area 
8 106 Fault: incorrect specification of (loose contact)
Closed impulse-transformer
(voltage value
at actual Temperature too low,
302 value output AUTOCAL wasn’t per-
(AC) then no longer formed, loose contact, Run AUTOCAL
changes) ambient temp. fluctuates and/or
temperature too high, fault area 
303 AUTOCAL wasn’t per- (loose contact)
(AC) formed, loose contact,
ambient temp. fluctuates
9 211 Data error Run AUTOCAL ---

Part 3 of 3:
NOTE: The specified error messages are initially output as warnings (alarm relay is open)
When the "START" signal is activated, the warning changes to a fault
(alarm relay is closed).

Error
code
IR signal incorrect, Fault area ,

10 111 ---
calibration not possible check configuration
Warning:
Open
UR signal incorrect, Fault area ,
11 112 ---
UR and IR signals incorrect, Fault area ,
12 113 Fault: ---
Closed
(voltage value Temperature fluctuates,
RES-420
114
at actual calibration not possible
value output
Ext. calibration
13 115 then no longer
temperature too high,
changes)
Ext. calibration
116
temperature fluctuates
Page 43
10.24 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 - Contacting to heatsealing band defective

PEX-W2/W3 current transformer - IR measuring wire from current transformer interrupted
signal 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 wire 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
- Contacting to heatsealing band defective
- Heatsealing band installed incorrectly, insulation at heatse-

 Total short-circuit aling bar ends missing or incorrectly installed
- Conducting part bypasses heatsealing band completely
- Up to software revision 027: DIP switches 1 - 3 configured

incorrectly (U2 range)
 UR signal incorrect
- As of software revision 100: U2 outside permissible range
from 0.4…120VAC
Page 44 RES-420
Fault area Explanation Possible causes
- Up to software revision 027: DIP switches 4+5 configured

incorrectly (I2 range)
IR signal incorrect
- As of software revision 100: I2 outside permissible range
 from 30…500A
Turns through PEX-W2/W3 cur- - Check number of turns (two or more turns required for
rent transformer incorrect currents < 30A)
 Internal controller fault - Hardware fault (replace controller)
RES-420 Page 45
Factory settings
11 Factory settings
The RESISTRON temperature controller RES-420 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 software ON 1 2 3 4 5 1, 3, 4, 5 OFF
revision 027)
These switches are automatically set by the AUT-
ORANGE function on all controllers as of software
revision 100.
Settings menu No. 101 [1] Heatsealing temperature: 0°C

No. 106 [2] Hold mode: OFF
No. 107 [3] AUTOCAL temperature: 20°C
Configuration menu No. 201 [20] Language German

This selection is NOT changed if the
factory settings are restored with
step 202 [21] in the Config. menu.
No. 203, 204 [22]
Alloy/range: Alloy-20/max. 300°C
No. 206 [23] Maximum temperature: 300°C
No. 213 Lock of „HAND“ key OFF
No. 214 [24] Cycle counter: 0
No. 215 [25] Alarm relay: Normal (contact closed by a fault)
No. 217 Temperature diagnosis: OFF
No. 218 Temp.diagnosis
delay time: 0s
No. 219 Heatup timeout: OFF
No. 220 [26] Measuring impulse length:Standard (1.7ms)
No. 221 Autocomp: OFF
No. 225 Temperature unit: Celsius
Up to software revision 027: The factory settings are restored if the "ENTER" key is
The controller can be reset with step 21 in the Configu- pressed. An acknowledgment message is displayed for
ration menu: approximately 2s.
The language which is selected with step 20

! in the Configuration menu remains set even if
the factory settings are restored.
Page 46 RES-420
Maintenance
11.1 Customer settings When the controller is first delivered, the

(as of software revision 100) ! "customer settings" are identical to the
Ropex settings.
The controller factory settings can be specified or
restored with step 202 in the Configuration menu. You After pressing the "ENTER" key in this menu step, you
can also store customer settings in addition to the are asked to confirm the new settings (safety query).
Ropex settings:
Another message appears if you now confirm these

The following settings are possible: settings by pressing the "ENTER" key for approxi-
mately 2seconds.
1. „Restore Ropex settings“
(Factory setting)
Selecting this option restores the menu values listed
in section 11 "Factory settings" on page 46. These
values correspond to the factory settings with which
the controller was delivered.
2. „Define customer settings“
Selecting this option saves the values that are cur- You can also cancel the new settings by pressing the
rently set in the controller Settings and Configura- "MENU", cursor "UP" or cursor "DOWN" keys.
tion menus as "customer settings". These "cus- Step 203 then appears on the display.
tomer settings" are independent of the Ropex
settings. Machine-specific settings can be stored in The language which is selected with step 201
the controller in this way.
! in the Configuration menu remains set even if
the previous settings are restored.
3. „Restore customer settings
Selecting this option restores the "customer set-
tings" that were saved as described in 2.
12 Maintenance
The controller requires no special maintenance. the impulse transformer – is recommended. Dust depo-
Regular inspection and/or tightening of the terminals – sits on the controller can be removed with dry com-
including the terminals for the winding connections on pressed air.
RES-420 Page 47
How to order
13 How to order
Contr. RES - 420- . / . . . VAC
L / 115: LC display, line voltage 115VAC, Art. No. 742011
V / 115: VF display, line voltage 115VAC, Art. No. 742021
Scope of supply: Controller includes connector plug-in parts (current transformer

must be ordered separately)
Modification MOD . . (optional, if required)

e.g.
01: MOD 01, Art. No. 800001 (amplifier for low voltage)
Please indicate the article numbers of the controller and the required modifications
(optional) in all orders,
e.g. RES-420-L/400VAC + MOD 01
(controller with LC display for 400VAC line voltage
and amplifier for low voltage)
Art. Nos. 742013 + 800001 must be ordered
Current transformer PEX-W3

Art. No. 885105
Line filter LF- . . 480

06: Continuous current 6A, 480VAC, Art. No. 885500
35: Continuous current 35A, 480VAC, Art. No. 885506
Impulse transformer
See ROPEX Application Report for design and ordering
information
Communication interface CI-USB-1

Art. No. 885650
Booster B- . . . 400
075: Max. pulse load 75A, 400VAC, Art. No. 885301
100: Max. pulse load 100A, 400VAC, Art. No. 885304
For more accessories: "Accessories" leaflet
Page 48 RES-420
Index
14 Index
A Heatsealing band type 9
Accessories 7 Heatup timeout 22
Adapter for top hat rail mounting 8 Hold mode 36
Alarm output 40
Alarm relay 10, 22 I
Alloy 20, 21, 24 Impulse heatsealing method 4
Ambient temperature 10 Impulse transformer 7, 14, 48
Application 4 Installation 10, 12
Application Report 12, 15, 19 Installation procedure 12
AUTOCAL 6, 23, 35 Installation regulations 12
AUTOCOMP 37
Automatic phase angle compensation 37
L
Automatic zero calibration 6, 23, 35
Line filter 7, 14, 15, 48
AUTOTUNE 6
Line frequency 6, 9
Line voltage 9
B Locking the "HAND" key 38
Booster 7, 17, 48
Booster connection 40
M
Burning in heatsealing band 22, 24
Maintenance 47
Manual mode 35
C Measurement cable 8
Celsius °C 38 Measuring impulse duration 37
Circuit breaker 14 Modifications 8, 48
CI-USB-1 7, 39, 48 MODs 8, 48
Communication interface 7, 39, 48 Monitoring current transformer 7
Controller configuration 19
Controls 24
O
Current transformer 7, 15, 48
Overheating of heatsealing band 6
Customer settings 47
Cycle counter 36
P
PEX-W2/-W3 3
D
PEX-W3 15, 48
Degree of protection 10
Phase angle compensation 37
Diagnostic interface 39
Power dissipation 10
Dimensions 11
Power supply 14
DIP switches 19
Principle of operation 5
Disabling Configuration menu 38
Display 25
Display brightness 39 R
Replacing heatsealing band 22, 24
E
Error messages 40 S
External switching amplifier 7, 17 Secondary current I2 19
Secondary voltage U2 19
Set point selection 9, 35
F
Standby mode 39
Factory settings 20, 46
"START" signal 23, 35
Fahrenheit °F 38
System diagnostics 39
Fault areas 44
System monitoring 40
Fault diagnosis 6
Front cover 7
T
TCR 3, 22
H
Temperature coefficient 3, 21, 22
HEAT 23, 35
RES-420 Page 49
Index
Temperature control 4 U
Temperature diagnosis 21 Undervoltage detection 39
Temperature indication 35
Temperature range 9, 20, 21
V
Temperature setting 35
View of controller 18
Temperature unit 38
Visualization software 39
Transformer 3, 7, 14, 48
Type of construction 9
W
Wiring 12, 14
Wiring diagram 16, 17
Page 50 RES-420

RES-420 - Control Tempe

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RESISTRON

Identical design to and compatible with RES-210, -211, -220, -221

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

1 Safety and warning notes

1.3 Impulse transformer

1.2 Heatsealing band

1.5 Line filter DIN EN 61010-1 Safety provisions for electrical

• etc. • Increased machine capacity

Heatsealing band R = f (T)

4 Description of the controller

5 Accessories and modifications

Line filter LF-xx480

Impulse transformer ITR-x

Communication interface CI-USB-1

Transparent front cover TFA-1

Adapter for top hat rail mounting, HS-Adapter-01

Lockable door TUER-S/K-1

Measurement cable UML-1

5.2 Modifications (MODs) MOD 33

Line voltage All controller manufactured as of December 2005

All controllers manufactured as of January 2004 up to November 2005

All controllers manufactured up to December 2003:

depending on device version ( Kap. 13 „How to order“ auf Seite 48)

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

Heatsealing band As of software revision 100:

Up to software revision 027:

Set point selection Via the Settings menu in the controller

Digital logic levels LOW (0V): 0…2VDC

Alarm relay Contact, potential-free, Umax = 50V (DC/AC), Imax = 0.2A

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

Power dissipation max. 25W

Display LC display (green), 4 lines, 20 characters, alternatively:

Ambient temperature +5…+45°C

Installation Installed in front panel cutout with (W x H) 138(+-0.2) x 68(+-0.2) mm

Weight Approx. 1.0kg (incl. connector plug-in parts)

Housing material Black plastic, type Noryl SE1 GFN2

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

If ferrules are used, they must be crimped in accordance

7 Dimensions/front panel cutout

panel cutout outline dimensions

rubber seal mounting clamp

front frame front panel terminal wires

8.2 Installation steps

Use heatseal bands with No

Heatsealing band R= f (T)

No additional Connect UR measuring

8.3 Power supply

Do not lay parallel Mounting plate (galvanized)

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

8.6 Wiring diagram (standard)

Line filter LF-xx480

8.7 Wiring diagram with booster

Line filter LF-xx480

9 Startup and operation

9.1 Front view of the controller

9.2 Rear view of the controller

As of software revision 100:

Printed wiring diagram